Mitsubishi MR-J4-10A User manual

SH (NA) 030107-G (1310) MEE Printed in Japan Specifications are subject to change without notice.
This Instruction Manual uses recycled paper.
MODEL
MODEL
CODE
General-Purpose AC Servo
MR-J4-_A_(-RJ) SERVO AMPLIFIER INSTRUCTION MANUAL
HEAD OFFICE : TOKYO BLDG MARUNOUCHI TOKYO 100-8310
MODEL
MR-J4-_A(-RJ)
MR-J4-_A4(-RJ)
SERVO AMPLIFIER
INSTRUCTION MANUAL
General-Purpose Interface AC Servo
1CW804
MR-J4-A INSTRUCTIONMANUAL
G
G

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 and inspections, 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. Otherwise, it
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 an electric shock, always connect the protective earth (PE) terminal (marked ) of the servo
amplifier to the protective earth (PE) of the cabinet.
When using a residual current device (RCD), select the type B.
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 it
directly or close to combustibles will lead to a fire.
Always connect a magnetic contactor between the power supply and the main circuit power supply (L1,
L2, and L3) of the servo amplifier, in order to configure a circuit that shuts down the power supply 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 a fire when the servo amplifier malfunctions.
When using the regenerative resistor, switch power off with the alarm signal. Not doing so may cause a
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 a molded-case circuit breaker to the power supply of the servo amplifier.

A - 3
3. To prevent injury, note the following
CAUTION
Only the voltage specified in the Instruction Manual should be applied to each terminal. Otherwise, a
burst, damage, 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 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 fault, injury, electric
shock, etc.
(1) Transportation and 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 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.
Leave specified clearances between the servo amplifier and the cabinet walls or other equipment.
Do not install or operate the servo amplifier and servo motor which have been damaged or have any
parts 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.
When you keep or use the equipment, please fulfill the following environment.
Items Environment
Operation 0 °C to 55 °C (non-freezing)
Ambient
temperature Storage -20 °C to 65 °C (non-freezing)
Operation
Ambient
humidity 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. 1000 m above sea level
Vibration resistance 5.9 m/s2at 10 Hz to 55 Hz (directions of X, Y, and Z axes)
When the equipment has been stored for an extended period of time, consult your local sales office.
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 the metal cabinet.
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 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 (heat method).Additionally,
disinfect and protect wood from insects before packing products.

A - 4
(2) Wiring
CAUTION
Wire the equipment correctly and securely. Otherwise, the servo motor may operate unexpectedly.
Do not install a power capacitor, surge killer, or radio noise filter (FR-BIF-(H) option) on the servo
amplifier output side.
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
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.
DOCOM
Control output
signal
Servo amplifier
RA
For sink output interface
24 V DC
DOCOM
Control output
signal
24 V DC
Servo amplifie
r
RA
For source output interface
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.
Connecting a servo motor for different axis to the U, V, W, or CN2 may cause a malfunction.
(3) Test run and adjustment
CAUTION
Before operation, check the parameter settings. Improper settings may cause some machines to perform
unexpected operation.
Never adjust or change the parameter values extremely as it will make operation unstable.
Do not close to moving parts at servo-on status.
(4) Usage
CAUTION
Provide an external emergency stop circuit to ensure that operation can be stopped and power switched
off immediately.
Do not disassemble, repair, or modify the equipment.
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.

A - 5
CAUTION
Use a noise filter, etc. to minimize the influence of electromagnetic interference. Electromagnetic
interference may be given to the electronic equipment used near the servo amplifier.
Burning or breaking a servo amplifier may cause a toxic gas. Do not burn or break it.
Use the servo amplifier with the specified servo motor.
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 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.
(5) 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 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.
(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 malfunction, it is recommend that the electrolytic capacitor be replaced every 10 years
when it is used in general environment. Please 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 - 6
DISPOSAL OF WASTE
Please dispose a servo amplifier, battery (primary battery) and other options according to your local laws and
regulations.
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
When using the STO function of the servo amplifier, refer to chapter 13.
For the MR-J3-D05 safety logic unit, refer to appendix 5.
Compliance with global standards
For the compliance with global standards, refer to appendix 4.
«About the manuals»
You must have this Instruction Manual and the following manuals to use this servo. Ensure to prepare
them to use the servo safely.
Relevant manuals
Manual name Manual No.
MELSERVO-J4 Series Instructions and Cautions for Safe Use of AC Servos
(Packed with the 200 V class servo amplifier)
IB(NA)0300175
MELSERVO-J4 Series Instructions and Cautions for Safe Use of AC Servos
(Packed with the 400 V class servo amplifier)
IB(NA)0300197
MR-J4 Servo Amplifier Instruction Manual (Troubleshooting) 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.

A - 7
«Wiring»
Wires mentioned in this Instruction Manual are selected based on the 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 [in]
Torque 1 [N•m] 141.6 [oz•in]
Moment of inertia 1 [(× 10-4 kg•m2)] 5.4675 [oz•in2]
Load (thrust load/axial load) 1 [N] 0.2248 [lbf]
Temperature N [°C] × 9/5 + 32 N [°F]

A - 8
MEMO

1
CONTENTS
1. FUNCTIONS AND CONFIGURATION 1- 1 to 1-44
1.1 Summary........................................................................................................................................... 1- 1
1.2 Function block diagram..................................................................................................................... 1- 2
1.3 Servo amplifier standard specifications ............................................................................................ 1- 9
1.4 Combinations of servo amplifiers and servo motors ....................................................................... 1-13
1.5 Function list...................................................................................................................................... 1-14
1.6 Model designation............................................................................................................................ 1-16
1.7 Structure .......................................................................................................................................... 1-17
1.7.1 Parts identification..................................................................................................................... 1-17
1.7.2 Removal and reinstallation of the front cover............................................................................ 1-29
1.8 Configuration including peripheral equipment ................................................................................. 1-31
2. INSTALLATION 2- 1 to 2- 6
2.1 Installation direction and clearances ................................................................................................ 2- 2
2.2 Keep out foreign materials................................................................................................................ 2- 3
2.3 Encoder cable stress ........................................................................................................................ 2- 4
2.4 Inspection items................................................................................................................................ 2- 4
2.5 Parts having service lives ................................................................................................................. 2- 5
3. SIGNALS AND WIRING 3- 1 to 3-70
3.1 Input power supply circuit ................................................................................................................. 3- 2
3.1.1 200 V class................................................................................................................................. 3- 3
3.1.2 400 V class................................................................................................................................. 3- 8
3.2 I/O signal connection example......................................................................................................... 3-11
3.2.1 Position control mode................................................................................................................ 3-11
3.2.2 Speed control mode .................................................................................................................. 3-14
3.2.3 Torque control mode ................................................................................................................. 3-17
3.3 Explanation of power supply system ............................................................................................... 3-20
3.3.1 Signal explanations ................................................................................................................... 3-20
3.3.2 Power-on sequence .................................................................................................................. 3-21
3.3.3 Wiring CNP1, CNP2, and CNP3 ............................................................................................... 3-22
3.4 Connectors and pin assignment ...................................................................................................... 3-25
3.5 Signal (device) explanations............................................................................................................ 3-28
3.6 Detailed explanation of signals........................................................................................................ 3-37
3.6.1 Position control mode................................................................................................................ 3-37
3.6.2 Speed control mode .................................................................................................................. 3-42
3.6.3 Torque control mode ................................................................................................................. 3-44
3.6.4 Position/speed control switching mode..................................................................................... 3-47
3.6.5 Speed/torque control switching mode....................................................................................... 3-49
3.6.6 Torque/position control switching mode.................................................................................... 3-51
3.7 Forced stop deceleration function ................................................................................................... 3-52
3.7.1 Forced stop deceleration function (SS1)................................................................................... 3-52
3.7.2 Base circuit shut-off delay time function ................................................................................... 3-54
3.7.3 Vertical axis freefall prevention function ................................................................................... 3-55
3.7.4 Residual risks of the forced stop function (EM2) ...................................................................... 3-55

2
3.8 Alarm occurrence timing chart......................................................................................................... 3-56
3.8.1 When you use the forced stop deceleration function................................................................ 3-56
3.8.2 When you do not use the forced stop deceleration function..................................................... 3-57
3.9 Interfaces ......................................................................................................................................... 3-58
3.9.1 Internal connection diagram...................................................................................................... 3-58
3.9.2 Detailed explanation of interfaces............................................................................................. 3-59
3.9.3 Source I/O interfaces ................................................................................................................ 3-63
3.10 Servo motor with an electromagnetic brake .................................................................................. 3-64
3.10.1 Safety precautions .................................................................................................................. 3-64
3.10.2 Timing chart ............................................................................................................................ 3-65
3.11 Grounding ...................................................................................................................................... 3-69
4. STARTUP 4- 1 to 4-42
4.1 Switching power on for the first time................................................................................................. 4- 2
4.1.1 Startup procedure ...................................................................................................................... 4- 2
4.1.2 Wiring check............................................................................................................................... 4- 3
4.1.3 Surrounding environment........................................................................................................... 4- 6
4.2 Startup in position control mode ....................................................................................................... 4- 6
4.2.1 Power on and off procedures..................................................................................................... 4- 6
4.2.2 Stop ............................................................................................................................................ 4- 7
4.2.3 Test operation ............................................................................................................................ 4- 8
4.2.4 Parameter setting....................................................................................................................... 4- 9
4.2.5 Actual operation ......................................................................................................................... 4- 9
4.2.6 Trouble at start-up...................................................................................................................... 4- 9
4.3 Startup in speed control mode......................................................................................................... 4-12
4.3.1 Power on and off procedures.................................................................................................... 4-12
4.3.2 Stop ........................................................................................................................................... 4-12
4.3.3 Test operation ........................................................................................................................... 4-13
4.3.4 Parameter setting...................................................................................................................... 4-14
4.3.5 Actual operation ........................................................................................................................ 4-14
4.3.6 Trouble at start-up..................................................................................................................... 4-14
4.4 Startup in torque control mode ........................................................................................................ 4-16
4.4.1 Power on and off procedures.................................................................................................... 4-16
4.4.2 Stop ........................................................................................................................................... 4-16
4.4.3 Test operation ........................................................................................................................... 4-17
4.4.4 Parameter setting...................................................................................................................... 4-18
4.4.5 Actual operation ........................................................................................................................ 4-18
4.4.6 Trouble at start-up..................................................................................................................... 4-19
4.5 Display and operation sections........................................................................................................ 4-20
4.5.1 Summary................................................................................................................................... 4-20
4.5.2 Display flowchart ....................................................................................................................... 4-21
4.5.3 Status display mode.................................................................................................................. 4-22
4.5.4 Diagnostic mode ....................................................................................................................... 4-29
4.5.5 Alarm mode............................................................................................................................... 4-31
4.5.6 Parameter mode ....................................................................................................................... 4-32
4.5.7 External I/O signal display......................................................................................................... 4-34
4.5.8 Output signal (DO) forced output .............................................................................................. 4-37
4.5.9 Test operation mode ................................................................................................................. 4-38

3
5. PARAMETERS 5- 1 to 5-58
5.1 Parameter list.................................................................................................................................... 5- 1
5.1.1 Basic setting parameters ([Pr. PA_ _ ])...................................................................................... 5- 2
5.1.2 Gain/filter setting parameters ([Pr. PB_ _ ])............................................................................... 5- 3
5.1.3 Extension setting parameters ([Pr. PC_ _ ]) .............................................................................. 5- 5
5.1.4 I/O setting parameters ([Pr. PD_ _ ]) ......................................................................................... 5- 7
5.1.5 Extension setting 2 parameters ([Pr. PE_ _ ])............................................................................ 5- 8
5.1.6 Extension setting 3 parameters ([Pr. PF_ _ ])........................................................................... 5-10
5.1.7 Linear servo motor/DD motor setting parameters ([Pr. PL_ _ ]) ............................................... 5-11
5.2 Detailed list of parameters ............................................................................................................... 5-12
5.2.1 Basic setting parameters ([Pr. PA_ _ ])..................................................................................... 5-12
5.2.2 Gain/filter setting parameters ([Pr. PB_ _ ]).............................................................................. 5-23
5.2.3 Extension setting parameters ([Pr. PC_ _ ]) ............................................................................. 5-34
5.2.4 I/O setting parameters ([Pr. PD_ _ ]) ........................................................................................ 5-46
5.2.5 Extension setting 2 parameters ([Pr. PE_ _ ])........................................................................... 5-52
5.2.6 Extension setting 3 parameters ([Pr. PF_ _ ])........................................................................... 5-54
5.2.7 Linear servo motor/DD motor setting parameters ([Pr. PL_ _ ]) ............................................... 5-56
6. NORMAL GAIN ADJUSTMENT 6- 1 to 6-24
6.1 Different adjustment methods........................................................................................................... 6- 1
6.1.1 Adjustment on a single servo amplifier ...................................................................................... 6- 1
6.1.2 Adjustment using MR Configurator2.......................................................................................... 6- 2
6.2 One-touch tuning .............................................................................................................................. 6- 3
6.2.1 One-touch tuning flowchart ........................................................................................................ 6- 3
6.2.2 Display transition and operation procedure of one-touch tuning ............................................... 6- 5
6.2.3 Caution for one-touch tuning..................................................................................................... 6-13
6.3 Auto tuning....................................................................................................................................... 6-14
6.3.1 Auto tuning mode ...................................................................................................................... 6-14
6.3.2 Auto tuning mode basis............................................................................................................. 6-15
6.3.3 Adjustment procedure by auto tuning ....................................................................................... 6-16
6.3.4 Response level setting in auto tuning mode ............................................................................. 6-17
6.4 Manual mode ................................................................................................................................... 6-18
6.5 2 gain adjustment mode .................................................................................................................. 6-21
7. SPECIAL ADJUSTMENT FUNCTIONS 7- 1 to 7-30
7.1 Filter setting ...................................................................................................................................... 7- 1
7.1.1 Machine resonance suppression filter ....................................................................................... 7- 2
7.1.2 Adaptive filter II........................................................................................................................... 7- 5
7.1.3 Shaft resonance suppression filter............................................................................................. 7- 7
7.1.4 Low-pass filter ............................................................................................................................ 7- 8
7.1.5 Advanced vibration suppression control II .................................................................................7-8
7.1.6 Command notch filter ................................................................................................................ 7-13
7.2 Gain switching function.................................................................................................................... 7-15
7.2.1 Applications............................................................................................................................... 7-15
7.2.2 Function block diagram ............................................................................................................. 7-16
7.2.3 Parameter.................................................................................................................................. 7-17
7.2.4 Gain switching procedure ......................................................................................................... 7-20
7.3 Tough drive function ........................................................................................................................ 7-23

4
7.3.1 Vibration tough drive function.................................................................................................... 7-23
7.3.2 Instantaneous power failure tough drive function ..................................................................... 7-25
7.4 Compliance with SEMI-F47 standard .............................................................................................. 7-28
8. TROUBLESHOOTING 8- 1 to 8- 8
9. OUTLINE DRAWINGS 9- 1 to 9-20
9.1 Servo amplifier.................................................................................................................................. 9- 1
9.2 Connector ........................................................................................................................................ 9-18
10. CHARACTERISTICS 10- 1 to 10-12
10.1 Overload protection characteristics .............................................................................................. 10- 1
10.2 Power supply capacity and generated loss .................................................................................. 10- 4
10.3 Dynamic brake characteristics...................................................................................................... 10- 7
10.3.1 Dynamic brake operation ....................................................................................................... 10- 7
10.3.2 Permissible load to motor inertia when the dynamic brake is used...................................... 10-10
10.4 Cable bending life ........................................................................................................................ 10-11
10.5 Inrush currents at power-on of main circuit and control circuit.................................................... 10-12
11. OPTIONS AND AUXILIARY EQUIPMENT 11- 1 to 11-94
11.1 Cable/connector sets.................................................................................................................... 11- 1
11.1.1 Combinations of cable/connector sets................................................................................... 11- 2
11.1.2 MR-D05UDL3M-B STO cable................................................................................................ 11- 5
11.2 Regenerative options.................................................................................................................... 11- 6
11.2.1 Combination and regenerative power.................................................................................... 11- 6
11.2.2 Selection of regenerative option ............................................................................................ 11- 8
11.2.3 Parameter setting.................................................................................................................. 11-11
11.2.4 Connection of regenerative option........................................................................................ 11-11
11.2.5 Dimensions ........................................................................................................................... 11-16
11.3 FR-BU2-(H) Brake unit ................................................................................................................ 11-20
11.3.1 Selection................................................................................................................................ 11-21
11.3.2 Brake unit parameter setting................................................................................................. 11-22
11.3.3 Connection example ............................................................................................................. 11-23
11.3.4 Dimensions ........................................................................................................................... 11-33
11.4 FR-RC-(H) power regeneration converter ................................................................................... 11-35
11.5 FR-CV-(H) power regeneration common converter .................................................................... 11-41
11.5.1 Model designation................................................................................................................. 11-41
11.5.2 Selection example................................................................................................................. 11-42
11.6 Junction terminal block MR-TB50................................................................................................ 11-50
11.7 MR Configurator2 ........................................................................................................................ 11-52
11.7.1 Specifications ........................................................................................................................ 11-52
11.7.2 System configuration............................................................................................................. 11-53
11.7.3 Precautions for using USB communication function............................................................. 11-54
11.8 Battery.......................................................................................................................................... 11-55
11.8.1 MR-BAT6V1SET battery....................................................................................................... 11-55
11.8.2 MR-BAT6V1BJ battery for junction battery cable ................................................................. 11-55

5
11.9 Selection example of wires.......................................................................................................... 11-56
11.10 Molded-case circuit breakers, fuses, magnetic contactors (recommended).............................. 11-60
11.11 Power factor improving DC reactors........................................................................................... 11-62
11.12 Power factor improving AC reactors........................................................................................... 11-66
11.13 Relays (recommended) .............................................................................................................. 11-69
11.14 Noise reduction techniques ........................................................................................................ 11-70
11.15 Earth-leakage current breaker.................................................................................................... 11-77
11.16 EMC filter (recommended).......................................................................................................... 11-80
11.17 External dynamic brake .............................................................................................................. 11-84
11.18 Heat sink outside mounting attachment (MR-J4ACN15K/MR-J3ACN)...................................... 11-90
12. ABSOLUTE POSITION DETECTION SYSTEM 12- 1 to 12-36
12.1 Summary....................................................................................................................................... 12- 1
12.1.1 Features ................................................................................................................................. 12- 1
12.1.2 Restrictions ............................................................................................................................ 12- 2
12.1.3 Structure................................................................................................................................. 12- 2
12.1.4 Parameter setting................................................................................................................... 12- 3
12.1.5 Confirmation of absolute position detection data................................................................... 12- 3
12.2 Battery........................................................................................................................................... 12- 4
12.2.1 Using MR-BAT6V1SET battery.............................................................................................. 12- 4
12.2.2 Using MR-BAT6V1BJ battery for junction battery cable........................................................ 12- 9
12.3 Standard connection example ..................................................................................................... 12-13
12.4 Signal explanation ....................................................................................................................... 12-14
12.5 Startup procedure ........................................................................................................................ 12-15
12.6 Absolute position data transfer protocol ...................................................................................... 12-16
12.6.1 Data transfer procedure ........................................................................................................ 12-16
12.6.2 Transfer method.................................................................................................................... 12-17
12.6.3 Home position setting............................................................................................................ 12-26
12.6.4 Use of servo motor with an electromagnetic brake............................................................... 12-28
12.6.5 How to process the absolute position data at detection of stroke end ................................. 12-29
12.7 Absolute position data transfer errors.......................................................................................... 12-29
12.8 Communication-based absolute position transfer system........................................................... 12-32
12.8.1 Serial communication command........................................................................................... 12-32
12.8.2 Absolute position data transfer protocol ............................................................................... 12-32
13. USING STO FUNCTION 13- 1 to 13-12
13.1 Introduction ................................................................................................................................... 13- 1
13.1.1 Summary................................................................................................................................ 13- 1
13.1.2 Terms related to safety .......................................................................................................... 13- 1
13.1.3 Cautions ................................................................................................................................. 13- 1
13.1.4 Residual risks of the STO function......................................................................................... 13- 2
13.1.5 Specifications ......................................................................................................................... 13- 3
13.1.6 Maintenance........................................................................................................................... 13- 4
13.2 STO I/O signal connector (CN8) and signal layouts..................................................................... 13- 4
13.2.1 Signal layouts......................................................................................................................... 13- 4
13.2.2 Signal (device) explanations .................................................................................................. 13- 5
13.2.3 How to pull out the STO cable ............................................................................................... 13- 5
13.3 Connection example ..................................................................................................................... 13- 6
13.3.1 Connection example for CN8 connector................................................................................ 13- 6

6
13.3.2 External I/O signal connection example using an MR-J3-D05 safety logic unit .................... 13- 7
13.3.3 External I/O signal connection example using an external safety relay unit ......................... 13- 9
13.4 Detailed description of interfaces ................................................................................................ 13-10
13.4.1 Sink I/O interface................................................................................................................... 13-10
13.4.2 Source I/O interface .............................................................................................................. 13-11
14. COMMUNICATION FUNCTION 14- 1 to 14-38
14.1 Structure ....................................................................................................................................... 14- 1
14.1.1 Configuration diagram............................................................................................................ 14- 1
14.1.2 Precautions for using RS-422/RS-232C/USB communication function ................................ 14- 3
14.2 Communication specifications ...................................................................................................... 14- 4
14.2.1 Outline of communication ...................................................................................................... 14- 4
14.2.2 Parameter setting................................................................................................................... 14- 4
14.3 Protocol......................................................................................................................................... 14- 5
14.3.1 Transmission data configuration............................................................................................ 14- 5
14.3.2 Character codes..................................................................................................................... 14- 6
14.3.3 Error codes............................................................................................................................. 14- 7
14.3.4 Checksum .............................................................................................................................. 14- 7
14.3.5 Time-out processing............................................................................................................... 14- 7
14.3.6 Retry processing .................................................................................................................... 14- 8
14.3.7 Initialization ............................................................................................................................ 14- 8
14.3.8 Communication procedure example ...................................................................................... 14- 9
14.4 Command and data No. list ......................................................................................................... 14-10
14.4.1 Reading command................................................................................................................ 14-10
14.4.2 Writing commands ................................................................................................................ 14-16
14.5 Detailed explanations of commands............................................................................................ 14-18
14.5.1 Data processing .................................................................................................................... 14-18
14.5.2 Status display mode.............................................................................................................. 14-20
14.5.3 Parameter ............................................................................................................................. 14-21
14.5.4 External I/O signal status (DIO diagnosis)............................................................................ 14-25
14.5.5 Input device on/off................................................................................................................. 14-27
14.5.6 Disabling/enabling I/O devices (DIO).................................................................................... 14-28
14.5.7 Input devices on/off (test operation)...................................................................................... 14-29
14.5.8 Test operation mode ............................................................................................................. 14-30
14.5.9 Output signal pin on/off (output signal (DO) forced output) .................................................. 14-34
14.5.10 Alarm history ....................................................................................................................... 14-35
14.5.11 Current alarm ...................................................................................................................... 14-36
14.5.12 Other commands................................................................................................................. 14-37
15. USING A LINEAR SERVO MOTOR 15- 1 to 15-28
15.1 Functions and configuration ......................................................................................................... 15- 1
15.1.1 Summary................................................................................................................................ 15- 1
15.1.2 Configuration including peripheral equipment ....................................................................... 15- 2
15.2 Signals and wiring......................................................................................................................... 15- 5
15.3 Operation and functions................................................................................................................ 15- 6
15.3.1 Startup.................................................................................................................................... 15- 6
15.3.2 Magnetic pole detection ......................................................................................................... 15- 9
15.3.3 Home position return............................................................................................................. 15-16
15.3.4 Test operation mode in MR Configurator2............................................................................ 15-20

7
15.3.5 Function................................................................................................................................. 15-21
15.3.6 Absolute position detection system....................................................................................... 15-24
15.4 Characteristics ............................................................................................................................. 15-25
15.4.1 Overload protection characteristics ...................................................................................... 15-25
15.4.2 Power supply capacity and generated loss .......................................................................... 15-26
15.4.3 Dynamic brake characteristics .............................................................................................. 15-27
15.4.4 Permissible load to motor mass ratio when the dynamic brake is used............................... 15-28
16. USING A DIRECT DRIVE MOTOR 16- 1 to 16-20
16.1 Functions and configuration ......................................................................................................... 16- 1
16.1.1 Summary................................................................................................................................ 16- 1
16.1.2 Configuration including peripheral equipment ....................................................................... 16- 2
16.2 Signals and wiring......................................................................................................................... 16- 3
16.3 Operation and functions................................................................................................................ 16- 4
16.3.1 Startup procedure .................................................................................................................. 16- 5
16.3.2 Magnetic pole detection ......................................................................................................... 16- 6
16.3.3 Function................................................................................................................................. 16-12
16.4 Absolute position detection system ............................................................................................. 16-14
16.5 Characteristics ............................................................................................................................. 16-15
16.5.1 Overload protection characteristics ...................................................................................... 16-15
16.5.2 Power supply capacity and generated loss .......................................................................... 16-17
16.5.3 Dynamic brake characteristics .............................................................................................. 16-18
17. FULLY CLOSED LOOP SYSTEM 17- 1 to 17-24
17.1 Functions and configuration ......................................................................................................... 17- 1
17.1.1 Function block diagram.......................................................................................................... 17- 1
17.1.2 Selecting procedure of control mode ..................................................................................... 17- 3
17.1.3 System configuration.............................................................................................................. 17- 4
17.2 Load-side encoder........................................................................................................................ 17- 6
17.2.1 LINEAR ENCODER ............................................................................................................... 17- 6
17.2.2 Rotary encoder....................................................................................................................... 17- 6
17.2.3 Configuration diagram of encoder cable................................................................................ 17- 7
17.2.4 MR-J4FCCBL03M branch cable............................................................................................ 17- 9
17.3 Operation and functions............................................................................................................... 17-10
17.3.1 Startup................................................................................................................................... 17-10
17.3.2 Home position return............................................................................................................. 17-17
17.3.3 Fully closed loop control error detection functions................................................................ 17-19
17.3.4 Auto tuning function .............................................................................................................. 17-20
17.3.5 Machine analyzer function .................................................................................................... 17-20
17.3.6 Test operation mode ............................................................................................................. 17-20
17.3.7 Absolute position detection system under fully closed loop system..................................... 17-21
17.3.8 About MR Configurator2 ....................................................................................................... 17-22
APPENDIX App.- 1 to App.-45
App. 1 Peripheral equipment manufacturer (for reference)..............................................................App.- 1
App. 2 Handling of AC servo amplifier batteries for the United Nations Recommendations on the
Transport of Dangerous Goods ............................................................................................App.- 1
App. 3 Symbol for the new EU Battery Directive..............................................................................App.- 3

8
App. 4 Compliance with global standards ........................................................................................App.- 3
App. 5 MR-J3-D05 Safety logic unit ................................................................................................App.-19
App. 6 EC declaration of conformity................................................................................................App.-37
App. 7 Analog monitor .....................................................................................................................App.-39
App. 8 Two-wire type encoder cable for HG-MR/HG-KR................................................................App.-43
App. 9 How to replace servo amplifier without magnetic pole detection.........................................App.-44

1. FUNCTIONS AND CONFIGURATION
1 - 1
1. FUNCTIONS AND CONFIGURATION
1.1 Summary
The Mitsubishi MELSERVO-J4 series general-purpose AC servo has further higher performance and higher
functions compared to the previous MELSERVO-J3 series.
The MELSERVO-J4 series compatible rotary servo motor is equipped with 22-bit (4194304 pulses/rev) high-
resolution absolute encoder. In addition, speed frequency response is increased to 2.5 kHz. Thus, faster and
more accurate control is enabled as compared to the MELSERVO-J3 series.
The servo amplifier has position, speed, and torque control modes. In the position control mode, the
maximum pulse train of 4 Mpulses/s is supported. Further, it can perform operation with the control modes
switched, e.g. position/speed control, speed/torque control and torque/position control. Hence, it is
applicable to a wide range of fields, not only precision positioning and smooth speed control of machine tools
and general industrial machines but also line control and tension control.
With one-touch tuning and real-time auto tuning, you can automatically adjust the servo gains according to
the machine.
The tough drive function and the drive recorder function, which are well-received in the MELSERVO-JN
series, have been improved. The MR-J4 servo amplifier supports the improved functions. Additionally, the
preventive maintenance support function detects an error in the machine parts. This function provides strong
support for the machine maintenance and inspection.
The MR-J4-_A_ servo amplifier supports the Safe Torque Off (STO) function. By combining with optional
MR-J3-D05, the servo amplifier supports Safe stop 1 (SS1) function.
The servo amplifier has a USB communication interface. Therefore, you can connect the servo amplifier to
the personal computer with MR Configurator2 installed to perform the parameter setting, test operation, gain
adjustment, and others.
In the MELSERVO-J4 series, servo amplifiers with the CN2L connector are also available as MR-J4-_A_-RJ.
By using the CN2L connector, an A/B/Z-phase differential output type external encoder can be connected to
the servo amplifier. In a fully closed loop system, a four-wire type external encoder is connectable as well.
The following table indicates the communication method of the external encoder compatible with the MR-J4-
_A_ and MR-J4-_A_-RJ servo amplifiers.
Table 1.1 Connectors to connect from external encoders
Connector
Operation
mode
External encoder
communication
method MR-J4-_A_ MR-J4-_A_-RJ
Two-wire type
Four-wire type
CN2
(Note 1, 4)
CN2
(Note 1)
Linear servo
motor system A/B/Z-phase
differential output type CN2L
(Note 5)
Two-wire type CN2
(Note 2, 3, 4)
Four-wire type
Fully closed
loop system A/B/Z-phase
differential output type
CN2L
Note 1. The MR-J4THCBL03M branch cable is necessary.
2. The MR-J4FCCBL03M branch cable is necessary.
3. When the communication method of the servo motor encoder is four-wire type,
MR-J4-_A_ cannot be used. Use an MR-J4-_A_-RJ.
4. This is used with software version A5 or later.
5. Connect a thermistor to CN2.

1. FUNCTIONS AND CONFIGURATION
1 - 2
1.2 Function block diagram
The function block diagram of this servo is shown below.
POINT
The diagram shows MR-J4-_A_-RJ as an example. The MR-J4-_A_ servo
amplifier does not have the CN2L connector.
(1) 200 V class
(a) MR-J4-500A(-RJ) or less
U U
U
Model position
Current
control
Actual
position
control
Actual
speed
control
Virtual
motor
Virtual
encoder
L11
L21
Cooling fan
(Note 3)
Encoder
(Note 4) N-CD
L3
L2
L1
Dynamic
brake
circuit
Power factor improving
DC reactor
Current
detection
Overcurrent
protection
Voltage
detection
(Note 2)
Power
supply
MCMCCB
Base
amplifier
STO
circuit
Position
command
input
Servo amplifier
U
V
W
U
V
W
P3 P4
Diode
stack Relay
P+
+
+B
RA
24 V DC
B1
B2
Optional battery
(for absolute position
detection system)
CN4
STO
switch
Model speed Model torque
M
CN2
CN8
Control
circuit
power
Model
position
control
Model
speed
control
Servo motor
CHARGE
lamp
Regene-
rative
TR
Current
encoder
Regenerative
option
CN5 CN3 CN6
Analog monitor
(two channel)
I/F
USB RS-422 D/AA/D
USB RS-422
Controller
Personal
computer
Analog
(two channel)
DI/O control
Servo-on
Input command pulse.
Start
Malfunction, etc
CN1
Electromagnetic
brake
Step-
down
circuit
(Note 1)
CN2L
External encoder
(Note 5)
(Note 6)

1. FUNCTIONS AND CONFIGURATION
1 - 3
Note 1. The built-in regenerative resistor is not provided for MR-J4-10A(-RJ).
2. For 1-phase 200 V AC to 240 V AC, connect the power supply to L1 and L3. Leave L2 open.
For the power supply specifications, refer to section 1.3.
3. Servo amplifiers MR-J4-70A(-RJ) or more have a cooling fan.
4. The MR-J4 servo amplifier has P3 and P4 in the upstream of the inrush current suppression circuit. They are different from P1
and P2 of the MR-J3 servo amplifiers.
5. This is for the MR-J4-_A-RJ servo amplifier. The MR-J4-_A servo amplifier does not have the CN2L connector.
6. The power factor improving AC reactor can also be used. In this case, the power factor improving DC reactor cannot be used.
When not using the power factor improving DC reactor, short P3 and P4.