Mitsubishi Electric MELSERVO HG-MR User manual

SH(NA)030113ENG-P(1805)MEE Printed in Japan Specifications are subject to change without notice.
This Instruction Manual uses recycled paper.
MODEL
MODEL
CODE
General-Purpose AC Servo
SERVO MOTOR INSTRUCTION MANUAL (Vol. 3)
HEAD OFFICE: TOKYO BLDG MARUNOUCHI TOKYO 100-8310
MODEL
HG-MR
HG-KR
HG-SR
HG-JR
HG-RR
HG-UR
HG-AK
SERVO MOTOR INSTRUCTION MANUAL (Vol. 3)
1CW949
MOTOR INSTRUCTIONMANUAL(3SYU)
P
P

A - 1
Safety Instructions
Please read the instructions carefully before using the equipment.
Do not attempt to install, operate, maintain or inspect the equipment until you have read through this
Instruction Manual and appended documents carefully and can use the equipment correctly. 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 (20 minutes or more for
converter unit and drive unit) until the charge lamp turns off. Then, confirm that the voltage between P+
and N- (L+ and L- for converter unit and drive unit) 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 (converter unit).
Ground the 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 motor until they have been installed. Otherwise, it may cause an electric
shock.
The cables should not be damaged, stressed, loaded, or pinched. Otherwise, it may cause an electric
shock.
To avoid an electric shock, insulate the connections of the power supply terminals.
2. To prevent fire, note the following
CAUTION
Install the servo motor on incombustible material. Installing them directly or close to combustibles will
lead to smoke or a fire.
Provide an adequate protection to prevent screws and other conductive matter, oil and other combustible
matter from entering the servo motor.
3. To prevent injury, note the following
CAUTION
Only the power/signal specified in the Instruction Manual must be supplied/applied to each terminal.
Otherwise, an electric shock, fire, injury, 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 motor, etc. may be hot while 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.
The surface temperature of the servo motor may exceed 100 ˚C depending on its mounting and
operating conditions.
During operation, never touch the rotor of the servo motor. Otherwise, it may cause injury.

A - 3
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.
Use the eyebolt of the servo motor for the transportation purpose only. Do not use the eyebolts to
transport the servo motor when it is mounted on a machine.
Do not overtighten the eyebolts of the servo motor. Tightening too hard may damage the tap.
Stacking in excess of the specified number of product packages is not allowed.
Do not hold the cables, connectors, shaft, or encoder when carrying the servo motor. Otherwise, it may
drop.
Install 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. Otherwise, it may cause injury.
The equipment must be installed in the specified direction.
Do not install or operate the servo motor which have been damaged or have any parts missing.
Do not block intake and exhaust areas of the servo motor with a cooling fan. Otherwise, it may cause a
malfunction.
Do not drop or strike the servo motor. Otherwise, injury, malfunction, etc. may occur.
Securely fix the servo motor to the machine. If being attached insecurely, the servo motor may come off
during operation.
The geared servo motor must be installed in the specified direction to prevent oil leakage.
When handling the servo motor, be careful with the sharp edges of the servo motor, shaft keyway, or
others.
Do not strike the connector. Otherwise, a connection failure, malfunction, etc. may occur.
Be sure to measure the motor vibration level with the servo motor mounted to the machine when
checking the vibration level. A great vibration may cause the early damage of a bearing, encoder, brake,
and gear reducer. The great vibration may also cause the poor connector connection or bolt looseness.
For the gain adjustment at the equipment startup, check the torque waveform and the speed waveform
with a measurement device, and then check that no vibration occurs. If the vibration occurs due to high
gain, the vibration may cause the early damage of the servo motor.
Take safety measures, e.g. provide covers, to prevent accidental access to the rotor of the servo motor
during operation.
Never hit the servo motor or shaft, especially when coupling the servo motor to the machine. Otherwise,
the encoder may malfunction.
Do not subject the servo motor shaft to more than the permissible load. Otherwise, the shaft may break.
To prevent a fire or injury from occurring in case of an earthquake or other natural disasters, securely
install, mount, and wire the servo motor in accordance with the Instruction Manual.

A - 4
CAUTION
When you keep or use the equipment, please fulfill the following environment.
Item Environment
Ambient temperature Operation 0 °C to 40 °C (non-freezing)
Storage -15 °C to 70 °C (non-freezing)
Ambient humidity Operation 10 %RH to 80 %RH (non-condensing)
Storage 10 %RH to 90 %RH (non-condensing)
Ambience Indoors (no direct sunlight), free from corrosive
gas, flammable gas, oil mist, dust, and dirt
Altitude Max. 2000 m above sea level (Note 2)
Vibration resistance
(Note 1)
HG-MR Series/HG-KR Series/HG-AK Series X, Y: 49 m/s2
HG-SR51/HG-SR81/HG-SR52(4)/
HG-SR102(4)/HG-SR152(4)/HG-JR53(4)/
HG-JR73(4)/HG-JR103(4)/HG-JR153(4)/
HG-JR203(4)/HG-JR353(4)/HG-JR503(4)/
HG-JR701M(4)/HG-JR11K1M(4)/
HG-JR15K1M(4)/HG-JR22K1M(4)/
HG-JR30K1M(4)/HG-JR37K1M(4)/
HG-JR601(4)/HG-JR801(4)/HG-JR12K1(4)/
HG-JR15K1(4)/HG-JR20K1(4)/HG-JR25K1(4)/
HG-RR Series/HG-UR72/HG-UR152
X, Y: 24.5 m/s2
HG-SR121/HG-SR201/HG-SR202(4)/
HG-SR352(4)/HG-UR202/HG-UR352/HG-UR502 X: 24.5 m/s2Y: 49 m/s2
HG-SR301/HG-SR421/HG-SR502(4)/
HG-SR702(4)/HG-JR703(4)/HG-JR903(4) X: 24.5 m/s2Y: 29.4 m/s2
HG-JR45K1M4/HG-JR55K1M4/
HG-JR30K1(4)/HG-JR37K1(4)
HG-JR110K24W0C/HG-JR150K24W0C/
HG-JR180K24W0C/HG-JR200K24W0C/
HG-JR220K24W0C
X: 9.8 m/s2Y: 9.8 m/s2
Note 1. Except the geared servo motor.
2. Contact your local sales office for the altitude for options. The HG-AK series servo motor is available at an altitude of
1000 m or less above sea level.
(2) Wiring
CAUTION
Wire the equipment correctly and securely. Otherwise, the servo motor may operate unexpectedly.
Make sure to connect the cables and connectors by using the fixing screws and the locking mechanism.
Otherwise, the cables and connectors may be disconnected during operation.
Do not install a power capacitor, surge killer, or radio noise filter (FR-BIF(-H) option) on the servo
amplifier (converter unit) output side.
To avoid a malfunction, connect the wires to the correct phase terminals (U/V/W) of the servo amplifier
(converter unit) and servo motor.

A - 5
CAUTION
Connect the servo amplifier (converter 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
(converter unit) Servo motor
Servo amplifier
(converter unit)
Do not connect AC power supply directly to the servo motor. Otherwise, it may cause a malfunction.
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.
(3) Test run and adjustment
CAUTION
Before operation, check the parameter settings. Improper settings may cause some machines to operate
unexpectedly.
Never adjust or change the parameter values extremely as it will make operation unstable.
(4) Usage
CAUTION
Provide an external emergency stop circuit to ensure that operation can be stopped and power switched
off immediately.
For equipment in which the moving part of the machine may collide against the load side, install a limit
switch or stopper to the end of the moving part. The machine may be damaged due to a collision.
Do not scratch the coated surface with hard objects nor clean the coated surface with an organic solvent.
Doing so may scuff the surface.
Do not disassemble, repair, or modify the product. Otherwise, an electric shock, fire, injury, etc. may
occur. Disassembled, repaired, and/or modified products are not covered under warranty.
Use the servo amplifier (converter unit) with the specified servo motor.
Correctly wire options and peripheral equipment, etc. in the correct combination. Otherwise, an electric
shock, fire, injury, etc. may occur.
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 incorrect wiring, 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.
If the dynamic brake is activated at power-off, alarm occurrence, etc., do not rotate the servo motor by an
external force. Otherwise, it may cause a fire.

A - 6
(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.
To prevent an electric shock, injury, or fire from occurring after an earthquake or other natural disasters,
ensure safety by checking conditions, such as the installation, mounting, wiring, and equipment before
switching the power on.
(6) Storage
CAUTION
Note the followings 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, check how to store the equipment.
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 servo motor output
shaft to confirm that nothing is wrong with the servo motor. When the servo motor is equipped with an
electromagnetic brake, check it after releasing the electromagnetic brake with the brake power supply.
When the product has been stored 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 Specifications and
Instruction Manual.

A - 7
DISPOSAL OF WASTE
Please dispose a servo motor and other options according to your local laws and regulations.
«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

1
CONTENTS
1. INTRODUCTION 1- 1 to 1-10
1.1 Rating plate....................................................................................................................................... 1- 1
1.2 Parts identification............................................................................................................................. 1- 3
1.3 Electromagnetic brake ...................................................................................................................... 1- 4
1.4 Servo motor shaft shapes................................................................................................................. 1- 6
1.5 Servo motor with functional safety.................................................................................................... 1- 7
2. INSTALLATION 2- 1 to 2- 8
2.1 Mounting direction............................................................................................................................. 2- 2
2.2 Cooling fan........................................................................................................................................ 2- 3
2.3 Load remove precautions ................................................................................................................. 2- 3
2.4 Permissible load for the shaft ........................................................................................................... 2- 4
2.5 Protection from oil and water ............................................................................................................ 2- 4
2.6 Cable................................................................................................................................................. 2- 5
2.7 Servo motor with oil seal................................................................................................................... 2- 5
2.8 Inspection items................................................................................................................................ 2- 6
2.9 Parts having service life.................................................................................................................... 2- 6
2.10 Restrictions when using the equipment at altitudes exceeding 1000 m and up to 2000 m
above sea level............................................................................................................................... 2- 7
2.11 Machine accuracies ........................................................................................................................ 2- 7
2.12 Mounting servo motors ................................................................................................................... 2- 8
3. CONNECTORS USED FOR SERVO MOTOR WIRING 3- 1 to 3-12
3.1 Selection of connectors .................................................................................................................... 3- 1
3.2 Wiring connectors (connector configurations A/B/C)........................................................................ 3- 5
3.3 Wiring connectors (connector configurations D/E/F/G/H) ................................................................ 3- 6
3.4 Wiring connectors (connector configurations J/K/L/M/N/P/Q/R) ..................................................... 3-10
4. CONNECTION OF SERVO AMPLIFIER AND SERVO MOTOR 4- 1 to 4-28
4.1 Connection instructions .................................................................................................................... 4- 2
4.1.1 HG-JR110K24W0C/HG-JR150K24W0C/HG-JR180K24W0C/HG-JR200K24W0C/
HG-JR220K24W0C.................................................................................................................... 4- 2
4.2 Wiring................................................................................................................................................ 4- 3
4.2.1 HG-MR series/HG-KR series servo motor................................................................................. 4- 3
4.2.2 HG-SR series/HG-JR series/HG-RR series/HG-UR series servo motor................................... 4- 8
4.2.3 HG-AK series servo motor ........................................................................................................ 4-16
4.3 Selection example of wires .............................................................................................................. 4-18
4.4 Servo amplifier terminal section....................................................................................................... 4-23
5. WIRING OPTION 5- 1 to 5-38
5.1 Cable/connector sets ........................................................................................................................ 5- 1
5.1.1 Combinations of cable/connector sets....................................................................................... 5- 2
5.1.2 Cable and connector list............................................................................................................. 5- 5
5.2 Encoder cable/connector sets ......................................................................................................... 5-11