Mitsubishi Electric MELSERVO-J4 series User manual

SH(NA)030109ENG-M(1612)MEE Printed in Japan Specifications are subject to change without notice.
This Instruction Manual uses recycled paper.
MODEL
MODEL
CODE
General-Purpose AC Servo
MELSERVO-J4 Servo amplifier INSTRUCTION MANUAL (TROUBLE SHOOTING)
HEAD OFFICE : TOKYO BLDG MARUNOUCHI TOKYO 100-8310
MELSERVO-J4 Servo amplifier
INSTRUCTION MANUAL (TROUBLE SHOOTING)
1CW808
MR-J4 INSTRUCTIONMANUAL
(TROUBLESHOOTING)
M
M

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 or inspection, turn off the power and wait for 15 minutes or more (20 minutes or more for
converter unit) until the charge lamp turns off. Then, confirm that the voltage between P+ and N-
(between L+ and L- for converter unit) is safe with a voltage tester and others. Otherwise, an electric
shock may occur. In addition, always confirm whether the charge lamp is off or not from the front of the
servo amplifier (converter unit).
Do not operate switches with wet hands. Otherwise, it may cause an electric shock.
2. To prevent fire, note the following
CAUTION
When you use an MR-J4 multi-axis servo amplifier, connecting an encoder for wrong axis to the CN2A,
CN2B, or CN2C connector may cause a fire.
3. To prevent injury, note the following
CAUTION
The servo amplifier (drive unit), converter unit heat sink, regenerative resistor, servo motor, etc. may
become hot while power is on or for some time after power-off. Take safety measures, e.g. provide
covers, to avoid accidentally touching the parts (cables, etc.) by hand.
4. Additional instructions
The following instructions should also be fully noted. Incorrect handling may cause a malfunction, injury,
electric shock, etc.
(1) Wiring
CAUTION
Wire the equipment correctly and securely. Otherwise, the servo motor may operate unexpectedly.
To avoid a malfunction of the servo motor, connect the wires to the correct phase terminals (U/V/W) of
the servo amplifier (drive unit) and the servo motor.
Connect the servo amplifier (drive unit) 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
(drive unit) Servo motor
Servo amplifier
(drive unit)
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 (drive unit).

A - 3
(2) Usage
CAUTION
Before resetting an alarm, make sure that the run signal of the servo amplifier (drive unit) is off in order to
prevent a sudden restart. Otherwise, it may cause an accident.
Use the servo amplifier (drive unit) and converter unit with the specified servo motor.
(3) 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 CALM (Common
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 - 4
«About the manual»
This Instruction Manual covers the following models. These include servo amplifiers (drive units) which
have optional units.
MR-J4-_A/MR-J4-_A4/MR-J4-_A1/MR-J4-_A-RJ/MR-J4-_A4-RJ/MR-J4-_A1-RJ
MR-J4-_B/MR-J4-_B4/MR-J4-_B1/MR-J4-_B-RJ/MR-J4-_B4-RJ/MR-J4-_B1-RJ
MR-J4W_-_B
MR-J4-_B-RJ010/MR-J4-_B4-RJ010
MR-J4-03A6/MR-J4-03A6-RJ/MR-J4W2-0303B6
MR-J4-_GF/MR-J4-_GF4/MR-J4-_GF-RJ/MR-J4-_GF4-RJ
MR-J4-DU_A/MR-J4-DU_A4/MR-J4-DU_A-RJ/MR-J4-DU_A4-RJ
MR-J4-DU_B/MR-J4-DU_B4/MR-J4-DU_B-RJ/MR-J4-DU_B4-RJ
MR-CV_
MR-CR55K/MR-CR55K4
The symbols in the target column mean as follows.
[A]: MR-J4-_A/MR-J4-_A4/MR-J4-_A1/MR-J4-_A-RJ/MR-J4-_A4-RJ/MR-J4-_A1-RJ/MR-J4-DU_A/
MR-J4-DU_A4/MR-J4-DU_A-RJ/MR-J4-DU_A4-RJ/MR-J4-03A6/MR-J4-03A6-RJ
[B]: MR-J4-_B/MR-J4-_B4/MR-J4-_B1/MR-J4-_B-RJ/MR-J4-_B4-RJ/MR-J4-_B1-RJ/
MR-J4-DU_B/MR-J4-DU_B4/MR-J4-DU_B-RJ/MR-J4-DU_B4-RJ
[WB]: MR-J4W_-_B/MR-J4W2-0303B6
[RJ010]: MR-J4-_B-RJ010/MR-J4-_B4-RJ010
[GF]: MR-J4-_GF/MR-J4-_GF4/MR-J4-_GF-RJ/MR-J4-_GF4-RJ
[Other]: For manufacturer adjustment

1
CONTENTS
1. TROUBLESHOOTING FOR SERVO AMPLIFIER (DRIVE UNIT) 1- 1 to 1-130
1.1 Explanation for the lists..................................................................................................................... 1- 1
1.2 Alarm list ........................................................................................................................................... 1- 3
1.3 Warning list ...................................................................................................................................... 1-13
1.4 Remedies for alarms........................................................................................................................ 1-16
1.5 Remedies for warnings .................................................................................................................... 1-92
1.6 Trouble which does not trigger alarm/warning .............................................................................. 1-116
1.7 Network module error codes.......................................................................................................... 1-129
2. TROUBLESHOOTING FOR MR-CV_POWER REGENERATION CONVERTER UNIT 2- 1 to 2- 8
2.1 Explanations of the lists .................................................................................................................... 2- 1
2.2 Alarm list ........................................................................................................................................... 2- 1
2.3 Warning list ....................................................................................................................................... 2- 2
2.4 Remedies for alarms......................................................................................................................... 2- 2
2.5 Remedies for warnings ..................................................................................................................... 2- 7
3. TROUBLESHOOTING FOR MR-CR55K(4) RESISTANCE REGENERATION CONVERTER UNIT 3- 1 to 3-10
3.1 Explanation for the lists..................................................................................................................... 3- 1
3.2 Alarm/warning list.............................................................................................................................. 3- 1
3.3 Remedies for alarms......................................................................................................................... 3- 2
3.4 Remedies for warnings ..................................................................................................................... 3- 8
4. DRIVE RECORDER 4- 1 to 4-10
4.1 How to use drive recorder.................................................................................................................. 4- 1
4.2 How to display drive recorder information ........................................................................................ 4-10
APPENDIX App.- 1 to App.- 1
App. 1 Detection points of [AL. 25], [AL. 92], and [AL. 9F]............................................................... App.- 1

2
MEMO

1. TROUBLESHOOTING FOR SERVO AMPLIFIER (DRIVE UNIT)
1 - 1
1. TROUBLESHOOTING FOR SERVO AMPLIFIER (DRIVE UNIT)
POINT
As soon as an alarm occurs, turn SON (Servo-on) off and interrupt the power.
[AL. 37 Parameter error] and warnings (except [AL. F0 Tough drive warning])
are not recorded in the alarm history.
[AL. 8D.1 CC-Link IE communication error 1] and [AL. 8D.2 CC-Link IE
communication error 2] are not recorded in the alarm history. For MR-J4-_GF_(-
RJ), these alarms are recorded by setting [Pr. PN06] to "_ _ _ 1".
When an error occurs during operation, the corresponding alarm or warning is displayed. When an alarm is
displayed, refer to section 1.4 and take the appropriate action. When an alarm occurs, ALM will turn off.
When an warning is displayed, refer to section 1.5 and take the appropriate action.
1.1 Explanation for the lists
(1) No./Name/Detail No./Detail name
Indicates each No./Name/Detail No./Detail name of alarms or warnings.
(2) Stop method
For the alarms and warnings in which "SD" is written in the stop method column, the servo motor stops
with the dynamic brake after forced stop deceleration. For the alarms and warnings in which "DB" or
"EDB" is written in the stop method column, the servo motor stops with the dynamic brake without forced
stop deceleration.
(3) Alarm deactivation
After its cause has been removed, the alarm can be deactivated in any of the methods marked in the
alarm deactivation column. Warnings are automatically canceled after the cause of occurrence is
removed. Alarms are deactivated with alarm reset, CPU reset, or cycling the power.
(a) MR-J4-_A_(-RJ)/MR-J4-DU_A_(-RJ)
Alarm deactivation Explanation
Alarm reset 1. Turning on RES (Reset) with input device
2. Pushing the "SET" button while the display of the servo amplifier is the current
alarm display status
3. Click "Occurring Alarm Reset" in the "Alarm Display" window of MR Configurator2
Cycling the power Turning the power off and then turning it on again.
(b) MR-J4-_B_(-RJ010)/MR-J4W_-_B/MR-J4-DU_B_(-RJ)/MR-J4-_GF_(-RJ)
Alarm deactivation Explanation
Alarm reset 1. Reset command from controller
2. Click "Occurring Alarm Reset" in the "Alarm Display" window of MR Configurator2
CPU reset Resetting the controller itself
Cycling the power Turning the power off and then turning it on again.
(4) Processing system (only for MR-J4W_-_B_)
Processing system of alarms is as follows.
Each axis: Alarm is detected for each axis.
Common: Alarm is detected as the whole servo amplifier.

1. TROUBLESHOOTING FOR SERVO AMPLIFIER (DRIVE UNIT)
1 - 2
(5) Stop system (only for MR-J4W_-_B_)
This means target axis to stop when the alarm occurs.
Each axis: Only alarming axis will stop.
All axes: All axes will stop.
(6) Alarm code (only MR-J4-_A_(-RJ)/MR-J4-DU_A_(-RJ))
To output alarm codes, set [Pr. PD34] to "_ _ _ 1" when using an MR-J4-_A_(-RJ)/MR-J4-DU_A_(-RJ).
Alarm codes are outputted by on/off of bit 0 to bit 2. Warnings ([AL. 90] to [AL. F3]) do not have alarm
codes. The alarm codes in the following table will be outputted when they occur. The alarm codes will
not be outputted in normal condition.
When using an MR-D01 extension IO unit, you can output alarm codes by setting [Pr. Po12] to "_ _ _ 1".
Alarm codes are outputted by on/off of bit 0 to bit 3.

1. TROUBLESHOOTING FOR SERVO AMPLIFIER (DRIVE UNIT)
1 - 3
1.2 Alarm list
No. Name
Detail
No. Detail name
Stop
method
(Note
2, 3)
Alarm deactivation Process-
ing
system
(Note 9)
Stop
system
(Note 9)
Alarm code (Note 8)
Alarm
reset
CPU
reset
Cycling
the
power
ACD3
(Bit 3)
ACD2
(Bit 2)
ACD1
(Bit 1)
ACD0
(Bit 0)
Alarm
10 Undervoltage
10.1 Voltage drop in the control
circuit power EDB Common All axes
0 0 1 0
10.2 Voltage drop in the main circuit
power SD Common All axes
11 Switch setting error
11.1 Axis number setting error/
Station number setting error DB Common All axes
11.2
Disabling control axis setting
error DB Common All axes
12.1 RAM error 1 DB Common All axes
12.2 RAM error 2 DB Common All axes
12 Memory error 1
(RAM)
12.3 RAM error 3 DB Common All axes 0 0 0 0
12.4 RAM error 4 DB Common All axes
12.5 RAM error 5 DB Common All axes
12.6 RAM error 6 DB
13 Clock error 13.1 Clock error 1 DB Common All axes 0 0 0 0
13.2 Clock error 2 DB Common All axes
14.1 Control process error 1 DB Common All axes
14.2 Control process error 2 DB Common All axes
14.3 Control process error 3 DB Common All axes
14.4 Control process error 4 DB Common All axes
Control process
error
14.5 Control process error 5 DB Common All axes 0 0 0 0
14 14.6 Control process error 6 DB Common All axes
14.7 Control process error 7 DB Common All axes
14.8 Control process error 8 DB Common All axes
14.9 Control process error 9 DB Common All axes
14.A Control process error 10 DB Common All axes
14.B Control process error 11 DB
15 Memory error 2
(EEP-ROM)
15.1 EEP-ROM error at power on DB Common All axes
0 0 0 0
15.2 EEP-ROM error during
operation DB Common All axes
15.4 Home position information read
error DB
16.1 Encoder initial communication -
Receive data error 1 DB Each
axis
Each
axis
16.2 Encoder initial communication -
Receive data error 2 DB Each
axis
Each
axis
16.3 Encoder initial communication -
Receive data error 3 DB Each
axis
Each
axis
16.5 Encoder initial communication -
Transmission data error 1 DB Each
axis
Each
axis
16.6 Encoder initial communication -
Transmission data error 2 DB Each
axis
Each
axis
16
Encoder initial
communication
error 1
16.7 Encoder initial communication -
Transmission data error 3 DB Each
axis
Each
axis 0 1 1 0
16.A Encoder initial communication -
Process error 1 DB Each
axis
Each
axis
16.B Encoder initial communication -
Process error 2 DB Each
axis
Each
axis
16.C Encoder initial communication -
Process error 3 DB Each
axis
Each
axis
16.D Encoder initial communication -
Process error 4 DB Each
axis
Each
axis
16.E Encoder initial communication -
Process error 5 DB Each
axis
Each
axis
16.F Encoder initial communication -
Process error 6 DB Each
axis
Each
axis