Mitsubishi Electric MR-J3- A User manual

SH (NA) 030038-L (1406) MEE Printed in Japan Specifications are subject to change without notice.

This Instruction Manual uses recycled paper.

MODEL

CODE

J3 Series MR-J3- A Servo Amplifier Instruction Manual L

General-Purpose AC Servo

MODEL

MR-J3- A

SERVO AMPLIFIER

INSTRUCTION MANUAL

General-Purpose Interface

J3 Series

L

1CW203

MR-J3-A INSTRUCTIONMANUAL

HEAD OFFICE : TOKYO BLDG MARUNOUCHI TOKYO 100-8310

A - 1

Safety Instructions

(Always read these instructions before using the equipment.)

Do not attempt to install, operate, maintain or inspect the converter unit, servo amplifier (drive unit) and servo

motor until you have read through this Instruction Manual, Installation guide, Servo motor Instruction Manual

(Vol.2) and appended documents carefully and can use the equipment correctly. Do not use the converter unit,

servo amplifier (drive unit) and servo motor until you have a full knowledge of the equipment, safety information

and instructions.

In this Instruction Manual, the safety instruction levels are classified into "WARNING" and "CAUTION".

WARNING

Indicates that incorrect handling may cause hazardous conditions,

resulting in death or severe injury.

CAUTION

Indicates that incorrect handling may cause hazardous conditions,

resulting in medium or slight injury to personnel or may cause physical

damage.

Note that the CAUTION level may lead to a serious consequence according to conditions. Please follow the

instructions of both levels because they are important to personnel safety.

What must not be done and what must be done are indicated by the following diagrammatic symbols.

: Indicates what must not be done. For example, "No Fire" is indicated by

.

: Indicates what must be done. For example, grounding is indicated by

.

In this Instruction Manual, instructions at a lower level than the above, instructions for other functions, and so

on are classified into "POINT".

After reading this installation guide, always keep it accessible to the operator.

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 (20 minutes or for drive

unit 30kW or more) until the charge lamp turns off. Then, confirm that the voltage between P(

) and

N(

) (L and L for drive unit 30kW or more) is safe with a voltage tester and others. Otherwise, an

electric shock may occur. In addition, always confirm from the front of the servo amplifier (converter unit),

whether the charge lamp is off or not.

Connect the converter unit, servo amplifier (drive unit) and servo motor to ground.

Any person who is involved in wiring and inspection should be fully competent to do the work.

Do not attempt to wire the converter unit, servo amplifier (drive unit) and servo motor until they have been

installed. Otherwise, you may get an electric shock.

Operate the switches with dry hand to prevent an electric shock.

The cables should not be damaged, stressed, loaded, or pinched. Otherwise, you may get an electric

shock.

During power-on or operation, do not open the front cover. You may get an electric shock.

Do not operate the converter unit and servo amplifier (drive unit) with the front cover removed. High-

voltage terminals and charging area are exposed and you may get an electric shock.

Except for wiring or periodic inspection, do not remove the front cover even if the power is off. The servo

amplifier (drive unit) is charged and you may get an electric shock.

2. To prevent fire, note the following

CAUTION

Install the converter unit, servo amplifier (drive unit), 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 L1, L2, and L3 of the

converter unit, servo amplifier (drive unit), and configure the wiring to be able to shut down the power

supply on the side of the converter unit, servo amplifier (drive unit) power supply. If a magnetic contactor

is not connected, continuous flow of a large current may cause a fire when the converter unit, servo

amplifier (drive unit) malfunctions.

When a regenerative resistor is used, use an alarm signal to switch main power off. Otherwise, a

regenerative transistor fault or the like may overheat the regenerative resistor, causing a fire.

Provide adequate protection to prevent screws and other conductive matter, oil and other combustible

matter from entering the converter unit, servo amplifier (drive unit), and servo motor.

Always connect a no-fuse breaker to the power supply of the servo amplifier (converter unit).

A - 3

3. To prevent injury, note the follow

CAUTION

Only the voltage specified in the Instruction Manual should be applied to each terminal, Otherwise, a

burst, damage, etc. may occur.

Connect the terminals correctly to prevent a burst, damage, etc.

Ensure that polarity ( , ) is correct. Otherwise, a burst, damage, etc. may occur.

Take safety measures, e.g. provide covers, to prevent accidental contact of hands and parts (cables, etc.)

with the converter unit and servo amplifier (drive unit) heat sink, regenerative resistor, servo motor, etc.

since they may be hot while power is on or for some time after power-off. Their temperatures may be high

and you may get burnt or a parts may damaged.

During operation, never touch the rotating parts of the servo motor. Doing so can cause injury.

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 products is not allowed.

Do not carry the servo motor by the cables, shaft or encoder.

Do not hold the front cover to transport the converter unit and servo amplifier (drive unit). The converter

unit and servo amplifier (drive unit) may drop.

Install the converter unit and servo amplifier (drive unit) in a load-bearing place in accordance with the

Instruction Manual.

Do not climb or stand on servo equipment. Do not put heavy objects on equipment.

The converter unit, servo amplifier (drive unit), and servo motor must be installed in the specified

direction.

Leave specified clearances between the converter unit, servo amplifier (drive unit), and control enclosure

walls or other equipment.

Do not install or operate the converter unit, servo amplifier (drive unit), and servo motor which has been

damaged or has any parts missing.

Do not block the intake and exhaust areas of the converter unit, servo amplifier (drive unit) and servo

motor which has a cooling fan. Doing so may cause faults.

Do not drop or strike converter unit, servo amplifier (drive unit), or servo motor. Isolate from all impact

loads.

Securely attach the servo motor to the machine. If attach insecurely, the servo motor may come off during

operation.

The servo motor with reduction gear must be installed in the specified direction to prevent oil leakage.

Take safety measures, e.g. provide covers, to prevent accidental access to the rotating parts of the servo

motor during operation.

Never hit the servo motor or shaft, especially when coupling the servo motor to the machine. The encoder

may become faulty.

Do not subject the servo motor shaft to more than the permissible load. Otherwise, the shaft may break.

A - 4

CAUTION

When you keep or use it, please fulfill the following environmental conditions.

Item

Environmental conditions

Converter unit servo amplifier (drive unit) Servo motor

Ambient

temperature

In

operation

[ ] 0 to 55 (non-freezing) 0 to 40 (non-freezing)

[ ] 32 to 131 (non-freezing) 32 to 104 (non-freezing)

In storage

[ ] 20 to 65 (non-freezing) 15 to 70 (non-freezing)

[ ] 4 to 149 (non-freezing) 5 to 158 (non-freezing)

Ambient

humidity

In operation 90%RH or less (non-condensing) 80%RH or less (non-condensing)

In storage 90%RH or less (non-condensing)

Ambience Indoors (no direct sunlight) Free from corrosive gas, flammable gas, oil mist, dust and dirt

Altitude Max. 1000m (3280 ft) above sea level

(Note)

Vibration

[m/s

2

]

5.9 or less at 10 to

55Hz (directions of

X, Y and Z axes)

HF-MP series HF-KP series X, Y: 49 m/s

2

HF-SP51 81 HF-SP52 to 152

HF-SP524 to 1524 HC-RP Series

HC-UP72

152 HF-JP Series

X, Y: 24.5 m/s

2

HF-SP121 201 HF-SP202 352

HF-SP2024

3524 HC-UP202 to 502

X: 24.5 m/s

2

Y: 49 m/s

2

HF-SP301 421 HF-SP502 702

HF-SP5024

7024

X: 24.5 m/s

2

Y: 29.4 m/s

2

HC-LP52 to 152 X: 9.8 m/s

2

Y: 24.5 m/s

2

HC-LP202 to 302 X: 19.6 m/s

2

Y: 49 m/s

2

HA-LP601 to 12K1 HA-LP701M to 15K1M

HA-LP502 to 22K2 HA-LP6014

12K14

HA-LP701M4

15K1M4 HA-LP11K24 to 22K24

X: 11.7 m/s

2

Y: 29.4 m/s

2

HA-LP15K1 to 37K1 HA-LP22K1M to 37K1M

HA-LP30K2

37K2 HA-LP15K14 to 37K14

HA-LP22K1M4 to 50K1M4 HA-LP30K24 to 55K24

X, Y: 9.8 m/s

2

Note. Except the servo motor with reduction gear.

When the equipment has been stored for an extended period of time, contact your local sales office.

(2) Wiring

CAUTION

Wire the equipment correctly and securely. Otherwise, the servo motor may operate unexpectedly.

Do not install a power capacitor, surge absorber or radio noise filter (FR-BIF-(H) option) between the

servo motor and servo amplifier (drive unit).

Connect the wires to the correct phase terminals (U, V, W) of the servo amplifier (drive unit) and servo

motor.

Not doing so may cause unexpected operation.

Connect the servo motor power terminal (U, V, W) to the servo motor power input terminal (U, V, W)

directly. Do not let a magnetic contactor, etc. intervene.

U

Servo motor

M

V

W

U

V

W

Servo amplifier

(drive unit)

U

M

V

W

U

V

W

Servo motor

Servo amplifier

(drive unit)

Do not connect AC power directly to the servo motor. Otherwise, a fault may occur.

A - 5

CAUTION

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

DICOM

24VDC

Servo amplifier

(drive unit)

RA

For sink output interface

DOCOM

Control output

signal

DICOM

24VDC

Servo amplifier

(drive unit)

RA

For source output interface

When the cable is not tightened enough to the terminal block (connector), the cable or terminal block

(connector) may generate heat because of the poor contact. Be sure to tighten the cable with specified

torque.

(3) Test run adjustment

CAUTION

Before operation, check the parameter settings. Improper settings may cause some machines to perform

unexpected operation.

The parameter settings must not be changed excessively. Operation will be insatiable.

(4) Usage

CAUTION

Provide an external emergency stop circuit to ensure that operation can be stopped and power switched

off immediately.

Any person who is involved in disassembly and repair should be fully competent to do the work.

Before resetting an alarm, make sure that the run signal of the servo amplifier (drive unit) is off to prevent

an accident. A sudden restart is made if an alarm is reset with the run signal on.

Do not modify the equipment.

Use a noise filter, etc. to minimize the influence of electromagnetic interference, which may be caused by

electronic equipment used near the converter unit and servo amplifier (drive unit).

Burning or breaking a converter unit and servo amplifier (drive unit) may cause a toxic gas. Do not burn or

break a converter unit and servo amplifier (drive unit).

Use the converter unit and servo amplifier (drive unit) 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.

A - 6

(5) Corrective actions

CAUTION

When it is assumed that a hazardous condition may take place at the occur due to a power failure or a

product fault, use a servo motor with an electromagnetic brake or an external brake mechanism for the

purpose of prevention.

Configure an electromagnetic brake circuit so that it is activated also by an external emergency stop

switch.

B

U

SON RA

Contacts must be opened by an

emergency stop switch.

Contacts must be opened by servo-on

(SON) OFF, trouble (ALM) and

electromagnetic brake interlock (MBR).

24VDC

Servo motor

Electromagnetic brake

When any alarm has occurred, eliminate its cause, ensure safety, and deactivate the alarm before

restarting operation.

When power is restored after an instantaneous power failure, keep away from the machine because the

machine may be restarted suddenly (design the machine so that it is secured against hazard if restarted).

(6) Maintenance, inspection and parts replacement

CAUTION

With age, the electrolytic capacitor of the converter unit and servo amplifier (drive unit) will deteriorate. To

prevent a secondary accident due to a fault, it is recommended to replace the electrolytic capacitor every

10 years when used in general environment. Please contact your local sales office.

(7) General instruction

To illustrate details, the equipment in the diagrams of this Specifications and 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 converter unit, servo amplifier (drive unit), 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 converter unit, servo amplifier (drive unit)

and/or converter unit may fail when the EEP-ROM reaches the end of its useful life.

Write to the EEP-ROM due to parameter setting changes

Home position setting in the absolute position detection system

Write to the EEP-ROM due to device changes

Precautions for Choosing the Products

Mitsubishi will not be held liable for damage caused by factors found not to be the cause of Mitsubishi;

machine damage or lost profits caused by faults in the Mitsubishi products; damage, secondary damage,

accident compensation caused by special factors unpredictable by Mitsubishi; damages to products other

than Mitsubishi products; and to other duties.

COMPLIANCE WITH THE EUROPEAN EC

DIRECTIVES

Refer to Appendix 9 for the compliance with EC Directives.

COMPLIANCE WITH UL/C-UL STANDARD

Refer to Appendix 10 for the compliance with UL/C-UL standard.

<<About the manuals>>

This Instruction Manual and the MELSERVO Servo Motor Instruction Manual (Vol.2) are required if you use

the General-Purpose AC servo MR-J3-A for the first time.

Relevant manuals

Manual name Manual No.

MELSERVO-J3 Series Instructions and Cautions for Safe Use of AC Servos

(Enclosed in converter unit and servo amplifier (drive unit).)

IB(NA)0300077

MELSERVO Servo Motor Instruction Manual (Vol.2) SH(NA)030041

EMC Installation Guidelines IB(NA)67310

Details of MR-J3-CR55K(4) and MR-J3-DU30KA(4) to MR-J3-DU55KA4 are described in chapter 13 of this

instruction manual.

For the products of 30kW or more, refer to chapter 15.

<<Wiring>>

Wires mentioned in this instruction manual are selected based on the ambient temperature of 40

(104 ).

A - 8

MEMO

1

CONTENTS

1. FUNCTIONS AND CONFIGURATION 1 - 1 to 1 -30

1.1 Summary .................................................................................................................................................. 1 - 1

1.2 Function block diagram ............................................................................................................................ 1 - 2

1.3 Servo amplifier standard specifica tions ................................................................................................... 1 - 5

1.4 Function list .............................................................................................................................................. 1 - 7

1.5 Model code definition ............................................................................................................................... 1 - 9

1.6 Combination with servo motor ................................................................................................................ 1 -10

1.7 Structure .................................................................................................................................................. 1 -12

1.7.1 Parts identification ............................................................................................................................ 1 -12

1.7.2 Removal and reinstallation of the front cover .................................................................................. 1 -19

1.8 Configuration including auxiliary equipment .......................................................................................... 1 -22

2. INSTALLATION 2 - 1 to 2 - 6

2.1 Installation direction and clearances ....................................................................................................... 2 - 2

2.2 Keep out foreign materials ....................................................................................................................... 2 - 4

2.3 Cable stress ............................................................................................................................................. 2 - 5

2.4 Inspection items ....................................................................................................................................... 2 - 5

2.5 Parts having service lives ........................................................................................................................ 2 - 6

3. SIGNALS AND WIRING 3 - 1 to 3 -78

3.1 Input power supply circuit ........................................................................................................................ 3 - 2

3.2 I/O signal connection example ............................................................................................................... 3 -10

3.2.1 Position control mode ....................................................................................................................... 3 -10

3.2.2 Speed control mode ......................................................................................................................... 3 -12

3.2.3 Torque control mode ........................................................................................................................ 3 -14

3.3 Explanation of power supply system ...................................................................................................... 3 -16

3.3.1 Signal explanations .......................................................................................................................... 3 -16

3.3.2 Power-on sequence ......................................................................................................................... 3 -17

3.3.3 CNP1, CNP2, CNP3 wiring method ................................................................................................ 3 -19

3.4 Connectors and signal arrangements .................................................................................................... 3 -27

3.5 Signal explanations ................................................................................................................................. 3 -30

3.6 Detailed description of the signals .......................................................................................................... 3 -40

3.6.1 Position control mode ....................................................................................................................... 3 -40

3.6.2 Speed control mode ......................................................................................................................... 3 -44

3.6.3 Torque control mode ........................................................................................................................ 3 -46

3.6.4 Position/speed control change mode .............................................................................................. 3 -49

3.6.5 Speed/torque control change mode ................................................................................................ 3 -51

3.6.6 Torque/position control change mode ............................................................................................. 3 -53

3.7 Alarm occurrence timing chart ................................................................................................................ 3 -54

3.8 Interfaces ................................................................................................................................................. 3 -55

3.8.1 Internal connection diagram ............................................................................................................ 3 -55

3.8.2 Detailed description of interfaces ..................................................................................................... 3 -56

3.8.3 Source I/O interfaces ....................................................................................................................... 3 -60

3.9 Treatment of cable shield external conductor ........................................................................................ 3 -61

2

3.10 Connection of servo amplifier and servo motor ................................................................................... 3 -62

3.10.1 Connection instructions .................................................................................................................. 3 -62

3.10.2 Power supply cable wiring diagrams ............................................................................................. 3 -63

3.11 Servo motor with an electromagnetic brake ......................................................................................... 3 -73

3.11.1 Safety precautions ......................................................................................................................... 3 -73

3.11.2 Setting ............................................................................................................................................. 3 -73

3.11.3 Timing charts .................................................................................................................................. 3 -74

3.11.4 Wiring diagrams (HF-MP series

HF-KP series servo motor)...................................................... 3 -76

3.12 Grounding .............................................................................................................................................. 3 -78

4. STARTUP 4 - 1 to 4 -18

4.1 Switching power on for the first time ....................................................................................................... 4 - 1

4.1.1 Startup procedure .............................................................................................................................. 4 - 1

4.1.2 Wiring check ...................................................................................................................................... 4 - 2

4.1.3 Surrounding environment .................................................................................................................. 4 - 3

4.2 Startup in position control mode .............................................................................................................. 4 - 4

4.2.1 Power on and off procedures ............................................................................................................ 4 - 4

4.2.2 Stop .................................................................................................................................................... 4 - 4

4.2.3 Test operation.................................................................................................................................... 4 - 5

4.2.4 Parameter setting .............................................................................................................................. 4 - 6

4.2.5 Actual operation ................................................................................................................................ 4 - 7

4.2.6 Trouble at start-up ............................................................................................................................. 4 - 7

4.3 Startup in speed control mode ................................................................................................................. 4 - 9

4.3.1 Power on and off procedures ............................................................................................................ 4 - 9

4.3.2 Stop ................................................................................................................................................... 4 -10

4.3.3 Test operation................................................................................................................................... 4 -11

4.3.4 Parameter setting ............................................................................................................................. 4 -12

4.3.5 Actual operation ............................................................................................................................... 4 -13

4.3.6 Trouble at start-up ............................................................................................................................ 4 -13

4.4 Startup in torque control mode ............................................................................................................... 4 -14

4.4.1 Power on and off procedures ........................................................................................................... 4 -14

4.4.2 Stop ................................................................................................................................................... 4 -15

4.4.3 Test operation .................................................................................................................................. 4 -16

4.4.4 Parameter setting ............................................................................................................................. 4 -17

4.4.5 Actual operation ............................................................................................................................... 4 -18

4.4.6 Trouble at start-up ............................................................................................................................ 4 -18

5. PARAMETERS 5 - 1 to 5 -54

5.1 Basic setting parameters (No.PA ) ................................................................................................... 5 - 1

5.1.1 Parameter list .................................................................................................................................... 5 - 1

5.1.2 Parameter write inhibit ...................................................................................................................... 5 - 2

5.1.3 Selection of control mode ................................................................................................................. 5 - 3

5.1.4 Selection of regenerative option ....................................................................................................... 5 - 5

5.1.5 Using absolute position detection system ........................................................................................ 5 - 6

5.1.6 Using electromagnetic brake interlock (MBR) .................................................................................. 5 - 6

5.1.7 Number of command input pulses per servo motor revolution ........................................................ 5 - 7

5.1.8 Electronic gear................................................................................................................................... 5 - 8

3

5.1.9 Auto tuning ....................................................................................................................................... 5 -12

5.1.10 In-position range ............................................................................................................................ 5 -13

5.1.11 Torque limit ..................................................................................................................................... 5 -14

5.1.12 Selection of command pulse input form ........................................................................................ 5 -15

5.1.13 Selection of servo motor rotation direction .................................................................................... 5 -16

5.1.14 Encoder output pulse ..................................................................................................................... 5 -16

5.2 Gain/filter parameters (No.PB

) ........................................................................................................ 5 -18

5.2.1 Parameter list ................................................................................................................................... 5 -18

5.2.2 Detail list ........................................................................................................................................... 5 -20

5.2.3 Position smoothing ........................................................................................................................... 5 -29

5.3 Extension setting parameters (No.PC

) ........................................................................................... 5 -30

5.3.1 Parameter list ................................................................................................................................... 5 -30

5.3.2 List of details ..................................................................................................................................... 5 -31

5.3.3 Analog monitor ................................................................................................................................. 5 -41

5.3.4 Alarm history clear ............................................................................................................................ 5 -43

5.4 I/O setting parameters (No.PD

) ...................................................................................................... 5 -44

5.4.1 Parameter list ................................................................................................................................... 5 -44

5.4.2 List of details ..................................................................................................................................... 5 -45

5.4.3 Using forward/reverse rotation stroke end to change the stopping pattern ................................... 5 -53

6. DISPLAY AND OPERATION SECTIONS 6 - 1 to 6 -22

6.1 Overview ................................................................................................................................................... 6 - 1

6.2 Display sequence ..................................................................................................................................... 6 - 2

6.3 Status display ........................................................................................................................................... 6 - 3

6.3.1 Display transition ............................................................................................................................... 6 - 3

6.3.2 Display examples .............................................................................................................................. 6 - 4

6.3.3 Status display list ............................................................................................................................... 6 - 5

6.3.4 Changing the status display screen .................................................................................................. 6 - 6

6.4 Diagnostic mode ...................................................................................................................................... 6 - 7

6.5 Alarm mode .............................................................................................................................................. 6 - 8

6.6 Parameter mode ..................................................................................................................................... 6 -10

6.6.1 Parameter mode transition ............................................................................................................... 6 -10

6.6.2 Operation example ........................................................................................................................... 6 -11

6.7 External I/O signal display ...................................................................................................................... 6 -13

6.8 Output signal (DO) forced output ............................................................................................................ 6 -16

6.9 Test operation mode ............................................................................................................................... 6 -17

6.9.1 Mode change .................................................................................................................................... 6 -17

6.9.2 JOG operation .................................................................................................................................. 6 -18

6.9.3 Positioning operation ........................................................................................................................ 6 -19

6.9.4 Motor-less operation ........................................................................................................................ 6 -21

7. GENERAL GAIN ADJUSTMENT 7 - 1 to 7 -12

7.1 Different adjustment methods .................................................................................................................. 7 - 1

7.1.1 Adjustment on a single servo a mplifier ............................................................................................. 7 - 1

7.1.2 Adjustment using MR Configurator ................................................................................................... 7 - 2

7.2 Auto tuning ............................................................................................................................................... 7 - 3

7.2.1 Auto tuning mode .............................................................................................................................. 7 - 3

4

7.2.2 Auto tuning mode basis .................................................................................................................... 7 - 4

7.2.3 Adjustment procedure by auto tunin g ............................................................................................... 7 - 5

7.2.4 Response level setting in auto tuning mode .................................................................................... 7 - 6

7.3 Manual mode 1 (simple manual adjustment) .......................................................................................... 7 - 7

7.4 Interpolation mode .................................................................................................................................. 7 -10

7.5 Differences between MELSERVO-J2-Super and MELSERVO-J3 in auto tuning ................................ 7 -11

8. SPECIAL ADJUSTMENT FUNCTIONS 8 - 1 to 8 -18

8.1 Function block diagram ............................................................................................................................ 8 - 1

8.2 Adaptive filter

........................................................................................................................................ 8 - 1

8.3 Machine resonance suppression filter ..................................................................................................... 8 - 4

8.4 Advanced vibration suppression control ................................................................................................. 8 - 6

8.5 Low-pass filter ......................................................................................................................................... 8 -10

8.6 Gain changing function ........................................................................................................................... 8 -10

8.6.1 Applications ...................................................................................................................................... 8 -10

8.6.2 Function block diagram .................................................................................................................... 8 -11

8.6.3 Parameters ....................................................................................................................................... 8 -12

8.6.4 Gain changing procedure ................................................................................................................. 8 -14

8.7 Vibration suppression control filter 2 ...................................................................................................... 8 -16

9. TROUBLESHOOTING 9 - 1 to 9 -26

9.1 Alarms and warning list ............................................................................................................................ 9 - 1

9.2 Remedies for alarms ................................................................................................................................ 9 - 2

9.3 Remedies for warnings ........................................................................................................................... 9 -15

9.4 Troubles without an alarm/warning ........................................................................................................ 9 -17

10. OUTLINE DRAWINGS 10- 1 to 10-12

10.1 Servo amplifier ...................................................................................................................................... 10- 1

10.2 Connector ............................................................................................................................................. 10-10

11. CHARACTERISTICS 11- 1 to 11 -12

11.1 Overload protection characteristics ...................................................................................................... 11- 1

11.2 Power supply equipment capacity and generated loss ....................................................................... 11- 3

11.3 Dynamic brake characteristics .............................................................................................................. 11- 6

11.3.1 Dynamic brake operation ............................................................................................................... 11- 6

11.3.2 The dynamic brake at the load inertia moment ............................................................................ 11-10

11.4 Cable flexing life ................................................................................................................................... 11-11

11.5 Inrush currents at power-on of main circuit and control circuit ........................................................... 11-11

12. OPTIONS AND AUXILIARY EQUIPMENT 12- 1 to 12 -100

12.1 Cable/connector sets ............................................................................................................................ 12- 1

12.1.1 Combinations of cable/connector sets .......................................................................................... 12- 2

12.1.2 Encoder cable/connector sets ...................................................................................................... 12-10

12.1.3 Motor power supply cables ........................................................................................................... 12-25

12.1.4 Motor brake cables ........................................................................................................................ 12-26

5

12.2 Regenerative options ........................................................................................................................... 12-27

12.3 FR-BU2-(H) brake unit ......................................................................................................................... 12-40

12.3.1 Selection ........................................................................................................................................ 12-41

12.3.2 Brake unit parameter setting ......................................................................................................... 12-41

12.3.3 Connection example ..................................................................................................................... 12-42

12.3.4 Outline dimension drawings .......................................................................................................... 12-49

12.4 Power regenerative converter ............................................................................................................. 12-51

12.5 Power regenerative common converter .............................................................................................. 12-54

12.6 External dynamic brake ....................................................................................................................... 12-62

12.7 Junction terminal block MR-TB50 ....................................................................................................... 12-67

12.8 MR Configurator ................................................................................................................................... 12-69

12.9 Battery unit MR-J3BAT ........................................................................................................................ 12-73

12.10 Heat sink outside mounting attachment (MR-J3ACN)...................................................................... 12-74

12.11 Selection example of wires ................................................................................................................ 12-76

12.12 No-fuse breakers, fuses, magnetic contactors ................................................................................. 12-81

12.13 Power factor improving DC reactor ................................................................................................... 12-82

12.14 Power factor improving reactors ........................................................................................................ 12-84

12.15 Relays (recommended) ..................................................................................................................... 12-85

12.16 Surge absorbers (recommended) ..................................................................................................... 12-86

12.17 Noise reduction techniques ............................................................................................................... 12-86

12.18 Leakage current breaker .................................................................................................................... 12-94

12.19 EMC filter (recommended) ............................................................................................................... 12-96

13. COMMUNICATION FUNCTION 13- 1 to 13-34

13.1 Configuration ......................................................................................................................................... 13- 1

13.2 Communication specifications .............................................................................................................. 13- 3

13.2.1 Communication overview ............................................................................................................... 13- 3

13.2.2 Parameter setting ........................................................................................................................... 13- 4

13.3 Protocol ................................................................................................................................................. 13- 5

13.3.1 Transmission data configuration .................................................................................................... 13- 5

13.3.2 Character codes ............................................................................................................................. 13- 6

13.3.3 Error codes ..................................................................................................................................... 13- 7

13.3.4 Checksum ....................................................................................................................................... 13- 7

13.3.5 Time-out ......................................................................................................................................... 13- 8

13.3.6 Retry ............................................................................................................................................... 13- 8

13.3.7 Initialization ..................................................................................................................................... 13- 9

13.3.8 Communication procedure example.............................................................................................. 13- 9

13.4 Command and data No. list ................................................................................................................. 13-10

13.4.1 Read commands ........................................................................................................................... 13-10

13.4.2 Write commands ........................................................................................................................... 13-14

13.5 Detailed explanations of commands ................................................................................................... 13-16

13.5.1 Data processing ............................................................................................................................ 13-16

13.5.2 Status display ................................................................................................................................ 13-18

13.5.3 Parameters .................................................................................................................................... 13-19

13.5.4 External I/O signal statuses (DIO diagnosis) ............................................................................... 13-22

13.5.5 Input device ON/OFF .................................................................................................................... 13-25

13.5.6 Disable/enable of I/O devices (DIO) ............................................................................................. 13-25

13.5.7 Input devices ON/OFF (test operation) ........................................................................................ 13-26

6

13.5.8 Test operation mode ..................................................................................................................... 13-27

13.5.9 Output signal pin ON/OFF output signal (DO) forced output ....................................................... 13-30

13.5.10 Alarm history ............................................................................................................................... 13-31

13.5.11 Current alarm .............................................................................................................................. 13-32

13.5.12 Other commands ......................................................................................................................... 13-33

14. ABSOLUTE POSITION DETECTION SYSTEM 14- 1 to 14-66

14.1 Outline ................................................................................................................................................... 14- 1

14.1.1 Features ......................................................................................................................................... 14- 1

14.1.2 Restrictions ..................................................................................................................................... 14- 2

14.2 Specifications ........................................................................................................................................ 14- 3

14.3 Battery replacement procedure ............................................................................................................ 14- 4

14.3.1 When replacing battery with the control circuit power ON ............................................................ 14- 4

14.3.2 When replacing battery with the control circuit power OFF .......................................................... 14- 4

14.4 Battery installation procedure ............................................................................................................... 14- 5

14.5 Procedure to replace battery with the control circuit power OFF ........................................................ 14- 5

14.5.1 Preparation for battery replacement .............................................................................................. 14- 5

14.5.2 Replacement procedure ................................................................................................................ 14- 6

14.6 Standard connection diagram ............................................................................................................... 14- 7

14.7 Signal explanation ................................................................................................................................. 14- 8

14.8 Startup procedure ................................................................................................................................. 14- 9

14.9 Absolute position data transfer protocol .............................................................................................. 14-10

14.9.1 Data transfer procedure ................................................................................................................ 14-10

14.9.2 Transfer method ............................................................................................................................ 14-11

14.9.3 Home position setting.................................................................................................................... 14-22

14.9.4 Use of servo motor with an electromagnetic brake ...................................................................... 14-24

14.9.5 How to process the absolute position data at detection of stroke end ........................................ 14-25

14.10 Examples of use ................................................................................................................................ 14-26

14.10.1 MELSEC FX

(2N)-32MT (FX(2N)-1PG) ......................................................................................... 14-26

14.10.2 MELSEC A1SD75 ....................................................................................................................... 14-38

14.10.3 MELSEC QD75 ........................................................................................................................... 14-51

14.11 Absolute position data transfer errors ............................................................................................... 14-59

14.11.1 Corrective actions ....................................................................................................................... 14-59

14.11.2 Error resetting conditions ............................................................................................................ 14-61

14.12 Communication-based ABS transfer system .................................................................................... 14-62

14.12.1 Serial communication command ................................................................................................ 14-62

14.12.2 Absolute position data transfer protocol ..................................................................................... 14-62

14.13 Confirmation of absolute position detection data .............................................................................. 14-66

15. SERVO AMPLIFIERS WITH A LARGE CAPACITY (30k TO 55kW) 15- 1 to 15-102

15.1. Functions and menus .......................................................................................................................... 15- 1

15.1.1 Function block diagram .................................................................................................................. 15- 2

15.1.2 Packing list ..................................................................................................................................... 15- 4

15.1.3 Standard specifications .................................................................................................................. 15- 5

15.1.4 Model definition .............................................................................................................................. 15- 8

15.1.5 Combinations of converter units, drive unit and servo motors ..................................................... 15- 9

15.1.6 Parts identification ......................................................................................................................... 15-10

7

15.1.7 Removal and reinstallation of the terminal block cover ............................................................... 15-13

15.1.8 Servo system with auxiliary equipment ........................................................................................ 15-19

15.2 Installation ............................................................................................................................................ 15-20

15.2.1 Installation direction and clearances ............................................................................................ 15-21

15.2.2 Inspection ...................................................................................................................................... 15-22

15.3 Signals and wiring ................................................................................................................................ 15-23

15.3.1 Magnetic contactor control connector (CNP1) ............................................................................. 15-24

15.3.2 Input power supply circuit ............................................................................................................. 15-26

15.3.3 Terminal ......................................................................................................................................... 15-31

15.3.4 How to use the connection bars ............................................................................................. 15-32

15.3.5 Connectors and signal arrangements .................................................................................... 15-33

15.3.6 Converter unit signal (device) explanations ........................................................................... 15-35

15.3.7 Timing chart ............................................................................................................................ 15-37

15.3.8 Servo motor side details ......................................................................................................... 15-45

15.4 Display section and operation section of the converter unit ............................................................... 15-47

15.4.1 Display flowchart ........................................................................................................................... 15-47

15.4.2 Status display mode ...................................................................................................................... 15-48

15.4.3 Diagnostic mode ........................................................................................................................... 15-49

15.4.4 Alarm mode ................................................................................................................................... 15-51

15.4.5 Parameter mode ........................................................................................................................... 15-52

15.5. Parameters for converter unit ............................................................................................................. 15-53

15.5.1 Parameter list ................................................................................................................................ 15-53

15.5.2 List of details .................................................................................................................................. 15-54

15.6 Troubleshooting ................................................................................................................................... 15-55

15.6.1 Converter unit ................................................................................................................................ 15-55

15.6.2 Drive unit........................................................................................................................................ 15-60

15.7 Outline drawings .........................................................................................................

......................... 15-62

15.7.1 Converter unit (MR-J3-CR55K(4)) ................................................................................................ 15-62

15.7.2 Drive unit........................................................................................................................................ 15-63

15.8 Characteristics...................................................................................................................................... 15-65

15.8.1 Overload protection characteristics .............................................................................................. 15-65

15.8.2 Power supply equipment capacity and generated loss ............................................................... 15-66

15.8.3 Dynamic brake characteristics ...................................................................................................... 15-67

15.8.4 Inrush currents at power-on of main circuit and control circuit .................................................... 15-70

15.9 Options ................................................................................................................................................. 15-70

15.9.1 Cables and connectors ................................................................................................................. 15-70

15.9.2 Regenerative option ...................................................................................................................... 15-74

15.9.3 External dynamic brake ................................................................................................................ 15-78

15.9.4 Selection example of wires ........................................................................................................... 15-81

15.9.5 No-fuse breakers, fuses, magnetic contactors ............................................................................. 15-83

15.9.6 Power factor improving DC reactor .............................................................................................. 15-84

15.9.7 Line noise filter (FR-BLF) .............................................................................................................. 15-85

15.9.8 Leakage current breaker ............................................................................................................... 15-86

15.9.9 EMC filter (recommended) ............................................................................................................ 15-88

15.9.10 FR-BU2-(H) brake unit ................................................................................................................ 15-90

16. PARAMETER UNIT (MR-PRU03) 16- 1 to 16-20

16.1 External appearance and key explanations ......................................................................................... 16- 2

8

16.2 Specifications ........................................................................................................................................ 16- 3

16.3 Outline dimension drawings ................................................................................................................. 16- 3

16.4 Connection with servo amplifier............................................................................................................ 16- 4

16.4.1 Single axis ...................................................................................................................................... 16- 4

16.4.2 Multidrop connection ...................................................................................................................... 16- 5

16.5 Display ................................................................................................................................................... 16- 7

16.5.1 Outline of screen transition ............................................................................................................ 16- 7

16.5.2 MR-PRU03 parameter unit setting ................................................................................................ 16- 8

16.5.3 Monitor mode (status display) ........................................................................................................ 16- 9

16.5.4 Alarm/diagnostic mode ................................................................................................................. 16-12

16.5.5 Parameter mode ........................................................................................................................... 16-14

16.5.6 Test operation mode ..................................................................................................................... 16-15

16.6 Error message list ................................................................................................................................ 16-19

APPENDIX App.- 1 to App.-23

App. 1 Parameter list ..................................................................................................................................App.- 1

App. 2 Signal layout recording paper ........................................................................................................App.- 3

App. 3 Status display block diagram .........................................................................................................App.- 4

App. 4 Change of connector sets to the RoHS compatible products .......................................................App.- 5

App. 5 MR-J3-200A-RT servo amplifier ....................................................................................................App.- 6

App. 6 Selection example of servo motor power cable .......................................................................... App.-10

App. 7 Handling of AC servo amplifier batteries for the United Nations

Recommendations on the Transport of Dangerous Goods ........................................................ App.-11

App. 8 Symbol for the new EU Battery Directive .................................................................................... App.-12

App. 9 Compliance with the European EC directives ............................................................................. App.-13

App. 10 Conformance with UL/C-UL standard ........................................................................................ App.-16

1 - 1

1. FUNCTIONS AND CONFIGURATION

1.1 Summary

The Mitsubishi MELSERVO-J3 series general-purpose AC servo is based on the MELSERVO-J2-Super series

and has further higher performance and higher functions.

It has position control, speed control and torque control modes. Further, it can perform operation with the

control modes changed, 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.

As this new series has the USB or RS-422 serial communication function, a MR Configurator installed personal

computer or the like can be used to perform parameter setting, test operation, status display monitoring, gain

adjustment, etc.

With real-time auto tuning, you can automatically adjust the servo gains according to the machine.

The MELSERVO-J3 series servo motor with an absolute position encoder which has the resolution of 262144

pulses/rev to ensure more accurate control as compared to the MELSERVO-J2-Super series. Simply adding a

battery to the servo amplifier makes up an absolute position detection system. This makes home position

return unnecessary at power-on or alarm occurrence by setting a home position once.

(1) Position control mode

An up to 1Mpps high-speed pulse train is used to control the speed and direction of a motor and execute

precision positioning of 262144 pulses/rev resolution.

The position smoothing function provides a choice of two different modes appropriate for a machine, so a

smoother start/stop can be made in response to a sudden position command.

A torque limit is imposed on the servo amplifier by the clamp circuit to protect the power transistor in the

main circuit from overcurrent due to sudden acceleration/deceleration or overload. This torque limit value

can be changed to any value with an external analog input or the parameter.

(2) Speed control mode

An external analog speed command (0 to

10VDC) or parameter-driven internal speed command (max. 7

speeds) is used to control the speed and direction of a servo motor smoothly.

There are also the acceleration/deceleration time constant setting in response to speed command, the

servo lock function at a stop time, and automatic offset adjustment function in response to external analog

speed command.

(3) Torque control mode

An external analog torque command (0 to

8VDC) is used to control the torque output by the servo motor.

To prevent unexpected operation under no load, the speed limit function (external or internal setting) is also

available for application to tension control, etc.

1 - 2

1. FUNCTIONS AND CONFIGURATION

1.2 Function block diagram

The function block diagram of this servo is shown below.

(1) MR-J3-350A or less

MR-J3-200A4 or less

CD

L

11

CN5 CN3 CN6

I/F

USB RS-422 D/AA/D

USB RS-422

CN4

MR-J3BAT

CN1

P

1

P

2

P( ) N( )

B

NFB

(Note 2)

Power

supply

MC

RA

24VDC

B1

B2

L1

L

2

L

3

L

21

Servo amplifier

U

V

W

U

V

W

Diode

stack

Regenerative

option

Power factor

improving DC

reactor

CHARGE

lamp

Regene-

rative TR

(Note 1)

Current

detector

M

Servo motor

Dynamic

brake circuit

Electro-

magnetic

brake

Encoder

Base

amplifier

Voltage

detection

Overcurrent

protection

Current

detection

Control

circuit

power

supply

(Note 3) Cooling fan

Relay

Pulse input

Model position

control

Model speed

control

Virtual

encoder

Virtual

motor

Model

position

Model

speed

Model torque

Actual position

control

Actual speed

control

Current

control

Optional battery

(for absolute position

detection system)

Analog monitor

(2 channels)

Personal

computer

D I/O control

Servo on

Command pulse train input

Start

Failure, etc

.

Analog

(2 channels)

Controller

CN2

Note 1. The built-in regenerative resistor is not provided for the MR-J3-10A(1).

2. For 1-phase 200 to 230VAC, connect the power supply to L

1, L2 and leave L3 open.

There is no L

3 for 1-phase 100 to 120VAC power supply. For the specification of power supply, refer to section 1.3.

3. Servo amplifiers MR-J3-70A or greater have a cooling fan.

1 - 3

1. FUNCTIONS AND CONFIGURATION

(2) MR-J3-350A4

MR-J3-500A(4) MR-J3-700A(4)

CN2

C

L

11

CN5 CN3 CN6

I/F

USB RS-422 D/AA/D

USB RS-422

CN4

MR-J3BAT

CN1

P

1

P

2

PN

B

NFB

(Note)

Power

supply

MC

RA

24VDC

B1

B2

L

1

L

2

L

3

L

21

Servo amplifier

U

V

W

U

V

W

Diode

stack

Regenerative

option

Power factor

improving DC

reactor

CHARGE

lamp

Regene-

rative TR

Current

detector

M

Servo motor

Dynamic

brake circuit

Electro-

magnetic

brake

Encoder

Base

amplifier

Voltage

detection

Overcurrent

protection

Current

detection

Control

circuit

power

supply

Cooling fan

Relay

Pulse input

Model position

control

Model speed

control

Virtual

encoder

Virtual

motor

Model

position

Model

speed

Model torque

Actual position

control

Actual speed

control

Current

control

Optional battery

(for absolute position

detection system)

Analog monitor

(2 channels)

Personal

computer

D I/O control

Servo on

Command pulse train input

Start

Failure, etc

.

Analog

(2 channels)

Controller

Note. For the specification of power supply, refer to section 1.3.

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