Mitsubishi Electric MELSERVO HC-KF Series User manual

L
Servo Motor Instruction Manual
SH (NA) 3181-L (0805) MEE Printed in Japan Specifications subject to change without notice.
This Instruction Manual uses recycled paper.
MODEL
MODEL
CODE 1CW940
MOTOR INSTRUCTION
General-Purpose AC Servo
MODEL
Servo Motor
INSTRUCTION MANUAL
L
HEAD OFFICE : TOKYO BLDG MARUNOUCHI TOKYO 100-8310

A - 1
Safety Instructions
(Always read these instructions before using the equipment.)
Do not attempt to install, operate, maintain or inspect the servo amplifier and servo motor until you have read
through this Instruction Manual, MELSERVO Servo Amplifier Installation Guide/Instruction Manual and
appended documents carefully and can use the equipment correctly. Do not use the servo amplifier and servo
motor 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 installation guide, always keep it accessible to the operator.

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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, always confirm from the front of the servo amplifier, whether the
charge lamp is off or not.
Connect the servo amplifier and servo motor to ground.
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, you
may get an electric shock.
Operate the switches with dry hand to prevent an electric shock.
The cables should not be damaged, stressed loaded, or pinched. Otherwise, you may get an electric
shock.
During power-on or operation, do not open the front cover of the servo amplifier. You may get 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 or 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.
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.
Always connect a magnetic contactor (MC) between the main circuit power supply and L1, L2, and L3 of
the servo amplifier, and configure the wiring to be able to shut down the power supply on the side of the
servo amplifier’s power supply. If a magnetic contactor (MC) is not connected, continuous flow of a large
current may cause a fire when the servo amplifier malfunctions.
When a regenerative resistor is used, use an alarm signal to switch main power off. Otherwise, a
regenerative transistor fault or the like may overheat the regenerative resistor, causing a fire.
3. To prevent injury, note the follow
CAUTION
Only the voltage specified in the Instruction Manual should be applied to each terminal, Otherwise, a
burst, damage, etc. may occur.
Connect the terminals correctly to prevent a burst, damage, etc.
Ensure that polarity ( , ) is correct. Otherwise, a burst, damage, etc. may occur.
Take safety measures, e.g. provide covers, to prevent accidental contact of hands and parts (cables, etc.)
with the servo amplifier heat sink, regenerative resistor, servo motor, etc. since they may be hot while
power is on or for some time after power-off. Their temperatures may be high and you may get burnt or a
parts may damaged.
During operation, never touch the rotating parts of the servo motor. Doing so can cause injury.

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4. Additional instructions
The following instructions should also be fully noted. Incorrect handling may cause a fault, injury, electric
shock, etc.
(1) Transportation and installation
CAUTION
Transport the products correctly according to their weights.
Use the eye-bolt of the servo motor to only transport the servo motor and do not use it to transport in the
condition to have installed a servo motor on the machine.
Stacking in excess of the specified number of products is not allowed.
Do not carry the servo motor by the cables, shaft or encoder.
Do not hold the front cover to transport the servo amplifier. The servo amplifier may drop.
Install the servo amplifier in a load-bearing place in accordance with the Instruction Manual.
Do not climb or stand on servo equipment. Do not put heavy objects on equipment.
The servo motor must be installed in the specified direction.
Leave specified clearances between the servo amplifier and control enclosure walls or other equipment.
Do not install or operate the servo motor which has been damaged or has any parts missing.
Do not block the intake/exhaust port of the servo motor which has a cooling fan.
Provide adequate protection to prevent screws and other conductive matter, oil and other combustible matter
from entering the servo amplifier and servo motor.
Do not drop or strike servo motor. Isolate from all impact loads.
When you keep or use it, please fulfill the following environmental conditions.
Environment Conditions
[] 0 to 40 (non-freezing)
In
Operation [] 32 to 104 (non-freezing)
[ ] 15 to 70 (non-freezing)
Ambient
temperature In Storage [] 5 to 158 (non-freezing)
In Operation 80%RH or less (non-condensing)
Ambient
humidity In Storage 90%RH or less (non-condensing)
Ambience Indoors (no direct sunlight)
Free from corrosive gas, flammable gas, oil mist, dust and dirt
Altitude Max. 1000m (3280 ft) above sea level
HC-KFS series
HC-MFS series HC-UFS13 to 73 X,Y:49
HC-SFS81
HC-SFS52 to 152
HC-SFS53 to 153
HC-SFS524 to 1524
HC-RFS series
HC-UFS72 152
X,Y:24.5
HC-SFS121 201
HC-SFS202 352
HC-SFS203 353
HC-SFS2024 3524
HC-UFS202 to 502
X:24.5
Y:49
HC-SFS301
HC-SFS502 702 HC-SFS5024 7024 X:24.5
Y:29.4
HC-AQ series
HC-KF series
HC-MF series
HA-FF series
HC-UF13 to 73 X,Y:19.6
HC-SF81
HC-SF52 to 152
HC-SF53 to 153
HC-RF series
HC-UF72 152
HC-LFS52 to 152
X:9.8
Y:24.5
HC-SF121 201
HC-SF202 352
HC-SF203 353
HC-UF202 to 502
HC-LFS202 302
X:19.6
Y:49
HA-LFS601 to 12K1
HA-LFS701M to 15K1M
HA-LFS502 to 22K2
HA-LFS6014 to 12K14
HA-LFS701M4 to 15K1M4
HA-LFS11K24 to 22K24
HA-LH11K2 to 22K2
HC-SF301
HC-SF502 702
X:11.7
Y:29.4
[m/s2]
HA-LFS15K1 to 37K1
HA-LFS22K1M to 37K1M
HA-LFS30K2 37K2
HA-LFS15K14 to 37K14
HA-LFS22K1M4 to 50K1M4
HA-LFS30K24 to 55K24
HA-LF series X,Y:9.8
HC-KFS series
HC-MFS series HC-UFS13 to 73 X,Y:161
HC-SFS81
HC-SFS52 to 152
HC-SFS53 to 153
HC-SFS524 to 1524
HC-RFS series
HC-UFS72 152
X,Y:80
(Note) Vibration
[ft/s2]
HC-SFS121 201
HC-SFS202 352
HC-SFS203 353
HC-SFS2024 3524
HC-UFS202 to 502
X:80
Y:161

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CAUTION
Environment Conditions
HC-SFS301
HC-SFS502 702 HC-SFS5024 7024 X:80
Y:96
HC-AQ series
HC-KF series
HC-MF series
HA-FF series
HC-UF13 to 73 X,Y:64
HC-SF81
HC-SF52 to 152
HC-SF53 to 153
HC-RF series
HC-UF72 152
HC-LFS52 to 152
X:32
Y:80
HC-SF121 201
HC-SF202 352
HC-SF203 353
HC-UF202 to 502
HC-LFS202 302
X:64
Y:161
HA-LFS601 to 12K1
HA-LFS701M to 15K1M
HA-LFS502 to 22K2
HA-LFS6014 to 12K14
HA-LFS701M4 to 15K1M4
HA-LFS11K24 to 22K24
HA-LH11K2 to 22K2
HC-SF301
HC-SF502 702
X:38.4
Y:96.5
(Note) Vibration [ft/s2]
HA-LFS15K1 to 37K1
HA-LFS22K1M to 37K1M
HA-LFS30K2 37K2
HA-LFS15K14 to 37K14
HA-LFS22K1M4 to 50K1M4
HA-LFS30K24 to 55K24
HA-LF series X,Y:32
Note. Except the servo motor with reduction gear.
Securely attach the servo motor to the machine. If attach insecurely, the servo motor may come off during
operation.
The servo motor with reduction gear must be installed in the specified direction to prevent oil leakage.
Take safety measures, e.g. provide covers, to prevent accidental access to the rotating parts of the servo
motor during operation.
Never hit the servo motor or shaft, especially when coupling the servo motor to the machine. The encoder
may become faulty.
Do not subject the servo motor shaft to more than the permissible load. Otherwise, the shaft may break.

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(2) Wiring
CAUTION
Wire the equipment correctly and securely. Otherwise, the servo motor may operate unexpectedly.
Do not install a power capacitor, surge absorber or radio noise filter (FR-BIF option) between the servo
motor and servo amplifier.
Connect the output terminals (U, V, W) correctly. Otherwise, the servo motor will operate improperly.
Connect the servo motor power terminal (U, V, W) to the servo motor power input terminal (U, V, W)
directly. Do not let a magnetic contactor, etc. intervene.
U
Servo motor
M
V
W
U
V
W
U
M
V
W
U
V
W
Servo amplifier Servo motorServo amplifier
Do not connect AC power directly to the servo motor. Otherwise, a fault may occur.
The surge absorbing diode installed on the DC output signal of the servo amplifier relay must be wired in
the specified direction. Otherwise, the forced stop and other protective circuits may not operate.
VIN
(24VDC)
Servo amplifier
RA
Control
output
signal
VIN
(24VDC)
Servo amplifier
RA
Control
output
signal
When the cable is not tightened enough to the terminal block (connector), the cable or terminal block
(connector) may generate heat because of the poor contact. Be sure to tighten the cable with specified
torque.
(3) Test run adjustment
CAUTION
Before operation, check the parameter settings. Improper settings may cause some machines to perform
unexpected operation.
The parameter settings must not be changed excessively. Operation will be insatiable.

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(4) Usage
CAUTION
Provide an external emergency stop circuit to ensure that operation can be stopped and power switched
off immediately.
Any person who is involved in disassembly and repair should be fully competent to do the work.
The STOP key of the parameter unit is only valid for test run. Provide an emergency stop key
independently of the STOP key. (MELSERVO-H series only)
Before resetting an alarm, make sure that the run signal into the servo amplifier is off to prevent an
accident. A sudden restart is made if an alarm is reset with the run signal on.
Do not modify the equipment.
Use a noise filter, etc. to minimize the influence of electromagnetic interference, which may be caused by
electronic equipment used near the servo amplifier.
Burning or breaking a servo amplifier may cause a toxic gas. Do not burn or break a servo amplifier.
Use the servo amplifier with the specified servo motor.
The electromagnetic brake on the servo motor is designed to hold the servo 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 servo motor shaft. To ensure
safety, install a stopper on the machine side.
(5) Corrective actions
CAUTION
When it is assumed that a hazardous condition may take place at the occur due to a power failure or a
product fault, use a servo motor with electromagnetic brake or an external brake mechanism for the
purpose of prevention.
Configure the electromagnetic brake circuit so that it is activated not only by the servo amplifier signals
but also by an external emergency (forced) stop signal.
Contacts must be open when
servo-on signal is off, when an
alarm (trouble) is present and when
an electromagnetic brake signal.
Electromagnetic brake
Circuit must be
opened during
emergency (force) stop.
SON RA EMG(EM1)
24VDC
Servo motor
When any alarm has occurred, eliminate its cause, ensure safety, and deactivate the alarm before
restarting operation.
When power is restored after an instantaneous power failure, keep away from the machine because the
machine may be restarted suddenly (design the machine so that it is secured against hazard if restarted).

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(6) Maintenance, inspection and parts replacement
CAUTION
With age, the electrolytic capacitor of the servo amplifier will deteriorate. To prevent a secondary accident
due to a fault, it is recommended to replace the electrolytic capacitor every 10 years when used in general
environment.
Please consult our sales representative.
(7) Storage
CAUTION
Note the following points when storing the servo motor for an extended period of time (guideline: three or
more months).
Always store the servo motor indoors in a clean and dry place.
If it is stored in a dusty or damp place, make adequate provision, e.g. cover the whole product.
If the insulation resistance of the winding decreases, reexamine the storage method.
Though the servo motor is rust-proofed before shipment using paint or rust prevention oil, rust may be
produced depending on the storage conditions or storage period.
If the servo motor is to be stored for longer than six months, apply rust prevention oil again especially to
the machined surfaces of the shaft, etc.
Before using the product after storage for an extended period of time, hand-turn the motor output shaft to
confirm that nothing is wrong with the servo motor. (When the servo motor is equipped with a brake,
make the above check after releasing the brake with the brake power supply.)
When the equipment has been stored for an extended period of time, consult Mitsubishi.
(8) General instruction
CAUTION
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.

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About processing of waste
When you discard servo amplifier, a battery (primary battery), and other option articles, please follow the law of
each country (area).
FOR MAXIMUM SAFETY
These products have been manufactured as a general-purpose part for general industries, and have not
been designed or manufactured to be incorporated in a device or system used in purposes related to
human life.
Before using the products for special purposes such as nuclear power, electric power, aerospace,
medicine, passenger movement vehicles or under water relays, contact Mitsubishi.
These products have been manufactured under strict quality control. However, when installing the product
where major accidents or losses could occur if the product fails, install appropriate backup or failsafe
functions in the system.
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 and/or converter unit may
fail 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
Precautions for Choosing the Products
Mitsubishi will not be held liable for damage caused by factors found not to be the cause of Mitsubishi;
machine damage or lost profits caused by faults in the Mitsubishi products; damage, secondary damage,
accident compensation caused by special factors unpredictable by Mitsubishi; damages to products other
than Mitsubishi products; and to other duties.
COMPLIANCE WITH EC DIRECTIVES
1. WHAT ARE EC DIRECTIVES?
The EC Directives were issued to standardize the regulations of the EU countries and ensure smooth
distribution of safety-guaranteed products. In the EU countries, the Machinery Directive (effective in
January, 1995), EMC Directive (effective in January, 1996) and Low Voltage Directive (effective in
January, 1997) of the EC Directives require that products to be sold should meet their fundamental safety
requirements and carry the CE marks (CE marking). CE marking applies to machines and equipment
into which servo amplifiers have been installed.
The servo amplifiers do not function independently but are designed for use with machines and
equipment.
Therefore, the CE marking does not apply to the servo amplifiers but applies to the machines and
equipment into which the servo amplifiers are installed.
This servo amplifier conforms to the standards related to the Low Voltage Directive to facilitate CE
marking on machines and equipment into which the servo amplifiers will be installed. To ensure ease of
compliance with the EMC Directive, Mitsubishi Electric prepared the "EMC INSTALLATION
GUIDELINES" (IB(NA)67310) which provides servo amplifier installation, control box making and other
procedures. Please contact your sales representative.

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2. PRECAUTIONS FOR COMPLIANCE
Use the servo motor compatible with the EN Standard.
Unless otherwise specified, the handling, performance, specifications and others of the EN Standard-
compatible models are the same as those of the standard models.
To comply with the EN Standard, also observe the following items strictly.
(1) Wiring
(a) Use a fixed terminal block to connect the power supply lead of the servo motor to the servo
amplifier. Do not connect cables directly.
Terminal block
(b) Use the servo motor side power connector which complies with the EN Standard.
The EN Standard-compliant power connector sets are available from us as options.
Power Connector Set Model Servo Motor Model
MR-PWCNF HC-FF C(B)-UE
MR-PWCNS1 HC-SF81(B)
HC-SF52(B) to 152(B)
HC-SF53(B) to 153(B)
HC-RF103(B) to 203(B)
HC-UF72(B) 152(B)
HC-SFS81(B)
HC-SFS52(B) to 152(B)
HC-SFS53(B) to 153(B)
HC-SFS524(B) to 1524(B)
HC-RFS103(B) to 203(B)
HC-UFS72(B) 152(B)
HC-LFS52(B) to 152(B)
MR-PWCNS2 HC-SF121(B) to 301(B)
HC-SF202(B) to 502(B)
HC-SF203(B) 353(B)
HC-RF353(B) 503(B)
HC-UF202(B) to 502(B)
HC-SFS121(B) to 301(B)
HC-SFS202(B) to 502(B)
HC-SFS203(B) 353(B)
HC-SFS2024(B) to 5024(B)
HC-RFS353(B) 503(B)
HC-UFS202(B) to 502(B)
HA-LFS502
HC-LFS202(B) 302(B)
MR-PWCNS3 HC-SF702(B) HC-SFS702(B)
HC-SFS7024(B)
HA-LFS702
(2) Installation
The flange of the machine mounted with the HC-MF(HC-MF-UE)/HC-KF(HC-KF-UE)/HC-AQ/HC-
MFS/HC-KFS must be connected to the earth ( ).
(3) Performing EMC tests
When EMC tests are run on a machine/device into which the servo motor has been installed, it must
conform to the electromagnetic compatibility (immunity/emission) standards after it has satisfied the
operating environment/electrical equipment specifications.
For the other EMC directive guidelines on the servo motor, refer to the EMC Installation Guidelines
(IB(NA)67310).