Mitsubishi Electric Melservo-J3 Series MR-J3-B User manual

J3
TransitionfromMELSERVO-J3/J3W
SeriestoJ4SeriesHandbook
Existing manufacturing assets are completely utilizable.
MELSERVO-J3/J3W to MELSERVO-J4

A - 1
SAFETY INSTRUCTIONS
Please read the instructions carefully before using the equipment.
To ensure correct usage of the equipment, make sure to read through this Replacement Manual, the
Instruction Manual, the Installation Guide, and the Appended Documents carefully before attempting to install,
operate, maintain, or inspect the equipment. Do not use the equipment until you have a full knowledge of the
equipment, safety information and instructions.
In this Replacement Manual, the safety instruction levels are classified under "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 prohibition (what must not be done). For example, "No Fire" is indicated by .
Indicates obligation (what must be done). For example, grounding is indicated by .
In this Replacement Manual, instructions of a lower level than the above, such as those that do not cause
physical damage or instructions for other functions, are classified under "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.
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. Doing so 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 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.
Always connect a magnetic contactor between the main circuit power supply and the converter unit and
L1/L2/L3 of the servo amplifier in order to configure a power supply shut-off 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 and fire when the converter unit or the servo amplifier (drive unit) malfunctions.
When using the regenerative resistor, switch power off with the alarm signal. Not doing so may cause
smoke and fire when a regenerative transistor malfunctions or the like may overheat the regenerative
resistor.
Provide adequate protection to prevent screws and other conductive matter, oil and other combustible
matter from entering the servo amplifier and servo motor.
Always connect one no-fuse breaker or one fuse for each servo amplifier between the power supply and
the main circuit power supply (L1/L2/L3) of the servo amplifier (including the converter unit) in order to
configure a power supply shut-off on the side of the servo amplifier's power supply. If a no-fuse breaker or
fuse is not connected, continuous flow of a large current may cause smoke and fire when the servo
amplifier malfunctions.

A - 3
3. Injury prevention
CAUTION
Only the voltage specified in the Instruction Manual should be applied to each terminal. Otherwise, a
burst, damage, etc. may occur.
The cables must be connected to the correct terminals. Otherwise, a burst, damage, etc. may occur.
Ensure that the polarity (+/-) is correct. Otherwise, a burst, damage, etc. may occur.
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 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, fire, etc.
(1) Transportation/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, cable and connector 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.
Secure the prescribed distance between the servo amplifier and the inner surface of the cabinet or other
devices.
Do not install or operate the servo amplifier and servo motor which have been damaged or have anyparts
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.
Do not drop or apply heavy impact on the servo amplifiers and the servo motors. Otherwise, injury,
malfunction, etc. may occur.
Do not strike the connector. Otherwise, a connection failure, malfunction, etc. may occur.
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) and free from corrosive gas, flammable gas, oil mist, dust, and dirt
Altitude The altitude varies depending on the model. (Check each servo amplifier instruction manual.)
Vibration resistance 5.9 m/s2or less at 10 to 55 Hz (directions of X, Y, Z axes)
Contact your local sales if the product has been stored for an extended period of time.
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.

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 a 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, such as heat treatment.
Additionally, disinfect and protect wood from insects before packing the products.
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 Servo Amplifier Instruction Manual
(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 (optional FR-BIF(-H)) on the output side
of the servo amplifier.
Because installation of these items may cause the servo motor to malfunction, connect the wires to the
correct phase terminals (U/V/W) of the servo amplifier and servo motor power supply.
Directly connect the servo amplifier power output (U/V/W) to the servo motor power input (U/V/W). Do not
let a magnetic contactor, etc. intervene. Otherwise, it may cause a malfunction.
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.
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.
To avoid a malfunction, do not connect the U, V, W, and CN2 phase terminals of the servo amplifier to the
servo motor of an incorrect axis.
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.
To prevent malfunction, avoid bundling power lines (input/output) and signal cables together or running
them in parallel to each other. Separate the power lines from the signal cables.
RA
RA
Servo amplifier Servo amplifier
DOCOM
Control output
signal
DOCOM
Control output
signal
24VDC24VDC
For sink output
interface
For source output
interface
U
M
V
W
U
V
W
U
M
V
W
U
V
W
Servo amplifier Servo motor Servo amplifier Servo motor

A - 5
(3) Trial run/adjustment
CAUTION
When executing a test run, follow the notice and procedures in this instruction manual. Otherwise, it may
cause a malfunction, damage to the machine, or personal injury.
Before operation, check the parameter settings. Improper settings may cause some machines to operate
unexpectedly.
Never perform extreme adjustment or changes to the parameters; otherwise, the operation may become
unstable.
Keep away from moving parts in a servo-on state.
(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 disassemble, repair, or modify the product.
Disassembled, repaired, and/or modified products are not covered under warranty.
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.
The effect of electromagnetic interference must be reduced by using a noise filter or by other means.
Electromagnetic interference may be given to the electronic equipment used near the servo amplifier.
Burning or disassembling a servo amplifier may generate toxic gases. Do not burn or break it.
Use the servo amplifier with the specified servo motor.
Correctly wire options and peripheral equipment, etc. in the correct combination. Otherwise, it may cause
an electric shock, fire, or injury.
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.
(5) Corrective actions
CAUTION
If it is assumed that a power failure, machine stoppage, or product malfunction may result in a hazardous
situation, use a servo motor with an electromagnetic brake or provide an external brake system for
holding purpose to prevent such hazard.

A - 6
CAUTION
Configure an electromagnetic brake circuit so that it is activated also by an external emergency stop switch.
When any alarm has occurred, eliminate its cause, ensure safety, and deactivate the alarm before
restarting operation.
If the molded-case circuit breaker or fuse is activated, be sure to remove the cause and secure safety
before switching the power on. If necessary, replace the servo amplifier and recheck the wiring.
Otherwise, it may cause smoke, fire, or an electric shock.
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) 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 a servo amplifier whose power has not been turned on for a long time, contact your local
sales office.
(7) General precautions
To illustrate details, the equipment in the diagrams of this Replacement 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 Instruction Manual.
B
U
Contacts must be opened with the ALM (malfunction)
off or the MBR (electromagnetic brake interlock) off.
Servo motor
Contacts must be opened with
the EMG stop switch.
Electromagnetic
brake
RA
24VDC

A - 7
Disposal of Waste
When disposing of this product, the following two laws are applicable, and it is necessary to consider each
law. In addition, because the following laws are effective only in Japan, local laws have priority outside Japan
(overseas). We ask that the local laws be displayed on the final products or that a notice be issued as
necessary.
1. Requirements of the Act on the Promotion of Effective Utilization of Resources
(Commonly known as: the Law for Promotion of Effective Utilization of Resources
Promotion Law)
(1) Please recycle this product whenever possible when it becomes unnecessary.
(2) It is recommended that this product be divided as necessary and sold to appropriate purchasers, as
recycled resources are usually divided into iron, electrical parts, and so on, which are then sold to
scrap processors.
2. Requirements of the Act on Waste Disposal & Cleaning (Commonly known as: The
Waste Disposal Treatment Cleaning Act)
(1) It is recommended to decrease waste through the sale of recyclables or through any other means as
shown in the preceding Paragraph 1.
(2) In case the unnecessary products cannot be sold and require disposal, such item falls under
Industrial waste in the above act.
(3) It is required that industrial waste be properly dealt with, including manifest management, by commissioning the
disposal to an industrial waste disposal contractor licensed under the act.
(4) Please dispose of batteries (primary batteries) used in servo amplifiers according to local regulations.
Measures against servo amplifier harmonics
This servo amplifier applies to "Harmonics control guidelines for customers receiving high voltage or special
high voltage power" (published by current Ministry of Economy, Trade and Industry). Consumers subject to
this guideline must check if a harmonic suppression measure is necessary, and measures must be enforced
when the limit level is exceeded.
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
STO function of the servo amplifier
See the applicable "Servo Amplifier Instruction Manual" when using the STO function of the servo amplifier.

A - 8
Dealing with overseas standards
See the following relevant manuals concerning dealing with overseas standards.
«About the manual»
This Replacement Manual and the following Instruction Manuals are necessary when using this servo for
the first time. Ensure to prepare them to use the servo safely.
Relevant manuals
Manual name Manual number
MELSERVO-J4 Series Instructions and Cautions for Safe Use of AC Servos
(Packed with the servo amplifier)
IB(NA)0300175
MELSERVO-J4 Servo Amplifier Instruction Manual (Troubleshooting Edition) SH(NA)030109
MELSERVO Servo Motor Instruction Manual (Vol. 3) (Note 1) SH(NA)030113
MELSERVO Linear Servo Motor Instruction Manual (Note 2) SH(NA)030110
MELSERVO Direct Drive Motor Instruction Manual (Note 3) SH(NA)030112
MELSERVO Linear Encoder Instruction Manual (Note 2, 4) SH(NA)030111
EMC Installation Guidelines IB(NA)67310
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.
«Cables used for wiring»
The wiring cables mentioned in this Replacement Manual are selected based on an ambient temperature
of 40°C.
«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]

1
CONTENTS
Part 1: Summary of MR-J3/MR-J3W Replacement 1- 1 to 1-14
1. SUMMARY OF MR-J3/MR-J3W REPLACEMENT ............................................................................. 1- 2
2. MAJOR REPLACEMENT TARGET MODEL....................................................................................... 1- 2
2.1 Servo Amplifier Replacement Target Model................................................................................. 1- 2
2.2 Servo Motor Replacement Target Model ..................................................................................... 1- 2
3. FLOW OF REPLACEMENT ................................................................................................................ 1- 3
3.1 Summary ...................................................................................................................................... 1- 3
3.1.1 Flow of Review on Replacement ......................................................................................... 1- 3
3.1.2 Configuration diagram ......................................................................................................... 1- 4
3.1.3 Changes from MR-J3 series to MR-J4 series ..................................................................... 1- 5
3.1.4 Changes from MR-J3W series to MR-J4 series .................................................................. 1- 7
3.2 Review on replacement ................................................................................................................ 1- 9
3.2.1 Checking the system prior to replacement .......................................................................... 1- 9
3.2.2 Determination of base replacement model.......................................................................... 1- 9
3.2.3 Attachment compatibility check .......................................................................................... 1-13
3.2.4 Detailed review on replacement model .............................................................................. 1-13
3.2.5 Peripheral equipment check ............................................................................................... 1-13
3.2.6 Startup procedure check..................................................................................................... 1-13
4. RELATED MATERIALS...................................................................................................................... 1-13
4.1 Catalog ........................................................................................................................................ 1-13
4.2 Instruction Manual ....................................................................................................................... 1-13
4.3 Replacement Tool for Replacing MR-J3 with MR-J4 .................................................................. 1-14
4.4 MITSUBISHI ELECTRIC FA Global Website .............................................................................. 1-14
Part 2: Review on Replacement of MR-J3-_A_ with MR-J4-_A_ 2- 1 to 2-64
1. SUMMARY........................................................................................................................................... 2- 2
2. CASE STUDY ON REPLACEMENT OF MR-J3-_A_.......................................................................... 2- 2
2.1 Review on Replacement Method.................................................................................................. 2- 2
2.2 Replacement Method ................................................................................................................... 2- 2
3. DIFFERENCES BETWEEN MR-J3-_A_ AND MR-J4-_A_ ................................................................. 2- 4
3.1 Function Comparison Table ......................................................................................................... 2- 4
3.2 Comparison of Standard Connection Diagrams........................................................................... 2- 6
3.3 List of Corresponding Connectors and Terminal Blocks .............................................................. 2- 8
3.4 Comparison of Peripheral Equipment ......................................................................................... 2-13
3.5 Comparison of Parameters.......................................................................................................... 2-14
3.5.1 Setting requisite parameters upon replacement................................................................. 2-14
3.5.2 Parameter comparison list .................................................................................................. 2-16
3.5.3 Comparison of parameter details ....................................................................................... 2-20
3.6 Important Points for Replacement ............................................................................................... 2-63
Part 3: Review on Replacement of MR-J3-_B_ with MR-J4-_B_ 3- 1 to 3-50
1. SUMMARY........................................................................................................................................... 3- 2
2. CASE STUDY ON REPLACEMENT OF MR-J3-_B_.......................................................................... 3- 2
2.1 Review on Replacement Method.................................................................................................. 3- 2
2.2 Replacement Method ................................................................................................................... 3- 3
3. DIFFERENCES BETWEEN MR-J3-_B_ AND MR-J4-_B_ ................................................................. 3- 6
3.1 Function Comparison Table ......................................................................................................... 3- 6