Mitsubishi Electric MR-J4W2-0303B6, MR-J4W3-444B, MR-J4W3-222B, MR-J4W2-77B, MR-J4W2-1010B Instruction Manual

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General-Purpose AC Servo

SSCNET /H Interface Multi-axis AC Servo

MODEL

MR-J4W2-_B MR-J4W3-_B MR-J4W2-0303B6

SERVO AMPLIFIER INSTRUCTION MANUAL

Safety Instructions

Please read the instructions carefully before using the equipment.

To use the equipment correctly, do not attempt to install, operate, maintain, or inspect the equipment until you have read through this Instruction Manual, Installation guide, and appended documents carefully. Do not use the equipment until you have a full knowledge of the equipment, safety information and instructions. In this Instruction Manual, the safety instruction levels are classified into "WARNING" and "CAUTION".

WARNING

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.

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.

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

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

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

A - 1

1. To prevent electric shock, note the following

WARNING

Before wiring and inspections, turn off the power and wait for 15 minutes or more until the charge lamp turns off. Then, confirm that the voltage between P+ and N- is safe with a voltage tester and others. Otherwise, an electric shock may occur. In addition, when confirming whether the charge lamp is off or not, always confirm it from the front of the servo amplifier. Ground the servo amplifier and servo motor securely. Any person who is involved in wiring and inspection should be fully competent to do the work. Do not attempt to wire the servo amplifier and servo motor until they have been installed. Otherwise, it may cause an electric shock. Do not operate switches with wet hands. Otherwise, it may cause an electric shock. The cables should not be damaged, stressed, loaded, or pinched. Otherwise, it may cause an electric shock. To prevent an electric shock, always connect the protective earth (PE) terminal (marked ) of the servo amplifier to the protective earth (PE) of the cabinet. To avoid an electric shock, insulate the connections of the power supply terminals.

2. To prevent fire, note the following

CAUTION

Install the servo amplifier, servo motor, and regenerative resistor on incombustible material. Installing them directly or close to combustibles will lead to smoke or a fire. Always connect a magnetic contactor between the power supply and the main circuit power supply (L1/ L2/L3) of the servo amplifier, in order to configure a circuit that shuts down the power supply on the side of the servo amplifier’s power supply. If a magnetic contactor is not connected, continuous flow of a large current may cause smoke or a fire when the servo amplifier malfunctions. Always connect a molded-case circuit breaker, or a fuse to each servo amplifier between the power supply and the main circuit power supply (L1/L2/L3) of the servo amplifier (including converter unit), in order to configure a circuit that shuts down the power supply on the side of the servo amplifier’s power supply. If a molded-case circuit breaker or fuse is not connected, continuous flow of a large current may cause smoke or a fire when the servo amplifier malfunctions. When using the regenerative resistor, switch power off with the alarm signal. Otherwise, a regenerative transistor malfunction or the like may overheat the regenerative resistor, causing smoke or a fire. Provide adequate protection to prevent screws and other conductive matter, oil and other combustible matter from entering the servo amplifier and servo motor.

3. To prevent injury, note the following

CAUTION

Only the power/signal specified in the Instruction Manual should be applied to each terminal. Otherwise, it may cause an electric shock, fire, injury, etc. Connect cables to the correct terminals. Otherwise, a burst, damage, etc., may occur. Ensure that polarity (+/-) is correct. Otherwise, a burst, damage, etc., may occur. The servo amplifier heat sink, regenerative resistor, servo motor, etc., may be hot while the power is on and for some time after power-off. Take safety measures such as providing covers to avoid accidentally touching them by hands and parts such as cables.

A - 2

4. Additional instructions

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

(1) Transportation and installation

CAUTION

Transport the products correctly according to their mass. Stacking in excess of the specified number of product packages is not allowed. Do not hold the cables or connectors when carrying the servo amplifier. Otherwise, it may drop. Install the servo amplifier and the servo motor in a load-bearing place in accordance with the Instruction Manual. Do not get on or put heavy load on the equipment. Otherwise, it may cause injury. The equipment must be installed in the specified direction. Maintain specified clearances between the servo amplifier and the inner surfaces of a control cabinet or other equipment. Do not install or operate the servo amplifier and servo motor which have been damaged or have any parts missing. Do not strike the connector. Otherwise, it may cause a connection failure, malfunction, etc. When you keep or use the equipment, please fulfill the following environment.

Item Environment

Ambient

temperature

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

Ambient humidity

Storage Ambience Indoors (no direct sunlight), free from corrosive gas, flammable gas, oil mist, dust, and dirt Altitude 2000 m or less above sea level (Contact your local sales office for the altitude for options.) Vibration resistance 5.9 m/s2, at 10 Hz to 55 Hz (X, Y, Z axes)

Do not block the intake and exhaust areas of the servo amplifier. Otherwise, it may cause a malfunction. Do not drop or apply heavy impact on the servo amplifiers and the servo motors. Otherwise, it may cause injury, malfunction, etc. When the product has been stored for an extended period of time, contact your local sales office. When handling the servo motor, be careful with the sharp edges of the servo motor. The servo amplifier must be installed in a metal cabinet. When fumigants that contain halogen materials, such as fluorine, chlorine, bromine, and iodine, are used for disinfecting and protecting wooden packaging from insects, they cause a malfunction when entering our products. Please take necessary precautions to ensure that remaining materials from fumigant do not enter our products, or treat packaging with methods other than fumigation, such as heat treatment. Additionally, disinfect and protect wood from insects before packing the products. To prevent a fire or injury in case of an earthquake or other natural disasters, securely install, mount, and wire the servo motor in accordance with the Instruction Manual.

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

Operation

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

A - 3

(2) Wiring

CAUTION

Wire the equipment correctly and securely. Otherwise, the servo motor may operate unexpectedly. Make sure to connect the cables and connectors by using the fixing screws and the locking mechanism. Otherwise, the cables and connectors may be disconnected during operation. Do not install a power capacitor, surge killer, or radio noise filter (optional FR-BIF) on the servo amplifier output side. To avoid a malfunction, connect the wires to the correct phase terminals (U/V/W) of the servo amplifier and servo motor. Connect the servo amplifier power output (U/V/W) to the servo motor power input (U/V/W) directly. Do not connect a magnetic contactor and others between them. Otherwise, it may cause a malfunction.

Servo amplifier

Servo motor

Servo motorServo amplifier

The connection diagrams in this Instruction Manual are shown for sink interfaces, unless stated otherwise. The surge absorbing diode installed to the DC relay for control output should be fitted in the specified direction. Otherwise, the converter unit and the drive unit will malfunction and will not output signals, disabling the emergency stop and other protective circuits.

Servo amplifier

DOCOM

Control output signal

For sink output interface

24 V DC

Servo amplifier

DOCOM

Control output signal

For source output interface

24 V DC

When the wires are not tightened enough to the terminal block, the wires or terminal block may generate heat because of the poor contact. Be sure to tighten the wires with specified torque. Connecting an encoder of wrong axis to the CN2A, CN2B, or CN2C connector may cause a malfunction. Connecting a servo motor of the wrong axis to the CNP3A, CNP3B, or CN3C connector may cause a malfunction. Configure a circuit to turn off EM2 or EM1 when the main circuit power supply is turned off to prevent an unexpected restart of the servo amplifier. To prevent malfunction, avoid bundling power lines (input/output) and signal cables together or running them in parallel to each other. Separate the power lines from the signal cables.

A - 4

(3) Test run and adjustment

CAUTION

When executing a test run, follow the notice and procedures in this instruction manual. Otherwise, it may cause a malfunction, damage to the machine, or injury. Before operation, check and adjust the parameter settings. Improper settings may cause some machines to operate unexpectedly. Never make a drastic adjustment or change to the parameter values as doing so will make the operation unstable. Do not get close to moving parts during the servo-on status.

(4) Usage

CAUTION

Provide an external emergency stop circuit to stop the operation and shut the power off immediately. For equipment in which the moving part of the machine may collide against the load side, install a limit switch or stopper to the end of the moving part. The machine may be damaged due to a collision. Do not disassemble, repair, or modify the product. Otherwise, it may cause an electric shock, fire, injury, etc. Disassembled, repaired, and/or modified products are not covered under warranty. Before resetting an alarm, make sure that the run signal of the servo amplifier is off in order to prevent a sudden restart. Otherwise, it may cause an accident. Use a noise filter, etc., to minimize the influence of electromagnetic interference. Electromagnetic interference may affect the electronic equipment used near the servo amplifier. Do not burn or destroy the servo amplifier. Doing so may generate a toxic gas. Use the servo amplifier with the specified servo motor. Wire options and peripheral equipment, etc. correctly in the specified combination. Otherwise, it may cause an electric shock, fire, injury, etc. 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 incorrect wiring, service life, and mechanical structure (e.g. where a ball screw and the servo motor are coupled via a timing belt), the electromagnetic brake may not hold the motor shaft. To ensure safety, install a stopper on the machine side. If the dynamic brake is activated at power-off, alarm occurrence, etc., do not rotate the servo motor by an external force. Otherwise, it may cause a fire.

A - 5

(5) Corrective actions

CAUTION

Ensure safety by confirming the power off, etc. before performing corrective actions. Otherwise, it may cause an accident. If it is assumed that a power failure, machine stoppage, or product malfunction may result in a hazardous situation, use a servo motor with an electromagnetic brake or provide an external brake system for holding purpose to prevent such hazard. Configure an electromagnetic brake circuit which is interlocked with an external emergency stop switch.

Contacts must be opened when CALM (AND malfunction) or MBR (Electromagnetic brake interlock) turns off.

Contacts must be opened with the emergency stop switch.

Servo motor

Electromagnetic brake

When an alarm occurs, eliminate its cause, ensure safety, and deactivate the alarm to restart operation. If the molded-case circuit breaker or fuse is activated, be sure to remove the cause and secure safety before switching the power on. If necessary, replace the servo amplifier and recheck the wiring. Otherwise, it may cause smoke, fire, or an electric shock. Provide an adequate protection to prevent unexpected restart after an instantaneous power failure. After an earthquake or other natural disasters, ensure safety by checking the conditions of the installation, mounting, wiring, and equipment before switching the power on to prevent an electric shock, injury, or fire.

24 V DC

(6) Maintenance, inspection and parts replacement

CAUTION

Make sure that the emergency stop circuit operates properly such that an operation can be stopped immediately and a power is shut off by the emergency stop switch. It is recommended that the servo amplifier be replaced every 10 years when it is used in general environment. When using the servo amplifier that has not been energized for an extended period of time, contact your local sales office.

(7) General instruction

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

A - 6

DISPOSAL OF WASTE

Please dispose a servo amplifier, battery (primary battery) and other options according to your local laws and regulations.

EEP-ROM life

The number of write times to the EEP-ROM, which stores parameter settings, etc., is limited to 100,000. If the total number of the following operations exceeds 100,000, the servo amplifier may malfunction when the EEP-ROM reaches the end of its useful life.

Write to the EEP-ROM due to parameter setting changes Write to the EEP-ROM due to device changes

STO function of the servo amplifier

The servo amplifier complies with safety integrity level 3 (SIL 3) of the IEC 61508:2010 functional safety standard. Refer to app. 15 for schedule. When using the STO function of the servo amplifier, refer to chapter 13. For the MR-J3-D05 safety logic unit, refer to app. 5.

Compliance with global standards

For the compliance with global standards, refer to app. 4.

«About the manuals»

You must have this Instruction Manual and the following manuals to use this servo. Ensure to prepare them to use the servo safely. When using an MR-J4W2-0303B6, refer to chapter 18.

Relevant manuals

Manual name Manual No. MELSERVO-J4 Servo Amplifier Instruction Manual (Troubleshooting) SH(NA)030109ENG MELSERVO Servo Motor Instruction Manual (Vol. 3) (Note 1) SH(NA)030113ENG MELSERVO Linear Servo Motor Instruction Manual (Note 2) SH(NA)030110ENG MELSERVO Direct Drive Motor Instruction Manual (Note 3) SH(NA)030112ENG MELSERVO Linear Encoder Instruction Manual (Note 2, 4) SH(NA)030111ENG MELSERVO EMC Installation Guidelines IB(NA)67310ENG

Note 1. It is necessary for using a rotary servo motor.

2. It is necessary for using a linear servo motor.

3. It is necessary for using a direct drive motor.

4. It is necessary for using a fully closed loop system.

A - 7

«Wiring»

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

«U.S. customary units»

U.S. customary units are not shown in this manual. Convert the values if necessary according to the following table.

Quantity SI (metric) unit U.S. customary unit Mass 1 [kg] 2.2046 [lb] Length 1 [mm] 0.03937 [inch] Torque 1 [N•m] 141.6 [oz•inch] Moment of inertia 1 [(× 10-4 kg•m2)] 5.4675 [oz•inch2] Load (thrust load/axial load) 1 [N] 0.2248 [lbf] Temperature N [°C] × 9/5 + 32 N [°F]

A - 8

1. FUNCTIONS AND CONFIGURATION 1- 1 to 1-14

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

1.2 Function block diagram ..................................................................................................................... 1- 3

1.3 Servo amplifier standard specifications ............................................................................................ 1- 4

1.3.1 Integrated 2-axis servo amplifier ................................................................................................ 1- 4

1.3.2 Integrated 3-axis servo amplifier ................................................................................................ 1- 6

1.3.3 Combinations of servo amplifiers and servo motors .................................................................. 1- 8

1.4 Function list ...................................................................................................................................... 1-10

1.5 Model designation ............................................................................................................................ 1-12

1.6 Parts identification ............................................................................................................................ 1-13

1.7 Configuration including auxiliary equipment .................................................................................... 1-14

2. INSTALLATION 2- 1 to 2- 8

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

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

2.3 Encoder cable stress ........................................................................................................................ 2- 3

2.4 SSCNET III cable laying ................................................................................................................... 2- 3

2.5 Inspection items ................................................................................................................................ 2- 5

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

2.7 Restrictions when using this product at altitude exceeding 1000 m and up to 2000 m

above sea level ................................................................................................................................. 2- 7

3. SIGNALS AND WIRING 3- 1 to 3-38

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

3.2 I/O signal connection example .......................................................................................................... 3- 5

3.2.1 For sink I/O interface .................................................................................................................. 3- 5

3.2.2 For source I/O interface ............................................................................................................. 3- 7

3.3 Explanation of power supply system ................................................................................................ 3- 8

3.3.1 Signal explanations .................................................................................................................... 3- 8

3.3.2 Power-on sequence .................................................................................................................. 3-10

3.3.3 Wiring CNP1, CNP2, and CNP3 ............................................................................................... 3-11

3.4 Connectors and pin assignment ...................................................................................................... 3-13

3.5 Signal (device) explanations ............................................................................................................ 3-14

3.5.1 Input device ............................................................................................................................... 3-14

3.5.2 Output device ............................................................................................................................ 3-15

3.5.3 Output signal ............................................................................................................................. 3-18

3.5.4 Power supply ............................................................................................................................. 3-18

3.6 Forced stop deceleration function ................................................................................................... 3-19

3.6.1 Forced stop deceleration func tion ............................................................................................. 3-19

3.6.2 Base circuit shut-off delay time function ................................................................................... 3-21

3.6.3 Vertical axis freefall prevention function ................................................................................... 3-22

3.6.4 Residual risks of the forced stop function (EM2) ...................................................................... 3-22

3.7 Alarm occurrence timing chart ......................................................................................................... 3-23

3.7.1 When you use the forced stop deceleration function ................................................................ 3-23

3.7.2 When you do not use the forced stop deceleration function ..................................................... 3-25

3.8 Interfaces ......................................................................................................................................... 3-26

3.8.1 Internal connection diagram ...................................................................................................... 3-26

3.8.2 Detailed description of interfaces .............................................................................................. 3-27

3.8.3 Source I/O interfaces ................................................................................................................ 3-28

3.9 SSCNET III cable connection .......................................................................................................... 3-29

3.10 Servo motor with an electromagnetic brake .................................................................................. 3-31

3.10.1 Safety precautions .................................................................................................................. 3-31

3.10.2 Timing chart ............................................................................................................................ 3-33

3.11 Grounding ...................................................................................................................................... 3-38

4. STARTUP 4- 1 to 4-20

4.1 Switching power on for the first time ................................................................................................. 4- 2

4.1.1 Startup procedure ...................................................................................................................... 4- 2

4.1.2 Wiring check ............................................................................................................................... 4- 3

4.1.3 Surrounding environment ........................................................................................................... 4- 4

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

4.3 Switch setting and display of the servo amplifier .............................................................................. 4- 6

4.3.1 Switches ..................................................................................................................................... 4- 6

4.3.2 Scrolling display ........................................................................................................................ 4-11

4.3.3 Status display of an axis ........................................................................................................... 4-12

4.4 Test operation .................................................................................................................................. 4-14

4.5 Test operation mode ........................................................................................................................ 4-14

4.5.1 Test operation mode in MR Configurator2 ................................................................................ 4-15

4.5.2 Motor-less operation in controller .............................................................................................. 4-17

5. PARAMETERS 5- 1 to 5-56

5.1 Parameter list .................................................................................................................................... 5- 2

5.1.1 Basic setting parameters ([Pr. PA_ _ ]) ...................................................................................... 5- 3

5.1.2 Gain/filter setting parameters ([Pr. PB_ _ ]) ............................................................................... 5- 4

5.1.3 Extension setting parameters ([Pr. PC_ _ ]) .............................................................................. 5- 5

5.1.4 I/O setting parameters ([Pr. PD_ _ ]) ......................................................................................... 5- 7

5.1.5 Extension setting 2 parameters ([Pr. PE_ _ ]) ............................................................................ 5- 8

5.1.6 Extension setting 3 parameters ([Pr. PF_ _ ]) ........................................................................... 5-10

5.1.7 Linear servo motor/DD motor setting parameters ([Pr. PL_ _ ]) ............................................... 5-11

5.2 Detailed list of parameters ............................................................................................................... 5-13

5.2.1 Basic setting parameters ([Pr. PA_ _ ]) ..................................................................................... 5-13

5.2.2 Gain/filter setting parameters ([Pr. PB_ _ ]) .............................................................................. 5-23

5.2.3 Extension setting parameters ([Pr. PC_ _ ]) ............................................................................. 5-37

5.2.4 I/O setting parameters ([Pr. PD_ _ ]) ........................................................................................ 5-44

5.2.5 Extension setting 2 parameters ([Pr. PE_ _ ]) ........................................................................... 5-48

5.2.6 Extension setting 3 parameters ([Pr. PF_ _ ]) ........................................................................... 5-50

5.2.7 Linear servo motor/DD motor setting parameters ([Pr. PL_ _ ]) ............................................... 5-53

6. NORMAL GAIN ADJUSTMENT 6- 1 to 6-28

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

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

6.1.2 Adjustment using MR Configurator2 .......................................................................................... 6- 2

6.2 One-touch tuning .............................................................................................................................. 6- 3

6.2.1 One-touch tuning flowchart ........................................................................................................ 6- 5

6.2.2 Display transition and operation procedure of one-touch tuning ............................................... 6- 7

6.2.3 Caution for one-touch tuning ..................................................................................................... 6-17

6.3 Auto tuning ....................................................................................................................................... 6-18

6.3.1 Auto tuning mode ...................................................................................................................... 6-18

6.3.2 Auto tuning mode basis ............................................................................................................. 6-19

6.3.3 Adjustment procedure by auto tuning ....................................................................................... 6-20

6.3.4 Response level setting in auto tuning mode ............................................................................. 6-21

6.4 Manual mode ................................................................................................................................... 6-22

6.5 2 gain adjustment mode .................................................................................................................. 6-25

7. SPECIAL ADJUSTMENT FUNCTIONS 7- 1 to 7-32

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

7.1.1 Machine resonance suppression filter ....................................................................................... 7- 2

7.1.2 Adaptive filter II ........................................................................................................................... 7- 5

7.1.3 Shaft resonance suppression filter ............................................................................................. 7- 7

7.1.4 Low-pass filter ............................................................................................................................ 7- 8

7.1.5 Advanced vibration suppression control II ................................................................................. 7- 8

7.1.6 Command notch filter ................................................................................................................ 7-13

7.2 Gain switching function .................................................................................................................... 7-15

7.2.1 Applications ............................................................................................................................... 7-15

7.2.2 Function block diagram ............................................................................................................. 7-16

7.2.3 Parameter .................................................................................................................................. 7-17

7.2.4 Gain switching procedure ......................................................................................................... 7-20

7.3 Tough drive function ........................................................................................................................ 7-24

7.3.1 Vibration tough drive function.................................................................................................... 7-24

7.3.2 Instantaneous power failure tough drive function ..................................................................... 7-26

7.4 Compliance with SEMI-F47 standard .............................................................................................. 7-30

7.5 Model adaptive control disabled ...................................................................................................... 7-32

8. TROUBLESHOOTING 8- 1 to 8-16

8.1 Explanation for the lists ..................................................................................................................... 8- 1

8.2 Alarm list ........................................................................................................................................... 8- 2

8.3 Warning list ...................................................................................................................................... 8-12

8.4 Troubleshooting at power on ........................................................................................................... 8-15

9. DIMENSIONS 9- 1 to 9- 6

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

9.2 Connector ......................................................................................................................................... 9- 4

10. CHARACTERISTICS 10- 1 to 10-10

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

10.2 Power supply capacity and generated loss .................................................................................. 10- 2

10.3 Dynamic brake characteristics ...................................................................................................... 10- 5

10.3.1 Dynamic brake operation ....................................................................................................... 10- 6

10.3.2 Permissible load to motor inertia when the dynamic brake is used ....................................... 10- 8

10.4 Cable bending life ......................................................................................................................... 10- 9

10.5 Inrush currents at power-on of main circuit and control circuit ..................................................... 10- 9

11. OPTIONS AND PERIPHERAL EQUIPMENT 11- 1 to 11-46

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

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

11.1.2 SSCNET III cable ................................................................................................................... 11- 4

11.1.3 Battery cable/junction battery cable ....................................................................................... 11- 6

11.1.4 MR-D05UDL3M-B STO cable ................................................................................................ 11- 7

11.2 Regenerative options .................................................................................................................... 11- 7

11.2.1 Combination and regenerative power .................................................................................... 11- 7

11.2.2 Selection of regenerative option ............................................................................................ 11- 8

11.2.3 Parameter setting .................................................................................................................. 11-10

11.2.4 Connection of regenerative option ........................................................................................ 11-11

11.2.5 Dimensions ........................................................................................................................... 11-12

11.3 Battery .......................................................................................................................................... 11-13

11.3.1 Selection of battery ............................................................................................................... 11-13

11.3.2 MR-BAT6V1SET-A battery ................................................................................................... 11-14

11.3.3 MR-BT6VCASE battery case ................................................................................................ 11-17

11.3.4 MR-BAT6V1 battery .............................................................................................................. 11-23

11.4 MR Configurator2 ........................................................................................................................ 11-24

11.4.1 Specifications ........................................................................................................................ 11-24

11.4.2 System configuration ............................................................................................................. 11-25

11.4.3 Precautions for using USB communication function ............................................................. 11-26

11.5 Selection example of wires .......................................................................................................... 11-27

11.6 Molded-case circuit breakers, fuses, magnetic contactors ......................................................... 11-29

11.7 Power factor improving AC reactors ............................................................................................ 11-31

11.8 Relays (recommended) ............................................................................................................... 11-32

11.9 Noise reduction techniques ......................................................................................................... 11-32

11.10 Earth-leakage current breaker ................................................................................................... 11-39

11.11 EMC filter (recommended) ................................................................................................

........ 11-42

11.12 Junction terminal block MR-TB26A ........................................................................................... 11-45

12. ABSOLUTE POSITION DETECTION SYSTEM 12- 1 to 12- 4

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

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

12.1.2 Structure ................................................................................................................................. 12- 1

12.1.3 Parameter setting ................................................................................................................... 12- 1

12.1.4 Confirmation of absolute position detection data ................................................................... 12- 2

12.2 Battery ........................................................................................................................................... 12- 3

12.2.1 Using MR-BAT6V1SET battery (only for MR-J4W2-0303B6) ............................................... 12- 3

12.2.2 Using MR-BT6VCASE battery case ....................................................................................... 12- 4

13. USING STO FUNCTION 13- 1 to 13-14

13.1 Introduction ................................................................................................................................... 13- 1

13.1.1 Summary ................................................................................................................................ 13- 1

13.1.2 Terms related to safety .......................................................................................................... 13- 1

13.1.3 Cautions ................................................................................................................................. 13- 1

13.1.4 Residual risks of the STO function ......................................................................................... 13- 2

13.1.5 Specifications ......................................................................................................................... 13- 3

13.1.6 Maintenance ........................................................................................................................... 13- 4

13.2 STO I/O signal connector (CN8) and signal layouts ..................................................................... 13- 4

13.2.1 Signal layouts ......................................................................................................................... 13- 4

13.2.2 Signal (device) explanations .................................................................................................. 13- 5

13.2.3 How to pull out the STO cable ............................................................................................... 13- 5

13.3 Connection example ..................................................................................................................... 13- 6

13.3.1 Connection example for CN8 connector ................................................................................ 13- 6

13.3.2 External I/O signal connection example using an MR-J3-D05 safety logic unit .................... 13- 7

13.3.3 External I/O signal connection example using an external safety relay unit ......................... 13- 9

13.3.4 External I/O signal connection example using a motion controller ....................................... 13-10

13.4 Detailed description of interfaces ................................................................................................ 13-11

13.4.1 Sink I/O interface ................................................................................................................... 13-11

13.4.2 Source I/O interface .............................................................................................................. 13-12

14. USING A LINEAR SERVO MOTOR 14- 1 to 14-32

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

14.1.1 Summary ................................................................................................................................ 14- 1

14.1.2 Servo system with auxiliary equipment .................................................................................. 14- 2

14.2 Signals and wiring ......................................................................................................................... 14- 3

14.3 Operation and functions ................................................................................................................ 14- 5

14.3.1 Startup .................................................................................................................................... 14- 5

14.3.2 Magnetic pole detection ......................................................................................................... 14- 8

14.3.3 Home position return ............................................................................................................. 14-16

14.3.4 Test operation mode in MR Configurator2 ............................................................................ 14-20

14.3.5 Operation from controller ...................................................................................................... 14-23

14.3.6 Function................................................................................................................................. 14-25

14.3.7 Absolute position detection system ....................................................................................... 14-27

14.4 Characteristics ............................................................................................................................. 14-28

14.4.1 Overload protection characteristics ...................................................................................... 14-28

14.4.2 Power supply capacity and generated loss .......................................................................... 14-29

14.4.3 Dynamic brake characteristics .............................................................................................. 14-31

14.4.4 Permissible load to motor mass ratio when the dynamic brake is used ............................... 14-32

15. USING A DIRECT DRIVE MOTOR 15- 1 to 15-24

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

15.1.1 Summary ................................................................................................................................ 15- 1

15.1.2 Servo system with auxiliary equipment .................................................................................. 15- 3

15.2 Signals and wiring ......................................................................................................................... 15- 4

15.3 Operation and functions ................................................................................................................ 15- 5

15.3.1 Startup procedure .................................................................................................................. 15- 6

15.3.2 Magnetic pole detection ......................................................................................................... 15- 7

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

15.3.4 Function................................................................................................................................. 15-16

15.4 Characteristics ............................................................................................................................. 15-18

15.4.1 Overload protection characteristics ...................................................................................... 15-18

15.4.2 Power supply capacity and generated loss .......................................................................... 15-19

15.4.3 Dynamic brake characteristics .............................................................................................. 15-21

16. FULLY CLOSED LOOP SYSTEM 16- 1 to 16-24

16.1 Functions and configuration ......................................................................................................... 16- 1

16.1.1 Function block diagram .......................................................................................................... 16- 1

16.1.2 Selecting procedure of control mode ..................................................................................... 16- 3

16.1.3 System configuration .............................................................................................................. 16- 4

16.2 Load-side encoder ........................................................................................................................ 16- 5

16.2.1 Linear encoder ....................................................................................................................... 16- 5

16.2.2 Rotary encoder ....................................................................................................................... 16- 5

16.2.3 Configuration diagram of encoder cable ................................................................................ 16- 5

16.2.4 MR-J4FCCBL03M branch cable ............................................................................................ 16- 6

16.3 Operation and functions ................................................................................................................ 16- 7

16.3.1 Startup .................................................................................................................................... 16- 7

16.3.2 Home position return ............................................................................................................. 16-14

16.3.3 Operation from controller ...................................................................................................... 16-17

16.3.4 Fully closed loop control error detection functions................................................................ 16-19

16.3.5 Auto tuning function .............................................................................................................. 16-20

16.3.6 Machine analyzer function .................................................................................................... 16-20

16.3.7 Test operation mode ............................................................................................................. 16-20

16.3.8 Absolute position detection system under fully closed loop system ..................................... 16-21

16.3.9 About MR Configurator2 ....................................................................................................... 16-22

17. APPLICATION OF FUNCTIONS 17- 1 to 17-72

17.1 J3 compatibility mode ................................................................................................................... 17- 1

17.1.1 Outline of J3 compatibility mode ............................................................................................ 17- 1

17.1.2 Operation modes supported by J3 compatibility mode .......................................................... 17- 1

17.1.3 J3 compatibility mode supported function list ........................................................................ 17- 2

17.1.4 How to switch J4 mode/J3 compatibility mode ...................................................................... 17- 5

17.1.5 How to use the J3 compatibility mode ................................................................................... 17- 6

17.1.6 Cautions for switching J4 mode/J3 compatibility mode ......................................................... 17- 7

17.1.7 Cautions for the J3 compatibility mode .................................................................................. 17- 7

17.1.8 Change of specifications of "J3 compatibility mode" switching process ................................ 17- 9

17.1.9 J3 extension function ............................................................................................................ 17-11

17.2 Scale measurement function ....................................................................................................... 17-65

17.2.1 Functions and configuration .................................................................................................. 17-65

17.2.2 Scale measurement encoder ................................................................................................ 17-67

17.2.3 How to use scale measurement function .............................................................................. 17-70

18. MR-J4W2-0303B6 SERVO AMPLIFIER 18- 1 to 18-54

18.1 Functions and configuration ......................................................................................................... 18- 1

18.1.1 Summary ................................................................................................................................ 18- 1

18.1.2 Function block diagram .......................................................................................................... 18- 2

18.1 3 Servo amplifier standard specifications ................................................................................. 18- 3

18.1.4 Combinations of servo amplifiers and servo motors .............................................................. 18- 4

18.1.5 Function list ............................................................................................................................ 18- 5

18.1.6 Model definition ...................................................................................................................... 18- 7

18.1.7 Parts identification .................................................................................................................. 18- 8

18.1.8 Configuration including peripheral equipment ....................................................................... 18- 9

18.2 Installation .................................................................................................................................... 18-10

18.2.1 Installation direction and clearances ..................................................................................... 18-11

18.2.2 Installation by DIN rail ........................................................................................................... 18-13

18.3 Signals and wiring ........................................................................................................................ 18-15

18.3.1 Input power supply circuit ..................................................................................................... 18-16

18.3.2 Explanation of power supply system ..................................................................................... 18-18

18.3.3 Selection of main circuit power supply/control circuit power supply ..................................... 18-22

18.3.4 Power-on sequence .............................................................................................................. 18-22

18.3.5 I/O Signal Connection Example ............................................................................................ 18-23

18.3.6 Connectors and pin assignment ........................................................................................... 18-26

18.3.7 Signal (device) explanations ................................................................................................. 18-27

18.3.8 Alarm occurrence timing chart .............................................................................................. 18-34

18.3.9 Interfaces .............................................................................................................................. 18-36

18.3.10 Grounding ........................................................................................................................... 18-39

18.4 Startup ......................................................................................................................................... 18-40

18.4.1 Startup procedure ................................................................................................................. 18-41

18.4.2 Troubleshooting when "24V ERROR" lamp turns on ............................................................ 18-42

18.4.3 Wiring check .......................................................................................................................... 18-42

18.4.4 Surrounding environment ...................................................................................................... 18-43

18.5 Switch setting and display of the servo amplifier ......................................................................... 18-44

18.6 Dimensions .................................................................................................................................. 18-45

18.7 Characteristics ............................................................................................................................. 18-46

18.7.1 Overload protection characteristics ...................................................................................... 18-46

18.7.2 Power supply capacity and generated loss .......................................................................... 18-47

18.7.3 Dynamic brake characteristics .............................................................................................. 18-47

18.7.4 Inrush currents at power-on of main circuit and control circuit ............................................. 18-49

18.8 Options and peripheral equipment .............................................................................................. 18-50

18.8.1 Cable/connector sets ............................................................................................................ 18-51

18.8.2 Combinations of cable/connector sets .................................................................................. 18-51

18.8.3 Selection example of wires ................................................................................................... 18-53

18.8.4 Circuit protector ..................................................................................................................... 18-54

APPENDIX App.- 1 to App.-59

App. 1 Auxiliary equipment manufacturer (for reference) ................................................................ App.- 1

App. 2 Handling of AC servo amplifier batteries for the United Nations Recommendations on the

Transport of Dangerous Goods ............................................................................................ App.- 1

App. 3 Symbol for the new EU Battery Directive .............................................................................. App.- 4

App. 4 Compliance with global standards ........................................................................................ App.- 5

App. 5 MR-J3-D05 Safety logic unit ................................................................................................ App.-21

App. 6 EC declaration of conformity ................................................................................................ App.-39

App. 7 How to replace servo amplifier without magnetic pole detection ......................................... App.-42

App. 8 Two-wire type encoder cable for HG-MR/HG-KR ................................................................ App.-43

App. 9 SSCNET III cable (SC-J3BUS_M-C) manufactured by Mitsubishi Electric System &

Service ................................................................................................................................. App.-45

App. 10 CNP_crimping connector ..................................................................................................... App.-45

App. 11 Recommended cable for servo amplifier power supply ....................................................... App.-46

App. 12 Special specification ............................................................................................................. App.-48

App. 13 Driving on/off of main circuit power supply with DC power supply ...................................... App.-51

App. 14 Optional data monitor function ............................................................................................. App.-53

App. 15 STO function with SIL 3 certification .................................................................................... App.-56

App. 16 Status of general-purpose AC servo products for compliance with the China RoHS

directive ................................................................................................................................ App.-58

1. FUNCTIONS AND CONFIGURATION

POINT

In MELSERVO-J4 series, ultra-small capacity servo amplifiers compatible with 48 V DC and 24 V DC power supplies are available as MR-J4W2-0303B6. Refer to chapter 18 for details of MR-J4W2-0303B6 servo amplifiers.

1.1 Summary

The MELSERVO-J4 series of multi-axis servo amplifiers inherits the high performance, sophisticated functions, and usability of the MR-J4-B servo amplifiers, and ensures space saving, reduced wiring, and energy saving. The MR-J4W_-B servo amplifier is connected to controllers, including a servo system controller, on the highspeed synchronous network, SSCNET III/H. The servo amplifier directly receives a command from a controller to drive a servo motor. One MR-J4W_-B servo amplifier can drive two or three servo motors. The footprint of one MR-J4W_-B servo amplifier is considerably smaller than that of two or three MR-J4-B servo amplifiers. You can install MRJ4W_-B servo amplifiers without clearance between them. This makes your system more compact. The multi-axis structure enables multiple axes to share the SSCNET III cable, control circuit power supply cable, and main circuit power supply cable. This ensures reduced wiring. For the MR-J4W_-B servo amplifier, the parameter settings allows you to use a rotary servo motor, linear servo motor, and direct drive motor for each axis. The axes can be connected to a rotary servo motor, linear servo motor, and direct drive motor, which have different capacity. Using a linear servo motor or direct drive motor simplifies the system, and using the MR-J4W_-B servo amplifier downsizes the equipment, enhances the equipment performance, and ensures space saving. Using regenerative energy generated when a servo motor decelerates ensures energy saving. Depending on the operating conditions, the regenerative option is not required. As the MR-J4-B servo amplifier, the MR-J4W_-B servo amplifier supports the one-touch tuning and the realtime auto tuning. This enables you to easily adjust the servo gain according to the machine. The tough drive function and the drive recorder function, which are well-received in the MELSERVO-JN series, have been improved. The MR-J4W_-B servo amplifier supports the improved functions. Additionally, the preventive maintenance support function detects an error in the machine parts. This function provides strong support for the machine maintenance and inspection. On the SSCNET III/H network, the stations are connected with a maximum distance of 100 m between them. This allows you to create a large system. The MR-J4W_-B servo amplifier supports the STO (Safe Torque Off) function. When the servo amplifier is connected to a SSCNET III/H-compatible servo system controller, in addition to the STO function, the servo amplifier also supports the SS1 (Safe Stop 1), SS2 (Safe Stop 2), SOS (Safe Operating Stop), SLS (SafelyLimited Speed), SBC (Safe Brake Control) and SSM (Safe Speed Monitor) functions. The servo amplifier has a USB communication interface. Therefore, you can connect the servo amplifier to the personal computer with MR Configurator2 installed to perform the parameter setting, test operation, gain adjustment, and others.

1 - 1

1. FUNCTIONS AND CONFIGURATION

Table 1.1 Connectors to connect external encoders

Operation mode External encoder communication method

Two-wire type

Linear servo motor system

A/B/Z-phase differential output method

Fully closed loop system

A/B/Z-phase differential output method

Scale measurement function

A/B/Z-phase differential output method

Note 1. The MR-J4THCBL03M branch cable is necessary.

2. The MR-J4FCCBL03M branch cable is necessary.

3. When the communication method of the servo motor encoder is four-wire type and A/B/Z-phase differential output method, MR-J4W2-_B cannot be used. Use an MR-J4-_B-RJ.

4. This is used with servo amplifiers with software version A3 or later.

5. This is used with servo amplifiers with software version A8 or later.

6. The synchronous encoder Q171ENC-W8 cannot be used due to the four-wire type.

Four-wire type

Two-wire type

Four-wire type (Note 6)

Two-wire type

Four-wire type (Note 6)

Connector

MR-J4W2-_B MR-J4W3-_B

CN2A (Note 1) CN2B (Note 1)

CN2A (Note 2, 3, 4) CN2B (Note 2, 3, 4)

CN2A (Note 2, 3, 5) CN2B (Note 2, 3, 5)

CN2A (Note 1) CN2B (Note 1) CN2C (Note 1)

1 - 2

1. FUNCTIONS AND CONFIGURATION

1.2 Function block diagram

The function block diagram of this servo is shown below.

Regenerativ

option

P+ C D

CNP2

Regenerative

CHARGE

lamp

Control (B-axis)

Control (C-axis)

Built-in regenerative resistor

STO circuit

Base

amplifier

TRM (A)

Overvoltage

Control (A-axis)

Model position

control (A)

Actual position

control (A)

(Note 2) Powe

uppl

MCCB MC

STO switch

Servo system

controller or

servo amplifier

Servo amplifier

or cap

CNP1

L11

L21

CNP2

CN8CN1ACN1B

U U

Diode

stack

I/F

Control

Relay

Cooling fan

(Note 1)

Control

circuit

power

supply

Overcurrent

(A)

Model speed

control (A)

Actual speed

control (A)

Current

detector

brake circuit (A)

Virtual

motor

Virtual

encoder

Current

control (A)

Dynamic

Current

detection

(A)

A-axis output

A-axis

F/B

B-axis output

B-axis

F/B

C-axis output

C-axis

A-axis Servo motor

CNP3ACN2ACNP3BCN2BCNP3CCN2C

B-axis Servo motor

C-axis Servo motor

F/B

Step-down

circuit

MR-BT6VCASE

CN4

Battery case +

CN5

USB

Personal computer

CN3

Digital I/O

control

Battery (for absolute position detection system)

Note 1. The MR-J4W2-22B has no cooling fan.

2. For 1-phase 200 V AC to 240 V AC, connect the power supply to L1 and L3. Leave L2 open. For the power supply specifications, refer to section 1.3.

1 - 3

1. FUNCTIONS AND CONFIGURATION

1.3 Servo amplifier standard specifications

1.3.1 Integrated 2-axis servo amplifier

Model MR-J4W2- 22B 44B 77B 1010B

Rated voltage 3-phase 170 V AC

Output

Main circuit power supply input

Voltage/Frequency 1-phase 200 V AC to 240 V AC, 50 Hz/60 Hz

Control circuit power supply input

Inrush current [A] Refer to section 10.5.

Interface power supply

Control method Sine-wave PWM control, current control method

Capacitor regeneration

Built-in regenerative resistance [W] 20 100 Dynamic brake Built-in SSCNET III/H command

communication cycle (Note 9) Communication function USB: Connect a personal computer (MR Configurator2 compatible) Encoder output pulse Compatible (A/B-phase pulse) Analog monitor None Fully closed loop control Compatible (Note 8) Scale measurement function Compatible (Note 10) Load-side encoder interface Mitsubishi Electric high-speed serial communication (Note 6)

Protective functions

Rated current (each axis) [A]

Voltage/Frequency 3-phase or 1-phase 200 V AC to 240 V AC, 50 Hz/60 Hz

Rated current (Note 11) [A]

Permissible voltage fluctuation

Permissible frequency fluctuation

Power supply capacity

Inrush current [A] Refer to section 10.5.

Rated current [A] 0.4 Permissible voltage

fluctuation Permissible

frequency fluctuation Power consumption

Voltage 24 V DC ± 10% Power supply

capacity

Reusable regenerative energy (Note 2) [J]

Moment of inertia J equivalent to the permissible charging amount (Note 3)

Mass equivalent to the permissible charging amount

(Note 4) [kg]

[× 10

-4

[kVA]

[W]

kg • m2]

LM-H3 3.8 4.7 9.8

LM-K2 LM-U2

Overcurrent shut-off, regenerative overvoltage shut-off, overload shut-off (electronic thermal),

1.5 2.8 5.8 6.0

3-phase 200 V AC to

240 V AC, 50 Hz/60 Hz

2.9 5.2 7.5 9.8

3-phase or 1-phase 170 V AC to 264 V AC

Within ±5%

Refer to section 10.2.

1-phase 170 V AC to 264 V AC

Within ±5%

0.35 A (Note 1)

17 21 44

3.45 4.26 8.92

8.5 10.5 22.0

0.222 ms, 0.444 ms, 0.888 ms

servo motor overheat protection, encoder error protection, regenerative error protection,

undervoltage protection, instantaneous power failure protection, overspeed protection, and

error excessive protection

3-phase 170 V AC to

264 V AC

1 - 4

1. FUNCTIONS AND CONFIGURATION

Model MR-J4W2- 22B 44B 77B 1010B Functional safety STO (IEC/EN 61800-5-2) (Note 7)

Standards certified by CB (Note 12)

Response performance

Test pulse input (STO)

(Note 5) Safety performance

Compliance with global standards

Structure (IP rating)

Close mounting Possible

Environment

Altitude 2000 m or less above sea level (Note 13) Vibration 5.9 m/s2 or less at 10 Hz to 55 Hz (directions of X, Y and Z axes) Mass [kg] 1.5 2.0

Note 1. 0.35 A is the value applicable when all I/O signals are used. The current capacity can be decreased by reducing the number of

2. Reusable regenerative energy corresponds to energy generated under the following conditions.

3. Moment of inertia when the motor decelerates from the rated speed to stop

4. Mass when the machine decelerates from the maximum speed to stop

5. Test pulse is a signal which instantaneously turns off a signal to the servo amplifier at a constant period for external circuit to

6. The load-side encoder is compatible only with two-wire type communication method. Not compatible with pulse train interface

7. STO is common for all axes.

8. Fully closed loop control is compatible with the servo amplifiers with software version A3 or later.

9. The command communication cycle depends on the controller specifications and the number of axes connected.

10. The scale measurement function is available for the MR-J4W2-_B servo amplifiers of software version A8 or later. Check the

11. This value is applicable when a 3-phase power supply is used.

12. The safety level depends on the setting value of [Pr. PF18 STO diagnosis error detection time] and whether STO input

13. Follow the restrictions in section 2.7 when using this product at altitude exceeding 1000 m and up to 2000 m above sea level.

Mean time to

dangerous failure

(MTTFd)

Diagnosis converge

(DC)

Average probability of

dangerous failures

per hour (PFH)

CE marking

UL standard UL 508C

Ambient

temperature

Ambient

humidity

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

I/O points.

Rotary servo motor: Regenerative energy is generated when the machine, whose moment of inertia is equivalent to the permissible charging amount, decelerates from the rated speed to stop. Linear servo motor: Regenerative energy is generated when the machine, whose mass is equivalent to the permissible

Direct drive motor: Regenerative energy is generated when the machine, whose moment of inertia is equivalent to the

Moment of inertia for two axes when two motors decelerate simultaneously Moment of inertia for each axis when multiple motors do not decelerate simultaneously The values also apply to the direct drive motor.

The primary-side (coil) mass is included. Mass for two axes when two motors decelerate simultaneously Mass for each axis when multiple motors do not decelerate simultaneously

self-diagnose.

(A/B/Z-phase differential output type).

Check the software version of the servo amplifier using MR Configurator2.

software version of the servo amplifier with MR Configurator2.

diagnosis by TOFB output is performed or not. For details, refer to the Function column of [Pr. PF18] in section 5.2.6.

Operation

Storage

Operation

Storage

charging amount, decelerates from the maximum speed to stop.

permissible charging amount, decelerates from the rated speed to stop.

EN ISO 13849-1 Category 3 PL e, IEC 61508 SIL 3, EN 62061 SIL CL3, EN 61800-5-2

8 ms or less (STO input off → energy shut off)

Natural cooling, open

(IP20)

0 °C to 55 °C (non-freezing)

-20 °C to 65 °C (non-freezing)

Test pulse interval: 1 Hz to 25 Hz

Test pulse off time: Up to 1 ms

MTTFd ≥ 100 [years] (314a)

DC = Medium, 97.6 [%]

-9

6.4 × 10

LVD: EN 61800-5-1

EMC: EN 61800-3

MD: EN ISO 13849-1, EN 61800-5-2, EN 62061

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

[1/h]

Force cooling, open (IP20)

1 - 5

1. FUNCTIONS AND CONFIGURATION

1.3.2 Integrated 3-axis servo amplifier

Model MR-J4W3- 222B 444B

Rated voltage 3-phase 170 V AC Output

Main circuit power supply input

Rated current [A] 0.4

Control circuit power supply input

Inrush current [A] Refer to section 10.5.

Interface power supply

Control method Sine-wave PWM control, current control method

Capacitor regeneration

Built-in regenerative resistance [W] 30 100 Dynamic brake Built-in SSCNET III/H command

communication cycle (Note 7) Communication function USB: Connect a personal computer (MR Configurator2 compatible) Encoder output pulse Not compatible Analog monitor None Fully closed loop control Not compatible Scale measurement function Not compatible

Protective functions

Rated current

(each axis) [A]

Power supply

/Frequency

Rated current

(Note 9) [A]

Permissible voltage

fluctuation

Permissible

frequency fluctuation

Power supply

capacity [kVA]

Inrush current [A] Refer to section 10.5.

Power supply

/Frequency

Permissible voltage

fluctuation

Permissible

frequency fluctuation

Power consumption

[W]

Voltage/Frequency 24 V DC ± 10%

Power supply

capacity

Reusable regenerative

energy (Note 2) [J]

Moment of inertia J

equivalent to the

permissible charging

amount (Note 3)

Mass

equivalent to

the

permissible

charging

amount

(Note 4) [kg]

-4

[× 10

kg • m2]

LM-H3 4.7 6.7

LM-K2 LM-U2

Overcurrent shut-off, regenerative overvoltage shut-off, overload shut-off (electronic thermal),

servo motor overheat protection, encoder error protection, regenerative error protection,

undervoltage protection, instantaneous power failure protection, overspeed protection, and

1.5 2.8

3-phase or 1-phase 200 V AC to 240 V AC, 50 Hz/60 Hz

4.3 7.8

3-phase or 1-phase 170 V AC to 264 V AC, 50 Hz/60 Hz

Within ±5%

Refer to section 10.2.

1-phase 200 V AC to 240 V AC, 50 Hz/60 Hz

1-phase 170 V AC to 264 V AC

Within ±5%

0.45 A (Note 1)

21 30

4.26 6.08

10.5 15.0

0.222 ms (Note 8), 0.444 ms, 0.888 ms

error excessive protection

1 - 6

1. FUNCTIONS AND CONFIGURATION

Model MR-J4W3- 222B 444B Functional safety STO (IEC/EN 61800-5-2) (Note 6)

Standards certified by

CB (Note 10)

Response

performance

Test pulse input (STO)

(Note 5) Safety performance

Compliance with global standards

Structure (IP rating) Force cooling, open (IP20) Close mounting Possible

Environment

Altitude 2000 m or less above sea level (Note 11) Vibration 5.9 m/s2 or less at 10 Hz to 55 Hz (directions of X, Y and Z axes) Mass [kg] 1.9

Mean time to

dangerous failure

(MTTFd)

Diagnosis converge

(DC)

Average probability of

dangerous failures

per hour (PFH)

CE marking

UL standard UL 508C

Ambient

temperature

Ambient

humidity

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

Operation

Storage

Operation

Storage

Note 1. 0.45 A is the value applicable when all I/O signals are used. The current capacity can be decreased by reducing the number of

I/O points.

2. Reusable regenerative energy corresponds to energy generated under the following conditions. Rotary servo motor: Regenerative energy is generated when the machine, whose moment of inertia is equivalent to the permissible charging amount, decelerates from the rated speed to stop. Linear servo motor: Regenerative energy is generated when the machine, whose mass is equivalent to the permissible

charging amount, decelerates from the maximum speed to stop.

Direct drive motor: Regenerative energy is generated when the machine, whose moment of inertia is equivalent to the

permissible charging amount, decelerates from the rated speed to stop.

3. Moment of inertia when the machine decelerates from the rated speed to stop Moment of inertia for three axes when three motors decelerate simultaneously Moment of inertia for each axis when multiple motors do not decelerate simultaneously The values also apply to the direct drive motor.

4. Mass when the machine decelerates from the maximum speed to stop The primary-side (coil) mass is included. Mass for three axes when three motors decelerate simultaneously Mass for each axis when multiple motors do not decelerate simultaneously

5. Test pulse is a signal which instantaneously turns off a signal to the servo amplifier at a constant period for external circuit to self-diagnose.

6. STO is common for all axes.

7. The command communication cycle depends on the controller specifications and the number of axes connected.

8. Servo amplifier with software version A3 or later is compatible with the command communication cycle of 0.222 ms. However, note that the following functions are not available when 0.222 ms is used: auto tuning (real time, one-touch, and vibration suppression control), adaptive filter II, vibration tough drive, and power monitoring.

9. This value is applicable when a 3-phase power supply is used.

10. The safety level depends on the setting value of [Pr. PF18 STO diagnosis error detection time] and whether STO input diagnosis by TOFB output is performed or not. For details, refer to the Function column of [Pr. PF18] in section 5.2.6.

11. Follow the restrictions in section 2.7 when using this product at altitude exceeding 1000 m and up to 2000 m above sea level.

EN ISO 13849-1 Category 3 PL e, IEC 61508 SIL 3, EN 62061 SIL CL3, EN 61800-5-2

8 ms or less (STO input off → energy shut off)

Test pulse interval: 1 Hz to 25 Hz

Test pulse off time: Up to 1 ms

MTTFd ≥ 100 [years] (314a)

DC = Medium, 97.6 [%]

-9

6.4 × 10

LVD: EN 61800-5-1

EMC: EN 61800-3

MD: EN ISO 13849-1, EN 61800-5-2, EN 62061

0 °C to 55 °C (non-freezing)

-20 °C to 65 °C (non-freezing)

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

[1/h]

1 - 7

1. FUNCTIONS AND CONFIGURATION

1.3.3 Combinations of servo amplifiers and servo motors

(1) MR-J4W2-_B servo amplifier

Servo amplifier

MR-J4W2-22B

MR-J4W2-44B

MR-J4W2-77B

MR-J4W2-1010B

HG-KR HG-MR HG-SR HG-UR HG-JR

053

13 23

053

13 23 43

43 73

Note 1. This is available with servo amplifiers with software version C8 or later.

2. This combination increases the maximum torque of the servo motor to 400%.

3. The combination increases the rated torque and the maximum torque.

Rotary servo motor

053

13 23

053

13 23 43

43 73

51 52

51 81 52

102

53 73

53 (Note 3)

103

Linear servo motor

(primary side)

LM-U2PAB-05M-0SS0 LM-U2PBB-07M-1SS0

LM-H3P2A-07P-BSS0 LM-H3P3A-12P-CSS0 LM-K2P1A-01M-2SS1 LM-U2PAB-05M-0SS0 LM-U2PAD-10M-0SS0 LM-U2PAF-15M-0SS0 LM-U2PBB-07M-1SS0

LM-H3P2A-07P-BSS0 LM-H3P3A-12P-CSS0 LM-H3P3B-24P-CSS0 LM-H3P3C-36P-CSS0 LM-H3P7A-24P-ASS0 LM-K2P1A-01M-2SS1 LM-K2P2A-02M-1SS1 LM-U2PAD-10M-0SS0 LM-U2PAF-15M-0SS0 LM-U2PBD-15M-1SS0 LM-U2PBF-22M-1SS0 LM-H3P2A-07P-BSS0 LM-H3P3A-12P-CSS0 LM-H3P3B-24P-CSS0 LM-H3P3C-36P-CSS0 LM-H3P7A-24P-ASS0 LM-K2P1A-01M-2SS1 LM-K2P2A-02M-1SS1 LM-U2PAD-10M-0SS0 LM-U2PAF-15M-0SS0 LM-U2PBD-15M-1SS0 LM-U2PBF-22M-1SS0

Direct drive motor

TM-RFM002C20 TM-RG2M002C30

(Note 1) TM-RU2M002C30

(Note 1) TM-RG2M004E30

(Note 1) TM-RU2M004E30

(Note 1) TM-RFM002C20 TM-RFM004C20 TM-RG2M002C30

(Note 1) TM-RU2M002C30

(Note 1) TM-RG2M004E30

(Note 1, 2) TM-RU2M004E30

(Note 1, 2) TM-RG2M009G30

(Note 1) TM-RU2M009G30

(Note 1) TM-RFM004C20 TM-RFM006C20 TM-RFM006E20 TM-RFM012E20 TM-RFM012G20 TM-RFM040J10

TM-RFM004C20 TM-RFM006C20 TM-RFM006E20 TM-RFM012E20 TM-RFM018E20 TM-RFM012G20 TM-RFM040J10

1 - 8

1. FUNCTIONS AND CONFIGURATION

(2) MR-J4W3-_B servo amplifier

Servo amplifier

MR-J4W3-222B

MR-J4W3-444B

Note 1. This is available with servo amplifiers with software version C8 or later.

2. This combination increases the maximum torque of the servo motor to 400%.

Rotary servo motor

HG-KR HG-MR

053

13 23

053

13 23 43

053

13 23

053

13 23 43

Linear servo motor

(primary side)

LM-U2PAB-05M-0SS0 LM-U2PBB-07M-1SS0

LM-H3P2A-07P-BSS0 LM-H3P3A-12P-CSS0 LM-K2P1A-01M-2SS1 LM-U2PAB-05M-0SS0 LM-U2PAD-10M-0SS0 LM-U2PAF-15M-0SS0 LM-U2PBB-07M-1SS0

Direct drive motor

TM-RFM002C20 TM-RG2M002C30

(Note 1) TM-RU2M002C30

(Note 1) TM-RG2M004E30

(Note 1) TM-RU2M004E30

(Note 1) TM-RFM002C20 TM-RFM004C20 TM-RG2M002C30

(Note 1) TM-RU2M002C30

(Note 1) TM-RG2M004E30

(Note 1, 2) TM-RU2M004E30

(Note 1, 2) TM-RG2M009G30

(Note 1) TM-RU2M009G30

(Note 1)

1 - 9

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.

Function Description

This realizes a high response and stable control following the ideal model. The two-degrees-of-freedom-model model adaptive control enables you to set a

Model adaptive control

Position control mode This servo amplifier is used as a position control servo. Speed control mode This servo amplifier is used as a speed control servo. Torque control mode This servo amplifier is used as a torque control servo.

High-resolution encoder

Absolute position detection system

Gain switching function

Advanced vibration suppression control II

Machine resonance suppression filter

Shaft resonance suppression filter

Adaptive filter II

Low-pass filter

Machine analyzer function

Robust filter

Slight vibration suppression control

Auto tuning

Regenerative option

Alarm history clear Alarm history is cleared. [Pr. PC21] Output signal selection

(Device settings) Output signal (DO) forced

output

Test operation mode

MR Configurator2

Linear servo system

Direct drive servo system Direct drive servo system can be configured to drive a direct drive motor. Chapter 15

One-touch tuning

response to the command and response to the disturbance separately. Additionally, this function can be disabled. Refer to section 7.5 for disabling this function. This is used by servo amplifiers with software version B4 or later. Check the software version with MR Configurator2.

High-resolution encoder of 4194304 pulses/rev is used as the encoder of the rotary servo motor compatible with the MELSERVO-J4 series.

Merely setting a home position once makes home position return unnecessary at every power-on.

Using an input device or gain switching conditions (including the servo motor speed) switches gains.

This function suppresses vibration at the arm end or residual vibration of the machine.

The machine resonance suppression filter is a filter function (notch filter) which decreases the gain of the specific frequency to suppress the resonance of the mechanical system.

When a load is mounted to the servo motor shaft, resonance by shaft torsion during driving may generate a mechanical vibration at high frequency. The shaft resonance suppression filter suppresses the vibration.

Servo amplifier detects mechanical resonance and sets filter characteristics automatically to suppress mechanical vibration.

Suppresses high-frequency resonance which occurs as servo system response is increased.

Analyzes the frequency characteristic of the mechanical system by simply connecting an MR Configurator2 installed personal computer and servo amplifier.

MR Configurator2 is necessary for this function. This function provides better disturbance response in case low response level that

load to motor inertia ratio is high for such as roll send axes. Suppresses vibration of ±1 pulse produced at a servo motor stop.

Automatically adjusts the gain to optimum value if load applied to the servo motor shaft varies.

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

The pins that output the output devices, including ALM (Malfunction) and INP (Inposition), can be assigned to certain pins of the CN3 connectors.

Output signal can be forced on/off independently of the servo status. Use this function for output signal wiring check and others. Jog operation, positioning operation, motor-less operation, DO forced output, and

program operation MR Configurator2 is necessary for this function. Using a personal computer, you can perform the parameter setting, test operation,

monitoring, and others. Linear servo system can be configured using a linear servo motor and linear

encoder.

One click on a certain button on MR Configurator2 adjusts the gains of the servo amplifier.

MR Configurator2 is necessary for this function.

Detailed

explanation

Chapter 12

Section 7.2

Section 7.1.5

Section 7.1.1

Section 7.1.3

Section 7.1.2

Section 7.1.4

[Pr. PE41]

[Pr. PB24]

Chapter 6

Section 11.2

[Pr. PD07] to [Pr. PD09]

Section 4.5.1 (1) (d)

Section 4.5

Section 11.4

Chapter 14

Section 6.2

1 - 10

1. FUNCTIONS AND CONFIGURATION

Function Description

Enables to avoid triggering [AL. 10 Undervoltage] using the electrical energy charged in the capacitor in case that an instantaneous power failure occurs during

SEMI-F47 function (Note)

Tough drive function

Drive recorder function

STO function

Servo amplifier life diagnosis function

Power monitoring function

Machine diagnostic function

Fully closed loop system

Scale measurement function

J3 compatibility mode

Continuous operation to torque control mode

Note. For servo system controllers which are available with this, contact your local sales office.

operation. Use a 3-phase for the input power supply of the servo amplifier. Using a 1-phase 200 V AC for the input power supply will not comply with the SEMI-F47 standard.

This function makes the equipment continue operating even under the condition that an alarm occurs.

The tough drive function includes two types: the vibration tough drive and the instantaneous power failure tough drive.

This function continuously monitors the servo status and records the status transition before and after an alarm for a fixed period of time. You can check the recorded data on the drive recorder window on MR Configurator2 by clicking the "Graph" button.

However, the drive recorder will not operate on the following conditions.

1. You are using the graph function of MR Configurator2.

2. You are using the machine analyzer function.

3. [Pr. PF21] is set to "-1".

4. The controller is not connected (except the test operation mode).

5. An alarm related to the controller is occurring. This function is a functional safety that complies with IEC/EN 61800-5-2. You can

create a safety system for the equipment easily. You can check the cumulative energization time and the number of on/off times of

the inrush relay. Before the parts of the servo amplifier, including a capacitor and relay, malfunction, this function is useful for finding out the time for their replacement.

MR Configurator2 is necessary for this function. This function calculates the power running and the regenerative power from the

data, including the speed and current, in the servo amplifier. MR Configurator2 can display the data, including the power consumption. Since the servo amplifier sends data to a servo system controller, you can analyze the data and display the data on a display with the SSCNET III/H system.

From the data in the servo amplifier, this function estimates the friction and vibrational component of the drive system in the equipment and recognizes an error in the machine parts, including a ball screw and bearing.

MR Configurator2 is necessary for this function. Fully closed system can be configured using the load-side encoder. (not available

with the MR-J4 3-axis servo amplifiers) This is used with servo amplifiers with software version A3 or later. Check the

software version with MR Configurator2. The function transmits position information of a scale measurement encoder to the

controller by connecting the scale measurement encoder in semi closed loop control.

Used by servo amplifiers with software version A8 or later. (not available with the MR-J4 3-axis servo amplifiers)

This amplifier has "J3 compatibility mode" which compatible with the previous MRJ3-B series. Refer to section 17.1 for software versions.

This enables to smoothly switch the mode from position control mode/speed control mode to torque control mode without stopping. This also enables to decrease load to the machine and high quality molding without rapid changes in speed or torque. For details of the continuous operation to torque control mode, refer to the manuals for servo system controllers.

Detailed

explanation

[Pr. PA20] [Pr. PE25] Section 7.4

Section 7.3

[Pr. PA23]

Chapter 13

Chapter 16

Section 17.2

Section 17.1

[Pr. PB03]

Servo system controller manuals

1 - 11

1. FUNCTIONS AND CONFIGURATION

1.5 Model designation

(1) Rating plate

The following shows an example of rating plate for explanation of each item.

AC SERVO

SER.A45001001

POWER: 200W×3 (A, B, C) INPUT: 3AC/AC200-240V 4.3A/7.5A 50/60Hz OUTPUT: 3PH170V 0-360Hz 1.5A×3 (A, B, C) STD.: IEC/EN 61800-5-1 MAN.: IB(NA)0300175 Max. Surrounding Air Temp.: 55°C IP20 (Except for fan finger guard)

TOKYO 100-8310, JAPAN MADE IN JAPAN

Note. Production year and month of the servo amplifier are indicated in a serial number on

MR-J4W3-222B

KCC-REI-MEK-TC300A612G51

the rating plate. The year and month of manufacture are indicated by the last one digit of the year and 1 to 9, X (10), Y (11), Z (12). For September 2011, the Serial No. is like, "SERIAL: _ 19 _ _ _ _ _ _".

DATE: 2014-05

(2) Model

The following describes what each block of a model name indicates. Not all combinations of the symbols are available.

Serial number Model

Capacity Applicable power supply Rated output current Standard, Manual number Ambient temperature IP rating

KC certification number, the year and month of manufacture

Country of origin

MR J DBWE2224-

Series

Number of axes

Number

Symbol

Note 1. Refer to App. 12.1 for details.

2. Type with a specially-coated servo amplifier board (IEC 60721-3-3 Class 3C2). Refer to app. 12.2 for details.

W2 W3

of axes

2 3

SSCNETIII/H interface

Rated output

Symbol

A-axis B-axis C-axis 22 44 77

1010

222 444

Rated output [kW]

0.2

0.4

0.75 1

0.2

0.4

0.2

0.4

0.75 1

0.2

0.4

0.2

0.4

Special specifications

Symbol Special specifications

None

-ED

Without a dynamic brake (Note 1) MR-J4W_-_B_ with a special coating specification

-EB (3C2) (Note 2)

Standard

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1. FUNCTIONS AND CONFIGURATION

1.6 Parts identification

(1)

(3)

(5)

(6)

(7)

(8)

(9)

(10)

(11)

(12)

Side view

123456

No. Name/Application

Display

(1)

(2)

(4)

(13)

(14)

(15)

(16)

(17)

(18)

(19)

(20)

Note 1. This figure shows the MR-J4 3-axis servo amplifier.

2. "External encoder" is a term for linear encoder used in the linear

The 3-digit, 7-segment LED shows the servo status and the alarm number.

Axis selection rotary switch (SW1)

(2)

Used to set the axis No. of servo amplifier. Control axis setting switch (SW2) The test operation switch, the disabling control

(3)

axis switch, and the auxiliary axis number setting switch are available.

USB communication connector (CN5)

(4)

Connect with the personal computer. Charge lamp Lit to indicate that the main circuit is charged.

(5)

While this lamp is lit, do not reconnect the cables.

Main circuit power connector (CNP1)

(6)

Connect the input power supply. Control circuit power connector (CNP2)

(7)

Connect the control circuit power supply or regenerative option.

(8) Rating plate Section 1.5

A-axis servo motor power connector (CNP3A)

(9)

Connect the A-axis servo motor. B-axis servo motor power connector (CNP3B)

(10)

Connect the B-axis servo motor. C-axis servo motor power connector (CNP3C)

(Note 1)

(11)

Connect the C-axis servo motor.

(12) Protective earth (PE) terminal Section 3.11

I/O signal connector (CN3)

(13)

Used to connect digital I/O signals. STO input signal connector (CN8)

(14)

Used to connect MR-J3-D05 safety logic unit and external safety relay.

SSCNET III cable connector (CN1A)

(15)

Used to connect the servo system controller or the previous axis servo amplifier.

SSCNET III cable connector (CN1B)

(16)

Used to connect the next axis servo amplifier. For the final axis, put a cap.

A-axis encoder connector (CN2A)

(17)

(Note

Used to connect the A-axis servo motor

encoder or external encoder. B-axis encoder connector (CN2B)

(18)

(Note

Used to connect the B-axis servo motor

encoder or external encoder. C-axis encoder connector (CN2C) (Note 1)

(19)

(Note

Used to connect the C-axis servo motor

encoder or linear encoder. Battery connector (CN4)

(20)

Used to connect the battery unit for absolute position data backup.

servo system, load-side encoder used in the fully closed loop system, and scale measurement encoder used with the scale measurement function in this manual.

"Servo Motor Instruction Manual (Vol.

3)" "Linear

Encoder Instruction Manual"

Detailed

explanation

Section 4.3

Section 11.4

Section 3.1 Section 3.3

Section 3.2 Section 3.4

Chapter 13

Section 3.2 Section 3.4

Section 3.4

Section 11.3

Chapter 12

1 - 13

+ 558 hidden pages

Mitsubishi Electric MR-J4W2-0303B6, MR-J4W3-444B, MR-J4W3-222B, MR-J4W2-77B, MR-J4W2-1010B Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Safety Instructions

DISPOSAL OF WASTE

STO function of the servo amplifier

Compliance with global standards

CONTENTS

1. FUNCTIONS AND CONFIGURATION

1.1 Summary

1.2 Function block diagram

1.3 Servo amplifier standard specifications

1.3.1 Integrated 2-axis servo amplifier

1.3.2 Integrated 3-axis servo amplifier

1.3.3 Combinations of servo amplifiers and servo motors

1.4 Function list

1.5 Model designation

1.6 Parts identification