Mitsubishi Electronics MR-J2S- CP User Manual

General-Purpose AC Servo
J2-Super Series
MODEL
MR-J2S- CP
SERVO AMPLIFIER INSTRUCTION MANUAL
G

Safety Instructions

(Always read these instructions before using the equipment.)
Do not attempt to install, operate, maintain or inspect the servo amplifier and servo motor until you have read through this Instruction Manual, Installation guide, Servo motor Instruction Manual and appended documents carefully and can use the equipment correctly. Do not use the servo amplifier and servo motor until you have a full knowledge of the equipment, safety information and instructions. In this Instruction Manual, the safety instruction levels are classified into "WARNING" and "CAUTION".
WARNING
CAUTION
Indicates that incorrect handling may cause hazardous conditions, 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.
Note that the CAUTION level may lead to a serious consequence according to conditions. Please follow the instructions of both levels because they are important to personnel safety. What must not be done and what must be done are indicated by the following diagrammatic symbols:
: Indicates what must not be done. For example, "No Fire" is indicated by
: Indicates what must be done. For example, grounding is indicated by
In this Instruction Manual, instructions at a lower level than the above, instructions for other functions, and so on are classified into "POINT". After reading this installation guide, always keep it accessible to the operator.
.
.
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1. To prevent electric shock, note the following:
WARNING
Before wiring or inspection, turn off the power and wait for 15 minutes or more until the charge lamp turns off. Then, confirm that the voltage between P and N is safe with a voltage tester and others. Otherwise, an electric shock may occur. In addition, always confirm from the front of the servo amplifier, whether the charge lamp is off or not.
Connect the servo amplifier and servo motor to ground.
Any person who is involved in wiring and inspection should be fully competent to do the work.
Do not attempt to wire the servo amplifier and servo motor until they have been installed. Otherwise, you may get an electric shock.
Operate the switches with dry hand to prevent an electric shock.
The cables should not be damaged, stressed, loaded, or pinched. Otherwise, you may get an electric shock.
During power-on or operation, do not open the front cover of the servo amplifier. You may get an electric shock.
Do not operate the servo amplifier with the front cover removed. High-voltage terminals and charging area are exposed and you may get an electric shock.
Except for wiring or periodic inspection, do not remove the front cover even of the servo amplifier if the power is off. The servo amplifier is charged and you may get an electric shock.
2. To prevent fire, note the following:
CAUTION
Install the servo amplifier, servo motor and regenerative resistor on incombustible material. Installing them directly or close to combustibles will lead to a fire.
Always connect a magnetic contactor (MC) between the main circuit power supply and L1, L2, and L3 of the servo amplifier, and configure the wiring to be able to shut down the power supply on the side of the servo amplifier’s power supply. If a magnetic contactor (MC) is not connected, continuous flow of a large current may cause a fire when the servo amplifier malfunctions.
When a regenerative resistor is used, use an alarm signal to switch main power off. Otherwise, a regenerative transistor fault or the like may overheat the regenerative resistor, causing a fire.
3. To prevent injury, note the follow
CAUTION
Only the voltage specified in the Instruction Manual should be applied to each terminal, Otherwise, a burst, damage, etc. may occur.
Connect the terminals correctly to prevent a burst, damage, etc.
Ensure that polarity ( , ) is correct. Otherwise, a burst, damage, etc. may occur.
Take safety measures, e.g. provide covers, to prevent accidental contact of hands and parts (cables, etc.) with the servo amplifier heat sink, regenerative resistor, servo motor, etc.since they may be hot while power is on or for some time after power-off. Their temperatures may be high and you may get burnt or a parts may damaged.
During operation, never touch the rotating parts of the servo motor. Doing so can cause injury.
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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 the servo amplifier. The servo amplifier may drop. Install the servo amplifier in a load-bearing place in accordance with the Instruction Manual. Do not climb or stand on servo equipment. Do not put heavy objects on equipment. The servo amplifier and servo motor must be installed in the specified direction. Leave specified clearances between the servo amplifier and control enclosure walls or other equipment. Do not install or operate the servo amplifier and servo motor which has been damaged or has any parts
missing.
Provide adequate protection to prevent screws and other conductive matter, oil and other combustible
matter from entering the servo amplifier and servo motor. Do not drop or strike servo amplifier or servo motor. Isolate from all impact loads. When you keep or use it, please fulfill the following environmental conditions.
Conditions
[ ] 0 to 55 (non-freezing) 0 to 40 (non-freezing)
Ambient temperature
[ ] 20 to 65 (non-freezing) 15 to 70 (non-freezing)
Ambient
In operation 90%RH or less (non-condensing) 80%RH or less (non-condensing)
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 HC-KFS Series
HC-SFS81
HC-SFS121 201
(Note) Vibration
HC-KFS Series
HC-SFS81
HC-SFS121 201
Note. Except the servo motor with reduction gear.
Environment
In operation
In storage
In storage 90%RH or less (non-condensing)
[
] 32 to 131 (non-freezing) 32 to 104 (non-freezing)
[ ] 4 to 149 (non-freezing) 5 to 158 (non-freezing)
2
[m/s
] 5.9 or less
2
] 19.4 or less
[ft/s
Servo amplifier Servo motor
HC-MFS Series
HC-UFS13 to 73
HC-SFS52 to 152 HC-SFS53 to 153
HC-RFS Series
HC-UFS 72
HC-SFS202 HC-SFS203
HC-UFS202
HC-SFS301
HC-MFS Series
HC-UFS 13 to 73
HC-SFS52 to 152 HC-SFS53 to 153
HC-RFS Series
HC-UFS 72
HC-SFS202 HC-SFS203
HC-UFS202
HC-SFS301
152
352 353
152
352 353
X
X
X : 24.5 Y : 49
X : 24.5 Y : 29.4
X
X
X : 80 Y : 161
X : 80 Y : 96
Y : 49
Y : 24.5
Y : 161
Y : 80
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CAUTION
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.
(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.
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.
Servo amplifier
U
V
W
Servo motor
U
V
W
U
M
V
W
Servo motorServo amplifier
U
V
M
W
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 emergency stop (EMG) and other protective circuits may not operate.
Servo amplifier Servo amplifier
COM
(24VDC)
Control
output
signal
RA
COM
(24VDC)
Control
output
signal
RA
When the cable is not tightened enough to the terminal block (connector), the cable or terminal block (connector) may generate heat because of the poor contact. Be sure to tighten the cable with specified torque.
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(3) Test run adjustment
CAUTION
Before operation, check the parameter settings. Improper settings may cause some machines to perform unexpected operation.
The parameter settings must not be changed excessively. Operation will be insatiable.
(4) Usage
CAUTION
Provide an external emergency stop circuit to ensure that operation can be stopped and power switched off immediately.
Any person who is involved in disassembly and repair should be fully competent to do the work.
Before resetting an alarm, make sure that the run signal of the servo amplifier is off to prevent an accident. A sudden restart is made if an alarm is reset with the run signal on.
Do not modify the equipment.
Use a noise filter, etc. to minimize the influence of electromagnetic interference, which may be caused by electronic equipment used near the servo amplifier.
Burning or breaking a servo amplifier may cause a toxic gas. Do not burn or break a servo amplifier.
Use the servo amplifier with the specified servo motor.
The electromagnetic brake on the servo motor is designed to hold the motor shaft and should not be used for ordinary braking.
For such reasons as service life and mechanical structure (e.g. where a 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 servo amplifier signals but also by an external forced stop (EMG).
Contacts must be open when servo-off, when an trouble (ALM) and when an electromagnetic brake interlock (MBR).
Servo motor
Circuit must be opened during forced stop (EMG).
EMGRA
24VDC
Electromagnetic brake
When any alarm has occurred, eliminate its cause, ensure safety, and deactivate the alarm before restarting operation.
When power is restored after an instantaneous power failure, keep away from the machine because the machine may be restarted suddenly (design the machine so that it is secured against hazard if restarted).
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(6) Maintenance, inspection and parts replacement
CAUTION
With age, the electrolytic capacitor of the servo amplifier will deteriorate. To prevent a secondary accident due to a fault, it is recommended to replace the electrolytic capacitor every 10 years when used in general environment.
Please consult our sales representative.
(7) General instruction
To illustrate details, the equipment in the diagrams of this Specifications and Instruction Manual may have been drawn without covers and safety guards. When the equipment is operated, the covers and safety guards must be installed as specified. Operation must be performed in accordance with this Specifications and Instruction Manual.

About processing of waste

When you discard servo amplifier, a battery (primary battery), and other option articles, please follow the law of each country (area).
FOR MAXIMUM SAFETY
These products have been manufactured as a general-purpose part for general industries, and have not been designed or manufactured to be incorporated in a device or system used in purposes related to human life.
Before using the products for special purposes such as nuclear power, electric power, aerospace, medicine, passenger movement vehicles or underwater relays, contact Mitsubishi.
These products have been manufactured under strict quality control. However, when installing the product where major accidents or losses could occur if the product fails, install appropriate backup or failsafe functions in the system.
EEP-ROM life
The number of write times to the EEP-ROM, which stores parameter settings, etc., is limited to 100,000. If the total number of the following operations exceeds 100,000, the servo amplifier and/or converter unit may fail when the EEP-ROM reaches the end of its useful life.
Write to the EEP-ROM due to parameter setting changes
Home position setting in the absolute position detection system
Write to the EEP-ROM due to device changes
Write to the EEP-ROM due to point table changes
PRECAUTIONS FOR CHOOSING THE PRODUCTS
Mitsubishi will not be held liable for damage caused by factors found not to be the cause of Mitsubishi; machine damage or lost profits caused by faults in the Mitsubishi products; damage, secondary damage, accident compensation caused by special factors unpredictable by Mitsubishi; damages to products other than Mitsubishi products; and to other duties.
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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 amplifiers have been installed.
(1) EMC directive
The EMC directive applies not to the servo units alone but to servo-incorporated machines and equipment. This requires the EMC filters to be used with the servo-incorporated machines and equipment to comply with the EMC directive. For specific EMC directive conforming methods, refer to the EMC Installation Guidelines (IB(NA)67310).
(2) Low voltage directive
The low voltage directive applies also to servo units alone. Hence, they are designed to comply with the low voltage directive. This servo is certified by TUV, third-party assessment organization, to comply with the low voltage directive.
(3) Machine directive
Not being machines, the servo amplifiers need not comply with this directive.
2. PRECAUTIONS FOR COMPLIANCE (1) Servo amplifiers and servo motors used
Use the servo amplifiers and servo motors which comply with the standard model.
Servo amplifier series :MR-J2S-10CP to MR-J2S-700CP MR-J2S-10CP1 to MR-J2S40CP1 Servo motor series :HC-KFS HC-MFS HC-SFS HC-RFS HC-UFS HA-LFS HC-LFS
(2) Configuration
Control box
Reinforced insulating type
Reinforced insulating transformer
No-fuse breaker
NFB
Magnetic contactor
MC
24VDC power supply
Servo amplifier
Servo motor
M
(3) Environment
Operate the servo amplifier at or above the contamination level 2 set forth in IEC60664-1. For this purpose, install the servo amplifier in a control box which is protected against water, oil, carbon, dust, dirt, etc. (IP54).
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(4) Power supply
(a) Operate the servo amplifier 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
servo amplifier to the protective earth (PE) of the control box.
) of the
(b) Do not connect two ground cables to the same protective earth (PE) terminal (marked ). Always
connect the cables to the terminals one-to-one.
PE terminals
PE terminals
(c) If a leakage current breaker is used to prevent an electric shock, the protective earth (PE) terminals
(marked
) of the servo amplifier must be connected to the corresponding earth terminals.
(6) Wiring
(a) The cables to be connected to the terminal block of the servo amplifier must have crimping
terminals provided with insulating tubes to prevent contact with adjacent terminals.
Crimping terminal
Insulating tube
Cable
(b) Use the servo motor side power connector which complies with the EN Standard. The EN Standard
compliant power connector sets are available from us as options. (Refer to section 14.1.4)
(7) Auxiliary equipment and options
(a) The circuit 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 cables described in section 14.2.1 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
(c) Use the EMC filter for noise reduction.
(8) Performing EMC tests
When EMC tests are run on a machine/device into which the servo amplifier has been installed, it must conform to the electromagnetic compatibility (immunity/emission) standards after it has satisfied the operating environment/electrical equipment specifications. For the other EMC directive guidelines on the servo amplifier, refer to the EMC Installation Guidelines (IB(NA)67310).
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CONFORMANCE WITH UL/C-UL STANDARD

(1) Servo amplifiers and servo motors used
Use the servo amplifiers and servo motors which comply with the standard model.
Servo amplifier series :MR-J2S-10CP to MR-J2S-700CP MR-J2S-10CP1 to MR-J2S-40CP1 Servo motor series :HC-KFS HC-MFS HC-SFS HC-RFS HC-UFS HA-LFS HC-LFS
(2) Installation
Install a cooling fan of 100CFM (2.8m provide cooling of at least equivalent capability.
(3) Short circuit rating
This servo amplifier 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, the servo amplifier conforms to the above circuit.
(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.
3
/min) air flow 4 [in] (10.16 [cm]) above the servo amplifier or
Servo amplifier Discharge time [min]
MR-J2S-10CP(1) 20CP(1) 1
MR-J2S-40CP(1) 60CP 2
MR-J2S-70CP to 350CP 3 MR-J2S-500CP 700CP 5
(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.
<<About the manuals>>
This Instruction Manual and the MELSERVO Servo Motor Instruction Manual are required if you use the MR-J2S-CP for the first time. Always purchase them and use the MR-J2S-CP safely.
Relevant manuals
Manual name Manual No.
MELSERVO-J2-Super Series To Use the AC Servo Safely IB(NA)0300010 MELSERVO Servo Motor Instruction Manual SH(NA)3181 EMC Installation Guidelines IB(NA)67310
A - 9
MEMO
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CONTENTS

1. FUNCTIONS AND CONFIGURATION 1- 1 to 1-26
1.1 Introduction.............................................................................................................................................. 1- 1
1.1.1 Function block diagram ................................................................................................................... 1- 1
1.1.2 System configuration........................................................................................................................ 1- 4
1.1.3 I/O devices ......................................................................................................................................... 1- 9
1.2 Servo amplifier standard specifications ............................................................................................... 1-10
1.3 Function list ............................................................................................................................................ 1-12
1.4 Model code definition ............................................................................................................................. 1-13
1.5 Combination with servo motor .............................................................................................................. 1-14
1.6 Structure.................................................................................................................................................. 1-15
1.6.1 Part names ....................................................................................................................................... 1-15
1.6.2 Removal and reinstallation of the front cover .............................................................................. 1-19
1.7 Servo system with auxiliary equipment............................................................................................... 1-21
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 3-42
3.1 Standard connection example ................................................................................................................ 3- 2
3.2 Internal connection diagram of servo amplifier ................................................................................... 3- 3
3.3 I/O signals................................................................................................................................................. 3- 4
3.3.1 Connectors and signal arrangements ............................................................................................. 3- 4
3.3.2 Signal (devices) explanations ..........................................................................................................3- 5
3.4 Detailed description of signals (devices) .............................................................................................. 3-13
3.4.1 Forward rotation start
3.4.2 Movement finish
3.4.3 Override ............................................................................................................................................ 3-16
3.4.4 Torque limit...................................................................................................................................... 3-17
3.5 Alarm occurrence timing chart .............................................................................................................3-19
3.6 Interfaces .................................................................................................................................................3-20
3.6.1 Common line .................................................................................................................................... 3-20
3.6.2 Detailed description of the interfaces ............................................................................................ 3-21
3.7 Input power supply circuit..................................................................................................................... 3-25
3.7.1 Connection example ........................................................................................................................ 3-25
3.7.2 Terminals.......................................................................................................................................... 3-27
3.7.3 Power-on sequence........................................................................................................................... 3-28
3.8 Connection of servo amplifier and servo motor ................................................................................... 3-29
3.8.1 Connection instructions ..................................................................................................................3-29
3.8.2 Connection diagram ........................................................................................................................ 3-29
3.8.3 I/O terminals .................................................................................................................................... 3-31
3.9 Servo motor with electromagnetic brake ............................................................................................. 3-33
Reverse rotation start Temporary stop/restart................................. 3-13
Rough match In position ............................................................................... 3-14
1
3.10 Grounding ............................................................................................................................................. 3-37
3.11 Servo amplifier terminal block (TE2) wiring method....................................................................... 3-38
3.11.1 For the servo amplifier produced later than Jan. 2006 ............................................................. 3-38
3.11.2 For the servo amplifier produced earlier than Dec. 2005 .......................................................... 3-40
3.12 Instructions for the 3M connector....................................................................................................... 3-42
4. OPERATION 4- 1 to 4-46
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- 8
4.2.3 Incremental value command system ............................................................................................. 4-10
4.2.4 Absolute value command/incremental value command specifying system ...............................4-12
4.2.5 Automatic operation timing chart.................................................................................................. 4-14
4.2.6 Automatic continuous operation .................................................................................................... 4-15
4.3 Manual operation mode .........................................................................................................................4-22
4.3.1 Jog operation .................................................................................................................................... 4-22
4.3.2 Manual pulse generator operation.................................................................................................4-24
4.4 Manual home position return mode ..................................................................................................... 4-26
4.4.1 Outline of home position return ..................................................................................................... 4-26
4.4.2 Dog type home position return ....................................................................................................... 4-28
4.4.3 Count type home position return ................................................................................................... 4-30
4.4.4 Data setting type home position return ........................................................................................ 4-31
4.4.5 Stopper type home position return ................................................................................................4-32
4.4.6 Home position ignorance (servo-on position defined as home position)..................................... 4-34
4.4.7 Dog type rear end reference home position return....................................................................... 4-35
4.4.8 Count type front end reference home position return.................................................................. 4-36
4.4.9 Dog cradle type home position return ...........................................................................................4-37
4.4.10 Home position return automatic return function....................................................................... 4-38
4.4.11 Automatic positioning function to the home position ................................................................4-39
4.5 Absolute position detection system....................................................................................................... 4-40
4.6 Serial communication operation ........................................................................................................... 4-43
4.6.1 Positioning operation in accordance with point tables ................................................................ 4-43
4.6.2 Positioning operation....................................................................................................................... 4-44
4.6.3 Multidrop system............................................................................................................................. 4-44
4.6.4 Group designation ........................................................................................................................... 4-45
5. PARAMETERS 5- 1 to 5-24
5.1 Parameter list .......................................................................................................................................... 5- 1
5.1.1 Parameter write inhibit ................................................................................................................... 5- 1
5.1.2 List ..................................................................................................................................................... 5- 2
5.2 Detailed explanation ..............................................................................................................................5-19
5.2.1 Electronic gear .................................................................................................................................5-19
5.2.2 Changing the status display screen............................................................................................... 5-20
5.2.3 S-pattern acceleration/deceleration ............................................................................................... 5-21
5.2.4 Analog output................................................................................................................................... 5-21
2
5.2.5 Changing the stop pattern using a limit switch ........................................................................... 5-24
5.2.6 Alarm history clear.......................................................................................................................... 5-24
5.2.7 Rough match output ........................................................................................................................ 5-24
5.2.8 Software limit................................................................................................................................... 5-24
6. MR Configurator (SERVO CONFIGURATION SOFTWARE) 6- 1 to 6-20
6.1 Specifications ...........................................................................................................................................6- 1
6.2 System configuration............................................................................................................................... 6- 1
6.3 Station setting.......................................................................................................................................... 6- 3
6.4 Parameters ............................................................................................................................................... 6- 4
6.5 Point table ................................................................................................................................................ 6- 6
6.6 Device assignment method ..................................................................................................................... 6- 8
6.7 Test operation .........................................................................................................................................6-12
6.7.1 Jog operation .................................................................................................................................... 6-12
6.7.2 Positioning operation....................................................................................................................... 6-14
6.7.3 Motor-less operation ........................................................................................................................ 6-16
6.7.4 Output signal (DO) forced output ..................................................................................................6-17
6.7.5 Single-step feed ................................................................................................................................ 6-18
6.8 Alarm history ..........................................................................................................................................6-19
7. DISPLAY AND OPERATION 7- 1 to 7-26
7.1 Display flowchart..................................................................................................................................... 7- 1
7.2 Status display .......................................................................................................................................... 7- 2
7.2.1 Display transition ............................................................................................................................. 7- 2
7.2.2 Display examples .............................................................................................................................. 7- 3
7.2.3 Status display list ............................................................................................................................. 7- 4
7.3 Diagnosis mode ........................................................................................................................................ 7- 5
7.3.1 Display transition ............................................................................................................................. 7- 5
7.3.2 Diagnosis mode list........................................................................................................................... 7- 6
7.4 Alarm mode .............................................................................................................................................. 7- 8
7.4.1 Display transition ............................................................................................................................. 7- 8
7.4.2 Alarm mode list................................................................................................................................. 7- 9
7.5 Point table mode ..................................................................................................................................... 7-11
7.5.1 Point table transition ...................................................................................................................... 7-11
7.5.2 Point table mode setting screen sequence..................................................................................... 7-12
7.5.3 Operation method ............................................................................................................................ 7-13
7.6 Parameter mode ..................................................................................................................................... 7-15
7.6.1 Parameter mode transition............................................................................................................. 7-15
7.6.2 Operation example .......................................................................................................................... 7-16
7.7 External I/O signal display.................................................................................................................... 7-18
7.8 Output signal (DO) forced output ......................................................................................................... 7-19
7.9 Test operation mode ............................................................................................................................... 7-20
7.9.1 Mode change..................................................................................................................................... 7-20
7.9.2 Jog operation .................................................................................................................................... 7-21
7.9.3 Positioning operation....................................................................................................................... 7-22
7.9.4 Motor-less operation ........................................................................................................................ 7-23
7.10 Teaching function ................................................................................................................................. 7-24
7.10.1 Preparations for teaching .............................................................................................................7-24
3
7.10.2 Position data setting method........................................................................................................ 7-25
8. GENERAL GAIN ADJUSTMENT 8- 1 to 8-12
8.1 Different adjustment methods ............................................................................................................... 8- 1
8.1.1 Adjustment on a single servo amplifier.......................................................................................... 8- 1
8.1.2 Adjustment using MR Configurator (servo configuration software) ........................................... 8- 2
8.2 Auto tuning .............................................................................................................................................. 8- 3
8.2.1 Auto tuning mode .............................................................................................................................8- 3
8.2.2 Auto tuning mode operation ............................................................................................................ 8- 4
8.2.3 Adjustment procedure by auto tuning............................................................................................ 8- 5
8.2.4 Response level setting in auto tuning mode .................................................................................. 8- 6
8.3 Manual mode 1 (simple manual adjustment) ....................................................................................... 8- 7
8.3.1 Operation of manual mode 1 ...........................................................................................................8- 7
8.3.2 Adjustment by manual mode 1 ....................................................................................................... 8- 7
8.4 Interpolation mode ................................................................................................................................. 8-10
8.5 Differences in auto tuning between MELSERVO-J2 and MELSERVO-J2-Super .......................... 8-11
8.5.1 Response level setting ..................................................................................................................... 8-11
8.5.2 Auto tuning selection....................................................................................................................... 8-11
9. SPECIAL ADJUSTMENT FUNCTIONS 9- 1 to 9-10
9.1 Function block diagram .......................................................................................................................... 9- 1
9.2 Machine resonance suppression filter ................................................................................................... 9- 1
9.3 Adaptive vibration suppression control................................................................................................. 9- 3
9.4 Low-pass filter ......................................................................................................................................... 9- 4
9.5 Gain changing function........................................................................................................................... 9- 5
9.5.1 Applications ....................................................................................................................................... 9- 5
9.5.2 Function block diagram ................................................................................................................... 9- 5
9.5.3 Parameters ........................................................................................................................................ 9- 6
9.5.4 Gain changing operation.................................................................................................................. 9- 8
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
11.3 MR-DP60 external digital display error........................................................................................... 11-10
12. OUTLINE DIMENSION DRAWINGS 12- 1 to 12- 8
12.1 Servo amplifiers................................................................................................................................... 12- 1
12.2 Connectors............................................................................................................................................ 12- 6
4
13. CHARACTERISTICS 13- 1 to 13- 8
13.1 Overload protection characteristics ................................................................................................... 13- 1
13.2 Power supply equipment capacity and generated loss .................................................................... 13- 2
13.3 Dynamic brake characteristics........................................................................................................... 13- 4
13.3.1 Dynamic brake operation............................................................................................................. 13- 4
13.3.2 The dynamic brake at the load inertia moment ........................................................................ 13- 6
13.4 Encoder cable flexing life .................................................................................................................... 13- 6
13.5 Inrush currents at power-on of main circuit and control circuit ....................................................13- 7
14. OPTIONS AND AUXILIARY EQUIPMENT 14- 1 to 14-50
14.1 Options.................................................................................................................................................. 14- 1
14.1.1 Regenerative options .................................................................................................................... 14- 1
14.1.2 FR-BU2 brake unit....................................................................................................................... 14- 9
14.1.3 Power regeneration converter ....................................................................................................14-15
14.1.4 Cables and connectors ................................................................................................................. 14-18
14.1.5 Junction terminal block (MR-TB20) .......................................................................................... 14-26
14.1.6 Maintenance junction card (MR-J2CN3TM) ............................................................................14-28
14.1.7 External digital display (MR-DP60) .......................................................................................... 14-30
14.1.8 Manual pulse generator (MR-HDP01) ...................................................................................... 14-32
14.1.9 Battery (MR-BAT, A6BAT)......................................................................................................... 14-33
14.2 Auxiliary equipment .......................................................................................................................... 14-34
14.2.1 Recommended wires.................................................................................................................... 14-34
14.2.2 Circuit breakers, fuses, magnetic contactors............................................................................ 14-36
14.2.3 Power factor improving reactors ................................................................................................ 14-36
14.2.4 Relays............................................................................................................................................ 14-37
14.2.5 Surge absorbers ...........................................................................................................................14-37
14.2.6 Noise reduction techniques......................................................................................................... 14-38
14.2.7 Leakage current breaker ............................................................................................................ 14-45
14.2.8 EMC filter.....................................................................................................................................14-47
14.2.9 Setting potentiometers for analog inputs.................................................................................. 14-50
15. COMMUNICATION FUNCTIONS 15- 1 to 15-40
15.1 Configuration ....................................................................................................................................... 15- 1
15.1.1 RS-422 configuration.................................................................................................................... 15- 1
15.1.2 RS-232C configuration ................................................................................................................. 15- 2
15.2 Communication specifications............................................................................................................ 15- 3
15.2.1 Communication overview............................................................................................................. 15- 3
15.2.2 Parameter setting......................................................................................................................... 15- 4
15.3 Protocol ................................................................................................................................................. 15- 5
15.4 Character codes ................................................................................................................................... 15- 7
15.5 Error codes ...........................................................................................................................................15- 8
15.6 Checksum ............................................................................................................................................. 15- 8
15.7 Time-out operation .............................................................................................................................. 15- 9
15.8 Retry operation ....................................................................................................................................15- 9
15.9 Initialization........................................................................................................................................ 15-10
15.10 Communication procedure example ...............................................................................................15-10
5
15.11 Command and data No. list.............................................................................................................15-11
15.11.1 Read commands ......................................................................................................................... 15-11
15.11.2 Write commands ........................................................................................................................ 15-14
15.12 Detailed explanations of commands............................................................................................... 15-17
15.12.1 Data processing.......................................................................................................................... 15-17
15.12.2 Status display ............................................................................................................................ 15-19
15.12.3 Parameter................................................................................................................................... 15-20
15.12.4 External I/O signal statuses..................................................................................................... 15-22
15.12.5 Input devices ON/OFF ..............................................................................................................15-24
15.12.6 Disable/enable of I/O devices (DIO) ......................................................................................... 15-25
15.12.7 Input devices ON/OFF (test operation) ................................................................................... 15-26
15.12.8 Test operation mode .................................................................................................................. 15-27
15.12.9 Output signal pin ON/OFF output signal (DO) forced output ..............................................15-30
15.12.10 Alarm history ...........................................................................................................................15-31
15.12.11 Current alarm.......................................................................................................................... 15-32
15.12.12 Point table ................................................................................................................................ 15-33
15.12.13 Servo amplifier group designation.........................................................................................15-39
15.12.14 Software version ...................................................................................................................... 15-40
APPENDIX App- 1 to App- 4
App 1. Status indication block diagram .................................................................................................App- 1
App 2. Junction terminal block (MR-TB20) terminal block labels ...................................................... App- 2
App 3. Combination of servo amplifier and servo motor ...................................................................... App- 3
App 4. Change of connector sets to the RoHS compatible products .................................................... App- 4
6
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 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 METHODS FOR DESIGNING
7
MEMO
8

1. FUNCTIONS AND CONFIGURATION

1. FUNCTIONS AND CONFIGURATION

1.1 Introduction

The MR-J2S-CP AC servo amplifier with built-in positioning functions is the MR-J2S-A general-purpose AC servo amplifier which incorporate single-axis positioning functions. These functions perform positioning operation by merely setting the position data (target positions), servo motor speeds, acceleration and deceleration time constants, etc. to point tables as if setting them in parameters. The servo amplifier is 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 31 points by using the MR Configurator (servo configuration 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-422 serial communication, or multi drop operation using RS-422 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, home position return is not required at power on, alarm occurrence, etc. The MR-J2S-CP AC servo amplifier with positioning function is made easier to use and higher in function by using it with the MR Configurator (servo configuration software).

1.1.1 Function block diagram

The function block diagram of this servo is shown below.
1 - 1
(
)
y
1. FUNCTIONS AND CONFIGURATION
(1) MR-J2S-350CP or less
Regenerative option
Note 2 Power suppl
NFB
MC
Servo amplifier
L
1
Diode stack
Relay
L2
L3
L
11
L21
Current control
Speed control
Model adaptive control
Position control
Position command creation
PDC
Regenerative transistor
CHARGE
lamp
(Note 3) Cooling fan
Control
power
supply
amplifier
Position
No.
data
1
1000
2
2000
3
4000
4
500
5
1000
6
2000
7
1000
8
1000
31
2000
A/D
CN1A CN1B
(Note 1)
Base
Acceleration time
Speed
constant
1000 80 2000 2000 2000 2000 1000 1000
1000
1000 2000
RS-232C
I/F
Voltage
detection
Point table
100
70 60 80 80
80 100 100
80
RS-422
CN3
Current
detector
Overcurrent
protection
Deceleration time constant
80
100
60 70 80 80
80 100 100
80
D/A
Dynamic
brake
Current
detection
Dwell
0 0
500
1000
0 0
0 0
0
Auxiliary
0 0 1 1 0
0
0 0 0
0
Servo motor
U
U
V
V
M
W
W
B1
Electro­magnetic
B2
brake
CN2
Encoder
MR-BAT
CON1
Optional battery (for absolute position detection system)
Analog monitor (2 channels)
Controller
RS-422/RS-232C
Analog (2 channels)
D I/O control Servo on Start Failure, etc.
To other servo amplifier
Note 1. The built-in regenerative resistor is not provided for the MR-J2S-10CP (1).
2. For 1-phase 230VAC, connect the power supply to L specification. L
3. Servo amplifiers MR-J2S-200CP have a cooling fan.
is not provided for a 1-phase 100 to120VAC power supply.
3
, L2 and leave L3 open. Refer to section 1.2 for the power supply
1
1 - 2
r
1. FUNCTIONS AND CONFIGURATION
(2) MR-J2S-500CP
700CP
Regenerative option
(Note) Power supply
NFB
MC
Servo amplifier
L
L
Diode
1
2
stack
Relay
L3
L11
L
21
Current control
Speed control
Model adaptive control
Position control
Position command creation
PNC
CHARGE
Cooling fan
Control
power supply
Position
No.
data
1
1000
2
2000
3
4000 4 5
1000 6
2000 7
1000
8
1000
31
2000
A/D
CN1A CN1B
Regenerative transistor
lamp
Base
amplifier
Speed
1000 80 2000 2000
500
2000 2000 1000 1000
1000
1000 2000
I/F
Voltage
detection
Acceleration time constant
100
100 100
RS-232C
RS-422
Point table
70 60 80 80 80
80
CN3
Current
detector
Overcurrent
protection
Deceleration time constant
80
100
60 70 80 80
80 100 100
80
D/A
Dynamic
brake
Current
detection
Dwell
0 0
500
1000
0 0
0 0
0
Auxiliary
0 0 1 1 0
0
0 0 0
0
Servo moto
U
U
V
V
M
W
W
B1
Electro­magnetic
B2
brake
CN2
Encoder
MR-BAT
CON1
Optional battery (for absolute position detection system)
Analog (2 channels)
Servo on Start Failure, etc.
Note. Refer to section 1.2 for the power supply specification.
D I/O control
To other servo amplifier
1 - 3
Analog monitor (2 channels)
Controller
RS-422/RS-232C
1. FUNCTIONS AND CONFIGURATION

1.1.2 System configuration

This section describes operations using this servo. 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 3.3.2.) The MR Configurator (servo configuration software) (refer to chapter 6) and personal computer are required to change or assign devices. Set the following values to the point table.
Name Setting range Unit
0.001[mm]
Position data 999999 to 999999
Servo motor speed 0 to max. speed [r/min] Acceleration time constant 0 to 20000 [ms] Deceleration time constant 0 to 20000 [ms] Dwell 0 to 20000 [ms]
Auxiliary function
(Refer to section 4.2)
0 to 3
0.01[mm]
0.1[mm] 1[mm]
(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 factory-set.
(b) Configuration
The following configuration uses external I/O signals. The personal computer is used with MR Configurator (servo configuration software) to set, change and monitor the parameters and point tables.
External I/O signals
Personal computer
Servo amplifier
MR Configurator (Servo configuration Software)
CN1A CN1B
CN2 CN3
Power supply
RS–232C
Servo motor
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 a forward rotation start (ST1) or reverse rotation start (ST2) 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.
External I/O signals
Servo amplifier
Personal computer
MR Configurator (Servo configuration Software)
CN1A CN1B
CN2 CN3
Power supply
RS–232C
Servo motor
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.
External I/O signals
Servo amplifier (axis 1)
Personal computer
MR Configurator (Servo configuration Software)
Power supply
External I/O signals
Power supply
CN1A CN1B
CN2 CN3
Servo amplifier (axis 2)
CN1A CN1B
CN2 CN3
Servo motor
RS–232C
RS–422
RS–232C/RS-422 converter
(to be prepared by the customer)
RS–422
To the next axis
Servo motor
1 - 6
1. FUNCTIONS AND CONFIGURATION
(3) Operation using communication
(a) Description
Analog input, forced stop (EMG) 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.
External I/O signals
Servo amplifier
Personal computer
MR Configurator (Servo configuration Software)
CN1A CN1B
CN2 CN3
Power supply
RS–232C
Servo motor
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.
External I/O signals
Servo amplifier (axis 1)
Personal computer
MR Configurator (Servo configuration Software)
Power supply
External I/O signals
Power supply
CN1A CN1B
CN2 CN3
Servo amplifier (axis 2)
CN1A CN1B
CN2 CN3
Servo motor
RS–232C
RS–422
RS–232C/RS-422 converter
(to be prepared by the customer)
RS–422
To the next axis
Servo motor
1 - 8
1. FUNCTIONS AND CONFIGURATION

1.1.3 I/O devices

This servo amplifier allows devices to be allocated to the pins of connector CN1A/CN1B as desired. The following devices can be allocated. For device details, refer to section 3.3.2.
Input device Symbol
Proximity dog DOG CN1A-8 Home position return completion ZP CN1A-18 Servo-on SON CN1B-15 Rough match CPO CN1B-4 Forward rotation stroke end LSP CN1B-16 Movement finish MEND CN1B-6 Reverse rotation stroke end LSN CN1B-17 Trouble ALM CN1B-18 Forward rotation start ST1 CN1B-8 Ready RD CN1B-19 Reverse rotation start ST2 CN1B-9 Electromagnetic brake interlock MBR Automatic/manual selection MD0 CN1B-7 Position range output POT Point table No. selection 1 DI0 CN1B-5 Warning output WNG Point table No. selection 2 DI1 CN1B-14 Battery warning output BWNG Point table No. selection 3 DI2 Limiting torque TLC Point table No. selection 4 DI3 Temporary stop PUS Point table No. selection 5 DI4 In position INP Forced stop EMG Point No. output 1 PT0 Reset RES Point No. output 2 PT1 Override selection OVR Point No. output 3 PT2 External torque limit selection TL Point No. output 4 PT3 Internal torque limit selection TL2 Point No. output 5 PT4 Proportion control PC Temporary stop/restart STP Manual pulse generator multiplication 1 Manual pulse generator multiplication 2 Gain switch CDP Teach TCH
TP0
TP1
Factory-
allocated pin
Output device Symbol
Factory-
allocated pin
1 - 9
1. FUNCTIONS AND CONFIGURATION

1.2 Servo amplifier standard specifications

Servo amplifier
Item
Voltage/frequency
Permissible voltage fluctuation
Permissible frequency fluctuation Within 5%
Power supply
Power supply capacity Refer to section13.2
Inrush current Refer to section13.5 Control system Sine-wave PWM control, current control system Dynamic brake Built-in
Protective functions
Operational specifications Position command input Speed command input
System
Operational specifications Position command input
Speed command input
System
Point table
Automatic continuous operation
Jog
Manual pulse generator
Dog type
Count type
Data setting type
Stopper type
Command system
Operation mode
Point table
number
input
Position
data input
Automatic
operation
mode
Manual
operation
mode
Manual
home
position
return
mode
MR-J2S-
10CP 20CP 40CP 60CP 70CP 100CP 200CP 350CP 500CP 700CP 10CP1 20CP1 40CP1
3-phase 200 to 230VAC, 50/60Hz or 1-phase 230VAC, 50/60Hz 3-phase 200 to 230VAC: 170 to 253VAC 1-phase 230VAC: 207 to 253VAC
Overcurrent shut-off, regenerative overvoltage shut-off, overload shut-off (electronic thermal relay), servo motor overheat protection, encoder error protection, regenerative brake error protection, undervoltage, instantaneous power failure protection, overspeed protection, excessive error protection
Positioning by specifying the point table No. (31 points)
Set in point table. 1-point feed length setting range: 1[ m] to 999.999[mm]
Set in point table. Acceleration/deceleration time is set in point table. S-pattern acceleration/deceleration time constant is set in parameter No.14. Signed absolute value command system, incremental value command system, signed absolute value command/incremental value command specifying system Positioning using RS-422 (232C) communication data
Setting through RS-422 (232C) communication 1-point feed length setting range: Setting through RS-422 (232C) communication Acceleration/deceleration time is also set through RS-422 (232C) communication. S-pattern acceleration/deceleration time constant is set in parameter No.14. Signed absolute value command system, incremental value command system, signed absolute value command/incremental value command specifying system Point table number input, position data input system Positioning operation is performed once in accordance with the position and speed commands. Varied speed operation (2 to 31 speeds), automatic continuous positioning operation (2 to 31 points) Jog operation is performed in accordance with the parameter-set speed command by contact input or through RS-422 (232C) communication. Manual feed is made by manual pulse generator. Command pulse multiplication: Home position return is made starting with Z-phase pulse after passage of proximity dog. Home position address may be set. Home position shift distance may be set. Home position return direction may be selected. Automatic at-dog home position return return/automatic stroke return function Home position return is made by counting encoder pulses after contact with proximity dog. Home position address may be set. Home position shift value may be set. Home position return direction may be set. Automatic at-dog home position return return/automatic stroke return function Home position return is made without dog. Home position may be set at any position by manual operation, etc. Home position address may be set. Home position return is made by pressing machine part against stroke end. Home position address may be set. Home position return direction may be set.
3-phase 200 to 230VAC, 50/60Hz
3-phase 170 to 253VAC
1[ m] to 999.999[mm]
1, 10 or 100 is selected using parameter.
1-phase 100 to 120VAC 50/60Hz
1-phase 85 to 127VAC
1 - 10
1. FUNCTIONS AND CONFIGURATION
Servo amplifier
MR-J2S-
Item
Home position ignorance (Servo-on position as home position)
Manual
home
position
return
mode
Operation mode
Automatic positioning to home
position
Other functions
Structure Self-cooled, open (IP00) Force-cooling, open (IP00)
Ambient
temperature
humidity
Ambient
Environment
Altitude Max. 1000m (3280ft) above sea level
Vibration
Mass
Dog type rear end reference
Count type front end reference
Dog cradle type
In Operation
In storage
In Operation Ambient In storage
10CP 20CP 40CP 60CP 70CP 100CP 200CP 350CP 500CP 700CP 10CP1 20CP1 40CP1
Position where servo-on (SON) is switched on is defined as home position. Home position address may be set.
Home position return is made with respect to the rear end of a proximity dog. Home position address may be set. Home position shift value may be set. Home position return direction may be set. Automatic at-dog home position return return/automatic stroke return function Home position return is made with respect to the front end of a proximity dog. Home position address may be set. Home position shift value may be set. Home position return direction may be set. Automatic at-dog home position return return/automatic stroke return function Home position return is made with respect to the front end of a proximity dog by the first Z-phase pulse. Home position address may be set. Home position shift value may be set. Home position return direction may be set. Automatic at-dog home position return return/automatic stroke return function High-speed automatic return to a defined home position.
Absolute position detection, backlash function Overtravel prevention using external limit switch Software stroke limit, override using external analog signal
Amplifier front button-operated teaching function/external teaching pendant input signal interface
[ ] 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
5.9 [m/s2] or less
19.4 [ft/s
[kg] 0.7 0.7 1.1 1.1 1.7 1.7 2.0 2.0 4.9 7.2 0.7 0.7 1.1
[lb]
2
] or less
1.5 1.5 2.4 2.4 3.75 3.75 4.4 4.4 10.8 15.87 1.5 1.5 2.4
Self-cooled, open (IP00)
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