Mitsubishi Electric MELSERVO-J4 series User manual

SH(NA)030143ENG-C(1611)MEE Printed in Japan Specifications are subject to change without notice.
This Instruction Manual uses recycled paper.
MODEL
MODEL
CODE
General-Purpose AC Servo
MR-J4-_A_-RJ MR-J4-03A6-RJ SERVO AMPLIFIER INSTRUCTION MANUAL (POSITIONING MODE)
HEAD OFFICE : TOKYO BLDG MARUNOUCHI TOKYO 100-8310
MODEL
MR-J4-_A_-RJ
MR-J4-03A6-RJ
C
General-Purpose Interface AC Servo
1CW819
SERVO AMPLIFIER
INSTRUCTION MANUAL
(POSITIONING MODE)
MR-J4-A-RJ
INSTRUCTIONMANUAL(ITIGIME)
C

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.
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A - 2
1. To prevent electric shock, note the following
WARNING
Before wiring or inspection, 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 a fire or smoke generation.
Always connect a magnetic contactor between the power supply and the main circuit power supply
(L1/L2/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.
In order to configure a circuit that shuts down the power supply on the side of the servo amplifier's
power supply, always connect one molded-case circuit breaker or fuse per one servo amplifier between
the power supply and the main circuit power supply (L1/L2/L3) of a servo amplifier. 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.
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A - 3
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.
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 the power is on
and for some time after power-off. Take safety measures such as providing covers to avoid accidentally
touching them by hands and parts such as cables.
4. Additional instructions
The following instructions should also be fully noted. Incorrect handling may cause a malfunction, 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.
Item Environment
Ambient
temperature
Operation 0 ˚C to 55 ˚C (non-freezing)
Storage -20 ˚C to 65 ˚C (non-freezing)
Ambient
humidity
Operation 5 %RH to 90 %RH (non-condensing)
Storage
Ambience Indoors (no direct sunlight), free from corrosive gas, flammable gas, oil mist, dust, and dirt
Altitude 2000 m or less above sea level (Contact your local sales office for the altitude for options.)
Vibration resistance 5.9 m/s2, at 10 Hz to 55 Hz (directions of X, Y and Z axes)
When the product 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 a metal cabinet.
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A - 4
CAUTION
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.
(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 (optional FR-BIF(-H)) on the servo
amplifier output side.
To avoid a malfunction, connect the wires to the correct phase terminals (U/V/W) of the servo amplifier
and servo motor.
Connect the servo amplifier power output (U/V/W) to the servo motor power input (U/V/W) directly. Do
not let a magnetic contactor, etc. intervene. Otherwise, it may cause a malfunction.
U
Servo motor
M
V
W
U
V
W
U
M
V
W
U
V
W
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
(DOCOMD)
Control output
signal
Servo amplifie
r
or MR-D01
RA
For sink output interface
24 V DC
DOCOM
(DOCOMD)
Control output
signal
24 V DC
Servo amplifier
or MR-D01
RA
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 of the wrong axis to U, V, W, or CN2 of the servo amplifier 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.
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A - 5
(3) Test run and adjustment
CAUTION
Before operation, check the parameter settings. Improper settings may cause some machines to operate
unexpectedly.
Never make a drastic adjustment or change to the parameter values as doing so will make the operation
unstable.
Do not get close to moving parts during the servo-on status.
(4) Usage
CAUTION
When it is assumed that a hazardous condition may occur due to a power failure or product malfunction,
use a servo motor with an external brake to prevent the condition.
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 which is interlocked with an external emergency stop switch.
Servo motor
Electromagnetic brake
B
RA
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.
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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 the servo amplifier that has not been energized for an extended period of 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 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
Write to the EEP-ROM due to point table changes
Write to the EEP-ROM due to program changes
STO function of the servo amplifier
When using the STO function of the servo amplifier, refer to chapter 13 of "MR-J4-_A_(-RJ) Servo Amplifier
Instruction Manual".
For the MR-J3-D05 safety logic unit, refer to app. 5 of "MR-J4-_A_(-RJ) Servo Amplifier Instruction Manual".
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A - 7
Compliance with global standards
For the compliance with global standards, refer to app. 4 of "MR-J4-_A_(-RJ) Servo Amplifier Instruction
Manual".
«About the manual»
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-_A_(-RJ) Servo Amplifier Instruction Manual SH(NA)030107ENG
MELSERVO MR-J4-_A_-RJ Servo Amplifier Instruction Manual (Modbus-RTU Protocol) (Note
5)
SH(NA)030175ENG
MELSERVO MR-J4-DU_(-RJ)/MR-CR55K_ Instruction Manual (Note 6) SH(NA)030153ENG
MELSERVO-J4 Servo Amplifier Instruction Manual (Troubleshooting) SH(NA)030109ENG
MELSERVO Servo Motor Instruction Manual (Vol. 3) (Note 1) SH(NA)030113ENG
MELSERVO Linear Servo Motor Instruction Manual (Note 2) SH(NA)030110ENG
MELSERVO Direct Drive Motor Instruction Manual (Note 3) SH(NA)030112ENG
MELSERVO Linear Encoder Instruction Manual (Note 2, 4) SH(NA)030111ENG
EMC Installation Guidelines IB(NA)67310ENG
Parameter Unit MR-PRU03 Instruction Manual (MR-J4) SH(NA)030186ENG
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 the Modbus-RTU communication function.
6. It is necessary for using the MR-J4-DU_A_(-RJ) drive unit or MR-CR55K_ converter unit.
This Instruction Manual does not describe the following items. The followings are the same as MR-J4-
_A_-RJ Servo amplifiers. For details of the items, refer to each chapter/section of the detailed explanation
field. "MR-J4-_A_" means "MR-J4-_A_(-RJ) Servo Amplifier Instruction Manual".
Item Detailed explanation
Installation MR-J4-_A_ chapter 2
Normal gain adjustment MR-J4-_A_ chapter 6
Special adjustment functions MR-J4-_A_ chapter 7
Dimensions MR-J4-_A_ chapter 9
Characteristics MR-J4-_A_ chapter 10
ABSOLUTE POSITION DETECTION SYSTEM (only 12.1
Summary and 12.2 Battery)
MR-J4-_A_ chapter 12
USING STO FUNCTION MR-J4-_A_ chapter 13
USING A LINEAR SERVO MOTOR (Note) MR-J4-_A_ chapter 15
USING A DIRECT DRIVE MOTOR MR-J4-_A_ chapter 16
FULLY CLOSED LOOP SYSTEM (Note) MR-J4-_A_ chapter 17
MR-J4-03A6-RJ SERVO AMPLIFIER MR-J4-_A_ chapter 18
Note. For the home position return, refer to each chapter indicated in the detailed
explanation field and chapter 4 in this Instruction Manual.
«Wiring»
Wires mentioned in this Instruction Manual are selected based on the ambient temperature of 40 ˚C.
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A - 8
«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]
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1
CONTENTS
1. FUNCTIONS AND CONFIGURATION 1- 1 to 1-12
1.1 For proper use of the positioning mode............................................................................................ 1- 1
1.2 Positioning mode specification list.................................................................................................... 1- 2
1.3 Function list....................................................................................................................................... 1- 5
1.4 Configuration including peripheral equipment ................................................................................. 1-10
2. SIGNALS AND WIRING 2- 1 to 2-46
2.1 I/O signal connection example.......................................................................................................... 2- 3
2.1.1 MR-J4-_A_-RJ 100 W or more .................................................................................................. 2- 3
2.1.2 MR-J4-03A6-RJ ......................................................................................................................... 2- 9
2.2 Connectors and pin assignment ...................................................................................................... 2-15
2.3 Signal (device) explanations............................................................................................................ 2-22
2.4 Analog override................................................................................................................................ 2-38
2.5 Internal connection diagram ............................................................................................................ 2-40
2.6 Power-on sequence......................................................................................................................... 2-45
2.6.1 MR-J4-_A_-RJ 100 W or more ................................................................................................. 2-45
2.6.2 MR-J4-03A6-RJ ........................................................................................................................ 2-46
3. DISPLAY AND OPERATION SECTIONS 3- 1 to 3-54
3.1 MR-J4-_A_-RJ 100 W or more ......................................................................................................... 3- 1
3.1.1 Display sequence....................................................................................................................... 3- 1
3.1.2 Status display............................................................................................................................. 3- 3
3.1.3 Diagnostic mode ....................................................................................................................... 3-12
3.1.4 Alarm mode ............................................................................................................................... 3-15
3.1.5 Point table setting...................................................................................................................... 3-17
3.1.6 Parameter mode ....................................................................................................................... 3-21
3.1.7 External I/O signal display......................................................................................................... 3-23
3.1.8 Output signal (DO) forced output .............................................................................................. 3-24
3.1.9 Single-Step feed........................................................................................................................ 3-25
3.1.10 Teaching function.................................................................................................................... 3-27
3.2 MR-J4-03A6-RJ ............................................................................................................................... 3-28
3.2.1 Display flowchart ....................................................................................................................... 3-28
3.2.2 Status display mode.................................................................................................................. 3-29
3.2.3 Diagnostic mode ....................................................................................................................... 3-34
3.2.4 Alarm mode ............................................................................................................................... 3-38
3.2.5 Point table setting...................................................................................................................... 3-40
3.2.6 Parameter mode ....................................................................................................................... 3-44
3.2.7 External I/O signal display......................................................................................................... 3-49
3.2.8 Output signal (DO) forced output .............................................................................................. 3-50
3.2.9 Step feed ................................................................................................................................... 3-51
3.2.10 Teaching function.................................................................................................................... 3-53
4. HOW TO USE THE POINT TABLE 4- 1 to 4-80
4.1 Startup .............................................................................................................................................. 4- 2
4.1.1 Power on and off procedures..................................................................................................... 4- 2
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