Mitsubishi Electronics MR-J2M-P8A User Manual

General-Purpose AC Servo

J2M Series

General-Purpose Interface Compatible

MODEL

MR-J2M-P8A MR-J2M- DU MR-J2M-BU

SERVO AMPLIFIER INSTRUCTION MANUAL

Safety Instructions

(Always read these instructions before using the equipment.)

Do not attempt to install, operate, maintain or inspect the units until you have read through this Instruction Manual, Installation Guide, Servo Motor Instruction Manual and appended documents carefully and can use the equipment properly. Do not use the units 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".

Indicates that incorrect handling may cause hazardous conditions,

WARNING

CAUTION

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:

resulting in death or severe injury.

Indicates that incorrect handling may cause hazardous conditions, resulting in medium or slight injury to personnel or may cause physical

damage.

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

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

In this Instruction Manual, instructions at a lower level than the above, instructions for other functions, and so on are classified into "POINT". After reading this Instruction Manual, always keep it accessible to the operator.

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1. To prevent electric shock, note the following:

WARNING

Before wiring or inspection, switch power off and wait for more than 15 minutes. Then, confirm the voltage is safe with voltage tester. Otherwise, you may get an electric shock.

Connect the base unit and servo motor to ground.

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

Do not attempt to wire for each unit and the servo motor until they are installed. Otherwise, you can obtain the 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

Do not install the base unit, servo motor and regenerative brake resistor on or near combustibles. Otherwise a fire may cause.

When each unit has become faulty, switch off the main base unit 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 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 brake 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.

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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 servo motor by the cables, shaft or encoder. Do not hold the front cover to transport each unit. Each unit may drop. Install the each unit in a load-bearing place in accordance with the Instruction Manual. Do not climb or stand on servo equipment. Do not put heavy objects on equipment. The servo amplifier controller and servo motor must be installed in the specified direction. Leave specified clearances between the base unit and control enclosure walls or other equipment. Do not install or operate the unit 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 each unit and servo motor. Do not drop or strike each unit or servo motor. Isolate from all impact loads. When you keep or use it, please fulfill the following environmental conditions.

Environment

During Ambient temperature

Ambient humidity

Ambience Indoors (no direct sunlight) Free from corrosive gas, flammable gas, oil mist, dust and dirt Altitude Max. 1000m (3280 ft) above sea level

(Note) Vibration

Note. Except the servo motor with reduction gear.

operation

In storage

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

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

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

] 32 to 131 (non-freezing) 32 to 104 (non-freezing) [ ] 20 to 65 (non-freezing) 15 to 70 (non-freezing) [

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

[m/s2] 5.9 or less

[ft/s

] 19.4 or less

Each unit Servo motor

Conditions

HC-KFS Series HC-MFS Series

HC-UFS13 to 43

HC-KFS Series HC-MFS Series

HC-UFS13 to 43

X Y : 49

X Y : 161

Securely attach the servo motor to the machine. If attach insecurely, the servo motor may come off during operation. The servo motor with reduction gear must be installed in the specified direction to prevent oil leakage. Take safety measures, e.g. provide covers, to prevent accidental access to the rotating parts of the servo motor during operation. Never hit the servo motor or shaft, especially when coupling the servo motor to the machine. The encoder may become faulty. Do not subject the servo motor shaft to more than the permissible load. Otherwise, the shaft may break. When the equipment has been stored for an extended period of time, consult Mitsubishi.

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(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 drive unit.

Connect the output terminals (U, V, W) correctly. Otherwise, the servo motor will operate improperly.

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.

drive unit

Servo Motor

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 and other protective circuits may not operate.

Interface unit

VIN

Control output

signal

Interface unit

VIN

Control output

signal

RARA

(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.

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(4) Usage

CAUTION

Provide an forced 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 MELSERVO-J2M.

Burning or breaking each unit may cause a toxic gas. Do not burn or break each unit.

Use the drive unit with the specified servo motor.

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

For such reasons as service life and mechanical structure (e.g. where a 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 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 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 interface unit signals but also by a forced stop (EMG_

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

)

Contacts must be open when servo-on (SON ) is off, when an trouble (ALM_ ) is present and

hen an electromagnetic brake

interlock (MBR ).

Servo motor

Electromagnetic brake

Circuit must be opened during forced stop (EMG_ ).

EMG_

24VDC

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 capacitor of the drive unit will deteriorate. To prevent a secondary accident due to a fault, it is recommended to replace the electrolytic capacitor every 10 years when used in general environment. Please consult our sales representative.

(7) General instruction

To illustrate details, the equipment in the diagrams of this Instruction Manual may have been drawn without covers and safety guards. When the equipment is operated, the covers and safety guards must be installed as specified. Operation must be performed in accordance with this Instruction Manual.

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

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.

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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 (MELSERVO-J2M is contained) 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 MELSERVO-J2M. Hence, they are designed to comply with the low voltage directive. MELSERVO-J2M is certified by TUV, third-party assessment organization, to comply with the low voltage directive. The MELSERVO-J2M complies with EN50178.

(3) Machine directive

Not being machines, MELSERVO-J2M need not comply with this directive.

2. PRECAUTIONS FOR COMPLIANCE

(1) Unit and servo motors used

Use each units and servo motors which comply with the standard model.

Interface unit :MR-J2M-P8A Drive unit :MR-J2MBase unit :MR-J2M-BU Servo motor :HC-KFS

HC-MFS HC-UFS

(2) Configuration

Reinforced insulating transformer

No-fuse breaker

NFB

Control box

Magnetic contactor

Reinforced insulating type

24VDC power supply

MELSERVOJ2M

Servo motor

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(3) Environment

Operate MELSERVO-J2M at or above the contamination level 2 set forth in IEC60664-1 For this purpose, install MELSERVO-J2M in a control box which is protected against water, oil, carbon, dust, dirt, etc. (IP54).

(4) Power supply

(a) Operate MELSERVO-J2M to meet the requirements of the overvoltage category II set forth in

IEC60664-1 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

base unit to the protective earth (PE) of the control box.

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

cables to the terminals one-to-one.

of the base unit must be connected to the corresponding earth terminals.

) of the

(d) The protective earth (PE) of the servo motor is connected to the protective earth of the base unit via

the screw which fastens the drive unit to the base unit. When fixing the drive unit to the base unit, therefore, tighten the accessory screw securely.

(6) 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 12.2.2.

(b) The sizes of the cables described in Section 12.2.1 meet the following requirements. To meet the

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

Ambient temperature: 40 (104) [ ( )] Sheath: PVC (polyvinyl chloride) Installed on wall surface or open table tray

(7) Performing EMC tests

When EMC tests are run on a machine/device into which MELSERVO-J2M 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 MELSERVO-J2M, refer to the EMC Installation Guidelines(IB(NA)67310).

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CONFORMANCE WITH UL/C-UL STANDARD

The MELSERVO-J2M complies with UL508C.

(1) Unit and servo motors used

Use the each units and servo motors which comply with the standard model.

Interface unit :MR-J2M-P8A Drive unit :MR-J2MBase unit :MR-J2M-BU Servo motor :HC-KFS

HC-MFS HC-UFS

(2) Installation

Install a fan of 100CFM (2.8m cooling of at least equivalent capability.

(3) Short circuit rating

MELSERVO-J2M conforms to the circuit whose peak current is limited to 5000A or less. Having been subjected to the short-circuit tests of the UL in the alternating-current circuit, MELSERVO-J2M conforms to the above circuit.

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

(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.

Base unit Discharge time [min]

MR-J2M-BU4 1 MR-J2M-BU6 1 MR-J2M-BU8 1

(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.

(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.

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<<About the manuals>>

This Instruction Manual and the MELSERVO Servo Motor Instruction Manual are required if you use MELSERVO-J2M for the first time. Always purchase them and use the MELSERVO-J2M safely. Also read the manual of the servo system controller.

Relevant manuals

Manual name Manual No.

MELSERVO-J2M Series To Use the AC Servo Safely (Packed with the MR-J2M-P8A, MR-J2MMELSERVO Servo Motor Instruction Manual SH(NA)3181 EMC Installation Guidelines IB(NA)67310

DU and MR-J2M-BU )

IB(NA)0300027

In this Instruction Manual, the drive unit, interface unit and base unit may be referred to as follows: Drive unit : DRU Interface unit : IFU Base unit : BU

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1. FUNCTIONS AND CONFIGURATION 1- 1 to 1-10

1.1 Overview................................................................................................................................................... 1- 1

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

1.3 Unit standard specifications................................................................................................................... 1- 3

1.4 Function list ............................................................................................................................................. 1- 4

1.5 Model code definition .............................................................................................................................. 1- 5

1.6 Combination with servo motor............................................................................................................... 1- 6

1.7 Parts identification.................................................................................................................................. 1- 7

1.8 Servo system with auxiliary equipment................................................................................................ 1- 9

2. INSTALLATION AND START UP 2- 1 to 2-10

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- 3

2.5 Mounting method ....................................................................................................................................2- 4

2.6 When switching power on for the first time.......................................................................................... 2- 6

2.7 Start up..................................................................................................................................................... 2- 7

3. SIGNALS AND WIRING 3- 1 to 3-48

3.1 Control signal line connection example................................................................................................. 3- 2

3.2 I/O signals of interface unit .................................................................................................................... 3- 5

3.2.1 Connectors and signal arrangements ............................................................................................. 3- 5

3.2.2 Signal explanations .......................................................................................................................... 3- 6

3.2.3 Detailed description of the signals................................................................................................. 3-11

3.2.4 Internal connection diagram ..........................................................................................................3-15

3.2.5 Interface............................................................................................................................................3-16

3.3 Signal and wiring for extension IO unit............................................................................................... 3-20

3.3.1 Connection example ........................................................................................................................ 3-20

3.3.2 Connectors and signal configurations ........................................................................................... 3-22

3.3.3 Signal explanations ......................................................................................................................... 3-23

3.3.4 Device explanations......................................................................................................................... 3-26

3.3.5 Detailed description of the device ..................................................................................................3-30

3.3.6 Device assignment method ............................................................................................................. 3-31

3.4 Signals and wiring for base unit ........................................................................................................... 3-35

3.4.1 Connection example for power line circuit ....................................................................................3-35

3.4.2 Connectors and signal configurations ........................................................................................... 3-37

3.4.3 Terminals.......................................................................................................................................... 3-38

3.4.4 Power-on sequence........................................................................................................................... 3-38

3.5 Connection of drive unit and servo motor ............................................................................................ 3-39

3.5.1 Connection instructions ..................................................................................................................3-39

3.5.2 Connection diagram ........................................................................................................................ 3-40

3.5.3 I/O terminals .................................................................................................................................... 3-41

3.6 Alarm occurrence timing chart .............................................................................................................3-42

3.7 Servo motor with electromagnetic brake ............................................................................................. 3-43

3.8 Grounding................................................................................................................................................ 3-46

3.9 Instructions for the 3M connector......................................................................................................... 3-47

4. OPERATION AND DISPLAY 4- 1 to 4-18

4.1 Display flowchart..................................................................................................................................... 4- 1

4.1.1 Normal indication ............................................................................................................................. 4- 2

4.1.2 If alarm/warning occurs ................................................................................................................... 4- 3

4.1.3 If test operation................................................................................................................................. 4- 4

4.2 Interface unit display .............................................................................................................................. 4- 5

4.2.1 Display flowchart of interface unit ................................................................................................. 4- 5

4.2.2 Status display of interface unit .......................................................................................................4- 6

4.2.3 Diagnostic mode of interface unit ................................................................................................... 4- 7

4.2.4 Alarm mode of interface unit........................................................................................................... 4- 8

4.2.5 Interface unit parameter mode ....................................................................................................... 4- 9

4.2.6 Interface unit output signal (DO) forced output...........................................................................4-10

4.3 Drive unit display ...................................................................................................................................4-11

4.3.1 Drive unit display sequence............................................................................................................ 4-11

4.3.2 Status display of drive unit............................................................................................................. 4-12

4.3.3 Diagnostic mode of drive unit......................................................................................................... 4-14

4.3.4 Alarm mode of drive unit ................................................................................................................ 4-15

4.3.5 Drive unit parameter mode ............................................................................................................4-16

4.3.6 Drive unit external input signal display ....................................................................................... 4-16

4.3.7 Drive unit external output signal display ..................................................................................... 4-17

4.3.8 Drive unit output signal (DO) forced output................................................................................. 4-18

5. PARAMETERS 5- 1 to 5-30

5.1 DRU parameter list................................................................................................................................. 5- 1

5.1.1 DRU parameter write inhibit .......................................................................................................... 5- 1

5.1.2 Lists.................................................................................................................................................... 5- 2

5.2 Interface unit ..........................................................................................................................................5-14

5.2.1 IFU parameter write inhibit........................................................................................................... 5-14

5.2.2 Lists...................................................................................................................................................5-14

5.3 Detailed description ...............................................................................................................................5-21

5.3.1 Electronic gear ................................................................................................................................. 5-21

5.3.2 Analog monitor................................................................................................................................. 5-25

5.3.3 Using forward rotation stroke end (LSP

) reverse rotation stroke end (LSN ) to change the

stopping pattern.............................................................................................................................. 5-28

5.3.4 Alarm history clear.......................................................................................................................... 5-28

5.3.5 Position smoothing ..........................................................................................................................5-29

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

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

6.1.1 Adjustment on a MELSERVO-J2M................................................................................................ 6- 1

6.1.2 Adjustment using MR Configurator (servo configuration software) ...........................................6- 2

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

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

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

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

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

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

6.3.1 Operation of manual mode 1 ........................................................................................................... 6- 7

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

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

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

7.1 Function block diagram ..........................................................................................................................7- 1

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

7.3 Adaptive vibration suppression control................................................................................................. 7- 3

7.4 Low-pass filter ......................................................................................................................................... 7- 4

7.5 Gain changing function........................................................................................................................... 7- 5

7.5.1 Applications....................................................................................................................................... 7- 5

7.5.2 Function block diagram ................................................................................................................... 7- 5

7.5.3 Parameters ........................................................................................................................................ 7- 6

7.5.4 Gain changing operation.................................................................................................................. 7- 8

8. INSPECTION 8- 1 to 8- 2

9. TROUBLESHOOTING 9- 1 to 9-14

9.1 Trouble at start-up .................................................................................................................................. 9- 1

9.2 Alarms and warning list ......................................................................................................................... 9- 4

9.3 Remedies for alarms................................................................................................................................ 9- 6

9.4 Remedies for warnings...........................................................................................................................9-13

10. OUTLINE DRAWINGS 10- 1 to 10-10

10.1 MELSERVO-J2M configuration example.........................................................................................10- 1

10.2 Unit outline drawings ......................................................................................................................... 10- 2

10.2.1 Base unit (MR-J2M-BU

) ...........................................................................................................10- 2

10.2.2 Interface unit (MR-J2M-P8A) .....................................................................................................10- 2

10.2.3 Drive unit (MR-J2M-

DU)......................................................................................................... 10- 3

10.2.4 Extension IO unit (MR-J2M-D01) ..............................................................................................10- 4

10.2.5 Battery unit (MR-J2M-BT).......................................................................................................... 10- 4

10.3 Connectors............................................................................................................................................ 10- 5

11. CHARACTERISTICS 11- 1 to 11- 6

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

11.2 Power supply equipment capacity and generated loss ....................................................................11- 2

11.3 Dynamic brake characteristics...........................................................................................................11- 4

11.4 Encoder cable flexing life ....................................................................................................................11- 6

12. OPTIONS AND AUXILIARY EQUIPMENT 12- 1 to 12-36

12.1 Options.................................................................................................................................................. 12- 1

12.1.1 Regenerative brake options ......................................................................................................... 12- 1

12.1.2 Cables and connectors ..................................................................................................................12- 8

12.1.3 Junction terminal block (MR-TB50) .......................................................................................... 12-17

12.1.4 Junction terminal block (MR-TB20) .......................................................................................... 12-19

12.1.5 Maintenance junction card (MR-J2CN3TM) ............................................................................12-21

12.1.6 MR Configurator (servo configurations software) .................................................................... 12-23

12.2 Auxiliary equipment ..........................................................................................................................12-24

12.2.1 Recommended wires ....................................................................................................................12-24

12.2.2 No-fuse breakers, fuses, magnetic contactors........................................................................... 12-26

12.2.3 Power factor improving reactors ................................................................................................12-27

12.2.4 Relays............................................................................................................................................ 12-28

12.2.5 Surge absorbers ...........................................................................................................................12-28

12.2.6 Noise reduction techniques.........................................................................................................12-28

12.2.7 Leakage current breaker ............................................................................................................ 12-34

12.2.8 EMC filter..................................................................................................................................... 12-35

13. COMMUNICATION FUNCTIONS 13- 1 to 13-32

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

13.1.1 RS-422 configuration.................................................................................................................... 13- 1

13.1.2 RS-232C configuration ................................................................................................................. 13- 3

13.2 Communication specifications............................................................................................................ 13- 4

13.2.1 Communication overview ............................................................................................................ 13- 4

13.2.2 Parameter setting .........................................................................................................................13- 5

13.3 Protocol ................................................................................................................................................. 13- 6

13.4 Character codes ...................................................................................................................................13- 7

13.5 Error codes ...........................................................................................................................................13- 8

13.6 Checksum .............................................................................................................................................13- 8

13.7 Time-out operation .............................................................................................................................. 13- 9

13.8 Retry operation .................................................................................................................................... 13- 9

13.9 Initialization........................................................................................................................................13-10

13.10 Communication procedure example ...............................................................................................13-10

13.11 Command and data No. list............................................................................................................. 13-11

13.11.1 Read commands .........................................................................................................................13-11

13.11.2 Write commands ........................................................................................................................13-13

13.12 Detailed explanations of commands ............................................................................................... 13-15

13.12.1 Data processing.......................................................................................................................... 13-15

13.12.2 Status display ............................................................................................................................13-17

13.12.3 Parameter...................................................................................................................................13-18

13.12.4 External I/O pin statuses (DIO diagnosis) ..............................................................................13-20

13.12.5 Disable/enable of external I/O signals (DIO) ..........................................................................13-23

13.12.6 External input signal ON/OFF (test operation) .....................................................................13-24

13.12.7 Test operation mode ..................................................................................................................13-25

13.12.8 Output signal pin ON/OFF (output signal (DO) forced output) ...........................................13-28

13.12.9 Alarm history ............................................................................................................................. 13-29

13.12.10 Current alarm .......................................................................................................................... 13-30

13.12.11 Other commands...................................................................................................................... 13-31

14. ABSOLUTE POSITION DETECTION SYSTEM 14- 1 to 14-12

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

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

14.1.2 Restrictions.................................................................................................................................... 14- 1

14.2 Specifications .......................................................................................................................................14- 2

14.3 Signal explanation............................................................................................................................... 14- 3

14.4 Serial communication command........................................................................................................ 14- 3

14.5 Startup procedure................................................................................................................................ 14- 4

14.6 Absolute position data transfer protocol ........................................................................................... 14- 5

14.6.1 Data transfer procedure............................................................................................................... 14- 5

14.6.2 Transfer method ...........................................................................................................................14- 6

14.6.3 Home position setting .................................................................................................................. 14- 9

14.6.4 How to process the absolute position data at detection of stroke end.................................... 14-10

14.7 Confirmation of absolute position detection data............................................................................ 14-11

APPENDIX App- 1 to App- 2

App 1. Status indication block diagram ................................................................................................. App- 1

Optional Servo Motor Instruction Manual CONTENTS

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 this 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 METHODS FOR DESIGNING

1. FUNCTIONS AND CONFIGURATION

1.1 Overview

The Mitsubishi general-purpose AC servo MELSERVO-J2M series is an AC servo which has realized wiring-saving, energy-saving and space-saving in addition to the high performance and high functions of the MELSERVO-J2-Super series. The MELSERVO-J2M series consists of an interface unit (abbreviated to the IFU) to be connected with a positioning unit, drive units (abbreviated to the DRU) for driving and controlling servo motors, and a base unit (abbreviated to the BU) where these units are installed. A torque limit is applied to the drive unit by the clamp circuit to protect the main circuit power transistors from overcurrent caused by abrupt acceleration/deceleration or overload. In addition, the torque limit value can be changed as desired using the parameter. The interface unit has an RS-232C or RS-422 serial communication function to allow the parameter setting, test operation, status indication monitoring, gain adjustment and others of all units to be performed using a personal computer or like where the MR Configurator (servo configuration software) is installed. By choosing the station number of the drive unit using the MR Configurator (servo configuration software), you can select the unit to communicate with, without changing the cabling. The real-time auto tuning function automatically adjusts the servo gains according to a machine. A maximum 500kpps high-speed pulse train is used to control the speed and direction of a motor and execute accurate positioning of 131072 pulses/rev resolution. The position smoothing function has two different systems to allow you to select the appropriate system for a machine, achieving a smoother start/stop in response to an abrupt position command. The MELSERVO-J2M series supports as standard the absolute position encoders which have 131072 pulses/rev resolution, ensuring control as accurate as that of the MELSERVO-J2-Super series. Simply adding the optional battery unit configures an absolute position detection system. Hence, merely setting a home position once makes it unnecessary to perform a home position return at power-on, alarm occurrence or like. The MELSERVO-J2M series has a control circuit power supply in the interface unit and main circuit converter and regenerative functions in the base unit to batch-wire the main circuit power input, regenerative brake connection and control circuit power supply input, achieving wiring-saving. In the MELSERVO-J2M series, main circuit converter sharing has improved the capacitor regeneration capability dramatically. Except for the operation pattern where all axes slow down simultaneously, the capacitor can be used for regeneration. You can save the energy which used to be consumed by the regenerative brake resistor.

Regenerative brake option

Control circuit power supply input

Main circuit power input

Forward rotation stroke end Reverse rotation stroke end Forced stop input

Input signal (Axes 1 to 4)

Input signal (Axes 5 to 8)

Extension IO unit MR-J2M-D01

Encoder pulse output extension DIO (Axes 1 to 4)

Encoder pulse output extension DIO (Axes 5 to 8)

Encoder cable

Servo motor power cable

Personal computer connection Monitor output Forced stop input Electromagnetic brake interlock output

1 - 1

1. FUNCTIONS AND CONFIGURATION

1.2 Function block diagram

Base unit Interface unit

CNP1B

CNP1A

CNP3

Inrush current

suppression

circuit

Regener-

ative TR

Power supply 3-phase 200 to

NFB MC

230VAC (Note) 1-phase 200 to 230VAC

Regenerative brake option

FR-BAL

Control circuit power suppy

Pulse train position command Pulse train position command

RS-232C

RS-422

D/A

Drive unit

Input signal

Stroke end

CN5

Forced stop

I/O signals

for slots 1 to 4,

CN1ACN1BCN3CNP2CN2CNP2CN2

e.g. servo-on

I/O signals

for slots 5 to 8,

e.g. servo-on

Personal computer

other servo amplifier

Analog monitor (3 channels)

Overcurrent

Base amplifie

Actual position control

Pulse counter

Pulse train position command

Model position

Model position control

protection

Actual speed control

Model speed control

Drive unit

Model speed

Current control

Virtual servo motor

Dynamic brake

Current detector

Current

detection

Model torque

Virtual encoder

Dynamic brake

Current

detection

Servo motor

(Earth)

U V

Encoder

Servo motor

(Earth)

U V

Drive unit

Dynamic brake

Current

detection

CON3A-3H CON3A-3H CON3A-3H

Note. For 1-phase 200 to 230VAC, connect the power supply to L1, L2 and leave L3 open.

1 - 2

CNP2CN2

Encoder

Servo motor

(Earth)

U V

Encoder

1. FUNCTIONS AND CONFIGURATION

1.3 Unit standard specifications

(1) Base unit

Model MR-J2M-BU4 MR-J2M-BU6 MR-J2M-BU8

Number of slots 4 slots 6 slots 8 slots

(Note)

Control circuit power supply

Main circuit power supply

Function Converter function, regenerative control, rushing into current control function

Protective functions

Mass

Note. The control circuit power supply is recorded to the interface unit.

Voltage/frequency 3-phase 200 to 230VAC or 1-phase 200 to 230VAC, 50/60Hz

Permissible voltage fluctuation 1-phase 170 to 253VAC

Permissible frequency fluctuation Within 5%

Inrush current 20A (5ms)

Voltage/frequency 3-phase 200 to 230VAC or 1-phase 200 to 230VAC, 50/60Hz Permissible voltage fluctuation 3-phase 170 to 253VAC or 1-phase 170 to 253VAC, 50/60 Hz Permissible frequency fluctuation Within 5% Maximum servo motor connection capacity [W] Continuous capacity [W] 1280 1920 2560 Inrush current 62.5A (15ms)

Regenerative overvoltage shut-off, regenerative fault protection, undervoltage /instantaneous power failure protection

[kg] 1.1 1.3 1.5

[lb] 2.4 2.9 3.3

1600 2400 3200

(2) Drive unit

Model MR-J2M-10DU MR-J2M-20DU MR-J2M-40DU MR-J2M-70DU

Power supply

Control system Sine-wave PWM control, current control system Dynamic brake Built-in

Protective functions

Structure Open (IP00) Cooling method Self-cooled Force-cooling (With built-in fan unit)

Mass

Voltage/frequency 270 to 311VDC Permissible voltage fluctuation 230 to 342VDC

Overcurrent shut-off, functions overload shut-off (electronic thermal relay), servo motor overheat protection, encoder fault protection, overspeed protection, excessive error protection

[kg] 0.4 0.4 0.4 0.7

[lb] 0.89 0.89 0.89 1.54

(3) Interface unit

Model MR-J2M-P8A

Control circuit power supply Power supply circuit for each unit(8 slots or less)

Pulse train interface 8 channels

Interface

DIO

AIO Analog monitor 3channels Structure Open (IP00)

Mass

[kg] 0.5

Forced stop input (2 points), alarm output (2 points), input signal (40 points), output signal (16 points)

[lb] 1.10

RS-232C interface 1 channel

RS-422 interface 1 channel

1 - 3

1. FUNCTIONS AND CONFIGURATION

1.4 Function list

The following table lists the functions of this servo. For details of the functions, refer to the Reference field.

(1) Drive unit (Abbreviation DRU)

Function Description Reference

High-resolution encoder High-resolution encoder of 131072 pulses/rev is used as a servo motor encoder.

Auto tuning

Gain changing function

Adaptive vibration suppression control

Low-pass filter

Position smoothing Speed can be increased smoothly in response to input pulse.

Slight vibration suppression control

Electronic gear Input pulses can be multiplied by 1/50 to 50.

Torque limit Servo motor torque can be limited to any value.

Command pulse selection Command pulse train form can be selected from among four different types.

Automatically adjusts the gain to optimum value if load applied to the servo motor shaft varies. You can switch between gains during rotation and gains during stop or use an external signal to change gains during operation. MELSERVO-J2M detects mechanical resonance and sets filter characteristics automatically to suppress mechanical vibration. Suppresses high-frequency resonance which occurs as servo system response is increased.

Suppresses vibration of 1 pulse produced at a servo motor stop.

Chapter 7

Section 7.5.4

Section 7.3

Section 7.4

DRU parameter No. 7 DRU parameter No.20

DRU parameters No. 3, 4, 69 to 71 Section 5.3.1 DRU parameters No.28 DRU parameter No. 21

(2) Interface unit (Abbreviation IFU)

Function Description Reference

Section 2.7

Position control mode This servo is used as position control servo.

I/O signal selection

Status display Servo status is shown on the 5-digit, 7-segment LED display

Analog monitor Servo status is output in terms of voltage in real time. Section 5.3.2

The servo-on (SON any other pins.

, ready (RD) and other input signals can be reassigned to

)

Section 3.1.2 Section 3.1.5

Section 3.2.6

Section 4.2.2 Section 4.3.2

(3) Base unit (Abbreviation BU)

Function Description Reference

Regenerative brake option

Used when the built-in regenerative brake resistor of the unit does not have sufficient regenerative capability for the regenerative power generated.

Section 12.1.1

(4) MR Configurator (servo configuration software)

Function Description Reference

Machine analyzer function Analyzes the frequency characteristic of the mechanical system.

Machine simulation

Gain search function Can simulate machine motions on the basis of the machine analyzer results. External I/O signal display Output signal (DO) forced output Test operation mode JOG operation and positioning operation are possible.

Can simulate machine motions on a personal computer screen on the basis of the machine analyzer results.

ON/OFF statuses of external I/O signals are shown on the display.

Output signal can be forced on/off independently of the servo status. Use this function for output signal wiring check, etc.

Section 4.3.7

Section 4.2.6 Section 4.3.8

1 - 4

1. FUNCTIONS AND CONFIGURATION

(5) Option unit

Function Description Reference

Absolute position detection system

Encoder pulse output

1.5 Model code definition

(1) Drive unit

(a) Rating plate

Merely setting a home position once makes home position return unnecessary at every power-on. Battery unit MR-J2M-BT (shortly correspondence schedule) is necessary. The encoder feedback is output from extension IO unit MR-J2M-D01 (shortly correspondence schedule) by the A output by the parameter can be changed.

SON

B Z phase pulse. The number of pulses

MODEL

POWER INPUT OUTPUT SERIAL TC300A***G51

(b) Model code

(2) Interface unit

(a) Rating plate

ALM

MR-J2M-40DU

400W DC270V-311V 170V 0-360Hz 2.3A N9Z95046

MITSUBISHI ELECTRIC

MR-J2M- DU

Rating plate

Model Capacity Applicable power supply Rated output current Serial number

Rating plate

Rated output

Symbol Capacity of applied servo motor

10 20 40 70 750

100 200 400

MITSUBISHI

MODEL

POWER : AC INPUT:

POWER

OUTPUT : SERIAL :

MITSUBISHI ELECTRIC CORPORATION

MADE IN JAPAN

(b) Model code

AC SERVO

MR-J2M-P8A

75W 2PH AC200-230V 50Hz 2PH AC200-230V 60Hz

DC5/12/20 4.6A/1.2/0.7A

AAAAG52

TC3

MR-J2M-P8A

AC SERVO

PASSED

Model

Input capacity

Applicable power supply

Output voltage / current

Serial number

Pulse train interface compatible

Rating plate

1 - 5

1. FUNCTIONS AND CONFIGURATION

(3) Base unit

(a) Rating plate

Rating plate

MITSUBISHI

MODEL

INPUT :

SERIAL:

N87B95046 BC336U246

MITSUBISHI ELECTRIC

MADE IN JAPAN

(b) Model code

MR-J2M-BU

MR-J2M-BU4

3PH 200-230 14A 50/60Hz

PASSED

Model Applicable power supply Serial number

Symbol

Number of slots

4 61920 8

Maximum servo motor connection capacity [W]

4 6 8

1600 2400 3200

Continuous capacity [W]

1280

2560

1.6 Combination with servo motor

The following table lists combinations of drive units and servo motors. The same combinations apply to the models with electromagnetic brakes and the models with reduction gears.

Drive unit

MR-J2M-10DU 053 13 053 13 13 MR-J2M-20DU 23 23 23 MR-J2M-40DU 43 43 43 MR-J2M-70DU 73 73 73

HC-KFS

Servo motor

HC-MFS HC-UFS

1 - 6

1. FUNCTIONS AND CONFIGURATION

1.7 Parts identification

(1) Drive unit

Status indicator LED Indicates the status of the drive unit. Blinking green: Servo off status Steady green: Servo on status Blinking red: Warning status Steady red: Alarm status

CN2 Encoder connector Connect the servo motor encoder

CNP2 Servo motor connector

For connection of servo motor power line cable

(2) Interface unit

Mounting screw

Rating plate

CN1 I/O signal (For 1 to 4 slots)

CN5 Forward rotation stroke end Reverse rotation stroke end Forced stop input

Display Indicates operating status or alarm.

Pushbutton switches Used to change status indication or set IFU parameters and DRU parameters.

Mounting screw

Display/setting cover

CN1B I/O signal (For 5 to 8 slots)

CN3 For connection of personal computer (RS-232C). Outputs analog monitor.

Charge lamp Lit when main circuit capacitor carries electrical charge. When this lamp is on, do not remove/reinstall any unit from/to base unit and do not unplug/plug cable and connector from/into any unit.

1 - 7

1. FUNCTIONS AND CONFIGURATION

(3) Base unit

The following shows the MR-J2M-BU4.

CNP1B Control circuit power input connector

CNP1 Regenerative brake option connecto

CON3A First slot connector

CON3C Third slot connector

CNP3 Main circuit power input connector

CON1,CON2 Interface unit connectors

CON3B Second slot connector

CON4 Option slot connector

CON5 Battery unit connecto

CON3D Fourth slot connector

1 - 8

1. FUNCTIONS AND CONFIGURATION

1.8 Servo system with auxiliary equipment

WARNING

3-phase 200V to 230VAC power supply (Note) 1-phase 200V to 230VAC

No-fuse breaker (NFB) or fuse

Magnetic contactor (MC)

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

Options and auxiliary equipment

No-fuse breaker

Magnetic contactor

MR Configurator (servo configuration software)

Regenerative brake option

Control circuit power supply

) of the base unit to the protective earth (PE) of the control box.

Reference

Section 12.2.2

Section 12.1.4

Command device (For 1 to 4 slots)

To CN1A

Options and auxiliary equipment

Regenerative brake option

Cables

Power factor improving reactor

Command device (For 5 to 8 slots)

To CN1B

Reference

Section 12.1.1

Section 12.2.1

Section 12.2.3

Powe

acto improving reacto (FR-BAL)

Main circuit power supply

P C

Machine contact

MR Configurator (servo configuration software MRZJW3-SETUP151E or later)

To CNP1A

To CNP3

To CNP1B

Encoder cable

To CN3

To CN5

Power supply lead

Personal computer

Note. For 1-phase 200 to 230VAC, connect the power supply to L1, L2 and leave L3 open.

1 - 9

1. FUNCTIONS AND CONFIGURATION

MEMO

1 - 10

2. INSTALLATION AND START UP

Stacking in excess of the limited number of products is not allowed. Install the equipment to incombustibles. Installing them directly or close to

combustibles will led to a fire.

Install the equipment in a load-bearing place in accordance with this Instruction

Manual.

Do not get on or put heavy load on the equipment to prevent injury. Use the equipment within the specified environmental condition range. Provide an adequate protection to prevent screws, metallic detritus and other

CAUTION

conductive matter or oil and other combustible matter from entering each unit.

Do not block the intake/exhaust ports of each unit. Otherwise, a fault may occur. Do not subject each unit to drop impact or shock loads as they are precision

equipment.

Do not install or operate a faulty unit. When the product has been stored for an extended period of time, consult

Mitsubishi.

When treating the servo amplifier, be careful about the edged parts such as the

corners of the servo amplifier.

2.1 Environmental conditions

The following environmental conditions are common to the drive unit, interface unit and base unit.

Environment Conditions

During Ambient temperature

Ambient humidity

Ambience

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

Vibration

operation

In storage

During operation

In storage

[ ]0 to 55 (non-freezing)

] 32 to 131 (non-freezing)

[ [ ] 20 to 65 (non-freezing)

] 4 to 149 (non-freezing)

[

90%RH or less (non-condensing)

Indoors (no direct sunlight)

Free from corrosive gas, flammable gas, oil mist, dust and dirt

[m/s2] 5.9 [m/s2] or less

[ft/s

] 19.4 [ft/s2] or less

2 - 1

2. INSTALLATION AND START UP

2.2 Installation direction and clearances

The equipment must be installed in the specified direction. Otherwise, a fault may

CAUTION

(1) Installation of one MELSERVO-J2M

occur.

Leave specified clearances between each unit and control box inside walls or other

equipment.

40mm(1.57inch) or more

(2) Installation of two or more MELSERVO-J2M

When installing two units vertically, heat generated by the lower unit influences the ambient temperature of the upper unit. Suppress temperature rises in the control box so that the temperature between the upper and lower units satisfies the environmental conditions. Also provide adequate clearances between the units or install a fan.

40mm(1.57inch) or more

Leave 100mm(3.94inch) or more clearance or install fan for forced air cooling.

40mm(1.57inch) or more

2 - 2

2. INSTALLATION AND START UP

(3) Others

When using heat generating equipment such as the regenerative brake option, install them with full consideration of heat generation so that MELSERVO-J2M is not affected. Install MELSERVO-J2M on a perpendicular wall in the correct vertical direction.

2.3 Keep out foreign materials

(1) When installing the unit in a control box, prevent drill chips and wire fragments from entering each

unit.

(2) Prevent oil, water, metallic dust, etc. from entering each unit through openings in the control box or a

fan installed on the ceiling.

(3) When installing the control box in a place where there are much toxic gas, dirt and dust, conduct an

air purge (force clean air into the control box from outside to make the internal pressure higher than the external pressure) to prevent such materials from entering the control box.

2.4 Cable stress

(1) The way of clamping the cable must be fully examined so that flexing stress and cable's own mass

stress are not applied to the cable connection.

(2) For use in any application where the servo motor moves, fix the cables (encoder, power supply, brake)

supplied with the servo motor, and flex the optional encoder cable or the power supply and brake wiring cables. Use the optional encoder cable within the flexing life range. Use the power supply and brake wiring cables within the flexing life of the cables.

(3) Avoid any probability that the cable sheath might be cut by sharp chips, rubbed by a machine corner

or stamped by workers or vehicles.

(4) For installation on a machine where the servo motor will move, the flexing radius should be made as

large as possible. Refer to section 11.4 for the flexing life.

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