General-Purpose AC Servo
J2 Series
C
Built-In Positioning Function
MR-J2-C
Servo Amplifier
Instruction Manual
A - 1
Safety Instructions
(Always read these instructions before using the equipment.)
Do not attempt to install, oper ate, mainta in or inspect the s ervo amplif ier and servo m otor until you hav e read
through this I nstruction M anual, Insta llation guide, Servo motor Instruction Manual a nd appende d docum ents
carefully and can us e th e equ i pment correctly. D o no t use the servo amplifier and s e r vo motor until you h a ve 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 CA U TION lev el may lea d t o a se riou s con se qu en ce a cco rdin g to con di tion s . Pl ea se fo ll ow th e
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, switch power off and wait for more than 10 minutes. Then, confirm the voltage
is safe with voltage tester. Otherwise, you may get an electric shock.
• 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.
2. To prevent fire, note the following:
CAUTION
• Do not install the servo amplifier, servo motor and regenerative brake resistor on or near combustibles.
Otherwise a fire may cause.
• When the servo amplifier has become faulty, switch off the main servo amplifier power side. Continuous
flow of a large current may cause a fire.
• When a regenerative brake resistor is used, use an alarm signal to switch main power off. Otherwise, a
regenerative brake transistor fault or the like may overheat the regenerative brake resistor, causing a fire.
3. To prevent injury, note the follow
CAUTION
• Only the vo ltage specified in t he Instruction Man ual should be ap plied to each terminal,, Otherw ise,, a
burst,, damage, etc. may occur.
• Connect the terminals correctly to prevent a burst, damage, etc.
• Ensure th a t polarity (
, ) is correct. Otherwise, a burst,, damage,, etc. may occur.
• During power-on or for some time after power-off, do not touch the servo amplifier fins, regenerative brake
resistor, servo motor, etc. Their temperatures may be high and you may get burnt.
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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 motor by the cables, shaft or encoder.
• Do not hold the front cover to transport the controller. The controller may drop.
• Install the servo amplifier in a weight-bearing place in accordance with the Instruction Manual.
• Do not climb or stand on servo equipment. Do not put heavy objects on equipment.
• The controller 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.
• Do not drop or strike servo amplifier or servo motor. Isolate from all impact loads.
• Use the servo amplifier and servo motor under the following environmental conditions:
Conditions
Environment
Servo Amplifier Servo Motor
[°C] 0 to 55 (non-freezing) 0 to 40 (non-freezing)
Ambient
temperature
[°F] 32 to 131 (non-freezing) 32 to 104 (non-freezing)
Ambient humidity 90%RH or less (non-condensing) 80%RH or less (non-condensing)
[°C] 20 to 65 (non-freezing) 15 to 70 (non-freezing)
Storage
temperature
[°F]
4 to 149 (non-freezing) 5 to 158 (non-freezing)
Storage humidity 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
HC-MF Series
HA-FF Series
HC-UF 13 to 73
X • Y : 49
HC-SF81
HC-SF52 to 152
HC-SF53 to 153
HC-UF 72 • 152
X • Y : 24.5
HC-SF121 • 201
HC-SF202 • 352
HC-SF203 • 353
HC-UF202
X : 24.5
Y : 49
[m/s2] 5.9 {0.6G} or less
HC-SF301
X : 24.5
Y : 29.4
HC-MF Series
HA-FF Series
HC-UF 13 to 73
X • Y : 161
HC-SF81
HC-SF52 to 152
HC-SF53 to 153
HC-UF 72 • 152
X • Y : 80
HC-SF121 • 201
HC-SF202 • 352
HC-SF203 • 353
HC-UF202
X : 80
Y : 161
Vibration
[ft/s
2
] 19.4 or less
HC-SF301
X : 80
Y : 96
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CAUTION
• Securely att a ch th e se rv o mot o r to th e mac h i ne . If a t ta ch in s e cur ely, the servo mot o r may co me o ff d u r i ng
operation.
• The servo motor with reduction gear must be installed in the specified direction to prevent oil leakage.
• For safety of p e rsonn el , alw ay s cov e r ro tating and moving pa rt s.
• 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.
(2) Wiring
CAUTION
• Wire the equipment correctly and securely. Otherwise, the servo motor may misoperate.
• Do not install a power capacitor, surge absorber or radio noise filter (FR-BIF option) between the servo
motor and servo amplifier.
• Connect the output terminals (U, V, W) correctly. Otherwise, the servo motor will operate improperly.
• 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 must be wired in the specified direction.
Otherwise, the emergency stop and other protective circuits may not operate.
COM
(24VDC)
Servo
Amplifier
RA
Control
output
signal
RA
Servo
Amplifier
COM
(24VDC)
Control
output
signal
(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 instable.
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 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.
• 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 ballscrew and the servo motor are
coupled via a timing belt), the electromagnetic brake may not hold the motor shaft. To ensure safety,
install a stoppe r on the mach in e side .
(5) Corrective actions
CAUTION
• When it is as sumed that a hazardous c ondition m ay take pl ace at t he occur due to a power fa ilure or a
product fault, use a servo motor with electromagnetic brake or an external brake mechanism for the
purpose of prev en ti on .
• Configure the electromagnetic brake circuit so that it is activated not only by the servo amplifier signals but
also by an external emergency stop signal.
EMGRA
24VDC
Contacts must be open when
servo is off or when an
alarm (trouble) is present.
Electromagnetic brake
Servo motor
Circuit must be
opend during
emergency stop.
• 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).
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(6) Maintenance, inspection and parts replacement
CAUTION
• With age, the electrolytic cap acitor will deterior ate. To prevent a secondary accide nt due to a faul t, it is
recommended to replace the electrolytic capacitor every 10 years when used in general environment.
Please consult our sales representative.
(7) Disposal
CAUTION
• Dispose of the product as general industrial waste.
(8) 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.
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COMPLIANCE WITH EC DIRECTIVES
1. WHAT ARE EC DIRE CTI VES ?
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 mar king). CE marking applies to machines and equipment
into which servo amplifiers have been installed.
(1) EMC Directive
The EMC Directive applies to a machine/equipment which incorporates the servo, not to the servo
alone. Hence, the EMC filter must be used to make this machine/equipment which incorporates the
servo comply with the EMC Directive. For specific methods to comply with the EMC Directive, refer to
the "EMC Installation Guidelines" (IB(NA)67310).
This servo has been approved by TUV, third-party evaluation organization, which confirmed that it
can comply with the EMC Directive in the methods given in the "EMC Installation Guidelines".
(2) Low Voltage Di re ctiv e
The Low Voltage Directive applies also to the servo alone. Therefore, our servo is designed to comply
with the Low Voltage Directive.
This servo has been approved by TUV, third-party evaluation organization, which confirmed that it
complies with the Low Voltage Directive.
(3) Machinery Directive
Since the servo amplifiers are not machines, they need not comply with this directive.
2. PRECAUTIONS FOR COMPLIANCE
Use the standard model of servo amplifier and the EN Standard-compliant model of HC-MF/HA-FF or the
standard model of HC-SF/HC-RF/HC-UF. In addition to the instructions provided in this Instruction
Manual, also follow the instructions be low. If the model i s not specifically d escribed to comp ly with the
EN Standard in this Instruction Manual, it has the same specifications as those of the standard models:
(1) Servo amplifiers and servo motors used
Use the following models of servo amplifiers and servo motors:
Servo amplifier series: MR-J2-10C to MR-J2-350C
Servo mot o r s e ri es : HC-KF
-UE
HC-MF
-UE
HC-SF
HC-RF
HC-UF
(2) Structure
Reinforced
insulating
transformer
NFB
MC
SM
No-fuse
breaker
Magnetic
contactor
Reinforced
insulating type
24VDC
power
supply
Servo
amplifier
Servo
motor
Control box
(3) Environment
Operate the servo amplifier at or above the contamination level 2 set forth in IEC664. For this purpose,
install the servo amplifier in a control box which is protected against water, oil, carbon, dust, dirt, etc.
(IP54).
A - 8
(4) Power supply
(a) Operate the servo amplifier to meet the requirements of the overvoltage category II set forth in
IEC664. For this purpose, a reinforced insulating transformer conforming to the IEC or EN
Standard should be used 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 as shown at right
below. Always connect the cables to the terminals one-to-one.
PE terminals
PE terminals
(c) If a leakage cur re nt br eaker is used to pr ev ent an el ec tri c s h ock, th e pr ot e ct iv e earth (PE) termina ls
of the servo ampli fi er mus t b e c onne ct ed t o t h e c orr es pondi n g eart h t ermi nal s.
(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) When the servo motor has a power supply lead, u se a fixed terminal block to connect it with the
servo amplifier. Do not connect cables directly.
Terminal block
(c) 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.
(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 14.2.2.
(b) The sizes of the cable s described in Section 14.2.2 mee t the following requ irements. To meet th e
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. The radio noise filter (FR-BIF) is not needed.
(8) Performing EMC tests
When EMC tests are run on a machine/device into which the servo amplifier has b een installed, i t must
conform to the electromagnetic compatibility (immunity/emission) standards after it has satisfied the
operating envir onm ent / el ect r ica l equipment speci fi ca t ions .
For the way of dealing with the EMC Directive on servo amplifiers, refer to the "EMC INSTALLATION
GUIDELINES(IB(NA)67310)".
A - 9
CONFORMANCE WITH UL/C-UL STANDARD
(1) Servo amplifiers and servo motors used
Use the following models of servo amplifiers and servo motors:
Servo amplifier series: MR-J2-10C to MR-J2-350C
Servo mot o r s e ri es : HC - KF
-UE
HC-MF
-UE
HC-SF
HC-RF
HC-UF
(2) Installation
Install a fan of 100CFM air flow 10.16 cm (4 in) above the servo amplifier or provide cooling of at least
equivalent capability.
(3) Short circuit rating
Having been subjected to UL tests in the alternating-current circuit who se peak current is limited to
5000A or less, this servo amplifier conforms to this circuit.
(4) Capacitor discharge time
The capacitor disch arg e time is as li sted below . To ensu re saf ety , do no t to uch the ch argin g sec tion f or
10 minutes after power-off.
Servo Amplifier Discharge Time [min]
MR-J2-10C • 20C 1
MR-J2-40C • 60C 2
MR-J2-70C to 350C 3
(5) Options and auxiliary equipment
Use products which conform to the UL/C-UL Standard.
About the Manu al s
This Servo Amplifier Instruction Manual and the MELSERVO Servo Motor Instruction Manual are
required if you use the MELSERVO-J2-C for the first time. Always purchase them and use the
MELSERVO-J2-C safely.
Relevant Manual
Manual Name Manual No.
MELSERVO-J2-C Installation Guide IB(NA)67367
MELSERVO Servo Motor Instruction Manual SH(NA)3181
EMC INSTALLATION GUIDELINES IB(NA)67310
A - 10
MEMO
1
CONTENTS
1. FUNCTIONS AND CONFIGURATION 1 - 1 to 1 -16
1.1 Introduction.............................................................................................................................................1 - 1
1.1.1 Function block diagram...................................................................................................................1 - 2
1.1.2 System configuration.......................................................................................................................1 - 3
1.1.3 I/O devices ........................................................................................................................................1 - 8
1.2 Function List...........................................................................................................................................1 - 9
1.3 Model Name Make-Up..........................................................................................................................1 -10
1.4 Combination with Servo Motor............................................................................................................1 -10
1.5 Parts Identification................................................................................................................................1 -11
1.6 Servo System with Auxiliary Equipment............................................................................................1- 14
2. INSTALLATION 2 - 1 to 2 - 4
2.1 Environmental conditions......................................................................................................................2 - 1
2.2 Installation direction and clearances ...................................................................................................2 - 2
2.3 Keep out foreign materials ....................................................................................................................2 - 3
2.4 Cable stress .............................................................................................................................................2 - 4
3. SIGNALS AND WIRING 3 - 1 to 3 - 34
3.1 Standard connection example ...............................................................................................................3 - 2
3.2 Common line ...........................................................................................................................................3 - 4
3.3 I/O Signals...............................................................................................................................................3 - 5
3.3.1 Connectors and signal arrangements............................................................................................3 - 5
3.3.2 Signal explanations .........................................................................................................................3 - 6
3.3.3 Additional function devices.............................................................................................................3 - 9
3.4 Detailed Description of the Signals .....................................................................................................3 -12
3.4.1 Start and stop signals.....................................................................................................................3 -12
3.4.2 Rough match, in-position...............................................................................................................3 -12
3.4.3 Override...........................................................................................................................................3 -13
3.4.4 Torque limit.....................................................................................................................................3 -14
3.5 Alarm Occurrence Timing Chart .........................................................................................................3 -17
3.6 Interfaces................................................................................................................................................3 -18
3.7 Power Supply System Circuit...............................................................................................................3 -21
3.7.1 Connection example........................................................................................................................3 -21
3.7.2 Terminals.........................................................................................................................................3 -22
3.7.3 Power-on sequence..........................................................................................................................3 -23
3.8 Connection of Servo Amplifier and Servo Motor................................................................................3 -24
3.8.1 Connection instructions .................................................................................................................3 -24
3.8.2 Connection diagram........................................................................................................................3 -24
3.8.3 I/O terminals...................................................................................................................................3 -26
3.9 Servo Motor with Electromagnetic Brake...........................................................................................3 -29
3.10 Grounding ............................................................................................................................................3 -32
3.11 Servo Amplifier Terminal Block (TE2) Wiring Method...................................................................3 -33
3.12 Instructions for the 3M Connector.....................................................................................................3 -34
2
4. OPERATION 4 - 1 to 4 -36
4.1 When Switching Power On for the First Time....................................................................................4 - 1
4.1.1 Pre-operation checks .......................................................................................................................4 - 1
4.1.2 Startup..............................................................................................................................................4 - 2
4.2 Automatic Operation Mode ...................................................................................................................4 - 5
4.2.1 What is automatic operation mode? ..............................................................................................4 - 5
4.2.2 Absolute value command system...................................................................................................4 - 9
4.2.3 Incremental value command system ............................................................................................4 -10
4.2.4 Automatic operation timing chart.................................................................................................4 -11
4.2.5 Automatic continuous operation ...................................................................................................4 -12
4.3 Manual Operation Mode.......................................................................................................................4 -17
4.3.1 Jog operation ...................................................................................................................................4 -17
4.3.2 Manual pulse generator operation................................................................................................4 -19
4.4 Manual Zeroing Mode...........................................................................................................................4 -21
4.4.1 Outline of zeroing............................................................................................................................4 -21
4.4.2 Dog type zeroing .............................................................................................................................4 -23
4.4.3 Count type zeroing..........................................................................................................................4 -25
4.4.4 Data setting type zeroing...............................................................................................................4 -26
4.4.5 Stopper type zeroing.......................................................................................................................4 -27
4.4.6 Zero ignorance (servo-on position defined as zero)......................................................................4 -28
4.4.7 Automatic zeroing return function ...............................................................................................4 -29
4.5 Absolute position detection system......................................................................................................4 -30
4.6 Serial Communication Operation ........................................................................................................4 -32
4.6.1 Positioning operation in accordance with point tables ...............................................................4 -32
4.6.2 Positioning operation...................................................................................................................... 4 -33
4.6.3 Multidrop system............................................................................................................................4 -33
4.6.4 Group designation...........................................................................................................................4 -34
5. PARAMETERS 5 - 1 to 5 -18
5.1 Parameter List........................................................................................................................................5 - 1
5.1.1 Parameter write inhibit ..................................................................................................................5 - 1
5.1.2 Lists...................................................................................................................................................5 - 2
5.2 Detailed Explanation ............................................................................................................................5 -13
5.2.1 Electronic gear ................................................................................................................................5 -13
5.2.2 Changing the status display screen..............................................................................................5 -14
5.2.3 S-pattern acceleration/deceleration..............................................................................................5 -14
5.2.4 Analog output..................................................................................................................................5 -15
5.2.5 Changing the stop pattern using a limit switch..........................................................................5 -16
5.2.6 Alarm history clear.........................................................................................................................5 -16
5.2.7 Rough match output.......................................................................................................................5 -17
5.2.8 Software limit..................................................................................................................................5 -17
6. SERVO CONFIGURATION SOFTWARE 6 - 1 to 6 -18
6.1 Specifications ..........................................................................................................................................6 - 1
6.2 System configuration..............................................................................................................................6 - 1
3
6.3 Station Setting........................................................................................................................................6 - 3
6.4 Parameters..............................................................................................................................................6 - 4
6.5 Point Table ..............................................................................................................................................6 - 6
6.6 Device Setting .........................................................................................................................................6 - 8
6.7 Test Operation .......................................................................................................................................6 -10
6.7.1 Jog operation ...................................................................................................................................6 -10
6.7.2 Positioning operation......................................................................................................................6 -12
6.7.3 Motor-less operation.......................................................................................................................6 -14
6.7.4 DO forced output.............................................................................................................................6 -15
6.7.5 Single-step feed...............................................................................................................................6 -16
6.8 Alarm History ........................................................................................................................................6 -17
7. DISPLAY AND OPERATION 7 - 1 to 7 -10
7.1 Display Flowchart ..................................................................................................................................7 - 1
7.2 Status Display.........................................................................................................................................7 - 2
7.3 Diagnostic Mode .....................................................................................................................................7 - 4
7.4 Alarm Mode.............................................................................................................................................7 - 4
7.5 Point Table Mode....................................................................................................................................7 - 5
7.6 Parameter Mode ..................................................................................................................................... 7 - 8
8. COMMUNICATION FUNCTIONS 8 - 1 to 8 -38
8.1 Configuration ..........................................................................................................................................8 - 1
8.1.1 RS-422 configuration.......................................................................................................................8 - 1
8.1.2 RS-232C configuration ....................................................................................................................8 - 2
8.2 Communication Specifications..............................................................................................................8 - 3
8.2.1 Parameter setting............................................................................................................................8 - 3
8.3 Protocol....................................................................................................................................................8 - 4
8.4 Character Codes .....................................................................................................................................8 - 6
8.5 Error Codes .............................................................................................................................................8 - 7
8.6 Checksum................................................................................................................................................8 - 7
8.7 Time-Out Operation...............................................................................................................................8 - 8
8.8 Retry Operation ......................................................................................................................................8 - 8
8.9 Initialization............................................................................................................................................8 - 9
8.10 Communication Procedure Example..................................................................................................8 - 9
8.11 Command and Data No. List..............................................................................................................8 -10
8.11.1 Read commands............................................................................................................................8 -10
8.11.2 Write commands...........................................................................................................................8 -15
8.12 Detailed Explanations of Commands................................................................................................8 -19
8.12.1 Data processing.............................................................................................................................8 -19
8.12.2 Status display................................................................................................................................8 -21
8.12.3 Parameter......................................................................................................................................8 -22
8.12.4 External I/O signal statuses........................................................................................................8 -24
8.12.5 Device ON/OFF.............................................................................................................................8 -26
8.12.6 Alarm history................................................................................................................................8 -27
8.12.7 Current alarm ...............................................................................................................................8 -28
8.12.8 Point table .....................................................................................................................................8 -30
8.12.9 Servo amplifier group designation..............................................................................................8 -36
8.12.10 Other commands.........................................................................................................................8 -37
4
9. ADJUSTMENT 9 - 1 to 9 -10
9.1 What Is Gain Adjustment?....................................................................................................................9 - 1
9.1.1 Difference between servo amplifier and other drives ..................................................................9 - 1
9.1.2 Basics of the servo system ..............................................................................................................9 - 2
9.2 Gain adjustment.....................................................................................................................................9 - 3
9.2.1 Parameters required for gain adjustment.....................................................................................9 - 3
9.2.2 Block diagram..................................................................................................................................9 - 3
9.2.3 What is auto tuning? .......................................................................................................................9 - 4
9.3 Gain Adjustment by Auto Tuning.........................................................................................................9 - 5
9.3.1 Adjustment method.........................................................................................................................9 - 5
9.3.2 Valid conditions................................................................................................................................9 - 5
9.4 Manual Gain Adjustment......................................................................................................................9 - 6
9.4.1 When machine rigidity is low.........................................................................................................9 - 6
9.4.2 When the machine vibrates due to machine resonance frequency.............................................9 - 7
9.4.3 Load inertia moment is 20 or more times .....................................................................................9 - 8
9.4.4 When shortening the settling time................................................................................................9 - 9
9.4.5 When the same gain is used for two or more axes ......................................................................9 -10
9.5 Slight vibration suppression control....................................................................................................9 -10
10. INSPECTION 10 - 1 to 10 - 2
11. TROUBLESHOOTING 11 - 1 to 11 - 10
11.1 Trouble at Start-Up............................................................................................................................11 - 1
11.2 When Alarm or Warning Has Occurred...........................................................................................11 - 2
11.2.1 Alarms and Warning list.............................................................................................................11 - 2
11.2.2 Remedies for alarms....................................................................................................................11 - 3
11.2.3 Remedies for Warnings...............................................................................................................11 - 9
12. SPECIFICATIONS 12 - 1 to 12 - 8
12.1 Servo Amplifier Standard Specifications .........................................................................................12 - 1
12.2 Outline Dimension Drawings............................................................................................................12 - 3
12.2.1 Servo amplifiers...........................................................................................................................12 - 3
12.2.2 Connectors....................................................................................................................................12 - 6
13. CHARACTERISTICS 13 - 1 to 13 - 8
13.1 Overload Protection Characteristics.................................................................................................13 - 1
13.2 Power Supply Equipment Capacity and Generated Loss ..............................................................13 - 3
13.3 Dynamic Brake Characteristics........................................................................................................13 - 5
13.4 Encoder Cable Flexing Life ...............................................................................................................13 - 7
14. OPTIONS AND AUXILIARY EQUIPMENT 14 - 1 to 14 -34
14.1 Options.................................................................................................................................................14 - 1
14.1.1 Regenerative brake options........................................................................................................14 - 1
14.1.2 Cables and connectors.................................................................................................................14 - 5
5
14.1.3 Junction terminal block (MR-TB20).........................................................................................14 -15
14.1.4 Maintenance junction card (MR-J2CN3TM) ...........................................................................14 -16
14.1.5 External digital display (MR-DP60).........................................................................................14 -17
14.1.6 Manual pulse generator (MR-HDP01) .....................................................................................14 -19
14.1.7 Battery (MR-BAT, A6BAT)........................................................................................................14 -20
14.2 Auxiliary Equipment.........................................................................................................................14 -21
14.2.1 Recommended wires...................................................................................................................14 -21
14.2.2 No-fuse breakers, fuses, magnetic contactors..........................................................................14 -23
14.2.3 Power factor improving reactors...............................................................................................14 -23
14.2.4 Relays...........................................................................................................................................14 -23
14.2.5 Surge absorbers ..........................................................................................................................14 -24
14.2.6 Noise reduction techniques........................................................................................................14 -24
14.2.7 Leakage current breaker............................................................................................................14 -30
14.2.8 EMC filter....................................................................................................................................14 -32
14.2.9 Setting potentiometers for analog inputs.................................................................................14 -33
6
Optional Servo Motor Instruction Manual CONTE NTS
The rough table of contents of the optional MELSERVO Servo Motor Instruction Manual is introduced
here for your reference. Note that the contents of the Servo Motor Instruction Manual are not included in
the Servo Amplifier Instruction Manual.
1.INTRODUCTION
2. INSTALLATION
3. CONNECTORS USED FOR SERVO MOTOR WIRING
4. INSPECTION
5. SPECIFICATIONS
6. CHARACTERISTICS
7. OUTLINE DIMENSION DRAWINGS
8. CALCULATION METHOD FOR DESIGN
1 - 1
1. FUNCTIONS AND CONFIGURATION
1. FUNCTIONS AND CONFIGURATION
1.1 Introduction
The MR-J2-C AC servo amplifier with bu ilt-in posi tioning functio ns is the MR-J2- A general-p urpose AC
servo amplifier which incorporate single-axis positioning functions. These functions perform positioning
operation by merely setting the position data (target positions), motor speeds, acceleration and
deceleration time cons tants, etc. to po int tables as if setting them in p arameters. The se rvo amplifier i s
the most appropriate to configure a program-free, simple positioning system or to simplify a system, for
example.
There are 3 points of point tables as standard, and they can be increased up to 15 points by using the
optional set-up software.
You can choose a configuration suitable for your purpose, e.g. simple positioning system using external
I/O signals (DI/O), operation using DI/O and RS-485 serial communication, or multi drop operation using
RS-485 serial communication.
All servo motors are equipped with an absolute position encoder as standard. An absolute position
detection system can be configured by merely adding a battery to the servo amplifier. Once the home
position has been set, zeroing is not required at power on, alarm occurrence, etc.
The MR-J2-C AC servo amplifier wit h positioning function is made easier to use and higher in function by
using it with the set-up software.
1 - 2
1. FUNCTIONS AND CONFIGURATION
1.1.1 Function block diagram
The function block diagram of the MELSERVO-J2-C is shown below.
1000
00
1000 1000
80 80 0 0
1000 1000 100 100
9
No.
Position Data
Speed
Acceleration
Time Constant
Deceleration
Time Constant
Dwell Time
1 1000 1000
80 80 0
2
2000 2000
100 100 0
3 4000 2000
70 60 500
4
500
2000
60 70 1000
5 1000 2000
80 80 0
6
2000 1000 80 80
7
8
0
1000
100 100 0
15
2000 2000 80 80
0
Speed
control
Position
control
Current
control
Position
command
creation
Point table
Model adaptive control
Regenerative brake
Base amplifier
Voltage
detection
Overcurrent
protection
Current
detection
Encoder
Dynamic
brake
Current
detector
Regenerative
brake
transistor
CHARGE
lamp
RADS
W
V
U
W
V
U
SM
Control
power
supply
(MR-J2-200C or more)
Fan
Electromagne
tic
brake
Servo motor
DCP
Regenerative brake option
NFB
Power supply
3-phase 200
t
o 230VAC or
single-phase
2
30VAC
MC
L1
L2
L11
L21
CON1
MR-BAT
Optional battery
(for absolute position)
A/D
CN1A•CN1B
Servo on
Start
Failure, etc.
RS-232C
CN3
RS-422 D/A
Analog
2CH
RS485/RS232C
Controller
To other servo
amplifier
E2
I/F
Aux
0
0
1
1
0
0
0
0
Servo amplifier
L3
CN2
Analog monitor 2CH
(Note 2)
(Note 1)
DI/O control
Note: 1. There is no wiring to the U phase for the MR-J2-100C or less.
2. The built-in regenerative brake resistor is not provided for the MR-J2-10C.
1 - 3
1. FUNCTIONS AND CONFIGURATION
1.1.2 System configuration
This section describes operations using the MELSERVO-J2-C.
You can arrange any configurations from a single-axis to max. 32-axis systems. Further, the connector
pins in the interface section allow you to assign the optimum signals to respective systems. (Refer to
Sections 1.1.3 and 3.3 .3.) Th e Set-u p So ftw are (re fer to Ch ap ter 6) and perso nal compu ter are re quire d to
change or assign devices.
Set the following values to the point table:
Name Setting Range Unit
Position data 999999 to 999999
0.001[mm]
0.01[mm]
0.1[mm]
1[mm]
Motor speed 0 to max. speed [r/min]
Acceleration time constant 0 to 20000 [ms]
Deceleration time constant 0 to 20000 [ms]
Dwell time 0 to 20000 [ms]
Auxiliary function 0 • 1
0: 1-point automatic operation
1: Automatic continuous operation
(1) Operation using external input signals
(a) Description
The following configuration example assumes that external input signals are used to control all
signals (devices).
The I/O signals are as fac t ory- set.
(b) Configuration
The following configuration uses external I/O signals. The personal computer is used with the Setup Software to set, change and monitor the parameters and point tables.
Servo amplifier
External I/O
signals
Power supply
3-phase 200VAC
or single-phase
230VAC
Servo motor
RS–232C
Set-up
Software
Personal
computer
CN1A CN1B
CN2 CN3
1 - 4
1. FUNCTIONS AND CONFIGURATION
(2) Operation using external input signals and communication
(a) Description
Communication can be used to change the point table data, choose the point table, change
parameter values, and confirm monitor data, for example. Enter the start signal through the
external I/O. Use this system when position data/speed setting or the host personal computer or
the like is used to change the parameter values, for example.
(b) Configuration
1) One servo amplifier is connected with the personal computer by RS-232C.
Servo amplifier
External I/O
signals
Power supply
3-phase 200VAC
or single-phase
230VAC
Servo motor
RS–232C
Set-up
Software
Personal
computer
CN1A CN1B
CN2 CN3
1 - 5
1. FUNCTIONS AND CONFIGURATION
2) Several (up to 32) servo amplifiers are connected with the personal computer by RS-422.
Use parameter No. 16 to change the communication system.
Servo amplifier (axis 1)
External I/O
signals
Power supply
3-phase 200VAC
or single-phase
230VAC
Servo motor
RS–422
Set-up
Software
Personal
computer
CN1A CN1B
CN2 CN3
Servo amplifier (axis 2)
External I/O
signals
Servo motor
CN1A CN1B
CN2 CN3
RS–232C
RS–232C/RS-422 converter
(to be prepared by the customer)
To the next axis
RS–422
Power supply
3-phase 200VAC
or single-phase
230VAC
1 - 6
1. FUNCTIONS AND CONFIGURATION
(3) Operation using communication
(a) Description
Analog input, emergency stop signal and other signals are controlled by external I/O signals and
the other devices controlled through communication. Also, you can set each point table, choose the
point table, and change or set parameter values, for example. Up to 32 axes may be controlled.
(b) Configuration
1) One servo amplifier is connected with the personal computer by RS-232C.
Servo amplifier
External I/O
signals
Power supply
3-phase 200VAC
or single-phase
230VAC
Servo motor
RS–232C
Set-up
Software
Personal
computer
CN1A CN1B
CN2 CN3
1 - 7
1. FUNCTIONS AND CONFIGURATION
2) Several (up to 32) servo amplifiers are connected with the personal computer by RS-422.
Use parameter No. 16 to change the communication system.
Servo amplifier (axis 1)
External I/O
signals
Power supply
3-phase 200VAC
or single-phase
230VAC
Servo motor
RS–422
Set-up
Software
Personal
computer
CN1A CN1B
CN2 CN3
Servo amplifier (axis 2)
External I/O
signals
Servo motor
CN1A CN1B
CN2 CN3
RS–232C
RS–232C/RS-422 converter
(to be prepared by the customer)
To the next axis
RS–422
Power supply
3-phase 200VAC
or single-phase
230VAC
1 - 8
1. FUNCTIONS AND CONFIGURATION
1.1.3 I/O devices
The MELSERVO-J2-C allows dev ice s to be allocated to the p in s of conne c tor CN1A/CN1B as desired. The
following devices can be allocated. For device details, refer to Section 3.3.3.
(1) Input devices
Device Symbol Description Factory-Allocated Pin
Proximity dog DOG Proximity dog signal input device for manual zeroing CN1A-8
Servo on SON Operation-ready signal input device CN1B-15
Forward rotation stroke end LSP Forward rotation stroke end signal input device CN1B-16
Reverse rotation stroke end LSN Reserve rotation stroke end signal input device CN1B-17
Forward rotation start ST1 F or war d ro tation start signal input device CN1B-8
Reverse rotation start ST2 Reserve rotation start signal input device CN1B-9
Automatic/manual selection MDO Automatic/manual mode selection signal input device CN1B-7
Point table No. selection 1 DI0 Point table No. selection signal input device CN1B-5
Point table No. selection 2 DI1 Point table No. selection signal input device CN1B-14
Point table No. selection 3 DI2 Point table No. select ion signal input dev ice
Point table No. selection 4 DI3 Point table No. select ion signal input dev ice
Emergency stop EMG Emergency stop input device
Alarm reset RES Alarm reset signal input device
Override selection OVR Override selection input device
External torque limit selection TL0 External torque limit selection input device
Internal torque limit selection TL1 Internal torque limit selection input device
Proportion control PC Proportion control input device
Temporary stop/restart STP Temporary stop/restart input device
Manual pulse generator
multiplication
TP0
TP1
Manual pulse generator multiplication input device
(2) Output devices
Device Symbol Description Factory-Allocated Pin
Zeroing comp l etion ZP Zeroing comp letion output dev ice CN1A-18
Rough ma tch CPO Rou gh match signal outpu t device CN1B-4
In position INP In-position signal output device CN1B-6
Trouble ALM Trouble signal output device CN1B-18
Ready RD Ready output device CN1B-19
Electromagnetic brake interlock MBR Electromagnetic brake interlock output device
Position range outp u t POT Position range output device
Warning output WNG Warning output device
Battery warning output BWNG Battery warning output device
Limiting torque TLC Torque limiting device
Temporary stop PUS Temporary stop output device
Dynamic brake interlock DBR Dynamic brake interlock output device
1 - 9
1. FUNCTIONS AND CONFIGURATION
1.2 Function List
The following table lists the functions of the MELSERVO-J2-C. For details of the functions, refer to the
corresponding chapters and sections.
Function Description Refer To
Positioning by automatic operation
Select the required ones from among 15 preset point tables
(moving distance, speed, acceleration time constant, deceleration
time constant, auxiliary function) and perform operation in
accordance with the set values.
Use the external DI signal or communication function to choose
the point tables.
Section 4.2
Varied speed operation
Servo motor speed can be varied continuously until the preset
moving distance is reached. (Max. set speeds: 15 speeds)
Section 4.2.5 (2)
Automatic continuous positioning
operation
By merely choosing one point table and starting operation,
positioning can be executed continuously in accordance with
several point tables.
Section 4.2.5 (1)
Manual zeroing
Dog type, count type, data setting type, stopper type, zero
ignorance
Section 4.4
Multidrop communicatio n
Up to 32 axes of MR-J2-C are controllable simultaneously by RS485 communication.
Section 4.6.3
Chapter 8
Absolute position detection system
By merely setting the home position once, zeroing need not be done
at each power on.
Section 4.5
Slight vibration suppression control Vibration of 1 pulse at servo motor stop is suppressed. Section 9.5
Electronic gear
The electronic gear is used to make adjustment so that the servo
amplifier setting matches the machine moving distance. Also,
changing the electronic gear value allows the machine to be moved
at any multiplication ratio to the moving distance using the servo
amplifier.
Section 5.2.1
Real-time auto tuning
The servo gain is automatically adjusted to the optimum value at
each start/stop.
Section 9.4
Manual gain adjustment
The gain is manually adjustable if the gain could not be adjusted
to the ideal value by real-time auto tuning.
Section 9.2
S-pattern acceleration/deceleration time
constant
Acceleration/deceleration can be made smoothly. Section 5.2.3
Analog monitor output The servo status is output in terms of voltage in real time. Section 5.2.4
Alarm history
By using the Set-up Software, the current alarm and five past
alarm numbers are stored and displayed.
Section 6.8
I/O signal selection (Device setting)
By using the Set-up Software, any devices can be assigned to 9
input, 5 output and 1 I/O pins.
Section 6.6
Torque limit
Servo motor-generated torque is limited.
Parameter 2 limit value
Analog input
1 limit value
Section 3.2.5
Override (speed limit)
The servo motor speed is limited by analog input.
The ratio of override to the set speed can be changed between 0 to
200%.
Section 3.2.4
Status display
The servo status is displayed. The servo amplifier display can
show up to 7 types or 15 types when the Set-up Software is used.
Section 7.2
Test operation mode
Jog operation , positioning op era t ion, motor-l ess operation, DO
forced output, 1-step feed
Section 6.7
Limit switch
The servo motor travel region can be limited using the forward
rotation stroke end (LSP) signal/reverse rotation stroke end (LSN)
signal.
Section 5.2.5
Software limit
The travel region is limited using parameters in terms of address.
The function similar to that of a limit switch is limited by
software.
Section 5.2.9
1 - 10
1. FUNCTIONS AND CONFIGURATION
1.3 Model Name Make-Up
(1) Name plate
Model
Capacity
Applicable power supply
Rated output current
Serial number
POWER
MITSUBISHI
AC SERVO
MADE IN JAPAN
MODEL
MR-J2-60C
MITSUBISHI ELECTRIC CORPORATION
:600W
:3.2A 3PH+1PH200-230V 50Hz
170V 0-360Hz 3.6A
POWER
INPUT
OUTPUT :
SERIAL
AC SERVO
:TC3XXAAAAG52
PASSED
3PH+1PH200-230V 60Hz
5.5A 1PH230V 50/60Hz
(2) Model
Name plate
MR–J2
Built-in positioning functions
Rated
output [W]
10010
Symbol
Rated output
20020
40040
60060
Series
75070
1000100
2000200
3500350
MR–J2–100C or less
MR–J2–200C 350C
Rated
output [W]
Symbol
C
Name plate
–
1.4 Combination with Servo Motor
The following table li st s combin a tions of servo amplifiers and servo mo to rs. T he sa me co mb ina t io ns ap ply
to the model s with e lectr omagn etic brake s, the m ode ls with red uction ge ars, the EN Stand ard-co mpli ant
models and the UL/C-UL Standard-compliant models.
Servo Motors
HC-SF (Note) HC-UF (Note)
Servo Amplifier
HC-MF
HA-FF
1000r/min 2000r/min 3000r/min
HC-RF
2000r/min 3000r/min
MR-J2-10C 053•13 053•13 13
MR-J2-20C 23 23 23
MR-J2-40C 43 33•43 43
MR-J2-60C 63 52 53
MR-J2-70C 73 72 73
MR-J2-100C 81 102 103
MR-J2-200C 121•201 152•202 153•203 103•153 152
MR-J2-350C 301 352 353 203 202
Note: The HC-UF73, HC-SF203 and 353 may not be connected depending on the production timing of the servo amplifier. Please
contact us.
1 - 11
1. FUNCTIONS AND CONFIGURATION
1.5 Parts Identification
(1) MR-J2-100C or less
Used to set data.
Used to change the
display or data in each
mode.
Used to change the
mode.
Refer To
Section4.5
Chapter7
Name/Application
Battery holder
Contains the battery for absolute position data backup.
Battery connector (CON1)
Used to connect the battery for absolute position data
backup.
Display
The four-digit, seven-segment LED shows the servo
status and alarm number.
MODE
UP
DOWN
SET
I/O signal connector (CN1A)
Used to connect digital I/O signals.
Communication connector (CN3)
Used to connect a command device (RS-485/RS-232C)
and output analog monitor data.
Name plate
Charge lamp
Lit to indicate that the main circuit is charged. While
this lamp is lit, do not reconnect the cables.
Encoder connector (CN2)
Connector for connection of the servo motor encoder.
Main circuit terminal block (TE1)
Used to connect the input power supply and servo
motor.
Protective earth (PE) terminal ( )
Ground terminal.
Section4.5
Operation section
Used to perform status display, diagnostic, alarm and
parameter and point table setting operations.
Chapter7
Section3.3
I/O signal connector (CN1B)
Used to connect digital I/O signals.
Section3.3
Chapter6
Chapter8
Section14.1.2
Section1.3
Section3.3
Section14.1.2
Control circuit terminal block (TE2)
Used to connect the control circuit power supply and
regenerative brake option.
Section3.7
Section3.7
Section14.1.1
Section3.10
1 - 12
1. FUNCTIONS AND CONFIGURATION
(2) MR-J2-200C or more
POINT
• This diagram shows the unit from which the front cover has been
removed. Refer to the next page for removal of the front cover.
Used to set data.
Used to change the
display or data in each
mode.
Used to change the
mode.
Refer To
Section4.5
Chapter7
Name/Application
Battery holder
Contains the battery for absolute position data backup.
Battery connector (CON1)
Used to connect the battery for absolute position data
backup.
Display
The four-digit, seven-segment LED shows the servo
status and alarm number.
MODE
UP
DOWN
SET
I/O signal connector (CN1A)
Used to connect digital I/O signals.
Communication connector (CN3)
Used to connect a command device (RS-485/RS232C)
and output analog monitor data.
Name plate
Charge lamp
Lit to indicate that the main circuit is charged. While
this lamp is lit, do not reconnect the cables.
Encoder connector (CN2)
Connector for connection of the servo motor encoder.
Main circuit terminal block (TE1)
Used to connect the input power supply and servo
motor.
Protectiv e earth (PE) termin al ( )
Ground terminal.
Section4.5
Operation section
Used to perform status display, diagnostic, alarm and
parameter and point table setting operations.
Chapter7
Section3.3
I/O signal connector (CN1B)
Used to connect digital I/O signals.
Section3.3
Chapter6
Chapter8
Section14.1.2
Section1.3
Section3.3
Section14.1.2
Control circuit terminal block (TE2)
Used to connect the control circuit power supply and
regenerative brake option.
Section3.2.1
Section3.2.1
Section14.1.1
Section3.6
Cooling fan
Mountin
g
hole (4 places
)
1 - 13
1. FUNCTIONS AND CONFIGURATION
Removal of the front cover Reinstallation of the front cover
Front cover
2)
1)
Front cover hook
(2 places)
Front cove r socket
(2 places)
2)
1)
1) Hold down the removing knob. 1) Insert the front cover hooks int o the front cover sockets of
the servo amplifier.
2) Pull the front cover toward you. 2) Press the front cover against the servo amplifier until the
removing knob clicks.
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