Yaskawa SGDH-01AEY901 Retrofit-Ready Servo Amplifier

Yaskawa SGDH-01AEY901 Retrofit-Ready Servo Amplifier for Sigma-II Control Systems

The Yaskawa SGDH-01AEY901 is a 100W single-axis servo amplifier from the Sigma-II series, designed for precision motion control in industrial automation environments. As legacy Sigma-I and early Sigma-II installations reach end-of-service life, the SGDH-01AEY901 has become a critical retrofit component for engineers tasked with modernizing aging control cabinets, replacing discontinued drives, and restoring production continuity without full system overhauls.

This unit supports analog command input and pulse train reference, making it directly compatible with a wide range of PLC platforms and motion controllers still in active use across manufacturing, packaging, semiconductor, and machine tool industries. Whether you are replacing a failed drive on a legacy line or executing a planned upgrade from an earlier Sigma-I amplifier, the SGDH-01AEY901 provides a reliable, specification-matched solution backed by a 12-month warranty and pre-shipment functional testing.

Upgrade Compatibility Table

Retrofit Planning for Existing Automation Systems

Successful integration of the SGDH-01AEY901 into an existing control system begins well before the physical swap. Engineers should start by auditing the current cabinet layout, identifying the servo amplifier’s position on the backplane or DIN rail, and confirming that the existing SGMAH-series servo motor is rated at 100W and uses the standard 2500 P/R incremental encoder. If the motor is a legacy SGMA-A5A or SGMA-01A from a Sigma-I system, a full motor-amplifier compatibility check is required, as the encoder connector pinout and feedback cable wiring differ between generations.

Power supply verification is a mandatory step. The SGDH-01AEY901 draws from a single-phase 200–230V AC source, and the existing cabinet power supply — often a Yaskawa JUSP-PSU or a third-party 24V DC control power unit — must be confirmed to provide adequate capacity, particularly when multiple axes share a common bus. In multi-axis cabinets, the SGDH-01AEY901 is frequently installed alongside SGDH-02AEY901 (200W) or SGDH-04AEY901 (400W) amplifiers on a shared rack, and total current draw must be recalculated after any axis substitution.

Terminal block wiring should be mapped against the CN1 connector pinout documented in the SGDH series user manual (SIEP S800000 26). Pay particular attention to the SEN signal (pin 4), which activates the absolute encoder battery backup circuit on compatible motor variants. If the replacement motor does not use an absolute encoder, this pin must be left open to avoid fault codes. The CN2 encoder cable — typically a JZSP-CHP00-xx shielded cable — should be inspected for continuity and replaced if the original installation predates 2010, as insulation degradation is common in high-temperature cabinet environments.

For systems previously controlled via a Mitsubishi MELSEC Q-series or iQ-R series PLC using QD75 or RD77 positioning modules, the analog ±10V speed reference output can be wired directly to CN1 pins 5 and 6 of the SGDH-01AEY901 without signal conditioning. Omron CJ1W-NC series motion control units are similarly compatible. If the upstream controller is a Siemens SIMATIC S7-300 with FM357 or FM458 motion modules, verify that the differential analog output is configured for ±10V range and that the enable signal logic (servo-on, alarm reset) is mapped correctly to the amplifier’s digital input terminals.

Where the original system used MECHATROLINK-I communication via an NS100 option card, engineers planning a protocol migration to MECHATROLINK-II should note that the SGDH-01AEY901 base unit does not natively support MECHATROLINK-II without the NS115 option card. In such cases, a parallel approach — retaining analog command wiring during the transition period while upgrading the motion controller to a Yaskawa MP2300 or MP3300 machine controller — allows phased migration without full production stoppage. The JUSP-OP05A-1 digital operator panel remains compatible across both configurations and can be used to monitor real-time fault codes, adjust Pn parameters, and execute JOG operations during commissioning.

Downtime Control During System Migration

Minimizing unplanned downtime during a servo amplifier replacement requires a structured pre-swap protocol. Before powering down the axis, use SigmaWin+ software connected via the CN3 RS-422 port to export the full parameter set (Pn000–Pn212) to a backup file. This file should be stored both locally and on a network share, as parameter loss is the most common cause of extended commissioning time after a drive swap.

Once the SGDH-01AEY901 is physically installed and wired, restore the parameter backup before enabling the servo. Confirm that Pn001 (control mode selection) matches the original configuration — typically set to 0 for speed control or 1 for position control via pulse train. Verify Pn50A and Pn50B (input signal allocation) to ensure that the PLC’s digital outputs for servo-on (S-ON), alarm reset (ALM-RST), and forward/reverse run prohibit (P-OT/N-OT) are mapped to the correct CN1 input pins.

For HMI continuity, if the machine uses a Yaskawa GP series or Proface GP4000 series touch panel connected to the amplifier’s RS-422 port for status monitoring, verify that the HMI screen tag addresses reference the correct register map for the Sigma-II series. Sigma-I register maps differ in several Pn parameter addresses, and mismatched HMI screens can generate false alarm displays that delay operator acceptance of the upgraded axis.

A controlled test sequence — JOG at 10% rated speed, ramp to 50%, then full-speed cycle — should be completed before returning the axis to automatic mode. Monitor the TGON (speed coincidence) and COIN (positioning completion) output signals at the PLC input module to confirm that the motion profile is executing correctly. Total swap and commissioning time for a prepared technician with a pre-backed-up parameter file is typically 45–90 minutes per axis, keeping production interruption within a single shift window.

Retrofit Support FAQ

Q1: Is the SGDH-01AEY901 a direct drop-in replacement for the SGDH-A5AEY901?
The SGDH-01AEY901 (100W) and SGDH-A5AEY901 (50W) share the same physical form factor and CN1/CN2 connector layout, but differ in rated output current and motor compatibility. Before substituting, confirm that the connected servo motor is rated at 100W (e.g., SGMAH-01A series) rather than 50W (SGMAH-A5A series). Using a 100W amplifier with a 50W motor will not cause immediate damage but may result in suboptimal current loop tuning and should be corrected by adjusting Pn401 (torque reference filter) and Pn100 (speed loop gain).

Q2: What wiring changes are required when replacing a Sigma-I SGDA-01A with this unit?
The CN1 connector pinout differs between Sigma-I (SGDA series) and Sigma-II (SGDH series). Specifically, the servo-on input moves from pin 29 (SGDA) to pin 40 (SGDH), and the encoder feedback connector changes from a 15-pin D-sub (CN2 on SGDA) to a 26-pin connector on the SGDH. A wiring adapter harness or full CN1/CN2 recabling is required. Do not attempt a direct connector swap without consulting the respective series wiring diagrams.

Q3: Does this unit ship with a pre-shipment functional test?
Yes. Each SGDH-01AEY901 unit undergoes a pre-shipment load test verifying servo-on response, encoder feedback signal integrity, and alarm output function. A test report is available upon request. The unit is covered by a 12-month warranty from the date of shipment, covering manufacturing defects and component failures under normal operating conditions.

Q4: Can this amplifier be used with third-party servo motors from Fanuc or Mitsubishi?
The SGDH-01AEY901 is optimized for use with Yaskawa SGMAH and SGMPH series servo motors. Use with third-party motors (e.g., Fanuc αiS or Mitsubishi HG-KR series) is not supported by Yaskawa and requires custom encoder interface wiring, manual gain tuning, and acceptance of full compatibility risk by the end user. For cross-brand retrofit projects, consult our technical team before ordering.

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