Mitsubishi Electric MELSERVO-J4 series User manual

SH (NA) 030109-D (1308) 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)
D
D

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 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.
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 a MR-J4 multi-axis servo amplifier, connecting an encoder for different axis to the CN2A,
CN2B, or CN2C connector may cause a fire.
3. To prevent injury, note the following
CAUTION
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 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, 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.
U
Servo motor
M
V
W
U
V
W
U
M
V
W
U
V
W
Servo amplifier Servo motorServo amplifier

A - 3
(2) Usage
CAUTION
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 the servo amplifier with the specified servo motor.
(3) Corrective actions
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 electromagnetic brake or external brake to prevent the condition.
Configure an electromagnetic brake circuit so that it is activated also by an external EMG stop switch.
Servo motor
Electromagnetic brake
B
RA
Contacts must be opened
with the EMG 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.
«About the manual»
This Instruction Manual covers the following models.
MR-J4-_A/MR-J4-_A4/MR-J4-_A-RJ/MR-J4-_A4-RJ
MR-J4-_B/MR-J4-_B4/MR-J4-_B-RJ/MR-J4-_B4-RJ
MR-J4W_-_B
MR-J4-_B-RJ010 + MR-J3-T10
The symbols in the target column mean as follows.
MR-J4-_A/MR-J4-_A4/MR-J4-_A-RJ/MR-J4-_A4-RJ: [A]
MR-J4-_B/MR-J4-_B4/MR-J4-_B-RJ/MR-J4-_B4-RJ: [B]
MR-J4W_-_B: [WB]
MR-J4-_B-RJ010 + MR-J3-T10: [RJ010]

A - 4
MEMO

1
CONTENTS
1. TROUBLESHOOTING 1- 1 to 1-72
1.1 Alarm and warning list ...................................................................................................................... 1- 1
1.2 Remedies for alarms......................................................................................................................... 1- 6
1.3 Remedies for warnings .................................................................................................................... 1-54
1.4 Trouble which does not trigger alarm/warning ................................................................................ 1-63
2. DRIVE RECORDER 2- 1 to 2-10
2.1 How to use drive recorder................................................................................................................. 2- 1
2.2 How to display drive recorder information ........................................................................................ 2- 9
APPENDIX App.- 1 to App.- 1
App. 1 Detection points of [AL. 25], [AL. 92], and [AL. 9F]...............................................................App.- 1

2
MEMO

1. TROUBLESHOOTING
1 - 1
1. TROUBLESHOOTING
1.1 Alarm and warning list
When an error occurs during operation, the corresponding alarm or warning is displayed. If any alarm or
warning has occurred, refer to section 1.2 and take the appropriate action. When an alarm occurs, ALM
(Malfunction) will turn off.
No. Name Detail No. Detail name
10 Undervoltage 10.1 Voltage drop in the control circuit power
10.2 Voltage drop in the main circuit power
11 Switch setting error 11.1 Axis number setting error
11.2 Disabling control axis setting error
12 Memory error 1 (RAM) 12.1 RAM error 1
Alarm
12.2 RAM error 2
12.3 RAM error 3
12.4 RAM error 4
12.5 RAM error 5
13 Clock error 13.1 Clock error 1
13.2 Clock error 2
14 Control process error 14.1 Control process error 1
14.2 Control process error 2
14.3 Control process error 3
14.4 Control process error 4
14.5 Control process error 5
14.6 Control process error 6
14.7 Control process error 7
14.8 Control process error 8
14.9 Control process error 9
14.A Control process error 10
15 Memory error 2 (EEP-ROM) 15.1 EEP-ROM error at power on
15.2 EEP-ROM error during operation
16 16.1 Encoder initial communication - Receive data error 1
Encoder initial communication
error 1 16.2 Encoder initial communication - Receive data error 2
16.3 Encoder initial communication - Receive data error 3
16.5 Encoder initial communication - Transmission data error 1
16.6 Encoder initial communication - Transmission data error 2
16.7 Encoder initial communication - Transmission data error 3
16.A Encoder initial communication - Process error 1
16.B Encoder initial communication - Process error 2
16.C Encoder initial communication - Process error 3
16.D Encoder initial communication - Process error 4
16.E Encoder initial communication - Process error 5
16.F Encoder initial communication - Process error 6
17 Board error 17.1 Board error 1
17.3 Board error 2
17.4 Board error 3
17.5 Board error 4
17.6 Board error 5
17.8 Board error 6 (Note)
19 Memory error 3 (Flash-ROM) 19.1 Flash-ROM error 1
19.2 Flash-ROM error 2
1A Servo motor combination error 1A.1 Servo motor combination error
1A.2 Servo motor control mode combination error
1E 1E.1 Encoder malfunction
Encoder initial communication
error 2 1E.2 Load-side encoder malfunction

1. TROUBLESHOOTING
1 - 2
No. Name Detail No. Detail name
1F 1F.1 Incompatible encoder
Encoder initial communication
error 3 1F.2 Incompatible load-side encoder
Alarm
20 20.1 Encoder normal communication - Receive data error 1
Encoder normal communication
error 1 20.2 Encoder normal communication - Receive data error 2
20.3 Encoder normal communication - Receive data error 3
20.5 Encoder normal communication - Transmission data error 1
20.6 Encoder normal communication - Transmission data error 2
20.7 Encoder normal communication - Transmission data error 3
20.9 Encoder normal communication - Receive data error 4
20.A Encoder normal communication - Receive data error 5
21 21.1 Encoder data error 1
Encoder normal communication
error 2 21.2 Encoder data update error
21.3 Encoder data waveform error
21.4 Encoder non-signal error
21.5 Encoder hardware error 1
21.6 Encoder hardware error 2
21.9 Encoder data error 2
24 Main circuit error 24.1 Ground fault detected by hardware detection circuit
24.2 Ground fault detected by software detection function
25.1 Servo motor encoder - Absolute position erased
25 Absolute position erased
25.2 Scale measurement encoder - Absolute position erased
27 27.1 Magnetic pole detection - Abnormal termination
Initial magnetic pole detection
error 27.2 Magnetic pole detection - Time out error
27.3 Magnetic pole detection - Limit switch error
27.4 Magnetic pole detection - Estimated error
27.5 Magnetic pole detection - Position deviation error
27.6 Magnetic pole detection - Speed deviation error
27.7 Magnetic pole detection - Current error
28 Linear encoder error 2 28.1 Linear encoder - Environment error
2A Linear encoder error 1 2A.1 Linear encoder error 1-1
2A.2 Linear encoder error 1-2
2A.3 Linear encoder error 1-3
2A.4 Linear encoder error 1-4
2A.5 Linear encoder error 1-5
2A.6 Linear encoder error 1-6
2A.7 Linear encoder error 1-7
2A.8 Linear encoder error 1-8
2B Encoder counter error 2B.1 Encoder counter error 1
2B.2 Encoder counter error 2
30 Regenerative error 30.1 Regeneration heat error
30.2 Regeneration signal error
30.3 Regeneration feedback signal error
31 Overspeed 31.1 Abnormal motor speed
32 Overcurrent 32.1 Overcurrent detected at hardware detection circuit (during operation)
32.2 Overcurrent detected at software detection function (during operation)
32.3 Overcurrent detected at hardware detection circuit (during a stop)
32.4 Overcurrent detected at software detection function (during a stop)
33 Overvoltage 33.1 Main circuit voltage error
34 SSCNET receive error 1 34.1 SSCNET receive data error
34.2 SSCNET connector connection error
34.3 SSCNET communication data error
34.4 Hardware error signal detection
35 Command frequency error 35.1 Command frequency error
36 SSCNET receive error 2 36.1 Continuous communication data error
37 Parameter error 37.1 Parameter setting range error
37.2 Parameter combination error

1. TROUBLESHOOTING
1 - 3
No. Name Detail No. Detail name
3A Inrush current suppression circuit
error
3A.1 Inrush current suppression circuit error
3D.1 Parameter combination error for driver communication on slave3D Parameter setting error for driver
communication 3D.2 Parameter combination error for driver communication on master
Alarm
3E Operation mode error 3E.1 Operation mode error
42 Servo control error 42.1 Servo control error by position deviation
42.2 Servo control error by speed deviation
42.3 Servo control error by torque/thrust deviation
Fully closed loop control error 42.8 Fully closed loop control error by position deviation
42.9 Fully closed loop control error by speed deviation
42.A Fully closed loop control error by position deviation (during command
stop)
45 Main circuit device overheat 45.1 Main circuit device overheat error
46 Servo motor overheat 46.1 Abnormal temperature of servo motor 1
46.2 Abnormal temperature of servo motor 2
46.3 Thermistor disconnected error
46.5 Abnormal temperature of servo motor 3
46.6 Abnormal temperature of servo motor 4
47 Cooling fan error 47.1 Cooling fan stop error
47.2 Cooling fan speed reduction error
50 Overload 1 50.1 Thermal overload error 1 during operation
50.2 Thermal overload error 2 during operation
50.3 Thermal overload error 4 during operation
50.4 Thermal overload error 1 during a stop
50.5 Thermal overload error 2 during a stop
50.6 Thermal overload error 4 during a stop
51 Overload 2 51.1 Thermal overload error 3 during operation
51.2 Thermal overload error 3 during a stop
52 Error excessive 52.1 Excess droop pulse 1
52.3 Excess droop pulse 2
52.4 Error excessive during 0 torque limit
52.5 Excess droop pulse 3
54 Oscillation detection 54.1 Oscillation detection error
56 Forced stop error 56.2 Over speed during forced stop
56.3 Estimated distance over during forced stop
63 STO timing error 63.1 STO1 off
63.2 STO2 off
70 70.1 Load-side encoder initial communication - Receive data error 1
Load-side encoder initial
communication error 1 70.2 Load-side encoder initial communication - Receive data error 2
70.3 Load-side encoder initial communication - Receive data error 3
70.5 Load-side encoder initial communication - Transmission data error 1
70.6 Load-side encoder initial communication - Transmission data error 2
70.7 Load-side encoder initial communication - Transmission data error 3
70.A Load-side encoder initial communication - Process error 1
70.B Load-side encoder initial communication - Process error 2
70.C Load-side encoder initial communication - Process error 3
70.D Load-side encoder initial communication - Process error 4
70.E Load-side encoder initial communication - Process error 5
70.F Load-side encoder initial communication - Process error 6