Mitsubishi Electric MR-J4 TM Series Bedienungsanleitung

SH(NA)030193-C(1604)MEE Printed in Japan Specifications are subject to change without notice.

This Instruction Manual uses recycled paper.

MODEL

CODE

General-Purpose AC Servo

MR-J4-_TM_ SERVO AMPLIFIER INSTRUCTION MANUAL

HEAD OFFICE : TOKYO BLDG MARUNOUCHI TOKYO 100-8310

MODEL

MR-J4-_TM_

Multi-network Interface AC Servo

SERVO AMPLIFIER

INSTRUCTION MANUAL

A - 1

Safety Instructions

Please read the instructions carefully before using the equipment.

To use the equipment correctly, do not attempt to install, operate, maintain, or inspect the equipment until

you have read through this Instruction Manual, Installation guide, and appended documents carefully. Do not

use the equipment until you have a full knowledge of the equipment, safety information and instructions.

In this Instruction Manual, the safety instruction levels are classified into "WARNING" and "CAUTION".

WARNING

Indicates that incorrect handling may cause hazardous conditions,

resulting in death or severe injury.

CAUTION Indicates that incorrect handling may cause hazardous conditions,

resulting in medium or slight injury to personnel or may cause physical

damage.

Note that the CAUTION level may lead to a serious consequence according to conditions.

Please follow the instructions of both levels because they are important to personnel safety.

What must not be done and what must be done are indicated by the following diagrammatic symbols.

Indicates what must not be done. For example, "No Fire" is indicated by .

Indicates what must be done. For example, grounding is indicated by .

In this Instruction Manual, instructions at a lower level than the above, instructions for other functions, and so

on are classified into "POINT".

After reading this Instruction Manual, keep it accessible to the operator.

A - 2

1. To prevent electric shock, note the following

WARNING

Before wiring and inspections, turn off the power and wait for 15 minutes or more until the charge lamp

turns off. Then, confirm that the voltage between P+ and N- is safe with a voltage tester and others.

Otherwise, an electric shock may occur. In addition, when confirming whether the charge lamp is off or

not, always confirm it from the front of the servo amplifier.

Ground the servo amplifier and servo motor securely.

Any person who is involved in wiring and inspection should be fully competent to do the work.

Do not attempt to wire the servo amplifier and servo motor until they have been installed. Otherwise, it

may cause an electric shock.

Do not operate switches with wet hands. Otherwise, it may cause an electric shock.

The cables should not be damaged, stressed, loaded, or pinched. Otherwise, it may cause an electric

shock.

During power-on or operation, do not open the front cover of the servo amplifier. Otherwise, it may cause

an electric shock.

Do not operate the servo amplifier with the front cover removed. High-voltage terminals and charging

area are exposed and you may get an electric shock.

Except for wiring and periodic inspection, do not remove the front cover of the servo amplifier even if the

power is off. The servo amplifier is charged and you may get an electric shock.

To prevent an electric shock, always connect the protective earth (PE) terminal (marked ) of the servo

amplifier to the protective earth (PE) of the cabinet.

To avoid an electric shock, insulate the connections of the power supply terminals.

2. To prevent fire, note the following

CAUTION

Install the servo amplifier, servo motor, and regenerative resistor on incombustible material. Installing

them directly or close to combustibles will lead to smoke or a fire.

Always connect a magnetic contactor between the power supply and the main circuit power supply (L1,

L2, and L3) of the servo amplifier, in order to configure a circuit that shuts down the power supply on the

side of the servo amplifier’s power supply. If a magnetic contactor is not connected, continuous flow of a

large current may cause smoke or a fire when the servo amplifier malfunctions.

Always connect a molded-case circuit breaker, or a fuse to each servo amplifier between the power

supply and the main circuit power supply (L1, L2, and L3) of the servo amplifier, in order to configure a

circuit that shuts down the power supply on the side of the servo amplifier’s power supply. If a molded-

case circuit breaker or fuse is not connected, continuous flow of a large current may cause smoke or a

fire when the servo amplifier malfunctions.

When using the regenerative resistor, switch power off with the alarm signal. Otherwise, a regenerative

transistor malfunction or the like may overheat the regenerative resistor, causing smoke or a fire.

Provide adequate protection to prevent screws and other conductive matter, oil and other combustible

matter from entering the servo amplifier and servo motor.

3. To prevent injury, note the following

CAUTION

Only the voltage specified in the Instruction Manual should be applied to each terminal. Otherwise, a

burst, damage, etc. may occur.

Connect cables to the correct terminals. Otherwise, a burst, damage, etc. may occur.

A - 3

CAUTION

Ensure that polarity (+/-) is correct. Otherwise, a burst, damage, etc. may occur.

The servo amplifier heat sink, regenerative resistor, servo motor, etc. may be hot while power is on or for

some time after power-off. Take safety measures, e.g. provide covers, to prevent accidental contact of

hands and parts (cables, etc.) with them.

4. Additional instructions

The following instructions should also be fully noted. Incorrect handling may cause a fault, injury, electric

shock, fire, etc.

(1) Transportation and installation

CAUTION

Transport the products correctly according to their mass.

Stacking in excess of the specified number of product packages is not allowed.

Do not hold the front cover when transporting the servo amplifier. Otherwise, it may drop.

Install the servo amplifier and the servo motor in a load-bearing place in accordance with the Instruction

Manual.

Do not get on or put heavy load on the equipment.

The equipment must be installed in the specified direction.

Leave specified clearances between the servo amplifier and the cabinet walls or other equipment.

Do not install or operate the servo amplifier and servo motor which have been damaged or have any

parts missing.

Do not block the intake and exhaust areas of the servo amplifier. Otherwise, it may cause a malfunction.

Do not drop or strike the servo amplifier and servo motor. Isolate them from all impact loads.

When you keep or use the equipment, please fulfill the following environment.

Items Environment

Ambient

temperature

Operation 0 °C to 55 °C (non-freezing)

Storage -20 °C to 65 °C (non-freezing)

Ambient

humidity

Operation 90 %RH or less (non-condensing)

Storage

Ambience Indoors (no direct sunlight), free from corrosive gas, flammable gas, oil mist, dust, and dirt

Altitude Max. 2000 m above sea level (Contact your local sales office for the altitude for options.)

Vibration resistance 5.9 m/s2at 10 Hz to 55 Hz (directions of X, Y, and Z axes)

When the equipment has been stored for an extended period of time, contact your local sales office.

When handling the servo amplifier, be careful about the edged parts such as corners of the servo

amplifier.

The servo amplifier must be installed in the metal cabinet.

When fumigants that contain halogen materials such as fluorine, chlorine, bromine, and iodine are used

for disinfecting and protecting wooden packaging from insects, they cause malfunction when entering our

products. Please take necessary precautions to ensure that remaining materials from fumigant do not

enter our products, or treat packaging with methods other than fumigation (heat method).Additionally,

disinfect and protect wood from insects before packing products.

A - 4

(2) Wiring

CAUTION

Wire the equipment correctly and securely. Otherwise, the servo motor may operate unexpectedly.

Do not install a power capacitor, surge killer, or radio noise filter (FR-BIF(-H) option) on the servo

amplifier output side.

To avoid a malfunction, connect the wires to the correct phase terminals (U, V, and W) of the servo

amplifier and servo motor.

Connect the servo amplifier power output (U, V, and W) to the servo motor power input (U, V, and W)

directly. Do not let a magnetic contactor, etc. intervene. Otherwise, it may cause a malfunction.

Servo motor

Servo amplifier Servo motorServo amplifier

The connection diagrams in this instruction manual are shown for sink interfaces, unless stated

otherwise.

The surge absorbing diode installed to the DC relay for control output should be fitted in the specified

direction. Otherwise, the emergency stop and other protective circuits may not operate.

DOCOM

24 V DC

Servo amplifier

For sink output interface

Control output

signal

DOCOM

Control output

signal

24 V DC

Servo amplifier

For source output interface

When the cable is not tightened enough to the terminal block, the cable or terminal block may generate

heat because of the poor contact. Be sure to tighten the cable with specified torque.

Connecting a servo motor for different axis to the U, V, W, or CN2 may cause a malfunction.

Configure a circuit to turn off EM2 or EM1 when the main circuit power is turned off to prevent an

unexpected restart of the servo amplifier.

(3) Test run and adjustment

CAUTION

Before operation, check the parameter settings. Improper settings may cause some machines to perform

unexpected operation.

Never adjust or change the parameter values extremely as it will make operation unstable.

Do not close to moving parts at servo-on status.

A - 5

(4) Usage

CAUTION

Provide an external emergency stop circuit to ensure that operation can be stopped and power switched

off immediately.

Do not disassemble, repair, or modify the equipment.

Before resetting an alarm, make sure that the run signal of the servo amplifier is off in order to prevent a

sudden restart. Otherwise, it may cause an accident.

Use a noise filter, etc. to minimize the influence of electromagnetic interference. Electromagnetic

interference may be given to the electronic equipment used near the servo amplifier.

Burning or breaking a servo amplifier may cause a toxic gas. Do not burn or break it.

Use the servo amplifier with the specified servo motor.

The electromagnetic brake on the servo motor is designed to hold the motor shaft and should not be

used for ordinary braking.

For such reasons as service life and mechanical structure (e.g. where a ball screw and the servo motor

are coupled via a timing belt), the electromagnetic brake may not hold the motor shaft. To ensure safety,

install a stopper on the machine side.

(5) Corrective actions

CAUTION

Ensure safety by confirming the power off, etc. before performing corrective actions. Otherwise, it may

cause an accident.

When it is assumed that a hazardous condition may occur due to a power failure or product malfunction,

use a servo motor with an electromagnetic brake or external brake to prevent the condition.

Configure an electromagnetic brake circuit so that it is activated also by an external Emergency stop

switch.

Servo motor

Electromagnetic brake

Contacts must be opened

with the Emergency stop switch.

Contacts must be opened when ALM

(Malfunction) or MBR (Electromagnetic

brake interlock) turns off.

24 V DC

When any alarm has occurred, eliminate its cause, ensure safety, and deactivate the alarm before

restarting operation.

Provide an adequate protection to prevent unexpected restart after an instantaneous power failure.

A - 6

(6) Maintenance, inspection and parts replacement

CAUTION

Make sure that the emergency stop circuit operates properly such that an operation can be stopped

immediately and a power is shut off by the emergency stop switch.

It is recommended that the servo amplifier be replaced every 10 years when it is used in general

environment.

When using a servo amplifier whose power has not been turned on for a long time, contact your local

sales office.

(7) General instruction

To illustrate details, the equipment in the diagrams of this Instruction Manual may have been drawn

without covers and safety guards. When the equipment is operated, the covers and safety guards must

be installed as specified. Operation must be performed in accordance with this Specifications and

Instruction Manual.

DISPOSAL OF WASTE

Please dispose a servo amplifier, battery (primary battery) and other options according to your local laws and

regulations.

EEP-ROM life

The number of write times to the EEP-ROM, which stores parameter settings, etc., is limited to 100,000. If

the total number of the following operations exceeds 100,000, the servo amplifier may malfunction when the

EEP-ROM reaches the end of its useful life.

Write to the EEP-ROM due to parameter setting changes

Write to the EEP-ROM due to device changes

STO function of the servo amplifier

When using the STO function of the servo amplifier, refer to chapter 13.

For the MR-J3-D05 safety logic unit, refer to app. 5.

Compliance with global standards

For the compliance with global standards, refer to app. 4.

A - 7

«About the manuals»

You must have this Instruction Manual and the following manuals to use this servo. Ensure to prepare

them to use the servo safely.

Relevant manuals

Manual name Manual No.

MELSERVO MR-J4-_TM_ SERVO AMPLIFIER INSTRUCTION MANUAL (EtherCAT) SH(NA)030208

MELSERVO MR-J4-_TM_ SERVO AMPLIFIER INSTRUCTION MANUAL (EtherNet/IP) SH(NA)030226

MELSERVO-J4 SERVO AMPLIFIER INSTRUCTION MANUAL (TROUBLESHOOTING) SH(NA)030109

MELSERVO MR-D30 INSTRUCTION MANUAL (Note 5) SH(NA)030132

MELSERVO Servo Motor Instruction Manual (Vol. 3) (Note 1) SH(NA)030113

MELSERVO Linear Servo Motor Instruction Manual (Note 2) SH(NA)030110

MELSERVO Direct Drive Motor Instruction Manual (Note 3) SH(NA)030112

MELSERVO Linear Encoder Instruction Manual (Note 2, 4) SH(NA)030111

EMC Installation Guidelines IB(NA)67310

Note 1. It is necessary for using a rotary servo motor.

2. It is necessary for using a linear servo motor.

3. It is necessary for using a direct drive motor.

4. It is necessary for using a fully closed loop system.

5. It is necessary for using an MR-D30 functional safety unit.

«Wiring»

Wires mentioned in this Instruction Manual are selected based on the ambient temperature of 40 °C.

«U.S. customary units»

U.S. customary units are not shown in this manual. Convert the values if necessary according to the

following table.

Quantity SI (metric) unit U.S. customary unit

Mass 1 [kg] 2.2046 [lb]

Length 1 [mm] 0.03937 [inch]

Torque 1 [N•m] 141.6 [oz•inch]

Moment of inertia 1 [(× 10-4 kg•m2)] 5.4675 [oz•inch2]

Load (thrust load/axial load) 1 [N] 0.2248 [lbf]

Temperature N [°C] × 9/5 + 32 N [°F]

A - 8

MEMO

CONTENTS

1. FUNCTIONS AND CONFIGURATION 1- 1 to 1-56

1.1 Summary........................................................................................................................................... 1- 1

1.2 Function block diagram..................................................................................................................... 1- 3

1.3 Servo amplifier standard specifications ........................................................................................... 1-13

1.4 Combinations of servo amplifiers and servo motors ....................................................................... 1-19

1.5 Function list...................................................................................................................................... 1-21

1.6 Model designation............................................................................................................................ 1-24

1.7 Structure .......................................................................................................................................... 1-25

1.7.1 Parts identification..................................................................................................................... 1-25

1.7.2 Removal and reinstallation of the front cover............................................................................ 1-38

1.7.3 Installation and removal of network module.............................................................................. 1-40

1.8 Configuration including peripheral equipment ................................................................................. 1-43

2. INSTALLATION 2- 1 to 2- 6

2.1 Installation direction and clearances ................................................................................................ 2- 2

2.2 Keeping out of foreign materials ....................................................................................................... 2- 4

2.3 Encoder cable stress ........................................................................................................................ 2- 4

2.4 Inspection items ................................................................................................................................ 2- 4

2.5 Parts having service lives ................................................................................................................. 2- 5

2.6 Restrictions when using the servo amplifiers at altitude exceeding 1000 m and up to 2000 m

above sea level ................................................................................................................................. 2- 6

3. SIGNALS AND WIRING 3- 1 to 3-42

3.1 Input power supply circuit ................................................................................................................. 3- 3

3.1.1 200 V class................................................................................................................................. 3- 4

3.1.2 400 V class................................................................................................................................ 3-10

3.1.3 100 V class................................................................................................................................ 3-14

3.2 I/O signal connection example......................................................................................................... 3-15

3.2.1 For sink I/O interface................................................................................................................. 3-15

3.2.2 For source I/O interface ............................................................................................................ 3-16

3.3 Explanation of power supply system ............................................................................................... 3-17

3.3.1 Signal explanations ................................................................................................................... 3-17

3.3.2 Power-on sequence .................................................................................................................. 3-18

3.3.3 Wiring CNP1, CNP2, and CNP3 ............................................................................................... 3-19

3.4 Connectors and pin assignment ...................................................................................................... 3-23

3.5 Signal (device) explanations............................................................................................................ 3-24

3.5.1 Input device ............................................................................................................................... 3-24

3.5.2 Output device ............................................................................................................................ 3-26

3.5.3 Output signal ............................................................................................................................. 3-27

3.5.4 Power supply............................................................................................................................. 3-27

3.6 Forced stop deceleration function ................................................................................................... 3-28

3.6.1 Forced stop deceleration function............................................................................................. 3-28

3.6.2 Base circuit shut-off delay time function ................................................................................... 3-29

3.6.3 Vertical axis freefall prevention function ................................................................................... 3-30

3.6.4 Residual risks of the forced stop function (EM2) ...................................................................... 3-30

3.7 Alarm occurrence timing chart ......................................................................................................... 3-31

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