Mitsubishi MR-J3 User manual

SH (NA) 030058-E (0806) MEE Printed in Japan Specifications subject to change without notice.

This Instruction Manual uses recycled paper.

MODEL

CODE

HEAD OFFICE : TOKYO BLDG MARUNOUCHI TOKYO 100-8310

J3 Series MR-J3- T Servo Amplifier Instruction Manual (CC-Link)

E

General-Purpose AC Servo

MODEL

MR-J3- T

SERVO AMPLIFIER

INSTRUCTION MANUAL

(CC-Link)

Built-in Positioning Function

J3 Series

E

A - 1

Safety Instructions

(Always read these instructions before using the equipment.)

Do not attempt to install, operate, maintain or inspect the servo amplifier 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 servo amplifier 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 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, always confirm from the front of the servo amplifier,

whether the charge lamp is off or not.

Connect the servo amplifier 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 servo amplifier 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 of the servo amplifier. You may get 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 or periodic inspection, do not remove the front cover even of the servo amplifier if the

power is off. The servo amplifier is charged and you may get an electric shock.

2. To prevent fire, note the following

CAUTION

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

directly or close to combustibles will lead to a fire.

Always connect a magnetic contactor (MC) between the main circuit power supply and L1, L2, and L3 of

the servo amplifier, and configure the wiring to be able to shut down the power supply on the side of the

servo amplifier’s power supply. If a magnetic contactor (MC) is not connected, continuous flow of a large

current may cause a fire when the servo amplifier 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.

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 servo amplifier 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.

A - 3

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 weights.

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 servo amplifier. The servo amplifier may drop.

Install the servo amplifier 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 servo amplifier and servo motor must be installed in the specified direction.

Leave specified clearances between the servo amplifier and control enclosure walls or other equipment.

Do not install or operate the servo amplifier and servo motor which has been damaged or has any parts

missing.

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

matter from entering the servo amplifier and servo motor.

Do not drop or strike servo amplifier or servo motor. Isolate from all impact loads.

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

Conditions

Environment

Servo amplifier Servo motor

[

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

In operation

[

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

[

]

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

Ambient

temperature

In storage

[

]

4 to 149 (non-freezing)

5 to 158 (non-freezing)

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

Ambient

humidity

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

HF-MP series HF-KP series X Y: 49

HF-SP51 81 HF-SP52 to 152

HF-SP524 to 1524 HC-RP Series

HC-UP72

152

X

Y: 24.5

HF-SP121

201 HF-SP202 352

HF-SP2024

3524 HC-UP202 to 502

X: 24.5 Y: 49

HF-SP301 421 HF-SP502 702

HF-SP5024

7024

X: 24.5 Y: 29.4

HC-LP52 to 152 X: 9.8 Y: 24.5

HC-LP202 to 302 X: 19.6 Y: 49

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

HA-LP502 to 22K2 HA-LP6014 to 12K14

HA-LP701M4 to 15K1M4 HA-LP11K24 to 22K24

X: 11.7 Y: 29.4

(Note)

Vibration

[m/s

2

] 5.9 or less

HA-LP15K1 to 25K1 HA-LP37K1M

HA-LP15K14 to 20K14 HA-LP22K1M4

X

Y: 9.8

Note. Except the servo motor with a reduction gear.

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

operation.

The servo motor with a 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.

When the equipment has been stored for an extended period of time, consult Mitsubishi.

A - 4

(2) Wiring

CAUTION

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

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

servo motor and servo amplifier.

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

U

M

V

W

U

V

W

Servo amplifier

Servo motorServo amplifier

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

The surge absorbing diode installed on the DC output signal relay of the servo amplifier must be wired in

the specified direction. Otherwise, the forced stop (EMG) and other protective circuits may not operate.

Control

output

signal

RA

DOCOM

DICOM

24VDC

Control

output

signal

RA

DOCOM

DICOM

24VDC

Servo amplifier Servo amplifier

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.

A - 5

(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 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 servo amplifier.

Burning or breaking a servo amplifier may cause a toxic gas. Do not burn or break a servo amplifier.

Use the servo amplifier with the specified servo motor.

The electromagnetic brake on the servo motor is designed to hold the motor shaft and should not be used

for ordinary braking.

For such reasons as service life and mechanical structure (e.g. where a ball screw and the servo motor

are coupled via a timing belt), the electromagnetic brake may not hold the motor shaft. To ensure safety,

install a stopper on the machine side.

(5) Corrective actions

CAUTION

When it is assumed that a hazardous condition may 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 the electromagnetic brake circuit so that it is activated not only by the servo amplifier signals

but also by an external forced stop (EMG).

Contacts must be open when

servo-off, when an trouble (ALM)

and when an electromagnetic brake

interlock (MBR).

Circuit must be

opened during

forced stop (EMG).

Electromagnetic brake

SON RA

EMG

24VDC

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 servo amplifier 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 consult our sales representative.

A - 6

(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.

About processing of waste

When you discard servo amplifier, a battery (primary battery), and other option articles, please follow the law of

each country (area).

FOR MAXIMUM SAFETY

These products have been manufactured as a general-purpose part for general industries, and have not

been designed or manufactured to be incorporated in a device or system used in purposes related to

human life.

Before using the products for special purposes such as nuclear power, electric power, aerospace,

medicine, passenger movement vehicles or under water relays, contact Mitsubishi.

These products have been manufactured under strict quality control. However, when installing the product

where major accidents or losses could occur if the product fails, install appropriate backup or failsafe

functions in the system.

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 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

Write to the EEP-ROM due to point table 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.

A - 7

COMPLIANCE WITH EC DIRECTIVES

1. WHAT ARE EC DIRECTIVES?

The EC directives were issued to standardize the regulations of the EU countries and ensure smooth

distribution of safety-guaranteed products. In the EU countries, the machinery directive (effective in January,

1995), EMC directive (effective in January, 1996) and low voltage directive (effective in January, 1997) of the

EC directives require that products to be sold should meet their fundamental safety requirements and carry the

CE marks (CE marking). CE marking applies to machines and equipment into which servo amplifiers have

been installed.

(1) EMC directive

The EMC directive applies not to the servo units alone but to servo-incorporated machines and equipment.

This requires the EMC filters to be used with the servo-incorporated machines and equipment to comply

with the EMC directive. For specific EMC directive conforming methods, refer to the EMC Installation

Guidelines (IB(NA)67310).

(2) Low voltage directive

The low voltage directive applies also to servo units alone. Hence, they are designed to comply with the low

voltage directive.

This servo is certified by TUV, third-party assessment organization, to comply with the low voltage directive.

(3) Machine directive

Not being machines, the servo amplifiers need not comply with this directive.

2. PRECAUTIONS FOR COMPLIANCE

(1) Servo amplifiers and servo motors used

Use the servo amplifiers and servo motors which comply with the standard model.

Servo amplifier :MR-J3-10T to MR-J3-22KT

MR-J3-10T1 to MR-J3-40T1

MR-J3-60T4 to MR-J3-22KT4

Servo motor :HF-MP

HF-KP

HF-SP

(Note)

HF-SP

4 (Note)

HC-RP

HC-UP

HC-LP

HA-LP

(Note)

HA-LP

4 (Note)

Note. For the latest information of compliance, contact Mitsubishi.

A - 8

(2) Configuration

The control circuit provide safe separation to the main circuit in the servo amplifier.

NFB

MC

No-fuse

breaker

Magnetic

contactor

Reinforced

insulating type

24VDC

power

supply

Servo

amplifier

Servo

motor

Control box

M

(3) Environment

Operate the servo amplifier at or above the contamination level 2 set forth in IEC60664-1. For this purpose,

install the servo amplifier in a control box which is protected against water, oil, carbon, dust, dirt, etc. (IP54).

(4) Power supply

(a) This servo amplifier can be supplied from star-connected supply with earthed neutral point of

overvoltage category III set forth in IEC60664-1. However, when using the neutral point of 400V class

for single-phase supply, a reinforced insulating transformer is required in the power input section.

(b) When supplying interface power from external, use a 24VDC power supply which has been insulation-

reinforced in I/O.

(5) Grounding

(a) To prevent an electric shock, always connect the protective earth (PE) terminals (marked

) of the

servo amplifier to the protective earth (PE) of the control box.

(b) Do not connect two ground cables to the same protective earth (PE) terminal (marked

). Always

connect the cables to the terminals one-to-one.

PE terminals

(c) If a leakage current breaker is used to prevent an electric shock, the protective earth (PE) terminals

(marked

) of the servo amplifier must be connected to the corresponding earth terminals.

A - 9

(6) Wiring

(a) The cables to be connected to the terminal block of the servo amplifier must have crimping terminals

provided with insulating tubes to prevent contact with adjacent terminals.

Crimping terminal

Insulating tube

Cable

(b) Use the servo motor side power connector which complies with the EN Standard. The EN Standard

compliant power connector sets are available from us as options. (Refer to section 14.1)

(7) Auxiliary equipment and options

(a) The no-fuse breaker and magnetic contactor used should be the EN or IEC standard-compliant

products of the models described in section 14.10.

Use a type B (Note) breaker. When it is not used, provide insulation between the servo amplifier and

other device by double insulation or reinforced insulation, or install a transformer between the main

power supply and servo amplifier.

Note. Type A: AC and pulse detectable

Type B: Both AC and DC detectable

(b) The sizes of the cables described in section 14.9 meet the following requirements. To meet the other

requirements, follow Table 5 and Appendix C in EN60204-1.

Ambient temperature: 40 (104) [°C (°F)]

Sheath: PVC (polyvinyl chloride)

Installed on wall surface or open table tray

(c) Use the EMC filter for noise reduction.

(8) Performing EMC tests

When EMC tests are run on a machine/device into which the servo amplifier has been installed, it must

conform to the electromagnetic compatibility (immunity/emission) standards after it has satisfied the

operating environment/electrical equipment specifications.

For the other EMC directive guidelines on the servo amplifier, refer to the EMC Installation Guidelines

(IB(NA)67310).

A - 10

CONFORMANCE WITH UL/C-UL STANDARD

(1) Servo amplifiers and servo motors used

Use the servo amplifiers and servo motors which comply with the standard model.

Servo amplifier :MR-J3-10T to MR-J3-22KT

MR-J3-10T1 to MR-J3-40T1

MR-J3-60T4 to MR-J3-22KT4

Servo motor :HF-MP

HF-KP

HF-SP

(Note)

HF-SP

4 (Note)

HC-RP

HC-UP

HC-LP

HA-LP

(Note)

HA-LP

4 (Note)

Note. For the latest information of compliance, contact Mitsubishi.

(2) Installation

Install a fan of 100CFM (2.8m

3

/min) air flow 4[in] (10.16[cm]) above the servo amplifier or provide cooling

of at least equivalent capability to ensure that the ambient temperature conforms to the environment

conditions (55

or less).

(3) Short circuit rating (SCCR: Short Circuit Current Rating)

Suitable For Use In A Circuit Capable Of Delivering Not More Than 100 kA rms Symmetrical Amperes, 500

Volts Maximum.

(4) Capacitor discharge time

The capacitor discharge time is as listed below. To ensure safety, do not touch the charging section for 15

minutes after power-off.

Servo amplifier

Discharge time

[min]

MR-J3-10T 20T 1

MR-J3-40T 60T(4) 10T1 20T1 2

MR-J3-70T 3

MR-J3-40T1 4

MR-J3-100T(4) 5

MR-J3-200T(4) 350T 9

MR-J3-350T4 500T(4) 700T(4) 10

MR-J3-11KT(4) 4

MR-J3-15KT(4) 6

MR-J3-22KT(4) 8

A - 11

(5) Options and auxiliary equipment

Use UL/C-UL standard-compliant products.

(6) Attachment of a servo motor

For the flange size of the machine side where the servo motor is installed, refer to “CONFORMANCE WITH

UL/C-UL STANDARD” in the Servo Motor Instruction Manual (Vol.2).

(7) About wiring protection

For installation in United States, branch circuit protection must be provided, in accordance with the National

Electrical Code and any applicable local codes.

For installation in Canada, branch circuit protection must be provided, in accordance with the Canada

Electrical Code and any applicable provincial codes.

<<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-T for the first time. Always purchase them and use the MR-J3-T

safely.

Relevant manuals

Manual name Manual No.

MELSERVO-J3 Series Instructions and Cautions for Safe Use of AC Servos IB(NA)0300077

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

EMC Installation Guidelines IB(NA)67310

<<About the wires used for wiring>>

Wiring wires mentioned in this instruction manual are selected based on the ambient temperature of 40°C

(104

).

A - 12

MEMO

1

CONTENTS

1. FUNCTIONS AND CONFIGURATION 1 - 1 to 1 -36

1.1 Introduction............................................................................................................................................... 1 - 1

1.1.1 Features of CC-Link communication functions ................................................................................ 1 - 1

1.1.2 Function block diagram..................................................................................................................... 1 - 2

1.1.3 System configuration......................................................................................................................... 1 - 5

1.2 Servo amplifier standard specifications................................................................................................... 1 - 7

1.3 Function list ............................................................................................................................................. 1 -13

1.4 Model code definition .............................................................................................................................. 1 -15

1.5 Combination with servo motor ................................................................................................................ 1 -16

1.6 Structure .................................................................................................................................................. 1 -17

1.6.1 Parts identification ............................................................................................................................ 1 -17

1.6.2 Removal and reinstallation of the front cover.................................................................................. 1 -23

1.7 Configuration including auxiliary equipment .......................................................................................... 1 -26

1.8 Selection of operation method................................................................................................................ 1 -34

2. INSTALLATION 2 - 1 to 2 - 4

2.1 Installation direction and clearances ....................................................................................................... 2 - 1

2.2 Keep out foreign materials....................................................................................................................... 2 - 3

2.3 Cable stress ............................................................................................................................................. 2 - 3

2.4 Inspection items ....................................................................................................................................... 2 - 4

2.5 Parts having service lives ........................................................................................................................ 2 - 4

3. CC-LINK COMMUNICATION FUNCTIONS 3 - 1 to 3 -60

3.1 Communication specifications ................................................................................................................. 3 - 1

3.2 System configuration ............................................................................................................................... 3 - 2

3.2.1 Configuration example ...................................................................................................................... 3 - 2

3.2.2 Wiring method ................................................................................................................................... 3 - 3

3.2.3 Station number setting ...................................................................................................................... 3 - 5

3.2.4 Communication baud rate setting..................................................................................................... 3 - 6

3.2.5 Occupied station count setting.......................................................................................................... 3 - 6

3.3 Functions .................................................................................................................................................. 3 - 7

3.3.1 Function block diagram..................................................................................................................... 3 - 7

3.3.2 Functions ........................................................................................................................................... 3 - 7

3.4 Servo amplifier setting ............................................................................................................................. 3 - 8

3.5 I/O signals (I/O devices) transferred to/from the programmable controller CPU ................................... 3 - 9

3.5.1 I/O signals (I/O devices).................................................................................................................... 3 - 9

3.5.2 Detailed explanation of I/O signals .................................................................................................. 3 -12

3.5.3 Monitor codes ................................................................................................................................... 3 -22

3.5.4 Instruction codes (RWwn+2

RWwn+3) ......................................................................................... 3 -23

3.5.5 Respond codes (RWrn+2) ............................................................................................................... 3 -31

3.5.6 Setting the CN6 external input signals ............................................................................................ 3 -32

3.6 Data communication timing charts ......................................................................................................... 3 -34

3.6.1 Monitor codes ................................................................................................................................... 3 -34

3.6.2 Instruction codes .............................................................................................................................. 3 -36

2

3.6.3 Remote register-based position/speed setting................................................................................ 3 -38

3.7 Function-by-function programming examples........................................................................................ 3 -41

3.7.1 System configuration example......................................................................................................... 3 -41

3.7.2 Reading the servo amplifier status .................................................................................................. 3 -44

3.7.3 Writing the operation commands..................................................................................................... 3 -45

3.7.4 Reading the data .............................................................................................................................. 3 -46

3.7.5 Writing the data ................................................................................................................................ 3 -49

3.7.6 Operation .......................................................................................................................................... 3 -52

3.8 Continuous operation program example................................................................................................ 3 -55

3.8.1 System configuration example when 1 station is occupied ............................................................ 3 -55

3.8.2 Program example when 1 station is occupied ................................................................................3 -56

3.8.3 System configuration example when 2 stations are occupied........................................................ 3 -58

3.8.4 Program example when 2 stations are occupied ............................................................................ 3 -59

4. SIGNALS AND WIRING 4 - 1 to 4 -54

4.1 Input power supply circuit ........................................................................................................................ 4 - 2

4.2 I/O signal connection diagram ................................................................................................................ 4 -10

4.3 Explanation of power supply system ...................................................................................................... 4 -11

4.3.1 Signal explanations .......................................................................................................................... 4 -11

4.3.2 Power-on sequence .........................................................................................................................4 -12

4.3.3 CNP1, CNP2, CNP3 wiring method ................................................................................................ 4 -14

4.4 Connectors and signal arrangements .................................................................................................... 4 -22

4.5 Signal (device) explanation..................................................................................................................... 4 -23

4.5.1 I/O devices........................................................................................................................................ 4 -23

4.5.2 Input signals ..................................................................................................................................... 4 -26

4.5.3 Output signals................................................................................................................................... 4 -26

4.5.4 Power supply.................................................................................................................................... 4 -27

4.6 Detailed description of signals (devices)................................................................................................ 4 -27

4.6.1 Forward rotation start

reverse rotation start temporary stop/restart........................................... 4 -27

4.6.2 Movement completion

rough match in position .......................................................................... 4 -28

4.6.3 Torque limit....................................................................................................................................... 4 -30

4.7 Alarm occurrence timing chart................................................................................................................ 4 -31

4.8 Interface................................................................................................................................................... 4 -32

4.8.1 Internal connection diagram ............................................................................................................ 4 -32

4.8.2 Detailed description of interfaces..................................................................................................... 4 -33

4.8.3 Source I/O interfaces .......................................................................................................................4 -35

4.9 Treatment of cable shield external conductor ........................................................................................ 4 -36

4.10 Connection of servo amplifier and servo motor ................................................................................... 4 -37

4.10.1 Connection instructions.................................................................................................................. 4 -37

4.10.2 Power supply cable wiring diagrams ............................................................................................. 4 -38

4.11 Servo motor with an electromagnetic brake......................................................................................... 4 -48

4.11.1 Safety precautions ......................................................................................................................... 4 -48

4.11.2 Timing charts.................................................................................................................................. 4 -49

4.11.3 Wiring diagrams (HF-MP series

HF-KP series servo motor) ..................................................... 4 -52

4.12 Grounding.............................................................................................................................................. 4 -53

3

5. OPERATION 5 - 1 to 5 -60

5.1 Switching power on for the first time ....................................................................................................... 5 - 1

5.1.1 Startup procedure.............................................................................................................................. 5 - 1

5.1.2 Wiring check ...................................................................................................................................... 5 - 2

5.1.3 Surrounding environment.................................................................................................................. 5 - 3

5.2 Startup ...................................................................................................................................................... 5 - 4

5.2.1 Power on and off procedures............................................................................................................ 5 - 4

5.2.2 Stop.................................................................................................................................................... 5 - 4

5.2.3 Test operation.................................................................................................................................... 5 - 5

5.2.4 Parameter setting .............................................................................................................................. 5 - 6

5.2.5 Point table setting.............................................................................................................................. 5 - 7

5.2.6 Actual operation ................................................................................................................................ 5 - 7

5.3 Servo amplifier display............................................................................................................................. 5 - 8

5.4 Automatic operation mode...................................................................................................................... 5 -10

5.4.1 What is automatic operation mode?................................................................................................ 5 -10

5.4.2 Automatic operation using point table ............................................................................................. 5 -12

5.4.3 Remote register-based position/speed setting................................................................................ 5 -22

5.5 Manual operation mode .......................................................................................................................... 5 -28

5.5.1 JOG operation .................................................................................................................................. 5 -28

5.5.2 Manual pulse generator ................................................................................................................... 5 -29

5.6 Manual home position return mode........................................................................................................ 5 -31

5.6.1 Outline of home position return........................................................................................................ 5 -31

5.6.2 Dog type home position return......................................................................................................... 5 -34

5.6.3 Count type home position return ..................................................................................................... 5 -36

5.6.4 Data setting type home position return............................................................................................ 5 -38

5.6.5 Stopper type home position return .................................................................................................. 5 -39

5.6.6 Home position ignorance (servo-on position defined as home position) ....................................... 5 -41

5.6.7 Dog type rear end reference home position return ......................................................................... 5 -42

5.6.8 Count type front end reference home position return ..................................................................... 5 -44

5.6.9 Dog cradle type home position return ............................................................................................. 5 -46

5.6.10 Dog type first Z-phase reference home position return ................................................................ 5 -48

5.6.11 Dog type front end reference home position return method......................................................... 5 -50

5.6.12 Dogless Z-phase reference home position return method ........................................................... 5 -52

5.6.13 Home position return automatic return function ............................................................................ 5 -54

5.6.14 Automatic positioning function to the home position..................................................................... 5 -55

5.7 Roll feed display function in roll feed mode............................................................................................ 5 -56

5.8 Absolute position detection system ........................................................................................................ 5 -57

6. PARAMETERS 6 - 1 to 6 -40

6.1 Basic setting parameters (No.PA )................................................................................................... 6 - 1

6.1.1 Parameter list .................................................................................................................................... 6 - 1

6.1.2 Parameter write inhibit ...................................................................................................................... 6 - 2

6.1.3 Selection of command system.......................................................................................................... 6 - 3

6.1.4 Selection of regenerative option ....................................................................................................... 6 - 3

6.1.5 Using absolute position detection system ........................................................................................ 6 - 4

6.1.6 Follow-up for absolute value command system in incremental system .......................................... 6 - 4

6.1.7 Feeding function selection ................................................................................................................ 6 - 5

4

6.1.8 Electronic gear................................................................................................................................... 6 - 6

6.1.9 Auto tuning ........................................................................................................................................ 6 - 7

6.1.10 In-position range.............................................................................................................................. 6 - 8

6.1.11 Torque limit...................................................................................................................................... 6 - 9

6.1.12 Selection of servo motor rotation direction.................................................................................... 6 -10

6.1.13 Encoder output pulse ..................................................................................................................... 6 -10

6.2 Gain/filter parameters (No. PB

)...................................................................................................... 6 -12

6.2.1 Parameter list ................................................................................................................................... 6 -12

6.2.2 Detail list ........................................................................................................................................... 6 -13

6.3 Extension setting parameters (No. PC

) ......................................................................................... 6 -20

6.3.1 Parameter list ................................................................................................................................... 6 -20

6.3.2 Detail list ........................................................................................................................................... 6 -21

6.3.3 S-pattern acceleration/deceleration................................................................................................. 6 -27

6.3.4 Alarm history clear............................................................................................................................ 6 -27

6.3.5 Rough match output......................................................................................................................... 6 -27

6.3.6 Software limit .................................................................................................................................... 6 -28

6.4 I/O setting parameters (No. PD

)..................................................................................................... 6 -29

6.4.1 Parameter list ................................................................................................................................... 6 -29

6.4.2 Detail list ........................................................................................................................................... 6 -30

6.4.3 Stopping method when the forward stroke end (LSP) or reverse stroke end (LSN) is valid ......... 6 -38

6.4.4 Stopping method when a software limit is detected........................................................................ 6 -39

7. MR Configurator 7 - 1 to 7 -26

7.1 Specifications ........................................................................................................................................... 7 - 1

7.2 System configuration ............................................................................................................................... 7 - 2

7.3 Station selection....................................................................................................................................... 7 - 4

7.4 Parameters ............................................................................................................................................... 7 - 5

7.5 Point table................................................................................................................................................. 7 - 7

7.6 Device assignment method ..................................................................................................................... 7 - 9

7.7 Test operation ......................................................................................................................................... 7 -13

7.7.1 Jog operation.................................................................................................................................... 7 -13

7.7.2 Positioning operation........................................................................................................................ 7 -15

7.7.3 Motor-less operation ........................................................................................................................ 7 -18

7.7.4 Output signal (DO) forced output..................................................................................................... 7 -19

7.7.5 Single-step feed ............................................................................................................................... 7 -20

7.8 Alarm ....................................................................................................................................................... 7 -23

7.8.1 Alarm display .................................................................................................................................... 7 -23

7.8.2 Batch display of data at alarm occurrence ...................................................................................... 7 -24

7.8.3 Alarm history..................................................................................................................................... 7 -26

8. PARAMETER UNIT (MR-PRU03) 8 - 1 to 8 -20

8.1 External appearance and key explanations ............................................................................................ 8 - 2

8.2 Specifications ........................................................................................................................................... 8 - 3

8.3 Outline dimension drawings..................................................................................................................... 8 - 3

8.4 Connection with servo amplifier............................................................................................................... 8 - 4

8.4.1 Single axis ......................................................................................................................................... 8 - 4

8.4.2 Multidrop connection ......................................................................................................................... 8 - 5

5

8.5 Display...................................................................................................................................................... 8 - 7

8.5.1 Outline of screen transition ............................................................................................................... 8 - 7

8.5.2 MR-PRU03 parameter unit setting ................................................................................................... 8 - 8

8.5.3 Monitor mode (status display)........................................................................................................... 8 - 9

8.5.4 Alarm/diagnostic mode .................................................................................................................... 8 -11

8.5.5 Parameter mode............................................................................................................................... 8 -13

8.5.6 Point table mode .............................................................................................................................. 8 -14

8.5.7 Test operation mode ........................................................................................................................ 8 -15

8.6 Error message list ................................................................................................................................... 8 -19

9. GENERAL GAIN ADJUSTMENT 9 - 1 to 9 -12

9.1 Different adjustment methods.................................................................................................................. 9 - 1

9.1.1 Adjustment on a single servo amplifier............................................................................................. 9 - 1

9.1.2 Adjustment using MR Configurator................................................................................................... 9 - 2

9.2 Auto tuning ............................................................................................................................................... 9 - 3

9.2.1 Auto tuning mode .............................................................................................................................. 9 - 3

9.2.2 Auto tuning mode operation.............................................................................................................. 9 - 4

9.2.3 Adjustment procedure by auto tuning............................................................................................... 9 - 5

9.2.4 Response level setting in auto tuning mode .................................................................................... 9 - 6

9.3 Manual mode 1 (simple manual adjustment).......................................................................................... 9 - 7

9.4 Interpolation mode .................................................................................................................................. 9 -11

9.5 Differences between MELSERVO-J2-Super and MELSERVO-J3 in auto tuning................................ 9 -12

10. SPECIAL ADJUSTMENT FUNCTIONS 10- 1 to 10-16

10.1 Function block diagram......................................................................................................................... 10- 1

10.2 Adaptive filter

...................................................................................................................................... 10- 1

10.3 Machine resonance suppression filter.................................................................................................. 10- 4

10.4 Advanced vibration suppression control .............................................................................................. 10- 6

10.5 Low-pass filter ...................................................................................................................................... 10-10

10.6 Gain changing function ........................................................................................................................ 10-10

10.6.1 Applications ................................................................................................................................... 10-10

10.6.2 Function block diagram................................................................................................................. 10-11

10.6.3 Parameters .................................................................................................................................... 10-12

10.6.4 Gain changing operation...............................................................................................................10-14

11. TROUBLESHOOTING 11- 1 to 11-14

11.1 Trouble at start-up................................................................................................................................. 11- 1

11.2 Operation at error occurrence ..............................................................................................................11- 2

11.3 CC-Link communication error............................................................................................................... 11- 2

11.4 When alarm or warning has occurred .................................................................................................. 11- 3

11.4.1 Alarms and warning list.................................................................................................................. 11- 3

11.4.2 Remedies for alarms...................................................................................................................... 11- 4

11.4.3 Remedies for warnings ................................................................................................................. 11-11

11.5 Point table error.................................................................................................................................... 11-13

6

12. OUTLINE DRAWINGS 12- 1 to 12-12

12.1 Servo amplifier ...................................................................................................................................... 12- 1

12.2 Connector ............................................................................................................................................. 12-10

13. CHARACTERISTICS 13- 1 to 13-10

13.1 Overload protection characteristics ...................................................................................................... 13- 1

13.2 Power supply equipment capacity and generated loss ....................................................................... 13- 3

13.3 Dynamic brake characteristics.............................................................................................................. 13- 6

13.3.1 Dynamic brake operation ............................................................................................................... 13- 6

13.3.2 The dynamic brake at the load inertia moment............................................................................. 13- 9

13.4 Cable flexing life...................................................................................................................................13-10

13.5 Inrush currents at power-on of main circuit and control circuit........................................................... 13-10

14. OPTIONS AND AUXILIARY EQUIPMENT 14- 1 to 14-90

14.1 Cable/connector sets ............................................................................................................................ 14- 1

14.1.1 Combinations of cable/connector sets ..........................................................................................14- 2

14.1.2 Encoder cable/connector sets ....................................................................................................... 14- 8

14.1.3 Motor power supply cables ........................................................................................................... 14-17

14.1.4 Motor brake cables........................................................................................................................ 14-18

14.2 Regenerative options ...........................................................................................................................14-19

14.3 FR-BU2-(H) brake unit ......................................................................................................................... 14-32

14.3.1 Selection ........................................................................................................................................ 14-33

14.3.2 Brake unit parameter setting......................................................................................................... 14-33

14.3.3 Connection example ..................................................................................................................... 14-34

14.3.4 Outline dimension drawings..........................................................................................................14-41

14.4 Power regeneration converter ............................................................................................................. 14-43

14.5 Power regeneration common converter.............................................................................................. 14-46

14.6 External dynamic brake ....................................................................................................................... 14-54

14.7 Battery MR-J3BAT ............................................................................................................................... 14-59

14.8 Heat sink outside mounting attachment (MR-J3ACN)........................................................................ 14-60

14.9 Selection example of wires .................................................................................................................. 14-62

14.10 No-fuse breakers, fuses, magnetic contactors ................................................................................. 14-68

14.11 Power factor improving DC reactor ................................................................................................... 14-69

14.12 Power factor improving reactors........................................................................................................ 14-71

14.13 Relays (recommended) ..................................................................................................................... 14-73

14.14 Surge absorbers (recommended) ..................................................................................................... 14-73

14.15 Noise reduction techniques ............................................................................................................... 14-74

14.16 Leakage current breaker.................................................................................................................... 14-81

14.17 EMC filter (recommended) ................................................................................................................ 14-83

14.18 MR-HDP01 manual pulse generator................................................................................................. 14-88

15. COMMUNICATION FUNCTION 15- 1 to 15-46

15.1 Configuration ......................................................................................................................................... 15- 1

15.2 Communication specifications .............................................................................................................. 15- 3

15.2.1 Communication overview............................................................................................................... 15- 3

15.2.2 Parameter setting ........................................................................................................................... 15- 4

7

15.3 Protocol .................................................................................................................................................15- 5

15.3.1 Transmission data configuration.................................................................................................... 15- 5

15.3.2 Character codes ............................................................................................................................. 15- 6

15.3.3 Error codes ..................................................................................................................................... 15- 7

15.3.4 Checksum....................................................................................................................................... 15- 7

15.3.5 Time-out operation ......................................................................................................................... 15- 8

15.3.6 Retry operation............................................................................................................................... 15- 8

15.3.7 Initialization..................................................................................................................................... 15- 9

15.3.8 Communication procedure example.............................................................................................. 15- 9

15.4 Command and data No. list ................................................................................................................. 15-10

15.4.1 Read commands ........................................................................................................................... 15-10

15.4.2 Write commands ........................................................................................................................... 15-14

15.5 Detailed explanations of commands ................................................................................................... 15-17

15.5.1 Data processing ............................................................................................................................15-17

15.5.2 Status display ................................................................................................................................ 15-19

15.5.3 Parameters .................................................................................................................................... 15-20

15.5.4 External I/O signal statuses (DIO diagnosis) ............................................................................... 15-23

15.5.5 Device ON/OFF.............................................................................................................................15-28

15.5.6 Disable/enable of I/O devices (DIO) ............................................................................................. 15-29

15.5.7 Input devices ON/OFF (test operation) ........................................................................................ 15-30

15.5.8 Test operation mode ..................................................................................................................... 15-31

15.5.9 Alarm history.................................................................................................................................. 15-37

15.5.10 Current alarm ..............................................................................................................................15-38

15.5.11 Point table.................................................................................................................................... 15-39

15.5.12 Servo amplifier group designation .............................................................................................. 15-45

15.5.13 Other commands......................................................................................................................... 15-46

16. INDEXER POSITIONING OPERATION 16- 1 to 16-112

16.1 Function................................................................................................................................................. 16- 1

16.1.1 Overview......................................................................................................................................... 16- 1

16.1.2 Servo amplifier standard specifications (functions only)............................................................... 16- 1

16.1.3 Function list .................................................................................................................................... 16- 2

16.2 I/O signals (I/O devices) transferred to/from the programmable controller CPU................................ 16- 3

16.2.1 I/O signals (I/O devices)................................................................................................................. 16- 3

16.2.2 Detailed explanation of I/O signals ................................................................................................ 16- 5

16.2.3 Monitor codes................................................................................................................................ 16-14

16.2.4 Instruction codes (RWwn

2 RWwn 3)................................................................................... 16-15

16.2.5 Respond codes (RWrn

2) .......................................................................................................... 16-22

16.3 Signal....................................................................................................................................................16-23

16.3.1 Signal (device) explanation........................................................................................................... 16-23

16.3.2 Detailed description of signals (devices) ...................................................................................... 16-26

16.4 Switching power on for the first time ................................................................................................... 16-29

16.4.1 Startup procedure ......................................................................................................................... 16-29

16.4.2 Wiring check ..................................................................................................................................16-30

16.4.3 Surrounding environment ............................................................................................................. 16-31

16.5 Startup .................................................................................................................................................. 16-32

16.5.1 Power on and off procedures........................................................................................................16-32

16.5.2 Stop................................................................................................................................................ 16-32

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