Mitsubishi Electric Conversion Unit for SSCNET of MR-J2S-B Compatible AC Servo MR-J4-_B_-RJ020/MR-J4-DU_B_-RJ020/MR-CR55K

SH(NA)030125ENG-G(1705)MEE Printed in Japan Specifications are subject to change without notice.

This Instruction Manual uses recycled paper.

MODEL

CODE

General-Purpose AC Servo

MR-J4-(DU)_B_-RJ020 MR-CR55K_ MR-J4-T20 SERVO AMPLIFIER INSTRUCTION MANUAL

HEAD OFFICE: TOKYO BLDG MARUNOUCHI TOKYO 100-8310

SERVO AMPLIFIER

INSTRUCTION MANUAL

Conversion Unit for SSCNET of MR-J2S-B

Compatible AC Servo

1CW814

MR-J4-B-RJ020 MR-J4-T20

INSTRUCTION

MODEL (Servo Amplifier)

MR-J4-_B_-RJ020

MODEL (Drive Unit)

MR-J4-DU_B_-RJ020

MODEL (Converter Unit)

MR-CR55K_

MODEL (Conversion Unit for SSCNET of MR-J2S-B)

MR-J4-T20

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 or inspection, turn off the power and wait for 15 minutes or more until the charge lamp

turns off. Then, confirm that the voltage between P+ and N- is safe with a voltage tester and others.

Otherwise, an electric shock may occur. In addition, when confirming whether the charge lamp is off or

not, always confirm it from the front of the servo amplifier.

Ground the servo amplifier and servo motor securely.

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

Do not attempt to wire the servo amplifier and servo motor until they have been installed. 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.

To avoid an electric shock, insulate the connections of the power supply terminals.

2. To prevent fire, note the following

CAUTION

Install the servo amplifier, servo motor, and regenerative resistor on incombustible material. Installing

them directly or close to combustibles will lead to smoke or a fire.

Always connect a magnetic contactor between the power supply and the main circuit power supply

(L1/L2/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 smoke or a fire when the servo amplifier malfunctions.

In order to configure a circuit that shuts down the power supply on the side of the servo amplifier’s power

supply, always connect one molded-case circuit breaker or fuse per one servo amplifier between the

power supply and the power supply (L1/L2/L3) of a servo amplifier. If a molded-case circuit breaker or

fuse is not connected, continuous flow of a large current may cause smoke or a fire when the servo

amplifier malfunctions.

When using the regenerative resistor, switch power off with the alarm signal. Otherwise, a regenerative

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

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

matter from entering the servo amplifier, servo motor, and MR-J4-T20.

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 the power is on

and for some time after power-off. Take safety measures such as providing covers to avoid accidentally

touching them by hands and parts such as cables.

4. Additional instructions

The following instructions should also be fully noted. Incorrect handling may cause a malfunction, injury,

electric shock, fire etc.

(1) Transportation and installation

CAUTION

Transport the products correctly according to their mass.

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. Otherwise, it may cause injury.

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 MR-J4-T20 which have been damaged or have any parts

missing.

Do not block the intake and exhaust areas of the servo amplifier and MR-J4-T20. Otherwise, it may

cause a malfunction.

Do not drop or strike the servo amplifier, servo motor, and MR-J4-T20. Isolate them from all impact

loads.

When you keep or use the equipment, please fulfill the following environment.

Item Environment

Ambient

temperature

Operation 0 °C to 55 °C (non-freezing)

Storage -20 °C to 65 °C (non-freezing)

Ambient

humidity

Operation

5 %RH to 90 %RH (non-condensing)

Storage

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

Altitude 2000 m or less above sea level (Contact your local sales office for the altitude for options.)

Vibration resistance 5.9 m/s

2

, at 10 Hz to 55 Hz (directions of X, Y and Z axes)

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

When handling the servo amplifier and MR-J4-T20, be careful about the edged parts such as corners of

them.

The servo amplifier and MR-J4-T20 must be installed in a metal cabinet.

A - 4

CAUTION

When fumigants that contain halogen materials such as fluorine, chlorine, bromine, and iodine are used

for disinfecting and protecting wooden packaging from insects, they cause 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.

(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 (optional FR-BIF(-H)) on the servo

amplifier output side.

To avoid a malfunction, connect the wires to the correct phase terminals (U/V/W) of the servo amplifier

and servo motor.

Connect the servo amplifier power output (U/V/W) to the servo motor power input (U/V/W) directly. Do

not let a magnetic contactor, etc. intervene. Otherwise, it may cause a malfunction.

U

Servo motor

M

V

W

U

V

W

U

M

V

W

U

V

W

Servo amplifier

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

24 V DC

Servo amplifier

RA

For sink output interface

Control output

signal

DOCOM

Control output

signal

24 V DC

Servo amplifier

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 of the incorrect axis to U, V, W, or CN2 of the servo amplifier may cause a

malfunction.

Configure a circuit to turn off EM2 or EM1 when the main circuit power is turned off to prevent an

unexpected restart of the servo amplifier.

A - 5

(3) Test run and adjustment

CAUTION

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

unexpectedly.

Never make a drastic adjustment or change to the parameter values as doing so will make the operation

unstable.

Do not get close to moving parts during the servo-on status.

(4) Usage

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 external brake to prevent the condition.

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.

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

Ensure safety by confirming the power off, etc. before performing corrective actions. Otherwise, it may

cause an accident.

When it is assumed that a hazardous condition may occur due to a power failure or product malfunction,

use a servo motor with an electromagnetic brake or external brake to prevent the condition.

Configure an electromagnetic brake circuit which is interlocked with an external emergency stop switch.

Servo motor

Electromagnetic brake

B

U

RA

Contacts must be opened

with the emergency stop switch.

Contacts must be opened when an

alarm occurs 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.

A - 6

(6) Maintenance, inspection and parts replacement

CAUTION

Make sure that the emergency stop circuit operates properly such that an operation can be stopped

immediately and a power is shut off by the emergency stop switch.

It is recommended that the servo amplifier be replaced every 10 years when it is used in general

environment.

When using the servo amplifier that has not been energized for an extended period of time, contact your

local sales office.

(7) General instruction

To illustrate details, the equipment in the diagrams of this Instruction Manual may have been drawn

without covers and safety guards. When the equipment is operated, the covers and safety guards must

be installed as specified. Operation must be performed in accordance with this Instruction Manual.

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

The STO function cannot be used when the servo amplifier is in the J2S compatibility mode.

To use the STO function, switch the operation mode to J4 mode. Refer to section 13.1 for the mode

switching procedure.

Compliance with global standards

Refer to app. 6 and 7 for the compliance with global standard.

A - 7

«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.

Servo amplifiers and drive units are written as servo amplifiers in this Instruction Manual under certain

circumstances, unless otherwise stated.

Relevant manuals

Manual name Manual No.

MELSERVO Servo Motor Instruction Manual (Vol. 3) SH(NA)030113ENG

MELSERVO Linear Encoder Instruction Manual (Note 1) SH(NA)030111ENG

MELSERVO-J4 Servo Amplifier Instruction Manual (Troubleshooting) (Note 2) SH(NA)030109ENG

MELSERVO-J4 Instructions and Cautions for Drive of HC/HA Series Servo Motor with MR-J4-

(DU)_B_-RJ020 (Note 3)

SH(NA)030127ENG

MELSERVO-J4 Conversion unit for SSCNET of MR-J2S-B MR-J4-T20 Installation Guide

(Packed with MR-J4-T20.)

IB(NA)0300204ENG

MELSERVO EMC Installation Guidelines IB(NA)67310ENG

Note 1. It is necessary for using the fully closed loop system.

2. It is necessary for using a converter unit.

3. It is necessary for using an HC series/HA series servo motor.

«Wiring»

Wires mentioned in this Instruction Manual are selected based on the ambient temperature of 40 °C.

A - 8

MEMO

1

CONTENTS

1. FUNCTIONS AND CONFIGURATION 1- 1 to 1-42

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

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

1.3 Standard specifications ..................................................................................................................... 1- 8

1.3.1 Servo amplifier standard specifications ..................................................................................... 1- 8

1.3.2 Conversion unit for SSCNET of MR-J2S-B ............................................................................... 1-13

1.4 Combinations of servo amplifiers and servo motors ....................................................................... 1-14

1.5 Function list ...................................................................................................................................... 1-16

1.6 Model designation ............................................................................................................................ 1-18

1.7 Structure .......................................................................................................................................... 1-19

1.7.1 Parts identification ..................................................................................................................... 1-19

1.7.2 Parts identification of MR-J4-T20 .............................................................................................. 1-26

1.7.3 Removal and reinstallation of the front cover............................................................................ 1-27

1.8 Installation and removal of MR-J4-T20 ............................................................................................ 1-29

1.9 Configuration including peripheral equipment ................................................................................. 1-33

2. INSTALLATION 2- 1 to 2- 8

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

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

2.3 Encoder cable stress ........................................................................................................................ 2- 4

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

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

2.6 Restrictions when using this product at altitude exceeding 1000 m and up to

2000 m above sea level .................................................................................................................... 2- 7

3. SIGNALS AND WIRING 3- 1 to 3-34

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

3.2 I/O signal connection example ......................................................................................................... 3-12

3.2.1 For sink I/O interface ................................................................................................................. 3-12

3.2.2 For source I/O interface ............................................................................................................ 3-14

3.3 Explanation of power supply system ............................................................................................... 3-15

3.3.1 Signal explanations ................................................................................................................... 3-15

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

3.3.3 Wiring CNP1, CNP2, and CNP3 ............................................................................................... 3-18

3.4 Connectors and pin assignment ...................................................................................................... 3-21

3.5 Signal (device) explanations ............................................................................................................ 3-23

3.5.1 Input device ............................................................................................................................... 3-23

3.5.2 Output device ............................................................................................................................ 3-23

3.5.3 Output signal ............................................................................................................................. 3-24

3.5.4 Power supply ............................................................................................................................. 3-24

3.6 Alarm occurrence timing chart ......................................................................................................... 3-25

3.7 Interfaces ......................................................................................................................................... 3-26

3.7.1 Internal connection diagram ...................................................................................................... 3-26

3.7.2 Detailed explanation of interfaces ............................................................................................. 3-27

3.7.3 Source I/O interfaces ................................................................................................................ 3-29

3.8 Servo motor with an electromagnetic brake .................................................................................... 3-30

2

3.8.1 Safety precautions .................................................................................................................... 3-30

3.8.2 Timing chart ............................................................................................................................... 3-31

3.9 Grounding ........................................................................................................................................ 3-34

4. STARTUP 4- 1 to 4-14

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- 5

4.2 Startup .............................................................................................................................................. 4- 6

4.3 Switch setting and display of the servo amplifier .............................................................................. 4- 7

4.3.1 Switches ..................................................................................................................................... 4- 7

4.3.2 Status display of an axis ............................................................................................................ 4- 9

4.4 Test operation .................................................................................................................................. 4-11

4.5 Test operation mode ........................................................................................................................ 4-11

4.5.1 Test operation mode in MR Configurator .................................................................................. 4-12

4.5.2 Motor-less operation in controller .............................................................................................. 4-14

5. PARAMETERS 5- 1 to 5-20

5.1 Parameter list .................................................................................................................................... 5- 1

5.1.1 Basic setting parameters ............................................................................................................ 5- 2

5.1.2 Adjustment parameters .............................................................................................................. 5- 2

5.1.3 Extension parameters ................................................................................................................ 5- 3

5.1.4 Extension parameters 2 ............................................................................................................. 5- 4

5.2 Detailed list of parameters ................................................................................................................ 5- 5

5.2.1 Basic setting parameters ............................................................................................................ 5- 5

5.2.2 Adjustment parameters ............................................................................................................. 5-10

5.2.3 Extension parameters ............................................................................................................... 5-14

6. NORMAL GAIN ADJUSTMENT 6- 1 to 6-10

6.1 Different adjustment methods ........................................................................................................... 6- 1

6.1.1 Adjustment on a single servo amplifier ...................................................................................... 6- 1

6.1.2 Adjustment using MR Configurator ............................................................................................ 6- 3

6.2 Auto tuning ........................................................................................................................................ 6- 3

6.2.1 Auto tuning mode ....................................................................................................................... 6- 3

6.2.2 Auto tuning mode basis .............................................................................................................. 6- 4

6.2.3 Adjustment procedure by auto tuning ........................................................................................ 6- 5

6.2.4 Response level setting in auto tuning mode .............................................................................. 6- 6

6.3 Manual mode 1 (simple manual adjustment) .................................................................................... 6- 7

6.3.1 Manual mode 1 basis ................................................................................................................. 6- 7

6.3.2 Adjustment by manual mode 1................................................................................................... 6- 7

6.4 Interpolation mode ............................................................................................................................ 6- 9

7. SPECIAL ADJUSTMENT FUNCTIONS 7- 1 to 7- 10

7.1 Filter setting ...................................................................................................................................... 7- 1

7.1.1 Machine resonance suppression filter ....................................................................................... 7- 1

7.1.2 Low-pass filter ............................................................................................................................ 7- 3

3

7.1.3 Adaptive vibration suppression control function ........................................................................ 7- 4

7.2 Gain switching function ..................................................................................................................... 7- 6

7.2.1 Applications ................................................................................................................................ 7- 6

7.2.2 Function block diagram .............................................................................................................. 7- 6

7.2.3 Parameter ................................................................................................................................... 7- 7

7.2.4 Gain switching procedure .......................................................................................................... 7- 9

8. TROUBLESHOOTING 8- 1 to 8-16

8.1 Alarm and warning list ...................................................................................................................... 8- 1

8.2 Remedies for alarms ......................................................................................................................... 8- 2

8.3 Remedies for warnings .................................................................................................................... 8-13

8.4 Troubleshooting at power on ........................................................................................................... 8-16

9. DIMENSIONS 9- 1 to 9-20

9.1 Servo amplifier .................................................................................................................................. 9- 1

9.2 MR-J4-T20 ....................................................................................................................................... 9-16

9.3 Connectors ....................................................................................................................................... 9-17

9.3.1 Servo amplifier side connectors ................................................................................................ 9-17

9.3.2 MR-J4-T20 connectors.............................................................................................................. 9-19

10. CHARACTERISTICS 10- 1 to 10-14

10.1 Overload protection characteristics .............................................................................................. 10- 1

10.2 Power supply capacity and generated loss .................................................................................. 10- 4

10.3 Dynamic brake characteristic s ...................................................................................................... 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 PERIPHERAL EQUIPMENT 11- 1 to 11-114

11.1 Cable/connector sets .................................................................................................................... 11- 1

11.1.1 Combinations of cable/connector sets ................................................................................... 11- 2

11.1.2 SSCNET cable ....................................................................................................................... 11- 6

11.1.3 RS-232C communication cable ............................................................................................ 11-10

11.1.4 Battery cable/junction battery cable ...................................................................................... 11-12

11.2 Regenerative option ..................................................................................................................... 11-13

11.2.1 Combination and regenerative power ................................................................................... 11-13

11.2.2 Selection of the regenerative option ..................................................................................... 11-15

11.2.3 Parameter setting .................................................................................................................. 11-17

11.2.4 Selection of the regenerative option ..................................................................................... 11-18

11.2.5 Dimensions ........................................................................................................................... 11-22

11.3 FR-BU2-(H) brake unit ................................................................................................................. 11-26

11.3.1 Selection................................................................................................................................ 11-27

11.3.2 Brake unit parameter setting ................................................................................................. 11-27

11.3.3 Connection example ............................................................................................................. 11-28

11.3.4 Dimensions ........................................................................................................................... 11-36

11.4 FR-RC-(H) power regeneration converter ................................................................................... 11-38

4

11.5 FR-CV-(H) power regeneration common converter .................................................................... 11-42

11.5.1 Model definition ..................................................................................................................... 11-42

11.5.2 Selection................................................................................................................................ 11-42

11.6 Junction terminal block PS7DW-20V14B-F (recommended) ...................................................... 11-49

11.7 MR Configurator .......................................................................................................................... 11-50

11.7.1 Specifications ........................................................................................................................ 11-50

11.7.2 Additional instructions ........................................................................................................... 11-51

11.7.3 System requirements ............................................................................................................ 11-52

11.7.4 Precautions for using RS-232C communication function ..................................................... 11-55

11.8 Battery .......................................................................................................................................... 11-56

11.8.1 Selection of battery ............................................................................................................... 11-56

11.8.2 MR-BAT6V1SET battery ....................................................................................................... 11-56

11.8.3 MR-BAT6V1BJ battery for junction battery cable ................................................................. 11-60

11.8.4 MR-BT6VCASE battery case ................................................................................................ 11-64

11.8.5 MR-BAT6V1 battery .............................................................................................................. 11-70

11.9 Selection example of wires .......................................................................................................... 11-71

11.10 Molded-case circuit breakers, fuses, magnetic contactors ....................................................... 11-76

11.11 Power factor improving DC reactor ........................................................................................... 11-79

11.12 Power factor improving AC reactor ............................................................................................ 11-82

11.13 Relay (recommended) ............................................................................................................... 11-85

11.14 Noise reduction techniques ....................................................................................................... 11-86

11.15 Earth-leakage current breaker ................................................................................................... 11-93

11.16 EMC filter (recommended) ........................................................................................................ 11-96

11.17 External dynamic brake ........................................................................................................... 11-103

11.18 Panel through attachment (MR-J4ACN15K/MR-J3ACN) ........................................................ 11-109

12. ABSOLUTE POSITION DETECTION SYSTEM 12- 1 to 12- 6

12.1 Summary ....................................................................................................................................... 12- 1

12.1.1 Features ................................................................................................................................. 12- 1

12.1.2 Structure ................................................................................................................................. 12- 2

12.1.3 Parameter setting ................................................................................................................... 12- 2

12.1.4 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- 5

12.2.3 Using MR-BT6VCASE battery case ....................................................................................... 12- 6

13. USING THE MR-J4-(DU)_B_-RJ020 IN THE J4 MODE 13- 1 to 13-66

13.1 Mode switching procedure ............................................................................................................ 13- 2

13.1.1 Switching from the J2S compatibility mode to the J4 mode .................................................. 13- 2

13.1.2 Switching from the J4 mode to the J2S compatibility mode .................................................. 13- 3

13.2 Parameter ..................................................................................................................................... 13- 3

13.2.1 Parameters for converter unit ................................................................................................ 13- 4

13.2.2 Parameters for converter unit/drive unit ................................................................................. 13- 7

13.3 Troubleshooting ........................................................................................................................... 13-51

13.3.1 Explanation for the lists ......................................................................................................... 13-51

13.3.2 Alarm list ................................................................................................................................ 13-52

13.3.3 Warning list ........................................................................................................................... 13-62

13.3.4 Troubleshooting at power on ................................................................................................ 13-65

5

14. MR-J4-DU_B_-RJ020 DRIVE UNIT/MR-CR55K_ CONVERTER UNIT 14- 1 to 14-124

14.1 Functions and configuration ......................................................................................................... 14- 1

14.1.1 Summary ................................................................................................................................ 14- 2

14.1.2 Function block diagram .......................................................................................................... 14- 3

14.1.3 Standard specifications .......................................................................................................... 14- 5

14.1.4 Combinations of converter units, drive units and servo motors ............................................. 14- 8

14.1.5 Model definition ...................................................................................................................... 14- 9

14.1.6 Structure ................................................................................................................................ 14-11

14.1.7 Configuration including peripheral equipment ...................................................................... 14-19

14.2 Installation .................................................................................................................................... 14-20

14.2.1 Installation direction and clearances ..................................................................................... 14-21

14.2.2 Keeping out of foreign materials ........................................................................................... 14-22

14.2.3 Inspection items .................................................................................................................... 14-22

14.2.4 Parts having service life ........................................................................................................ 14-23

14.2.5 Restrictions when using the servo amplifiers at altitude exceeding 1000 m and up to

2000 m above sea level ........................................................................................................ 14-24

14.3 Signals and wiring ........................................................................................................................ 14-25

14.3.1 Input power supply circuit ..................................................................................................... 14-26

14.3.2 Explanation of power supply system ..................................................................................... 14-36

14.3.3 Connectors and pin assignment ........................................................................................... 14-40

14.3.4 Signal (device) explanations ................................................................................................. 14-42

14.3.5 Alarm occurrence timing chart .............................................................................................. 14-43

14.3.6 Interfaces .............................................................................................................................. 14-49

14.3.7 Grounding ............................................................................................................................. 14-51

14.4 Start up ........................................................................................................................................ 14-52

14.4.1 Switching power on for the first time ..................................................................................... 14-53

14.4.2 Startup ................................................................................................................................... 14-56

14.4.3 Display and operation section of the converter unit .............................................................. 14-57

14.5 Parameters

.................................................................................................................................. 14-63

14.5.1 Parameters for converter unit ............................................................................................... 14-63

14.5.2 Parameters for drive unit ....................................................................................................... 14-66

14.6 Troubleshooting ........................................................................................................................... 14-67

14.7 Dimensions .................................................................................................................................. 14-68

14.7.1 Converter unit (MR-CR55K_) ................................................................................................ 14-69

14.7.2 Drive unit ............................................................................................................................... 14-70

14.8 Characteristics ............................................................................................................................. 14-72

14.8.1 Overload protection characteristics ...................................................................................... 14-72

14.8.2 Power supply capacity and generated loss .......................................................................... 14-74

14.8.3 Dynamic brake characteristics .............................................................................................. 14-76

14.8.4 Inrush currents at power-on of main circuit/control circuit .................................................... 14-79

14.9 Options and peripheral equipment .............................................................................................. 14-80

14.9.1 Cable/connector sets ............................................................................................................ 14-81

14.9.2 Regenerative option .............................................................................................................. 14-83

14.9.3 External dynamic brake......................................................................................................... 14-89

14.9.4 Selection example of wires ................................................................................................... 14-93

14.9.5 Molded-case circuit breakers, fuses, magnetic contactors ................................................... 14-95

14.9.6 Power factor improving DC reactor ....................................................................................... 14-97

14.9.7 Noise reduction techniques ................................................................................................... 14-98

14.9.8 Earth-leakage current breaker ............................................................................................ 14-102

6

14.9.9 EMC filter (recommended) .................................................................................................. 14-104

14.9.10 FR-BU2-(H) Brake Unit ..................................................................................................... 14-106

15. FULLY CLOSED LOOP SYSTEM 15- 1 to 15-40

15.1 Functions and configuration ......................................................................................................... 15- 1

15.1.1 Function block diagram .......................................................................................................... 15- 1

15.1.2 Selecting procedure of control mode ..................................................................................... 15- 3

15.1.3 System configuration .............................................................................................................. 15- 4

15.2 Load-side encoder ........................................................................................................................ 15- 5

15.2.1 Linear encoder ....................................................................................................................... 15- 6

15.2.2 Rotary encoder ....................................................................................................................... 15- 7

15.2.3 Configuration diagram of encoder cable ................................................................................ 15- 7

15.3 Operation and functions ................................................................................................................ 15- 8

15.3.1 Startup .................................................................................................................................... 15- 8

15.3.2 Home position return ............................................................................................................. 15-17

15.3.3 Operation from controller ...................................................................................................... 15-24

15.3.4 Fully closed loop control error detection functions................................................................ 15-27

15.3.5 Auto tuning function .............................................................................................................. 15-28

15.3.6 Machine analyzer function .................................................................................................... 15-28

15.3.7 Test operation mode ............................................................................................................. 15-28

15.3.8 Absolute position detection system under fully closed loop system ..................................... 15-29

15.3.9 About MR Configurator ......................................................................................................... 15-30

15.4 Detailed list of parameters ........................................................................................................... 15-33

15.4.1 Basic setting parameters ...................................................................................................... 15-33

15.4.2 Adjustment parameters ......................................................................................................... 15-34

15.4.3 Extension parameters ........................................................................................................... 15-36

15.5 Troubleshooting ........................................................................................................................... 15-39

15.6 Details on linear encoder errors ([AL. 2A]) for respective manufacturers ................................... 15-39

APPENDIX App. - 1 to App. -58

App. 1 Using the HC series/HA series servo motor ......................................................................... App.- 1

App. 2 Linear encoders compatible with MR-J2S ............................................................................ App.- 3

App. 3 Peripheral equipment manufacturer (for reference) .............................................................. App.- 4

App. 4 Handling of AC servo amplifier batteries for the United Nations Recommendations

on the Transport of Dangerous Goods ................................................................................. App.- 4

App. 5 Symbol for the new EU Battery Directive .............................................................................. App.- 7

App. 6 Compliance with global standards for servo amplifier .......................................................... App.- 8

App. 7 Compliance with global standards for converter unit and drive unit .................................... App.-24

App. 8 Analog monitor ..................................................................................................................... App.-38

App. 9 Special specification ............................................................................................................. App.-47

App. 10 Setting of added parameters for MR-J4-_B_-RJ020 servo amplifier ................................... App.-49

App. 11 Driving on/off of main circuit power supply with DC power supply ...................................... App.-56

App. 12 Status of general-purpose AC servo products for compliance

with the China RoHS directive ............................................................................................. App.-57

1. FUNCTIONS AND CONFIGURATION

1 - 1

1. FUNCTIONS AND CONFIGURATION

POINT

Refer to chapter 14 for the MR-CR55K_ converter unit and MR-J4-DU_B_-

RJ020 drive unit.

1.1 Summary

This Instruction Manual explains about the MR-J4-_B_-RJ020 AC servo amplifiers compatible with a

conversion unit for SSCNET of MR-J2S-B, and the MR-J4-T20 conversion unit for SSCNET of MR-J2S-B.

Always use MR-J4-T20 with MR-J4-_B_-RJ020.

MR-J4-_B_-RJ020 can be connected to SSCNET of MR-J2S-B by being used with MR-J4-T20.

MR-J4-_B_-RJ020 servo amplifiers have "J2S compatibility mode (factory setting)" and "J4 mode" as the

operation mode. The "J2S compatibility mode" is the operation mode compatible with the previous functions

of the MR-J2S-B series.

This Instruction Manual explains when the "J2S compatibility mode" is used except for in chapter 13.

When using the servo amplifier in "J4 mode", refer to chapter 13.

When you use an MR-J4-_B_-RJ020 servo amplifier, please note the following items.

(1) When an HG series servo motor is used in the J2S compatibility mode, the encoder resolution per servo

motor revolution will be 131072 pulses/rev (17 bits), not 4194303 pulses/rev (22 bits)

(2) It may be required to change existing equipment program because the initialization time after power on

is different between MR-J2S-_B_ servo amplifier and MR-J4-_B_-RJ020 servo amplifier. Especially

when using it in vertical motion applications, please be careful of electromagnetic brake release time.

The moving part can fall.

(3) Motor-less operation cannot be used with MR Configurator. To use motor-less operation, set "_ 1 _ _" in

[Pr. 24].

(4) When using [Pr. 13 Position loop gain 1] of MR-J4-_B_-RJ020 and MR-J2S-_B_ simultaneously such as

in the interpolation mode, check droop pulses for each axis and readjust gains as necessary.

(5) MR-J4-_B_-RJ020 servo amplifier is not compatible with adaptive vibration suppression control.

(6) Power is not supplied from the SSCNET cable connection connector to the encoder. When using the

MR-J4-_B_-RJ020 servo amplifier in absolute position detection system, always connect a battery to the

CN4 connector.

(7) When the servo amplifier is set to the J2S compatibility mode, it supports the fully closed loop system. In

the fully closed loop control mode, when an HG series servo motor is used for the load-side encoder, the

resolution of the load-side encoder will be 131072 pulses/rev (17 bits), which is the same as that of the

servo motor side. Refer to chapter 15 for details.

1. FUNCTIONS AND CONFIGURATION

1 - 2

1.2 Function block diagram

The function block diagram of this servo is shown below.

(1) MR-J4-500B-RJ020 or less/MR-J4-350B4-RJ020 or less

L11

L21

(Note 6)

Cooling fan

(Note 3)

Encoder

N-CD

L3

L2

L1

Dynamic

brake circuit

(Note 5)

Power factor improving

DC reactor

Current

detection

Overcurrent

protection

Voltage

detection

(Note 2)

Power

supply

MCMCCB

Base

amplifier

STO

circuit

CN5

USB D/A

Analog monitor

(2 channels)

CN3

Servo amplifier

U

V

W

U

V

W

P3 P4 (Note 4)

Diode

stack

Relay

P+

+

B

RA

24 V DC

B1

B2

M

CN2

CN8

Control

circuit

power

supply

Servo motor

CHARGE

lamp

Regene-

rative

TR

Current

encoder

Digital

I/O control

Regenerative

option

U U

U

RS-232C

CN30

RS-232C

Personal

computer

Servo system

controller or

servo amplifier

Servo amplifier

or termination

connector

CN10A CN10B

MR-J4-T20

(Note 7)

CN7 CN9

I/F Control

(Note 1)

Electromagnetic

brake

Model position

Current

control

Actual

position

control

Actual

speed

control

Virtual

motor

Virtual

encoder

Position

command

input

Battery

(for absolute position

detection system)

CN4

Model speed Model torque

Model

position

control

Model

speed

control

Step-

down

circuit

CN2L

External encoder

1. FUNCTIONS AND CONFIGURATION

1 - 3

Note 1. The built-in regenerative resistor is not provided for MR-J4-10B-RJ020.

2. For 1-phase 200 V AC to 240 V AC, connect the power supply to L1 and L3. Leave L2 open.

For power supply specifications, refer to section 1.3.1.

3. The MR-J4-70B-RJ020 or more, MR-J4-200B4-RJ020 and MR-J4-350B4-RJ020 servo amplifiers have a cooling fan.

4. 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 MR-J3 servo amplifiers.

5. 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.

6. This is not used when the servo amplifier is in the J2S compatibility mode. Always attach the short-circuit connector came with

a servo amplifier.

7. Used to change the servo amplifier mode. Refer to section 13.1 for the mode selection procedure.

1. FUNCTIONS AND CONFIGURATION

1 - 4

(2) MR-J4-700B-RJ020/MR-J4-500B4-RJ020/MR-J4-700B4-RJ020

CN5

USB D/A

CN3

L11

L21

N-C

MCMCCB

U

V

W

U

V

W

P3 P4 (Note 2)

P+

+

B

RA

24 V DC

B1

B2

M

CN2

CN8

L3

L2

L1

U U

U

(Note 4)

RS-232C

CN30

RS-232C

CN10A CN10B

MR-J4-T20

(Note 5)

CN7

CN9

(Note 1)

Power

supply

(Note 3)

Power factor improving

DC reactor

Servo amplifier

Diode

stack

Relay

Regenerative

option

Dynamic

brake circuit

Servo motor

CHARGE

lamp

Regene-

rative

TR

Current

encoder

Cooling fan

Electromagnetic

brake

Encoder

Current

detection

Overcurrent

protection

Voltage

detection

Base

amplifier

STO

circuit

Control

circuit

power

supply

Analog monitor

(2 channels)

Digital

I/O control

Personal

computer

Servo system

controller or

servo amplifier

Servo amplifier

or termination

connector

I/F Control

Model position

Current

control

Actual

position

control

Actual

speed

control

Virtual

motor

Virtual

encoder

Position

command

input

Battery

(for absolute position

detection system)

CN4

Model speed Model torque

Model

position

control

Model

speed

control

Step-

down

circuit

CN2L

External encoder

Note 1. For power supply specifications, refer to section 1.3.1.

2. 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 MR-J3 servo amplifiers.

3. 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.

4. This is not used when the servo amplifier is in the J2S compatibility mode. Always attach the short-circuit connector came with

a servo amplifier.

5. Used to change the servo amplifier mode. Refer to section 13.1 for the mode selection procedure.

1. FUNCTIONS AND CONFIGURATION

1 - 5

(3) MR-J4-11KB-RJ020/MR-J4-15KB-RJ020/MR-J4-22KB-RJ020/MR-J4-11KB4-RJ020/

MR-J4-15KB4-RJ020/MR-J4-22KB4-RJ020

Current

detector

L11

L21

Cooling fan

Encoder

N-C

Power factor

improving DC reactor

Current

detection

Overcurrent

protection

Voltage

detection

(Note 1)

Power

supply

MCMCCB

Base

amplifier

STO

circuit

D/A

Analog monitor

(2 channels)

CN3

Servo amplifier

P3 P4

(Note 2)

P+

+

B

RA

24 V DC

B1

B2

M

CN2

Control

circuit

power

supply

Servo motor

Charge

lamp

Regene-

rative

TR

Digital

I/O control

Regenerative resistor

or

regenerative option

L3

L2

L1

U U

U

Thyristor

(Note 6)

External

dynamic brake

(optional)

U

V

W

U

V

W

(Note 3)

Diode

stack

CN8

CN5

USB

I/F Control

RS-232C

CN30

RS-232C

Personal

computer

Servo system

controller or

servo amplifier

Servo amplifier

or terminal

connector

CN10A CN10B

MR-J4-T20

(Note 5)

CN7 CN9

(Note 4)

Electromagnetic

brake

Model position

Current

control

Actual

position

control

Actual

speed

control

Virtual

motor

Virtual

encoder

Position

command

input

Battery

(for absolute position

detection system)

CN4

Model speed Model torque

Model

position

control

Model

speed

control

Step-

down

circuit

CN2L

External encoder

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Mitsubishi Electric Conversion Unit for SSCNET of MR-J2S-B Compatible AC Servo MR-J4-_B_-RJ020/MR-J4-DU_B_-RJ020/MR-CR55K_/MR-J4-T20 SERVO AMPLIFIER User manual

Mitsubishi Electric Conversion Unit for SSCNET of MR-J2S-B Compatible AC Servo MR-J4-_B_-RJ020/MR-J4-DU_B_-RJ020/MR-CR55K_/MR-J4-T20 SERVO AMPLIFIER User manual

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