Mitsubishi Electronics Digital Car Amplifier Mr J2M P8A Users Manual
MR-J2M-P8A to the manual 836d4606-1a30-4e7f-a709-db39fc7ef971
2015-02-09
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General-Purpose AC Servo J2M Series General-Purpose Interface Compatible MODEL MR-J2M-P8A MR-J2M- DU MR-J2M-BU SERVO AMPLIFIER INSTRUCTION MANUAL E Safety Instructions (Always read these instructions before using the equipment.) Do not attempt to install, operate, maintain or inspect the units until you have read through this Instruction Manual, Installation Guide, Servo Motor Instruction Manual and appended documents carefully and can use the equipment properly. Do not use the units until you have a full knowledge of the equipment, safety information and instructions. In this Instruction Manual, the safety instruction levels are classified into "WARNING" and "CAUTION". WARNING Indicates that incorrect handling may cause hazardous conditions, resulting in death or severe injury. CAUTION Indicates that incorrect handling may cause hazardous conditions, resulting in medium or slight injury to personnel or may cause physical damage. Note that the CAUTION level may lead to a serious consequence according to conditions. Please follow the instructions of both levels because they are important to personnel safety. What must not be done and what must be done are indicated by the following diagrammatic symbols: : Indicates what must not be done. For example, "No Fire" is indicated by : Indicates what must be done. For example, grounding is indicated by . . In this Instruction Manual, instructions at a lower level than the above, instructions for other functions, and so on are classified into "POINT". After reading this Instruction Manual, always keep it accessible to the operator. A- 1 1. To prevent electric shock, note the following: WARNING Before wiring or inspection, switch power off and wait for more than 15 minutes. Then, confirm the voltage is safe with voltage tester. Otherwise, you may get an electric shock. Connect the base unit and servo motor to ground. Any person who is involved in wiring and inspection should be fully competent to do the work. Do not attempt to wire for each unit and the servo motor until they are installed. Otherwise, you can obtain the electric shock. Operate the switches with dry hand to prevent an electric shock. The cables should not be damaged, stressed, loaded, or pinched. Otherwise, you may get an electric shock. During power-on or operation, do not open the front cover of the servo amplifier. You may get an electric shock. Do not operate the servo amplifier with the front cover removed. High-voltage terminals and charging area are exposed and you may get an electric shock. Except for wiring or periodic inspection, do not remove the front cover even of the servo amplifier if the power is off. The servo amplifier is charged and you may get an electric shock. 2. To prevent fire, note the following: CAUTION Do not install the base unit, servo motor and regenerative brake resistor on or near combustibles. Otherwise a fire may cause. When each unit has become faulty, switch off the main base unit power side. Continuous flow of a large current may cause a fire. When a regenerative brake resistor is used, use an alarm signal to switch main power off. Otherwise, a regenerative brake transistor fault or the like may overheat the regenerative brake resistor, causing a fire. 3. To prevent injury, note the follow CAUTION Only the voltage specified in the Instruction Manual should be applied to each terminal. Otherwise, a burst, damage, etc. may occur. Connect the terminals correctly to prevent a burst, damage, etc. Ensure that polarity ( , ) is correct. Otherwise, a burst, damage, etc. may occur. Take safety measures, e.g. provide covers, to prevent accidental contact of hands and parts (cables, etc.) with the servo amplifier heat sink, regenerative brake resistor, servo motor, etc.since they may be hot while power is on or for some time after power-off. Their temperatures may be high and you may get burnt or a parts may damaged. During operation, never touch the rotating parts of the servo motor. Doing so can cause injury. A- 2 4. Additional instructions The following instructions should also be fully noted. Incorrect handling may cause a fault, injury, electric shock, etc. (1) Transportation and installation CAUTION Transport the products correctly according to their weights. Stacking in excess of the specified number of products is not allowed. Do not carry the servo motor by the cables, shaft or encoder. Do not hold the front cover to transport each unit. Each unit may drop. Install the each unit in a load-bearing place in accordance with the Instruction Manual. Do not climb or stand on servo equipment. Do not put heavy objects on equipment. The servo amplifier controller and servo motor must be installed in the specified direction. Leave specified clearances between the base unit and control enclosure walls or other equipment. Do not install or operate the unit and servo motor which has been damaged or has any parts missing. Provide adequate protection to prevent screws and other conductive matter, oil and other combustible matter from entering each unit and servo motor. Do not drop or strike each unit or servo motor. Isolate from all impact loads. When you keep or use it, please fulfill the following environmental conditions. Environment Ambient temperature Ambient humidity Ambience Altitude [ ] [ ] [ ] In storage [ ] During operation In storage During operation 2 [m/s ] (Note) Vibration 2 [ft/s ] Conditions Each unit Servo motor 0 to 55 (non-freezing) 0 to 40 (non-freezing) 32 to 131 (non-freezing) 32 to 104 (non-freezing) 20 to 65 (non-freezing) 15 to 70 (non-freezing) 4 to 149 (non-freezing) 5 to 158 (non-freezing) 90%RH or less (non-condensing) 80%RH or less (non-condensing) 90%RH or less (non-condensing) Indoors (no direct sunlight) Free from corrosive gas, flammable gas, oil mist, dust and dirt Max. 1000m (3280 ft) above sea level HC-KFS Series 5.9 or less HC-MFS Series X Y : 49 HC-UFS13 to 43 HC-KFS Series 19.4 or less X Y : 161 HC-MFS Series HC-UFS13 to 43 Note. Except the servo motor with reduction gear. Securely attach the servo motor to the machine. If attach insecurely, the servo motor may come off during operation. The servo motor with reduction gear must be installed in the specified direction to prevent oil leakage. Take safety measures, e.g. provide covers, to prevent accidental access to the rotating parts of the servo motor during operation. Never hit the servo motor or shaft, especially when coupling the servo motor to the machine. The encoder may become faulty. Do not subject the servo motor shaft to more than the permissible load. Otherwise, the shaft may break. When the equipment has been stored for an extended period of time, consult Mitsubishi. A- 3 (2) Wiring CAUTION Wire the equipment correctly and securely. Otherwise, the servo motor may misoperate. Do not install a power capacitor, surge absorber or radio noise filter (FR-BIF option) between the servo motor and drive unit. Connect the output terminals (U, V, W) correctly. Otherwise, the servo motor will operate improperly. Connect the servo motor power terminal (U, V, W) to the servo motor power input terminal (U, V, W) directly. Do not let a magnetic contactor, etc. intervene. drive unit Servo Motor U U V V W W Do not connect AC power directly to the servo motor. Otherwise, a fault may occur. The surge absorbing diode installed on the DC output signal relay of the servo amplifier must be wired in the specified direction. Otherwise, the forced stop and other protective circuits may not operate. Interface unit Interface unit VIN VIN SG SG Control output signal Control output signal RA RA (3) Test run adjustment CAUTION Before operation, check the parameter settings. Improper settings may cause some machines to perform unexpected operation. The parameter settings must not be changed excessively. Operation will be insatiable. A- 4 (4) Usage CAUTION Provide an forced stop circuit to ensure that operation can be stopped and power switched off immediately. Any person who is involved in disassembly and repair should be fully competent to do the work. Before resetting an alarm, make sure that the run signal of the servo amplifier is off to prevent an accident. A sudden restart is made if an alarm is reset with the run signal on. Do not modify the equipment. Use a noise filter, etc. to minimize the influence of electromagnetic interference, which may be caused by electronic equipment used near MELSERVO-J2M. Burning or breaking each unit may cause a toxic gas. Do not burn or break each unit. Use the drive unit with the specified servo motor. The electromagnetic brake on the servo motor is designed to hold the motor shaft and should not be used for ordinary braking. For such reasons as service life and mechanical structure (e.g. where a ballscrew and the servo motor are coupled via a timing belt), the electromagnetic brake may not hold the motor shaft. To ensure safety, install a stopper on the machine side. (5) Corrective actions CAUTION When it is assumed that a hazardous condition may take place at the occur due to a power failure or a product fault, use a servo motor with electromagnetic brake or an external brake mechanism for the purpose of prevention. Configure the electromagnetic brake circuit so that it is activated not only by the interface unit signals but also by a forced stop (EMG_ ). Contacts must be open when Circuit must be servo-on (SON ) is off, when an opened during trouble (ALM_ ) is present and forced stop when an electromagnetic brake (EMG_ ). interlock (MBR ). Servo motor RA EMG_ 24VDC Electromagnetic brake When any alarm has occurred, eliminate its cause, ensure safety, and deactivate the alarm before restarting operation. When power is restored after an instantaneous power failure, keep away from the machine because the machine may be restarted suddenly (design the machine so that it is secured against hazard if restarted). A- 5 (6) Maintenance, inspection and parts replacement CAUTION With age, the electrolytic capacitor of the drive unit will deteriorate. To prevent a secondary accident due to a fault, it is recommended to replace the electrolytic capacitor every 10 years when used in general environment. Please consult our sales representative. (7) General instruction To illustrate details, the equipment in the diagrams of this Instruction Manual may have been drawn without covers and safety guards. When the equipment is operated, the covers and safety guards must be installed as specified. Operation must be performed in accordance with this Instruction Manual. About processing of waste When you discard servo amplifier, a battery (primary battery), and other option articles, please follow the law of each country (area). FOR MAXIMUM SAFETY These products have been manufactured as a general-purpose part for general industries, and have not been designed or manufactured to be incorporated in a device or system used in purposes related to human life. Before using the products for special purposes such as nuclear power, electric power, aerospace, medicine, passenger movement vehicles or under water relays, contact Mitsubishi. These products have been manufactured under strict quality control. However, when installing the product where major accidents or losses could occur if the product fails, install appropriate backup or failsafe functions in the system. EEP-ROM life The number of write times to the EEP-ROM, which stores parameter settings, etc., is limited to 100,000. If the total number of the following operations exceeds 100,000, the servo amplifier and/or converter unit may fail when the EEP-ROM reaches the end of its useful life. Write to the EEP-ROM due to parameter setting changes Home position setting in the absolute position detection system Write to the EEP-ROM due to device changes Precautions for Choosing the Products Mitsubishi will not be held liable for damage caused by factors found not to be the cause of Mitsubishi; machine damage or lost profits caused by faults in the Mitsubishi products; damage, secondary damage, accident compensation caused by special factors unpredictable by Mitsubishi; damages to products other than Mitsubishi products; and to other duties. A- 6 COMPLIANCE WITH EC DIRECTIVES 1. WHAT ARE EC DIRECTIVES? The EC directives were issued to standardize the regulations of the EU countries and ensure smooth distribution of safety-guaranteed products. In the EU countries, the machinery directive (effective in January, 1995), EMC directive (effective in January, 1996) and low voltage directive (effective in January, 1997) of the EC directives require that products to be sold should meet their fundamental safety requirements and carry the CE marks (CE marking). CE marking applies to machines and equipment into which servo (MELSERVO-J2M is contained) have been installed. (1) EMC directive The EMC directive applies not to the servo units alone but to servo-incorporated machines and equipment. This requires the EMC filters to be used with the servo-incorporated machines and equipment to comply with the EMC directive. For specific EMC directive conforming methods, refer to the EMC Installation Guidelines (IB(NA)67310). (2) Low voltage directive The low voltage directive applies also to MELSERVO-J2M. Hence, they are designed to comply with the low voltage directive. MELSERVO-J2M is certified by TUV, third-party assessment organization, to comply with the low voltage directive. The MELSERVO-J2M complies with EN50178. (3) Machine directive Not being machines, MELSERVO-J2M need not comply with this directive. 2. PRECAUTIONS FOR COMPLIANCE (1) Unit and servo motors used Use each units and servo motors which comply with the standard model. Interface unit Drive unit Base unit Servo motor :MR-J2M-P8A :MR-J2M- DU :MR-J2M-BU :HC-KFS HC-MFS HC-UFS (2) Configuration Control box Reinforced insulating type Reinforced insulating transformer No-fuse breaker Magnetic contactor NFB MC A- 7 24VDC power supply MELSERVOJ2M Servo motor M (3) Environment Operate MELSERVO-J2M at or above the contamination level 2 set forth in IEC60664-1 For this purpose, install MELSERVO-J2M in a control box which is protected against water, oil, carbon, dust, dirt, etc. (IP54). (4) Power supply (a) Operate MELSERVO-J2M to meet the requirements of the overvoltage category II set forth in IEC60664-1 For this purpose, a reinforced insulating transformer conforming to the IEC or EN standard should be used in the power input section. (b) When supplying interface power from external, use a 24VDC power supply which has been insulation-reinforced in I/O. (5) Grounding (a) To prevent an electric shock, always connect the protective earth (PE) terminals (marked base unit to the protective earth (PE) of the control box. ) of the (b) Do not connect two ground cables to the same protective earth (PE) terminal. Always connect the cables to the terminals one-to-one. (c) If a leakage current breaker is used to prevent an electric shock, the protective earth (PE) terminals of the base unit must be connected to the corresponding earth terminals. (d) The protective earth (PE) of the servo motor is connected to the protective earth of the base unit via the screw which fastens the drive unit to the base unit. When fixing the drive unit to the base unit, therefore, tighten the accessory screw securely. (6) Auxiliary equipment and options (a) The no-fuse breaker and magnetic contactor used should be the EN or IEC standard-compliant products of the models described in Section 12.2.2. (b) The sizes of the cables described in Section 12.2.1 meet the following requirements. To meet the other requirements, follow Table 5 and Appendix C in EN60204-1. Ambient temperature: 40 (104) [ ( )] Sheath: PVC (polyvinyl chloride) Installed on wall surface or open table tray (c) Use the EMC filter for noise reduction. (7) Performing EMC tests When EMC tests are run on a machine/device into which MELSERVO-J2M has been installed, it must conform to the electromagnetic compatibility (immunity/emission) standards after it has satisfied the operating environment/electrical equipment specifications. For the other EMC directive guidelines on MELSERVO-J2M, refer to the EMC Installation Guidelines(IB(NA)67310). A- 8 CONFORMANCE WITH UL/C-UL STANDARD The MELSERVO-J2M complies with UL508C. (1) Unit and servo motors used Use the each units and servo motors which comply with the standard model. Interface unit Drive unit Base unit Servo motor :MR-J2M-P8A :MR-J2M- DU :MR-J2M-BU :HC-KFS HC-MFS HC-UFS (2) Installation Install a fan of 100CFM (2.8m3/min) air flow 4 [in] (10.16 [cm]) above the servo amplifier or provide cooling of at least equivalent capability. (3) Short circuit rating MELSERVO-J2M conforms to the circuit whose peak current is limited to 5000A or less. Having been subjected to the short-circuit tests of the UL in the alternating-current circuit, MELSERVO-J2M conforms to the above circuit. (4) Capacitor discharge time The capacitor discharge time is as listed below. To ensure safety, do not touch the charging section for 15 minutes after power-off. Base unit MR-J2M-BU4 MR-J2M-BU6 MR-J2M-BU8 Discharge time [min] 1 1 1 (5) Options and auxiliary equipment Use UL/C-UL standard-compliant products. (6) Attachment of a servo motor For the flange size of the machine side where the servo motor is installed, refer to “CONFORMANCE WITH UL/C-UL STANDARD” in the Servo Motor Instruction Manual. (7) About wiring protection For installation in United States, branch circuit protection must be provided, in accordance with the National Electrical Code and any applicable local codes. For installation in Canada, branch circuit protection must be provided, in accordance with the Canada Electrical Code and any applicable provincial codes. A- 9 <> This Instruction Manual and the MELSERVO Servo Motor Instruction Manual are required if you use MELSERVO-J2M for the first time. Always purchase them and use the MELSERVO-J2M safely. Also read the manual of the servo system controller. Relevant manuals Manual name MELSERVO-J2M Series To Use the AC Servo Safely (Packed with the MR-J2M-P8A, MR-J2M- DU and MR-J2M-BU MELSERVO Servo Motor Instruction Manual EMC Installation Guidelines Manual No. ) IB(NA)0300027 SH(NA)3181 IB(NA)67310 In this Instruction Manual, the drive unit, interface unit and base unit may be referred to as follows: Drive unit : DRU Interface unit : IFU Base unit : BU A - 10 CONTENTS 1. FUNCTIONS AND CONFIGURATION 1- 1 to 1-10 1.1 Overview................................................................................................................................................... 1- 1 1.2 Function block diagram .......................................................................................................................... 1- 2 1.3 Unit standard specifications................................................................................................................... 1- 3 1.4 Function list ............................................................................................................................................. 1- 4 1.5 Model code definition .............................................................................................................................. 1- 5 1.6 Combination with servo motor............................................................................................................... 1- 6 1.7 Parts identification.................................................................................................................................. 1- 7 1.8 Servo system with auxiliary equipment................................................................................................ 1- 9 2. INSTALLATION AND START UP 2- 1 to 2-10 2.1 Environmental conditions....................................................................................................................... 2- 1 2.2 Installation direction and clearances .................................................................................................... 2- 2 2.3 Keep out foreign materials ..................................................................................................................... 2- 3 2.4 Cable stress .............................................................................................................................................. 2- 3 2.5 Mounting method .................................................................................................................................... 2- 4 2.6 When switching power on for the first time.......................................................................................... 2- 6 2.7 Start up..................................................................................................................................................... 2- 7 3. SIGNALS AND WIRING 3- 1 to 3-48 3.1 Control signal line connection example................................................................................................. 3- 2 3.2 I/O signals of interface unit .................................................................................................................... 3- 5 3.2.1 Connectors and signal arrangements............................................................................................. 3- 5 3.2.2 Signal explanations .......................................................................................................................... 3- 6 3.2.3 Detailed description of the signals................................................................................................. 3-11 3.2.4 Internal connection diagram .......................................................................................................... 3-15 3.2.5 Interface............................................................................................................................................ 3-16 3.3 Signal and wiring for extension IO unit............................................................................................... 3-20 3.3.1 Connection example ........................................................................................................................ 3-20 3.3.2 Connectors and signal configurations ........................................................................................... 3-22 3.3.3 Signal explanations ......................................................................................................................... 3-23 3.3.4 Device explanations......................................................................................................................... 3-26 3.3.5 Detailed description of the device .................................................................................................. 3-30 3.3.6 Device assignment method ............................................................................................................. 3-31 3.4 Signals and wiring for base unit ........................................................................................................... 3-35 3.4.1 Connection example for power line circuit.................................................................................... 3-35 3.4.2 Connectors and signal configurations ........................................................................................... 3-37 3.4.3 Terminals.......................................................................................................................................... 3-38 3.4.4 Power-on sequence........................................................................................................................... 3-38 3.5 Connection of drive unit and servo motor ............................................................................................ 3-39 3.5.1 Connection instructions .................................................................................................................. 3-39 3.5.2 Connection diagram ........................................................................................................................ 3-40 3.5.3 I/O terminals .................................................................................................................................... 3-41 3.6 Alarm occurrence timing chart ............................................................................................................. 3-42 1 3.7 Servo motor with electromagnetic brake ............................................................................................. 3-43 3.8 Grounding................................................................................................................................................ 3-46 3.9 Instructions for the 3M connector......................................................................................................... 3-47 4. OPERATION AND DISPLAY 4- 1 to 4-18 4.1 Display flowchart..................................................................................................................................... 4- 1 4.1.1 Normal indication ............................................................................................................................. 4- 2 4.1.2 If alarm/warning occurs ................................................................................................................... 4- 3 4.1.3 If test operation................................................................................................................................. 4- 4 4.2 Interface unit display .............................................................................................................................. 4- 5 4.2.1 Display flowchart of interface unit ................................................................................................. 4- 5 4.2.2 Status display of interface unit ....................................................................................................... 4- 6 4.2.3 Diagnostic mode of interface unit ................................................................................................... 4- 7 4.2.4 Alarm mode of interface unit........................................................................................................... 4- 8 4.2.5 Interface unit parameter mode ....................................................................................................... 4- 9 4.2.6 Interface unit output signal (DO) forced output........................................................................... 4-10 4.3 Drive unit display ................................................................................................................................... 4-11 4.3.1 Drive unit display sequence............................................................................................................ 4-11 4.3.2 Status display of drive unit............................................................................................................. 4-12 4.3.3 Diagnostic mode of drive unit......................................................................................................... 4-14 4.3.4 Alarm mode of drive unit ................................................................................................................ 4-15 4.3.5 Drive unit parameter mode ............................................................................................................ 4-16 4.3.6 Drive unit external input signal display ....................................................................................... 4-16 4.3.7 Drive unit external output signal display ..................................................................................... 4-17 4.3.8 Drive unit output signal (DO) forced output................................................................................. 4-18 5. PARAMETERS 5- 1 to 5-30 5.1 DRU parameter list................................................................................................................................. 5- 1 5.1.1 DRU parameter write inhibit .......................................................................................................... 5- 1 5.1.2 Lists.................................................................................................................................................... 5- 2 5.2 Interface unit .......................................................................................................................................... 5-14 5.2.1 IFU parameter write inhibit........................................................................................................... 5-14 5.2.2 Lists................................................................................................................................................... 5-14 5.3 Detailed description ............................................................................................................................... 5-21 5.3.1 Electronic gear ................................................................................................................................. 5-21 5.3.2 Analog monitor................................................................................................................................. 5-25 5.3.3 Using forward rotation stroke end (LSP ) reverse rotation stroke end (LSN ) to change the stopping pattern .............................................................................................................................. 5-28 5.3.4 Alarm history clear.......................................................................................................................... 5-28 5.3.5 Position smoothing .......................................................................................................................... 5-29 6. GENERAL GAIN ADJUSTMENT 6- 1 to 6-10 6.1 Different adjustment methods ............................................................................................................... 6- 1 6.1.1 Adjustment on a MELSERVO-J2M................................................................................................ 6- 1 6.1.2 Adjustment using MR Configurator (servo configuration software) ........................................... 6- 2 6.2 Auto tuning .............................................................................................................................................. 6- 3 6.2.1 Auto tuning mode ............................................................................................................................. 6- 3 2 6.2.2 Auto tuning mode operation ............................................................................................................ 6- 4 6.2.3 Adjustment procedure by auto tuning............................................................................................ 6- 5 6.2.4 Response level setting in auto tuning mode .................................................................................. 6- 6 6.3 Manual mode 1 (simple manual adjustment)....................................................................................... 6- 7 6.3.1 Operation of manual mode 1 ........................................................................................................... 6- 7 6.3.2 Adjustment by manual mode 1 ....................................................................................................... 6- 7 6.4 Interpolation mode .................................................................................................................................. 6- 9 7. SPECIAL ADJUSTMENT FUNCTIONS 7- 1 to 7-10 7.1 Function block diagram .......................................................................................................................... 7- 1 7.2 Machine resonance suppression filter ................................................................................................... 7- 1 7.3 Adaptive vibration suppression control................................................................................................. 7- 3 7.4 Low-pass filter ......................................................................................................................................... 7- 4 7.5 Gain changing function........................................................................................................................... 7- 5 7.5.1 Applications....................................................................................................................................... 7- 5 7.5.2 Function block diagram ................................................................................................................... 7- 5 7.5.3 Parameters ........................................................................................................................................ 7- 6 7.5.4 Gain changing operation.................................................................................................................. 7- 8 8. INSPECTION 8- 1 to 8- 2 9. TROUBLESHOOTING 9- 1 to 9-14 9.1 Trouble at start-up .................................................................................................................................. 9- 1 9.2 Alarms and warning list ......................................................................................................................... 9- 4 9.3 Remedies for alarms................................................................................................................................ 9- 6 9.4 Remedies for warnings........................................................................................................................... 9-13 10. OUTLINE DRAWINGS 10- 1 to 10-10 10.1 MELSERVO-J2M configuration example......................................................................................... 10- 1 10.2 Unit outline drawings ......................................................................................................................... 10- 2 10.2.1 Base unit (MR-J2M-BU ) ........................................................................................................... 10- 2 10.2.2 Interface unit (MR-J2M-P8A) ..................................................................................................... 10- 2 10.2.3 Drive unit (MR-J2M- DU)......................................................................................................... 10- 3 10.2.4 Extension IO unit (MR-J2M-D01) .............................................................................................. 10- 4 10.2.5 Battery unit (MR-J2M-BT).......................................................................................................... 10- 4 10.3 Connectors............................................................................................................................................ 10- 5 11. CHARACTERISTICS 11- 1 to 11- 6 11.1 Overload protection characteristics ................................................................................................... 11- 1 11.2 Power supply equipment capacity and generated loss .................................................................... 11- 2 11.3 Dynamic brake characteristics........................................................................................................... 11- 4 11.4 Encoder cable flexing life .................................................................................................................... 11- 6 12. OPTIONS AND AUXILIARY EQUIPMENT 12- 1 to 12-36 12.1 Options.................................................................................................................................................. 12- 1 3 12.1.1 Regenerative brake options ......................................................................................................... 12- 1 12.1.2 Cables and connectors.................................................................................................................. 12- 8 12.1.3 Junction terminal block (MR-TB50) .......................................................................................... 12-17 12.1.4 Junction terminal block (MR-TB20) .......................................................................................... 12-19 12.1.5 Maintenance junction card (MR-J2CN3TM) ............................................................................ 12-21 12.1.6 MR Configurator (servo configurations software).................................................................... 12-23 12.2 Auxiliary equipment .......................................................................................................................... 12-24 12.2.1 Recommended wires.................................................................................................................... 12-24 12.2.2 No-fuse breakers, fuses, magnetic contactors........................................................................... 12-26 12.2.3 Power factor improving reactors ................................................................................................ 12-27 12.2.4 Relays............................................................................................................................................ 12-28 12.2.5 Surge absorbers ........................................................................................................................... 12-28 12.2.6 Noise reduction techniques......................................................................................................... 12-28 12.2.7 Leakage current breaker ............................................................................................................ 12-34 12.2.8 EMC filter..................................................................................................................................... 12-35 13. COMMUNICATION FUNCTIONS 13- 1 to 13-32 13.1 Configuration ....................................................................................................................................... 13- 1 13.1.1 RS-422 configuration.................................................................................................................... 13- 1 13.1.2 RS-232C configuration ................................................................................................................. 13- 3 13.2 Communication specifications............................................................................................................ 13- 4 13.2.1 Communication overview ............................................................................................................ 13- 4 13.2.2 Parameter setting......................................................................................................................... 13- 5 13.3 Protocol ................................................................................................................................................. 13- 6 13.4 Character codes ................................................................................................................................... 13- 7 13.5 Error codes ........................................................................................................................................... 13- 8 13.6 Checksum ............................................................................................................................................. 13- 8 13.7 Time-out operation .............................................................................................................................. 13- 9 13.8 Retry operation .................................................................................................................................... 13- 9 13.9 Initialization........................................................................................................................................ 13-10 13.10 Communication procedure example ............................................................................................... 13-10 13.11 Command and data No. list............................................................................................................. 13-11 13.11.1 Read commands......................................................................................................................... 13-11 13.11.2 Write commands........................................................................................................................ 13-13 13.12 Detailed explanations of commands............................................................................................... 13-15 13.12.1 Data processing.......................................................................................................................... 13-15 13.12.2 Status display ............................................................................................................................ 13-17 13.12.3 Parameter................................................................................................................................... 13-18 13.12.4 External I/O pin statuses (DIO diagnosis)..............................................................................13-20 13.12.5 Disable/enable of external I/O signals (DIO) .......................................................................... 13-23 13.12.6 External input signal ON/OFF (test operation) ..................................................................... 13-24 13.12.7 Test operation mode .................................................................................................................. 13-25 13.12.8 Output signal pin ON/OFF (output signal (DO) forced output) ........................................... 13-28 13.12.9 Alarm history ............................................................................................................................. 13-29 13.12.10 Current alarm.......................................................................................................................... 13-30 13.12.11 Other commands...................................................................................................................... 13-31 4 14. ABSOLUTE POSITION DETECTION SYSTEM 14- 1 to 14-12 14.1 Outline.................................................................................................................................................. 14- 1 14.1.1 Features......................................................................................................................................... 14- 1 14.1.2 Restrictions.................................................................................................................................... 14- 1 14.2 Specifications ....................................................................................................................................... 14- 2 14.3 Signal explanation............................................................................................................................... 14- 3 14.4 Serial communication command........................................................................................................ 14- 3 14.5 Startup procedure................................................................................................................................ 14- 4 14.6 Absolute position data transfer protocol ........................................................................................... 14- 5 14.6.1 Data transfer procedure............................................................................................................... 14- 5 14.6.2 Transfer method ........................................................................................................................... 14- 6 14.6.3 Home position setting .................................................................................................................. 14- 9 14.6.4 How to process the absolute position data at detection of stroke end.................................... 14-10 14.7 Confirmation of absolute position detection data............................................................................ 14-11 APPENDIX App- 1 to App- 2 App 1. Status indication block diagram ................................................................................................. App- 1 5 Optional Servo Motor Instruction Manual CONTENTS The rough table of contents of the optional MELSERVO Servo Motor Instruction Manual is introduced here for your reference. Note that the contents of the Servo Motor Instruction Manual are not included in this Instruction Manual. 1. INTRODUCTION 2. INSTALLATION 3. CONNECTORS USED FOR SERVO MOTOR WIRING 4. INSPECTION 5. SPECIFICATIONS 6. CHARACTERISTICS 7. OUTLINE DIMENSION DRAWINGS 8. CALCULATION METHODS FOR DESIGNING 6 1. FUNCTIONS AND CONFIGURATION 1. FUNCTIONS AND CONFIGURATION 1.1 Overview The Mitsubishi general-purpose AC servo MELSERVO-J2M series is an AC servo which has realized wiring-saving, energy-saving and space-saving in addition to the high performance and high functions of the MELSERVO-J2-Super series. The MELSERVO-J2M series consists of an interface unit (abbreviated to the IFU) to be connected with a positioning unit, drive units (abbreviated to the DRU) for driving and controlling servo motors, and a base unit (abbreviated to the BU) where these units are installed. A torque limit is applied to the drive unit by the clamp circuit to protect the main circuit power transistors from overcurrent caused by abrupt acceleration/deceleration or overload. In addition, the torque limit value can be changed as desired using the parameter. The interface unit has an RS-232C or RS-422 serial communication function to allow the parameter setting, test operation, status indication monitoring, gain adjustment and others of all units to be performed using a personal computer or like where the MR Configurator (servo configuration software) is installed. By choosing the station number of the drive unit using the MR Configurator (servo configuration software), you can select the unit to communicate with, without changing the cabling. The real-time auto tuning function automatically adjusts the servo gains according to a machine. A maximum 500kpps high-speed pulse train is used to control the speed and direction of a motor and execute accurate positioning of 131072 pulses/rev resolution. The position smoothing function has two different systems to allow you to select the appropriate system for a machine, achieving a smoother start/stop in response to an abrupt position command. The MELSERVO-J2M series supports as standard the absolute position encoders which have 131072 pulses/rev resolution, ensuring control as accurate as that of the MELSERVO-J2-Super series. Simply adding the optional battery unit configures an absolute position detection system. Hence, merely setting a home position once makes it unnecessary to perform a home position return at power-on, alarm occurrence or like. The MELSERVO-J2M series has a control circuit power supply in the interface unit and main circuit converter and regenerative functions in the base unit to batch-wire the main circuit power input, regenerative brake connection and control circuit power supply input, achieving wiring-saving. In the MELSERVO-J2M series, main circuit converter sharing has improved the capacitor regeneration capability dramatically. Except for the operation pattern where all axes slow down simultaneously, the capacitor can be used for regeneration. You can save the energy which used to be consumed by the regenerative brake resistor. Input signal (Axes 5 to 8) Extension IO unit MR-J2M-D01 Input signal (Axes 1 to 4) Regenerative brake option Encoder pulse output extension DIO (Axes 1 to 4) Control circuit power supply input Encoder pulse output extension DIO (Axes 5 to 8) Encoder cable Servo motor power cable Main circuit power input Forward rotation stroke end Reverse rotation stroke end Forced stop input Personal computer connection Monitor output Forced stop input Electromagnetic brake interlock output 1- 1 1. FUNCTIONS AND CONFIGURATION 1.2 Function block diagram Control circuit power suppy L11 L21 Pulse train position command Pulse train position command L1 L2 L3 P N C Input signal Stroke end Forced stop I/O signals for slots 1 to 4, e.g. servo-on I/O signals for slots 5 to 8, e.g. servo-on RS-232C CN3 CNP1A Regenerative brake option CNP3 Inrush current suppression circuit FR-BAL MC RS-422 Regenerative TR Power supply 3-phase NFB 200 to 230VAC (Note) 1-phase 200 to 230VAC CN5 CNP1B CN1A Interface unit CN1B Base unit D/A Personal computer or other servo amplifier Analog monitor (3 channels) Drive unit Servo motor Overcurrent protection Base amplifier Actual position control Pulse counter Actual speed control Model position Model position control Model speed Model speed control Pulse train position command Current detection U V W (Earth) M CN2 CON3A-3H Current detector CNP2 Dynamic brake Encoder Current control Model torque Virtual Virtual servo encoder motor Drive unit Servo motor U V W (Earth) M CN2 Current detection CNP2 CON3A-3H Dynamic brake Encoder Drive unit Servo motor U V W (Earth) M CN2 Current detection CNP2 CON3A-3H Dynamic brake Encoder Note. For 1-phase 200 to 230VAC, connect the power supply to L1, L2 and leave L3 open. 1- 2 1. FUNCTIONS AND CONFIGURATION 1.3 Unit standard specifications (1) Base unit Model Number of slots (Note) Voltage/frequency Control Permissible voltage fluctuation circuit power supply Main circuit power supply MR-J2M-BU4 MR-J2M-BU6 MR-J2M-BU8 4 slots 6 slots 8 slots 3-phase 200 to 230VAC or 1-phase 200 to 230VAC, 50/60Hz 1-phase 170 to 253VAC Permissible frequency fluctuation Within 5% Inrush current 20A (5ms) Voltage/frequency 3-phase 200 to 230VAC or 1-phase 200 to 230VAC, 50/60Hz Permissible voltage fluctuation 3-phase 170 to 253VAC or 1-phase 170 to 253VAC, 50/60 Hz Permissible frequency fluctuation Within 5% Maximum servo motor connection 1600 capacity [W] Continuous capacity [W] 1280 Inrush current 2400 3200 1920 2560 62.5A (15ms) Function Converter function, regenerative control, rushing into current control function Regenerative overvoltage shut-off, regenerative fault protection, Protective functions undervoltage /instantaneous power failure protection Mass [kg] 1.1 1.3 1.5 [lb] 2.4 2.9 3.3 Note. The control circuit power supply is recorded to the interface unit. (2) Drive unit Model Power Voltage/frequency supply Permissible voltage fluctuation MR-J2M-10DU MR-J2M-20DU MR-J2M-40DU MR-J2M-70DU 270 to 311VDC 230 to 342VDC Control system Sine-wave PWM control, current control system Dynamic brake Built-in Overcurrent shut-off, functions overload shut-off (electronic thermal relay), servo Protective functions motor overheat protection, encoder fault protection, overspeed protection, excessive error protection Structure Open (IP00) Cooling method Self-cooled Mass Force-cooling (With built-in fan unit) [kg] 0.4 0.4 0.4 0.7 [lb] 0.89 0.89 0.89 1.54 (3) Interface unit Model MR-J2M-P8A Control circuit power supply Power supply circuit for each unit(8 slots or less) Pulse train interface 8 channels Interface RS-232C interface 1 channel RS-422 interface 1 channel Forced stop input (2 points), alarm output (2 points), input signal (40 points), DIO output signal (16 points) AIO Analog monitor 3channels Structure Mass Open (IP00) [kg] 0.5 [lb] 1.10 1- 3 1. FUNCTIONS AND CONFIGURATION 1.4 Function list The following table lists the functions of this servo. For details of the functions, refer to the Reference field. (1) Drive unit (Abbreviation DRU) Function High-resolution encoder Auto tuning Gain changing function Adaptive vibration suppression control Low-pass filter Description High-resolution encoder of 131072 pulses/rev is used as a servo motor encoder. Automatically adjusts the gain to optimum value if load applied to the servo motor shaft varies. You can switch between gains during rotation and gains during stop or use an external signal to change gains during operation. MELSERVO-J2M detects mechanical resonance and sets filter characteristics automatically to suppress mechanical vibration. Suppresses high-frequency resonance which occurs as servo system response is increased. Position smoothing Speed can be increased smoothly in response to input pulse. Slight vibration suppression control Suppresses vibration of 1 pulse produced at a servo motor stop. Electronic gear Input pulses can be multiplied by 1/50 to 50. Torque limit Servo motor torque can be limited to any value. Command pulse selection Command pulse train form can be selected from among four different types. Reference Chapter 7 Section 7.5.4 Section 7.3 Section 7.4 DRU parameter No. 7 DRU parameter No.20 DRU parameters No. 3, 4, 69 to 71 Section 5.3.1 DRU parameters No.28 DRU parameter No. 21 (2) Interface unit (Abbreviation IFU) Function Description Reference Position control mode This servo is used as position control servo. Section 2.7 Section 3.1.2 Section 3.1.5 I/O signal selection The servo-on (SON ), ready (RD ) and other input signals can be reassigned to any other pins. Section 3.2.6 Status display Servo status is shown on the 5-digit, 7-segment LED display Analog monitor Servo status is output in terms of voltage in real time. Section 4.2.2 Section 4.3.2 Section 5.3.2 (3) Base unit (Abbreviation BU) Function Description Used when the built-in regenerative brake resistor of the unit does not have Regenerative brake option sufficient regenerative capability for the regenerative power generated. Reference Section 12.1.1 (4) MR Configurator (servo configuration software) Function Description Machine analyzer function Analyzes the frequency characteristic of the mechanical system. Can simulate machine motions on a personal computer screen on the basis of the Machine simulation machine analyzer results. Gain search function Can simulate machine motions on the basis of the machine analyzer results. External I/O signal ON/OFF statuses of external I/O signals are shown on the display. display Output signal (DO) forced output Test operation mode Output signal can be forced on/off independently of the servo status. Use this function for output signal wiring check, etc. JOG operation and positioning operation are possible. 1- 4 Reference Section 4.3.7 Section 4.2.6 Section 4.3.8 1. FUNCTIONS AND CONFIGURATION (5) Option unit Function Description Reference Merely setting a home position once makes home position return unnecessary at every power-on. Battery unit MR-J2M-BT (shortly correspondence schedule) is necessary. The encoder feedback is output from extension IO unit MR-J2M-D01 (shortly correspondence schedule) by the A B Z phase pulse. The number of pulses output by the parameter can be changed. Absolute position detection system Encoder pulse output 1.5 Model code definition (1) Drive unit (a) Rating plate SON ALM Rating plate MODEL Model Capacity Applicable power supply Rated output current Serial number MR-J2M-40DU POWER 400W INPUT DC270V-311V OUTPUT 170V 0-360Hz 2.3A SERIAL N9Z95046 TC300A***G51 MITSUBISHI ELECTRIC Rating plate (b) Model code MR-J2M- DU Rated output Symbol Capacity of applied servo motor 10 100 20 200 40 400 70 750 (2) Interface unit (a) Rating plate MITSUBISHI MODEL MR-J2M-P8A AC ACSERVO SERVO Model Input capacity POWER : 75W AC INPUT:2PH AC200-230V 50Hz POWER 2PH AC200-230V 60Hz Applicable power supply OUTPUT : DC5/12/20 4.6A/1.2/0.7A SERIAL : A5 TC3 AAAAG52 MITSUBISHI ELECTRIC CORPORATION MADE IN JAPAN Rating plate Output voltage / current Serial number PASSED (b) Model code MR-J2M-P8A Pulse train interface compatible 1- 5 1. FUNCTIONS AND CONFIGURATION (3) Base unit (a) Rating plate Rating plate MITSUBISHI MODEL Model Applicable power supply Serial number MR-J2M-BU4 INPUT : 3PH 200-230 14A 50/60Hz SERIAL: N87B95046 BC336U246 MITSUBISHI ELECTRIC PASSED MADE IN JAPAN (b) Model code MR-J2M-BU Symbol Number of slots Maximum servo motor connection capacity [W] Continuous capacity [W] 4 6 8 4 6 8 1600 2400 3200 1280 1920 2560 1.6 Combination with servo motor The following table lists combinations of drive units and servo motors. The same combinations apply to the models with electromagnetic brakes and the models with reduction gears. Drive unit Servo motor HC-MFS HC-KFS HC-UFS MR-J2M-10DU 053 13 053 13 13 MR-J2M-20DU 23 23 23 MR-J2M-40DU 43 43 43 MR-J2M-70DU 73 73 73 1- 6 1. FUNCTIONS AND CONFIGURATION 1.7 Parts identification (1) Drive unit Mounting screw Status indicator LED Indicates the status of the drive unit. Blinking green: Servo off status Steady green: Servo on status Blinking red: Warning status Steady red: Alarm status Rating plate CN2 Encoder connector Connect the servo motor encoder CNP2 Servo motor connector For connection of servo motor power line cable (2) Interface unit Display Indicates operating status or alarm. Pushbutton switches Used to change status indication or set IFU parameters and DRU parameters. Mounting screw Display/setting cover CN1A I/O signal (For 1 to 4 slots) CN1B I/O signal (For 5 to 8 slots) CN5 Forward rotation stroke end Reverse rotation stroke end Forced stop input CN3 For connection of personal computer (RS-232C). Outputs analog monitor. Charge lamp Lit when main circuit capacitor carries electrical charge. When this lamp is on, do not remove/reinstall any unit from/to base unit and do not unplug/plug cable and connector from/into any unit. 1- 7 1. FUNCTIONS AND CONFIGURATION (3) Base unit The following shows the MR-J2M-BU4. CNP1B Control circuit power input connector CON3A First slot connector CON3C Third slot connector CNP1A Regenerative brake option connector CON4 Option slot connector CNP3 Main circuit power input connector CON5 Battery unit connector CON1,CON2 Interface unit connectors CON3B Second slot connector 1- 8 CON3D Fourth slot connector 1. FUNCTIONS AND CONFIGURATION 1.8 Servo system with auxiliary equipment WARNING To prevent an electric shock, always connect the protective earth (PE) terminal (terminal marked ) of the base unit to the protective earth (PE) of the control box. 3-phase 200V to 230VAC power supply (Note) 1-phase 200V to 230VAC Options and auxiliary equipment No-fuse breaker (NFB) or fuse Reference Regenerative brake option Section 12.1.1 Magnetic contactor Section 12.2.2 Cables Section 12.2.1 L11 Control circuit power supply L21 Command device (For 1 to 4 slots) Power factor improving reactor Section 12.2.3 Command device (For 5 to 8 slots) Regenerative brake option To CN1A Power factor improving reactor (FR-BAL) Reference Section 12.2.2 MR Configurator Section 12.1.4 (servo configuration software) Magnetic contactor (MC) Options and auxiliary equipment No-fuse breaker L1 L2 L3 P C To CNP1A To CN1B To CNP1B Encoder cable Main circuit power supply To CNP3 To CN3 To CN5 Machine contact Power supply lead MR Configurator Personal computer (servo configuration software MRZJW3-SETUP151E or later) Note. For 1-phase 200 to 230VAC, connect the power supply to L1, L2 and leave L3 open. 1- 9 1. FUNCTIONS AND CONFIGURATION MEMO 1 - 10 2. INSTALLATION AND START UP 2. INSTALLATION AND START UP CAUTION Stacking in excess of the limited number of products is not allowed. Install the equipment to incombustibles. Installing them directly or close to combustibles will led to a fire. Install the equipment in a load-bearing place in accordance with this Instruction Manual. Do not get on or put heavy load on the equipment to prevent injury. Use the equipment within the specified environmental condition range. Provide an adequate protection to prevent screws, metallic detritus and other conductive matter or oil and other combustible matter from entering each unit. Do not block the intake/exhaust ports of each unit. Otherwise, a fault may occur. Do not subject each unit to drop impact or shock loads as they are precision equipment. Do not install or operate a faulty unit. When the product has been stored for an extended period of time, consult Mitsubishi. When treating the servo amplifier, be careful about the edged parts such as the corners of the servo amplifier. 2.1 Environmental conditions The following environmental conditions are common to the drive unit, interface unit and base unit. Environment Ambient temperature Conditions During [ ] 0 to 55 (non-freezing) operation [ ] 32 to 131 (non-freezing) [ ] 20 to 65 (non-freezing) [ ] 4 to 149 (non-freezing) In storage Ambient During operation humidity In storage 90%RH or less (non-condensing) Indoors (no direct sunlight) Ambience Free from corrosive gas, flammable gas, oil mist, dust and dirt Altitude Vibration Max. 1000m (3280 ft) above sea level 2 5.9 [m/s ] or less 2 2 19.4 [ft/s ] or less [m/s ] 2 [ft/s ] 2- 1 2. INSTALLATION AND START UP 2.2 Installation direction and clearances CAUTION The equipment must be installed in the specified direction. Otherwise, a fault may occur. Leave specified clearances between each unit and control box inside walls or other equipment. 40mm(1.57inch) or more 40mm(1.57inch) or more 40mm(1.57inch) or more (1) Installation of one MELSERVO-J2M 40mm(1.57inch) or more 40mm(1.57inch) or more Leave 100mm(3.94inch) or more clearance or install fan for forced air cooling. 40mm(1.57inch) or more 2- 2 40mm(1.57inch) or more 40mm(1.57inch) or more (2) Installation of two or more MELSERVO-J2M When installing two units vertically, heat generated by the lower unit influences the ambient temperature of the upper unit. Suppress temperature rises in the control box so that the temperature between the upper and lower units satisfies the environmental conditions. Also provide adequate clearances between the units or install a fan. 2. INSTALLATION AND START UP (3) Others When using heat generating equipment such as the regenerative brake option, install them with full consideration of heat generation so that MELSERVO-J2M is not affected. Install MELSERVO-J2M on a perpendicular wall in the correct vertical direction. 2.3 Keep out foreign materials (1) When installing the unit in a control box, prevent drill chips and wire fragments from entering each unit. (2) Prevent oil, water, metallic dust, etc. from entering each unit through openings in the control box or a fan installed on the ceiling. (3) When installing the control box in a place where there are much toxic gas, dirt and dust, conduct an air purge (force clean air into the control box from outside to make the internal pressure higher than the external pressure) to prevent such materials from entering the control box. 2.4 Cable stress (1) The way of clamping the cable must be fully examined so that flexing stress and cable's own mass stress are not applied to the cable connection. (2) For use in any application where the servo motor moves, fix the cables (encoder, power supply, brake) supplied with the servo motor, and flex the optional encoder cable or the power supply and brake wiring cables. Use the optional encoder cable within the flexing life range. Use the power supply and brake wiring cables within the flexing life of the cables. (3) Avoid any probability that the cable sheath might be cut by sharp chips, rubbed by a machine corner or stamped by workers or vehicles. (4) For installation on a machine where the servo motor will move, the flexing radius should be made as large as possible. Refer to section 11.4 for the flexing life. 2- 3 2. INSTALLATION AND START UP 2.5 Mounting method (1) Base unit As shown below, mount the base unit on the wall of a control box or like with M5 screws. Wall (2) Interface unit/drive unit (MR-J2M-40DU or less) The following example gives installation of the drive unit to the base unit. The same also applies to the interface unit. Sectional view Base unit Drive unit Wall 1) Catch Positioning hole 1) Hook the catch of the drive unit in the positioning hole of the base unit. Sectional view 2) Base unit Drive unit Wall 2) Using the catch hooked in the positioning hole as a support, push the drive unit in. 2- 4 2. INSTALLATION AND START UP Sectional view 3) 3) Wall 3) Tighten the M4 screw supplied for the base unit to fasten the drive unit to the base unit. POINT Securely tighten the drive unit fixing screw. Sectional view Wall (3) Drive unit (MR-J2M-70DU) When using the MR-J2M-70DU, install it on two slots of the base unit. The slot number of this drive unit is that of the left hand side slot of the two occupied slots, when they are viewed from the front of the base unit. 2- 5 2. INSTALLATION AND START UP 2.6 When switching power on for the first time Before starting operation, check the following: (1) Wiring (a) Check that the control circuit power cable, main circuit power cable and servo motor power cable are fabricated properly. (b) Check that the control circuit power cable is connected to the CNP1B connector and the main circuit power cable is connected to the CNP3 connector. (c) Check that the servo motor power cable is connected to the drive unit CNP2 connector. (d) Check that the base unit is earthed securely. Also check that the drive unit is screwed to the base unit securely. (e) When using the regenerative brake option, check that the cable using twisted wires is fabricated properly and it is connected to the CNP1A connector properly. (f) When the MR-J2M-70DU is used, it is wired to have the left-hand side slot number of the two slots. (g) 24VDC or higher voltages are not applied to the pins of connector CN3. (h) SD and SG of connector CN1A CN1B CN3 CN4A CN4B and CN5 are not shorted. (i) The wiring cables are free from excessive force. (j) Check that the encoder cable and servo motor power cable connected to the drive unit are connected to the same servo motor properly. (k) When stroke end limit switches are used, the signals across LSP -SG and LSN -SG are on during operation. (2) Parameters (a) Check that the drive unit parameters are set to correct values using the servo system controller screen or MR Configurator (servo configuration software). (b) Check that the interface unit parameters are set to correct values using the interface unit display or MR Configurator (servo configuration software). (3) Environment Signal cables and power cables are not shorted by wire offcuts, metallic dust or the like. (4) Machine (a) The screws in the servo motor installation part and shaft-to-machine connection are tight. (b) The servo motor and the machine connected with the servo motor can be operated. 2- 6 2. INSTALLATION AND START UP 2.7 Start up WARNING Do not operate the switches with wet hands. You may get an electric shock. Do not operate the controller with the front cover removed. High-voltage terminals and charging area exposed and you may get an electric shock. During power-on or for some time after power-off, do not touch or close a parts (cable etc.) to the regenerative brake resistor, servo motor, etc. Their temperatures may be high and you may get burnt or a parts may damaged. CAUTION Before starting operation, check the parameters. Some machines may perform unexpected operation. Take safety measures, e.g. provide covers, to prevent accidental contact of hands and parts (cables, etc.) with the servo amplifier heat sink, regenerative brake resistor, servo motor, etc.since they may be hot while power is on or for some time after power-off. Their temperatures may be high and you may get burnt or a parts may damaged. During operation, never touch the rotating parts of the servo motor. Doing so can cause injury. Connect the servo motor with a machine after confirming that the servo motor operates properly alone. 2- 7 2. INSTALLATION AND START UP (1) Power on Switching on the main circuit power/control circuit power places the interface unit display in the scroll status as shown below. In the absolute position detection system, first power-on results in the absolute position lost (A.25) alarm and the servo system cannot be switched on. This is not a failure and takes place due to the uncharged capacitor in the encoder. The alarm can be deactivated by keeping power on for a few minutes in the alarm status and then switching power off once and on again. Also in the absolute position detection system, if power is switched on at the servo motor speed of 500r/min or higher, position mismatch may occur due to external force or the like. Power must therefore be switched on when the servo motor is at a stop. (2) Test operation Using JOG operation in the test operation mode, make sure that the servo motor operates. (Refer to Section 6.8.2.) (3) Parameter setting Set the parameters according to the structure and specifications of the machine. Refer to Chapter 5 for the parameter definitions. After setting the parameters, switch power off once. 2- 8 2. INSTALLATION AND START UP (4) Slot number confirmation Confirm the slot number in the interface unit display section of the installed drive unit. For MR-J2M-BU4 Display First slot Third slot Slot number Drive unit status Slot number Second slot Fourth slot (5) Servo-on Switch the servo-on in the following procedure: 1) Switch on main circuit/control power supply. 2) Turn on the servo-on (SON ). When the servo-on status is established, operation is enabled and the servo motor is locked. At this time, the interface unit displays "@ d@". (@ represents the slot number.) (6) Command pulse input Entry of a pulse train from the positioning device rotates the servo motor. At first, run it at low speed and check the rotation direction, etc. If it does not run in the intended direction, check the input signal. On the status display, check the speed, command pulse frequency, load factor, etc. of the servo motor. When machine operation check is over, check automatic operation with the program of the positioning device. This servo amplifier has a real-time auto tuning function under model adaptive control. Performing operation automatically adjusts gains. The optimum tuning results are provided by setting the response level appropriate for the machine in DRU parameter No. 2. (Refer to chapter 7.) (7) Home position return Make home position return as required. 2- 9 2. INSTALLATION AND START UP (8) Stop In any of the following statuses, the servo amplifier interrupts and stops the operation of the servo motor: Refer to Section 3.8, (2) for the servo motor equipped with electromagnetic brake. Note that the stop pattern of forward rotation stroke end (LSP ) reverse rotation stroke end (LSN ) OFF is as described below. (a) Servo-on (SON ) OFF The base circuit is shut off and the servo motor coasts. (b) Alarm occurrence When an alarm occurs, the base circuit is shut off and the dynamic brake is operated to bring the servo motor to a sudden stop. (c) Forced stop (EMG_ ) OFF The base circuit is shut off and the dynamic brake is operated to bring the servo motor to a sudden stop. Servo forced stop warning (A.E6) occurs. (d) Forward rotation stroke end (LSP ) reverse rotation stroke end (LSN ) OFF The droop pulse value is erased and the servo motor is stopped and servo-locked. It can be run in the opposite direction. POINT A sudden stop indicates deceleration to a stop at the deceleration time constant of zero. 2 - 10 3. SIGNALS AND WIRING 3. SIGNALS AND WIRING WARNING Any person who is involved in wiring should be fully competent to do the work. Before starting wiring, make sure that the voltage is safe in the tester more than 10 minutes after power-off. Otherwise, you may get an electric shock. Ground the base unit and the servo motor securely. Do not attempt to wire each unit and servo motor until they have been installed. Otherwise, you may get an electric shock. The cables should not be damaged, stressed excessively, loaded heavily, or pinched. Otherwise, you may get an electric shock. Wire the equipment correctly and securely. Otherwise, the servo motor may misoperate, resulting in injury. Connect cables to correct terminals to prevent a burst, fault, etc. Ensure that polarity ( , ) is correct. Otherwise, a burst, damage, etc. may occur. The surge absorbing diode installed to the DC relay designed for control output should be fitted in the specified direction. Otherwise, the signal is not output due to a fault, disabling the forced stop and other protective circuits. Interface unit CAUTION Interface unit VIN VIN SG SG Control output signal RA Control output signal RA Use a noise filter, etc. to minimize the influence of electromagnetic interference, which may be given to electronic equipment used near each unit. Do not install a power capacitor, surge suppressor or radio noise filter (FR-BIF option) with the power line of the servo motor. When using the regenerative brake resistor, switch power off with the alarm signal. Otherwise, a transistor fault or the like may overheat the regenerative brake resistor, causing a fire. Do not modify the equipment. 3- 1 3. SIGNALS AND WIRING 3.1 Control signal line connection example POINT Refer to Section 3.4 for connection of the power supply line and to Section 3.5 for connection with servo motors. MR-J2M-P8A (Note 13) CN1A(Note 4) (Note 2) Positioning module QD70 CON1 Slot 1 Slot 2 Slot 3 Slot 4 Symbol A1 B1 24G 24V B14 B13 B3 B4 B16 B15 B6 B7 A14 A13 A3 A4 B2 B18 B17 B5 A2 A5 B20 B19 A18 A17 A20 A19 A16 CLEAR COM A15 CLEAR A6 PULSE COM PULSE F A7 PULSE R PG RD 11 33 6 28 RA INP 35 8 30 3 RA ALM_A 10 32 9 31 21, 46, 50 49 (Note 8) OP_VIN 47 SG 1 VIN 26 OPC 2 CR 12 34 7 PG 44 42 40 PP 19 17 15 NG 45 43 41 NP 20 18 16 OP 25 24 23 48 OP_COM Plate SD (Note 13) CN1B(Note 4) 5 4 SON RES LG P5 (Note 13) COM PG (Note 2) (Note 7) Slot 5 B14 B13 B3 B4 Slot 6 B16 B15 B6 B7 B2 B18 B17 B5 B20 B19 (Note 13) A2 A18 A17 A5 A20 A19 PULSE R PG COM PG Slot 6 29 38 13 39 14 22 Slot 7 Slot 8 RD 11 33 6 28 RA INP 35 8 30 3 RA ALM_B 32 31 5 4 SON RES LG P5 27 37 36 OP_VIN OP_COM SD 3- 2 37 36 RA SG VIN OPC CR PG PP NG NP OP Symbol Slot 7 Slot 8 A14 A16 CLEAR COM CLEAR A13 A15 A3 A6 PULSE COM PULSE F A4 A7 27 Symbol Slot 5 (Note 8) CON2 Slot 2 Slot 3 Slot 4 RA (Note 7) 24VDC power supply Symbol Slot 1 12 44 19 45 20 25 10 9 21, 46, 50 49 47 1 26 2 34 7 42 40 17 15 43 41 18 16 24 23 48 Plate 29 38 13 39 14 22 3. SIGNALS AND WIRING (Note 9) MR Configurator (servo configuration Personal computer software) (Note 5)CN3 CN3 Communication cable (Note 13) CN5 Symbol Slot 1 (Note 6) LSP LSN SG 4 MO1 A 14 MO2 A 7 MO3 A Slot 2 Slot 3 Slot 4 3 4 5 6 7 10 11 (Note 6) 13 14 LG Base unit CON3A (Slot 1) Slot 6 Slot 7 Slot 8 11 12 (Note 12) Monitor output Max. +1mA meter Zero-center Plate SD 8 (Note 13) CN5 LSP LSN 10k 10k 1 2 Symbol Slot 5 10k 15 16 Drive unit (Note 5) CN2 17 18 CN5 Symbol Slot 1 to 8 (Note 3, 6) EMG_A EMG_B 20 19 CON3B (Slot 2) Drive unit (Note 5) CN2 MR-J2M-P8A Drive unit CON3H (Slot 8) (Note 5) CN2 (Note 11) Battery unit MR-J2M-BT MR-J2MBTCBL M (Note 10)MR-J2M-D01 CON4 (Note 1) 3- 3 CN4A CN4B 3. SIGNALS AND WIRING Note 1. To prevent an electric shock, always connect the protective earth (PE) terminal (terminal marked ) of the base unit to the protective earth (PE) of the control box. 2. Connect the diode in the correct direction. If it is connected reversely, the servo amplifier will be faulty and will not output signals, disabling the forced stop and other protective circuits. 3. The forced stop switch (normally closed contact) must be installed. 4. CN1A CN1B, CN4A CN4B have the same shape. Wrong connection of the connectors will lead to a fault. 5. CN2 and CN3 have the same shape. Wrong connection of the connectors can cause a fault. 6. When starting operation, always connect the forced stop (EMG_A) and forward/reverse rotation stroke end (LSN /LSP ) with SG. (Normally closed contacts) 7. Trouble (ALM_ ) is connected with COM in normal alarm-free condition. When this signal is switched off (at occurrence of an alarm), the output of the programmable controller should be stopped by the sequence program. 8. Always connect P5-OP_VIN when using the 5V output (P5). Keep them open when supplying external power. 9. Use MRZJW3-SETUP151E. 10. Refer to Section 3.3 for the MR-J2M-D01 extension IO unit. 11. The MR-J2M-BT battery unit is required to configure an absolute position detection system. Refer to Chapter 14 for details. 12. When connecting the personal computer together with monitor outputs 1, 2, use the maintenance junction card (MR-J2CN3TM). (Refer to Section 12.1.2) 13. in Symbol indicates a slot number. 3- 4 3. SIGNALS AND WIRING 3.2 I/O signals of interface unit 3.2.1 Connectors and signal arrangements POINT The connector pin-outs shown above are viewed from the cable connector wiring section side. (1) Signal arrangement CN1A 2 OPC 4 RES4 6 RD3 8 INP2 10 SON2 12 CR1 14 NP4 16 NP3 18 NP2 20 NP1 22 OP4 24 OP2 1 SG 3 INP4 5 SON4 7 CR3 9 RES2 11 RD1 13 PP4 15 PP3 17 PP2 19 PP1 21 LG 23 OP3 25 OP1 CN1B 27 ALM_A 26 VIN 29 28 CR4 RD4 31 RES3 30 INP3 33 32 RD2 35 SON3 34 INP1 CR2 37 SON1 36 39 RES1 38 NG4 PG4 41 40 NG3 PG3 43 42 NG2 PG2 45 44 NG1 PG1 47 OP_VIN 46 LG 49 48 P5 MR-J2M-P8A 2 OPC 4 RES8 6 RD7 8 INP6 10 SON6 12 CR5 14 NP8 16 NP7 18 NP6 20 NP5 22 OP8 24 OP6 OP_COM 50 LG CN5 2 LSN1 4 LSN2 6 LSN3 8 SG 10 LSN4 1 LSP1 3 LSP2 5 LSP3 7 LSP4 9 12 LSN5 14 LSN6 16 LSN7 18 LSN8 20 EMG_A 1 SG 3 INP8 5 SON8 7 CR7 9 RES6 11 RD5 13 PP8 15 PP7 17 PP6 19 PP5 21 LG 23 OP7 25 OP5 27 ALM_B 26 VIN 29 28 CR8 RD8 31 RES7 30 INP7 33 32 RD6 35 SON7 34 INP5 CR6 37 SON5 36 39 RES5 38 NG8 PG8 41 40 NG7 PG7 43 42 NG6 PG6 45 44 NG5 PG5 47 OP_VIN 46 LG 49 48 P5 OP_COM 50 LG CN3 11 LSP5 13 LSP6 15 LSP7 17 LSP8 19 The connector frames are connected with the PE (earth) terminal inside the servo amplifier. 2 RXD 4 MO1 6 8 10 TRE EMG_B 3- 5 1 LG 3 LG 5 RDP 7 MO3 9 SDP 12 TXD 14 MO2 16 18 20 P5 11 LG 13 15 RDN 17 19 SDN 3. SIGNALS AND WIRING 3.2.2 Signal explanations For the I/O interfaces (symbols in I/O column in the table), refer to Section 3.2.5. The pin No.s in the connector pin No. column are those in the initial status. (1) Input signals Signal Symbol Connector Functions/Applications pin No. Servo-on 1 SON 1 CN1A-37 SON 1: Servo-on signal for slot 1 Servo-on 2 SON 2 CN1A-10 SON 2: Servo-on signal for slot 2 Servo-on 3 SON 3 CN1A-32 SON 3: Servo-on signal for slot 3 Servo-on 4 SON 4 CN1A-5 SON 4: Servo-on signal for slot 4 Servo-on 5 SON 5 CN1B-37 SON 5: Servo-on signal for slot 5 Servo-on 6 SON 6 CN1B-10 Servo-on 7 SON 7 CN1B-32 Servo-on 8 SON 8 CN1B-5 I/O division DI-1 SON 6: Servo-on signal for slot 6 SON 7: Servo-on signal for slot 7 SON 8: Servo-on signal for slot 8 Connect SON -SG to switch on the base circuit and make the servo amplifier ready to operate (servo-on). Disconnect SON -SG to shut off the base circuit and coast the servo motor (servo off). Reset 1 RES 1 CN1A-36 RES 1: Reset signal for slot 1 Reset 2 RES 2 CN1A-9 RES 2: Reset signal for slot 2 Reset 3 RES 3 CN1A-31 RES 3: Reset signal for slot 3 Reset 4 RES 4 CN1A-4 RES 4: Reset signal for slot 4 Reset 5 RES 5 CN1B-36 RES 5: Reset signal for slot 5 Reset 6 RES 6 CN1B-9 Reset 7 RES 7 CN1B-31 Reset 8 RES 8 CN1B-4 DI-1 RES 6: Reset signal for slot 6 RES 7: Reset signal for slot 7 RES 8: Reset signal for slot 8 Disconnect RES -SG for more than 50ms to reset the alarm. Some alarms cannot be deactivated by the reset (RES ). Refer to Section 9.2. Shorting RES -SG in an alarm-free status shuts off the base circuit. The base circuit is not shut off when " 1 parameter No. 51 (Function selection 6). 3- 6 " is set in DRU 3. SIGNALS AND WIRING Signal Forward rotation Symbol LSP 1 Connector CN5-1 stroke end 1 Forward rotation CN5-3 LSP 3 CN5-5 LSP 4 CN5-7 LSP 5 CN5-11 LSN 1: Reverse rotation stroke end signal for slot 1 LSP 6 CN5-13 LSN 3: Reverse rotation stroke end signal for slot 3 LSP 7 CN5-15 LSP 8 CN5-17 LSN 1 CN5-2 LSN 2 CN5-4 LSN 3 CN5-6 LSP 4: Forward rotation stroke end signal for slot 4 stroke end 6 Forward rotation stroke end 7 Forward rotation stroke end 8 Reverse rotation stroke end 1 Reverse rotation stroke end 2 Reverse rotation LSN 2: Reverse rotation stroke end signal for slot 2 LSN 4: Reverse rotation stroke end signal for slot 4 LSN 5: Reverse rotation stroke end signal for slot 5 LSN 6: Reverse rotation stroke end signal for slot 6 LSN 7: Reverse rotation stroke end signal for slot 7 LSN 8: Reverse rotation stroke end signal for slot 8 To start operation, short LSP -SG and/or LSN -SG. Open them to bring the motor to a sudden stop and make it servo-locked. 1" in parameter No. 22 (Function selection 4) to make a Set " slow stop. (Refer to Section 5.1.2.) stroke end 3 Reverse rotation LSP 7: Forward rotation stroke end signal for slot 7 LSP 8: Forward rotation stroke end signal for slot 8 stroke end 5 Forward rotation LSP 5: Forward rotation stroke end signal for slot 5 LSP 6: Forward rotation stroke end signal for slot 6 stroke end 4 Forward rotation (Note) Input signals LSP LSN Operation CCW CW direction direction LSN 4 CN5-10 1 1 LSN 5 CN5-12 0 1 1 0 LSN 6 CN5-14 0 0 LSN 7 CN5-16 LSN 8 CN5-18 Forced stop A EMG_A CN5-20 EMG_A: Forced stop signal for slots 1 to 8 Forced stop B EMG_B CN5-19 EMG_B: Forced stop signal for slots 1 to 8 stroke end 4 Reverse rotation stroke end 5 Reverse rotation stroke end 6 Reverse rotation DI-1 LSP 3: Forward rotation stroke end signal for slot 3 LSP 2 stroke end 3 Forward rotation LSP 1: Forward rotation stroke end signal for slot 1 I/O division LSP 2: Forward rotation stroke end signal for slot 2 stroke end 2 Forward rotation Functions/Applications pin No. Note. 0: LSP /LSN -SG off (open) 1: LSP /LSN -SG on (short) stroke end 7 Reverse rotation stroke end 8 Disconnect EMG_ -SG to bring the servo motor to forced stop state, in which the servo is switched off and the dynamic brake is operated. Connect EMG_ -SG in the forced stop state to reset that state. When either of EMG-A and EMG-B is to be used, short the unused signal with SG. 3- 7 DI-1 3. SIGNALS AND WIRING Signal Symbol Connector Functions/Applications pin No. Clear 1 CR 1 CN1A-12 CR 1: Clear signal for slot 1 Clear 2 CR 2 CN1A-34 CR 2: Clear signal for slot 2 Clear 3 CR 3 CN1A-7 CR 3: Clear signal for slot 3 Clear 4 CR 4 CN1A-29 CR 4: Clear signal for slot 4 Clear 5 CR 5 CN1B-12 CR 5: Clear signal for slot 5 Clear 6 CR 6 CN1B-34 Clear 7 CR 7 CN1B-7 Clear 8 CR 8 CN1B-29 I/O division DI-1 CR 6: Clear signal for slot 6 CR 7: Clear signal for slot 7 CR 8: Clear signal for slot 8 Connect CR -SG to clear the position control counter droop pulses on its leading edge. The pulse width should be 10ms or more. When the DRU parameter No.42 (Input signal selection 1) setting is " 1 ", the pulses are always cleared while CR -SG are connected. Forward rotation pulse train 1 Reverse rotation PP 1 CN1A-19 PP 1 NP 1 PG 1 NG 1: Forward/reverse rotation pulse train for slot 1 NP 1 CN1A-20 PP 2 NP 2 PG 2 NG 2: Forward/reverse rotation pulse train for slot 2 PG 1 CN1A-44 PP 3 NP 3 PG 3 NG 3: Forward/reverse rotation pulse train for slot 3 pulse train 1 NG 1 CN1A-45 PP 4 NP 4 PG 4 NG 4: Forward/reverse rotation pulse train for slot 4 Forward rotation pulse train 2 Reverse rotation PP 2 CN1A-17 PP 5 NP 5 PG 5 NG 5: Forward/reverse rotation pulse train for slot 5 NP 2 CN1A-18 PP 6 NP 6 PG 6 NG 6: Forward/reverse rotation pulse train for slot 6 PG 2 CN1A-42 PP 7 NP 7 PG 7 NG 7: Forward/reverse rotation pulse train for slot 7 pulse train 2 NG 2 CN1A-43 Forward rotation pulse train 3 Reverse rotation PP 3 CN1A-15 NP 3 CN1A-16 PG 3 CN1A-40 pulse train 3 NG 3 CN1A-41 Forward rotation pulse train 4 Reverse rotation PP 4 CN1A-13 NP 4 CN1A-14 PG 4 CN1A-38 pulse train 4 NG 4 CN1A-39 PP 8 NP 8 PG 8 NG 8: Forward/reverse rotation pulse train for slot 8 Used to enter a command pulse train. In the open collector system (max. input frequency 200kpps): Forward rotation pulse train across PP -SG Reverse rotation pulse train across NP -SG In the differential receiver system (max. input frequency 500kpps): Forward rotation pulse train across PG -PP Reverse rotation pulse train across NG -NP The command pulse train form can be changed using DRU parameter No. Forward rotation pulse train 5 Reverse rotation PP 5 CN1B-19 NP 5 CN1B-20 PG 5 CN1B-44 pulse train 5 NG 5 CN1B-45 Forward rotation pulse train 6 Reverse rotation PP 6 CN1B-17 NP 6 CN1B-18 PG 6 CN1B-42 pulse train 6 NG 6 CN1B-43 Forward rotation pulse train 7 Reverse rotation PP 7 CN1B-15 NP 7 CN1B-16 PG 7 CN1B-40 pulse train 7 NG 7 CN1B-41 Forward rotation pulse train 8 Reverse rotation PP 8 CN1B-13 NP 8 CN1B-14 PG 8 CN1B-38 pulse train 8 NG 8 CN1B-39 21 (Function selection 3). 3- 8 DI-2 3. SIGNALS AND WIRING (2) Output signals Signal Symbol Connector Functions/Applications pin No. Trouble A ALM_A CN1A-27 ALM_A: Alarm signal for slot 1 to 4 Trouble B ALM_B CN1B-27 ALM_B: Alarm signal for slot 5 to 8 I/O division DO-1 ALM -SG are disconnected when power is switched off or the protective circuit is activated to shut off the base circuit. Without alarm, ALM -SG are connected within about 3s after power on. Ready 1 RD 1 CN1A-11 RD 1: Ready signal for slot 1 Ready 2 RD 2 CN1A-33 RD 2: Ready signal for slot 2 Ready 3 RD 3 CN1A-6 RD 3: Ready signal for slot 3 Ready 4 RD 4 CN1A-28 RD 4: Ready signal for slot 4 Ready 5 RD 5 CN1B-11 RD 5: Ready signal for slot 5 Ready 6 RD 6 CN1B-33 Ready 7 RD 7 CN1B-6 Ready 8 RD 8 CN1B-28 In position 1 INP 1 CN1A-35 INP 1: In position signal for slot 1 In position 2 INP 2 CN1A-8 INP 2: In position signal for slot 2 In position 3 INP 3 CN1A-30 INP 3: In position signal for slot 3 In position 4 INP 4 CN1A-3 INP 4: In position signal for slot 4 In position 5 INP 5 CN1B-35 INP 5: In position signal for slot 5 In position 6 INP 6 CN1B-8 In position 7 INP 7 CN1B-30 In position 8 INP 8 CN1B-3 DO-1 RD 6: Ready signal for slot 6 RD 7: Ready signal for slot 7 RD 8: Ready signal for slot 8 RD -SG are connected when the servo is switched on and the servo amplifier is ready to operate. DO-1 INP 6: In position signal for slot 6 INP 7: In position signal for slot 7 INP 8: In position signal for slot 8 INP -SG are connected when the number of droop pulses is in the preset in-position range. The in-position range can be changed using DRU parameter No. 5. When the in-position range is increased, INP -SG may be kept connected during low-speed rotation. Encoder Z-phase OP 1 CN1A-25 Encoder Z-phase OP 2 CN1A-24 OP 3 CN1A-23 OP 4 CN1A-22 CN1B-25 Outputs the zero-point signal of the encoder. One pulse is output per OP 6 CN1B-24 position is reached. (Negative logic) OP 7 CN1B-23 OP 8 CN1B-22 MO1 CN3-4 pulse 6 Encoder Z-phase OP 7: Encoder Z-phase pulse signal for slot 7 OP 5 pulse 5 Encoder Z-phase OP 5: Encoder Z-phase pulse signal for slot 5 OP 8: Encoder Z-phase pulse signal for slot 8 pulse 4 Encoder Z-phase OP 3: Encoder Z-phase pulse signal for slot 3 OP 6: Encoder Z-phase pulse signal for slot 6 pulse 3 Encoder Z-phase DO-2 OP 4: Encoder Z-phase pulse signal for slot 4 pulse 2 Encoder Z-phase OP 1: Encoder Z-phase pulse signal for slot 1 OP 2: Encoder Z-phase pulse signal for slot 2 pulse 1 servo motor revolution. OP and LG are connected when the zero-point The minimum pulse width is about 400 s. For home position return using this pulse, set the creep speed to 100r/min. or less. pulse 7 Encoder Z-phase pulse 8 Analog monitor 1 Analog monitor 2 MO2 CN3-14 Analog monitor 3 MO3 CN3-7 Used to output the data set in IFU parameter No.3 (Analog monitor 1 Analog output) to across MO1-LG in terms of voltage. Resolution 10 bits output Used to output the data set in IFU parameter No.4 (Analog monitor 2 Analog output) to across MO2-LG in terms of voltage. Resolution 10 bits output Used to output the data set in IFU parameter No.5 (Analog monitor 3 Analog output) to across MO3-LG in terms of voltage. Resolution 10 bits output 3- 9 3. SIGNALS AND WIRING (3) Communication POINT Refer to Chapter 13 for the communication function. Signal RS-422 I/F RS-422 Symbol Connector Functions/Applications pin No. SDP CN3-9 RS-422 and RS-232C functions cannot be used together. SDN CN3-19 Choose either one in IFU parameter No. 16. RDP CN3-5 RDN CN3-15 TRE CN3-10 termination Termination resistor connection terminal of RS-422 interface. When the servo amplifier is the termination axis, connect this terminal to RDN (CN3-15). RS-232C I/F RXD CN3-2 RS-422 and RS-232C functions cannot be used together. TXD CN3-12 Choose either one in IFU parameter No. 0. (4) Power supply Signal Digital I/F power Symbol VIN supply input Connector Functions/Applications pin No. CN1A-26 Driver power input terminal for digital interface. CN1B-26 Input 24VDC (300mA or more) for input interface. 24VDC 10% Digital I/F SG common CN1A-1 Common terminal of VIN. Pins are connected internally. CN1B-1 Separated from LG. CN5-8 5V output P5 CN1A-49 Internal power supply for encoder Z-phase pulses. Connect P5-OP_VIN when using CN1B-49 this power supply as an encoder Z-phase pulse common. CN3-20 Encoder Z-phase OP_VIN pulse power 5VDC 5% CN1A-47 Power input for encoder Z-phase pulse common. Connect P5-OP_VIN when using CN1B-47 the 5V output (P5) as an encoder Z-phase pulse common. Supply power to OP_VIN supply when using an external power supply as an encoder Z-phase pulse common. At this time, do not connect P5-OP_VIN. Encoder Z-phase pulse common Control common OP_COM LG CN1A-48 Common for encoder Z-phase pulses. Power input to OP_VIN is output from CN1B-48 OP_COM. CN1A-50 Common terminal for MO1, MO2 and MO3. CN1A-46 CN1A-21 CN1B-50 CN1B-46 CN1B-21 CN3-1 CN3-3 CN3-11 CN3-13 Shield SD Plate Connect the external conductor of the shield cable. 3 - 10 3. SIGNALS AND WIRING 3.2.3 Detailed description of the signals (1) Pulse train input (a) Input pulse waveform selection Encoder pulses may be input in any of three different forms, for which positive or negative logic can be chosen. Set the command pulse train form in DRU parameter No. 21. Arrow or in the table indicates the timing of importing a pulse train. A- and B-phase pulse trains are imported after they have been multiplied by 4. Pulse train form Forward rotation Forward rotation Reverse rotation DRU parameter No. 21 command command (Command pulse train) PP pulse train Reverse rotation Negative logic pulse train 0010 NP PP Pulse train sign 0011 NP L H PP A-phase pulse train 0012 B-phase pulse train NP Forward rotation pulse train Positive logic Reverse rotation pulse train PP 0000 NP PP Pulse train sign NP 0001 L H PP A-phase pulse train B-phase pulse train 0002 NP 3 - 11 3. SIGNALS AND WIRING (b) Connections and waveforms 1) Open collector system Connect as shown below: Servo amplifier 24VDC OPC PP Approx. 1.2k NP Approx. 1.2k SD The explanation assumes that the input waveform has been set to the negative logic and forward and reverse rotation pulse trains (DRU parameter No.21 has been set to 0010). The waveforms in the table in (a), (1) of this section are voltage waveforms of PP and NP based on SG. Their relationships with transistor ON/OFF are as follows: Forward rotation pulse train (transistor) Reverse rotation pulse train (transistor) (ON) (OFF) (ON) (OFF) (ON) (OFF) (OFF) (ON) (OFF) (ON) (OFF) (ON) Forward rotation command 3 - 12 Reverse rotation command 3. SIGNALS AND WIRING 2) Differential line driver system Connect as shown below: Servo amplifier PP PG NP NG SD The explanation assumes that the input waveform has been set to the negative logic and forward and reverse rotation pulse trains (DRU parameter No.21 has been set to 0010). For the differential line driver, the waveforms in the table in (a), (1) of this section are as follows. The waveforms of PP , PG , NP and NG are based on that of the ground of the differential line driver. Forward rotation pulse train PP PG Reverse rotation pulse train NP NG Forward rotation command 3 - 13 Reverse rotation command 3. SIGNALS AND WIRING (2) In-position (INP ) PF-SG are connected when the number of droop pulses in the deviation counter falls within the preset in-position range (DRU parameter No. 5). INP -SG may remain connected when low-speed operation is performed with a large value set as the in-position range. Servo-on(SON ) ON OFF Yes Alarm No In-position range Droop pulses In position(INP ) ON OFF (3) Ready (RD ) Servo-on(SON ON OFF Yes Alarm Ready(RD ) No ) 100ms less ON OFF 3 - 14 10ms less 10ms less 3. SIGNALS AND WIRING 3.2.4 Internal connection diagram MR-J2M-P8A (Note) CN1A symbol slot 1 slot 2 SG CR RES CN1A (Note) slot 4 slot 1 26 1 VIN SON slot 3 37 12 36 32 7 31 5 29 4 2 PG 44 42 40 38 PP 19 17 15 13 NG 45 43 41 39 NP 20 18 16 14 Approx.6.8k Approx.6.8k Approx.100 Approx.100 Approx.1.2k 5V ALM_A 33 6 28 RD 35 8 30 3 INP 25 24 23 22 OP 21, 46, 50 5VDC Approx.1.2k P5 47 48 OP_VIN OP_COM Plate slot 6 slot 7 slot 8 44 42 40 38 PP 19 17 15 13 NG 45 43 41 39 NP 20 18 16 14 Approx.100 slot 6 25 Approx.100 SG 37 12 36 10 34 9 32 7 31 5 29 4 Approx.1.2k slot 8 symbol 24 OP_VIN OP_COM P5 23 22 OP LG 21, 46, 50 27 ALM_B 11 33 6 28 RD 35 8 30 3 INP Plate SD Approx.6.8k Plate SD Approx.6.8k slot 7 47 48 49 Approx.1.2k 26 1 VIN RES slot 5 2 PG CR SD CN1B (Note) OPC SON LG 49 (Note) CN1B symbol slot 5 slot 4 symbol 11 Plate SD slot 3 27 10 34 9 OPC slot 2 CN5 CN3 symbol slot 1 to 8 EMG_A 20 EMG_B 19 4 MO1 14 MO2 7 MO3 11 LG Approx.6.8k Approx.6.8k (Note) CN5 symbol slot 1 slot 2 slot 3 slot 4 LSP 1 3 5 7 LSN 2 4 6 10 Approx.6.8k Approx.6.8k (Note) CN5 symbol slot 5 slot 6 slot 7 slot 8 LSP 11 13 15 17 LSN 12 14 16 18 SG Note. 8 Approx.6.8k Approx.6.8k in Symbol indicates the slot number. 3 - 15 Plate SD 12 2 9 19 5 15 TXD RXD SDP SDN RDP RDN 3. SIGNALS AND WIRING 3.2.5 Interface (1) Common line The following diagram shows the power supply and its common line. Interface unit INP 24VDC RA VIN SON DI-1 SD MO1 MO2 MO3 , etc. SG OPC (Note) , etc. Analog monitor output LG PG NG PG NP SDP SDN RDP RDN LG SG SD Base unit RS-422 TXD RXD Drive unit RS-232C Servo motor encoder MR MRR LG SD Servo motor M E Extension IO unit LA, etc. Differential line driver output 35mA max. LAR, etc. LG SD Ground MBR SG DI-1 VIN EM1 24VDC Note. Assumes a differential line driver pulse train input. 3 - 16 RA 3. SIGNALS AND WIRING (2) Detailed description of the interfaces This section gives the details of the I/O signal interfaces (refer to I/O Division in the table) indicated in Sections 3.2.2. Refer to this section and connect the interfaces with the external equipment. (a) Digital input interface DI-1 Give a signal with a relay or open collector transistor. Interface unit 24VDC 300mA or more VIN For transistor R: Approx. 4.7k SON etc. Approx. 5mA Switch SG TR VCES 1.0V I CE0 100 A (b) Digital output interface DO-1 A lamp, relay or photocoupler can be driven. Provide a diode (D) for an inductive load, or an inrush current suppressing resister (R) for a lamp load. (Permissible current: 40mA or less, inrush current: 100mA or less) 1) Inductive load Interface unit VIN Load ALM_ etc. 24VDC 10% SG Opposite polarity of diode will fail interface unit. 2) Lamp load Interface unit VIN R ALM_ etc. SG 3 - 17 24VDC 10% 3. SIGNALS AND WIRING (c) Pulse train input interface DI-2 Give a pulse train signal in an open collector or differential line driver system. 1) Open collector system Interface unit 24VDC OPC Max. input pulse frequency 200kpps 2m(78.74in) or less PP Approx. 1.2k , NP SD tHL tc tLH tHL tc 2 s tF 3 s 0.9 0.1 PP tc tLH 0.2 s tF NP 2) Differential line driver system Interface unit Max. input pulse frequency 500kpps 10m (393.70in) or less Am26LS31 or equivalent PG PG (NG tHL ) About 100 ) tLH tHL tc 0.7 s tF 3 s 0.9 0.1 tc NP (NP SD tc PP PP tLH NG 3 - 18 tF 0.1 s 3. SIGNALS AND WIRING (d) Encoder pulse output DO-2 1) Open collector system Max. intake current 35mA Interface unit Interface unit OP 5 to 24VDC OP Photocoupler LG LG SD SD 2) Differential line driver system Max. output current 35mA extension IO unit (LB LA , LZ ) extension IO unit Am26LS32 or equivalent LA , LZ ) (LB 100 150 LAR (LBR , LZR ) LAR (LBR , LZR ) LG SD SD Sarvo motor CCW rotation LA LAR T LB LBR /2 LZ LZR 400 s or more OP (e) Analog output Output voltage: 4V Max. output current: 0.5mA Resolution: 10bit Interface unit MO 10k A LG SD 3 - 19 Reading in one or both directions 1mA meter. High-speed photocoupler 3. SIGNALS AND WIRING 3.3 Signal and wiring for extension IO unit 3.3.1 Connection example POINT The pins without symbols can be assigned any devices using the MR Configurator (servo configuration software). MR-J2M-D01 (Note 3) 24VDC (Note 2) CN4A VIN 11, 36 SG 12, 37 1 Approx. 6.8k 2 3 4 5 6 7 8 26 27 28 29 30 31 32 33 Approx. 6.8k CN4B-11 (Note 2) CN4A (Note 1) 9 RA1 10 RA2 34 RA3 35 RA4 (Note 2) CN4A 13, 38 LG 50 LA1 25 LAR1 49 LB1 24 LBR1 48 LZ1 23 LZR1 47 LA2 22 LAR2 46 LB2 21 LBR2 45 LZ2 20 LZR2 44 LA3 19 LAR3 43 LB3 18 LBR3 42 LZ3 17 LZR3 41 LA4 16 LAR4 40 LB4 15 LBR4 39 LZ4 14 LZR4 plate SD 3 - 20 Encoder A-phase pulse 1 (Differential line driver system) Encoder B-phase pulse 1 (Differential line driver system) Encoder Z-phase pulse 1 (Differential line driver system) Encoder A-phase pulse 2 (Differential line driver system) Encoder B-phase pulse 2 (Differential line driver system) Encoder Z-phase pulse 2 (Differential line driver system) Encoder A-phase pulse 3 (Differential line driver system) Encoder B-phase pulse 3 (Differential line driver system) Encoder Z-phase pulse 3 (Differential line driver system) Encoder A-phase pulse 4 (Differential line driver system) Encoder B-phase pulse 4 (Differential line driver system) Encoder Z-phase pulse 4 (Differential line driver system) 3. SIGNALS AND WIRING (Note 2) CN4B 1 Approx. 6.8k 2 3 4 5 6 7 8 26 27 28 29 30 31 32 33 Approx. 6.8k SG 12, 37 CN4A-11 VIN 11, 36 (Note 2) CN4B 13, 38 LG 50 LA5 25 LAR5 49 LB5 24 LBR5 48 LZ5 23 LZR5 47 LA6 22 LAR6 46 LB6 21 LBR6 45 LZ6 20 LZR6 44 LA7 19 LAR7 43 LB7 18 LBR7 42 LZ7 17 LZR7 41 LA8 16 LAR8 40 LB8 15 LBR8 39 LZ8 14 LZR8 plate SD (Note 2) CN4B Encoder A-phase pulse 5 (Differential line driver system) Encoder B-phase pulse 5 (Differential line driver system) Encoder Z-phase pulse 5 (Differential line driver system) Encoder A-phase pulse 6 (Differential line driver system) Encoder B-phase pulse 6 (Differential line driver system) Encoder Z-phase pulse 6 (Differential line driver system) Encoder A-phase pulse 7 (Differential line driver system) Encoder B-phase pulse 7 (Differential line driver system) Encoder Z-phase pulse 7 (Differential line driver system) Encoder A-phase pulse 8 (Differential line driver system) Encoder B-phase pulse 8 (Differential line driver system) Encoder Z-phase pulse 8 (Differential line driver system) (Note 1) 9 RA7 10 RA8 34 RA9 35 RA10 MR-J2M-D01 Note 1. Connect the diodes in the correct orientation. Opposite connection may cause the servo amplifier to be faulty and disable the signals from being output, making the forced stop and other protective circuits inoperative. 2. The signals having the same name are connected to the inside of the servo amplifier. 3. Always connect 24VDC (200mA). 3 - 21 3. SIGNALS AND WIRING 3.3.2 Connectors and signal configurations (1) Signal configurations POINT The pin configurations of the connectors are as viewed from the cable connector wiring section. The pins without symbols can be assigned any devices using the MR Configurator (servo configuration software). CN4A 49 LB1 47 LA2 45 LZ2 43 LB3 41 LA4 39 LZ4 37 SG 35 33 31 29 27 50 LA1 48 LZ1 46 LB2 44 LA3 42 LZ3 40 LB4 38 LG 36 VIN 34 32 30 28 26 24 LBR1 22 LAR2 20 LZR2 18 LBR3 16 LAR4 14 LZR4 12 SG 10 8 6 4 2 CN4B 25 LAR1 23 LZR1 21 LBR2 19 LAR3 17 LZR3 15 LBR4 13 LG 11 VIN 9 49 LB5 47 LA6 45 LZ6 43 LB7 41 LA8 39 LZ8 37 SG 35 33 7 31 5 29 3 27 1 50 LA5 48 LZ5 46 LB6 44 LA7 42 LZ7 40 LB8 38 LG 36 VIN 34 32 30 28 26 3 - 22 24 LBR5 22 LAR6 20 LZR6 18 LBR7 16 LAR8 14 LZR8 12 SG 10 8 6 4 2 25 LAR5 23 LZR5 21 LBR6 19 LAR7 17 LZR7 15 LBR8 13 LG 11 VIN 9 7 5 3 1 3. SIGNALS AND WIRING 3.3.3 Signal explanations For the IO interfaces (system in I/O column in the table), refer to section 3.2.5. (1) Input signal Signal Symbol Connector CN4A-1 CN4A-2 CN4A-3 CN4A-4 I/O Functions/Applications pin No. division No signals are factory-assigned to these pins. Using the MR Configurator (servo configuration software), you can assign the input devices for corresponding slots as signals. Refer to Section 3.3.4 for assignable devices. CN4A-5 Device Name Symbol Device Name Symbol CN4A-6 Servo-on SON Forward rotation stroke end LSP CN4A-7 Reset RES Reverse rotation stroke end LSN CN4A-8 Proportion control PC Clear CN4A-26 Internal torque limit selection TL1 (Note) External torque limit TL CN4A-27 Electronic gear selection 1 CM1 (Note) Speed selection 1 SP1 CN4A-28 Electronic gear selection 2 CM2 (Note) Speed selection 2 SP2 CN4A-29 Gain switching selection CDP (Note) Speed selection 3 SP3 CN4A-30 Note. You cannot select these devices when using the MR-J2M-P8A interface CN4A-31 DI-1 CR unit. CN4A-32 CN4A-33 CN4B-1 CN4B-2 CN4B-3 CN4B-4 CN4B-5 CN4B-6 CN4B-7 CN4B-8 CN4B-26 CN4B-27 CN4B-28 CN4B-29 CN4B-30 CN4B-31 CN4B-32 CN4B-33 (2) Output signal Signal Symbol Connector CN4A-9 CN4A-10 CN4A-34 CN4A-35 CN4B-9 CN4B-10 CN4B-34 CN4B-35 I/O Functions/Applications pin No. division No signals are factory-assigned to these pins. Using the MR Configurator (servo configuration software), you can assign the input devices for corresponding slots as signals. Refer to Section 3.3.4 for assignable devices. Device Name Ready Electromagnetic brake interlock In position (Note) Up to speed Zero speed detection Symbol RD MBR INP SA ZSP Device Name Limiting torque (Note) Limiting speed Trouble Warning Battery warning Symbol TLC VLC ALM_ WNG BWNG Note. You cannot select these devices when using the MR-J2M-P8A interface unit. 3 - 23 DO-1 3. SIGNALS AND WIRING Connector Signal Symbol Encoder A-phase pulse 1 Encoder B-phase pulse 1 LA1 LAR1 LB1 LBR1 LZ1 CN4A-50 CN4A-25 CN4A-49 CN4A-24 CN4A-48 LZR1 CN4A-23 Encoder Z-phase pulse 1 Functions/Applications pin No. As LA , LAR , LB and LBR , the pulses per servo motor revolution set in the DRU parameter No. 27 (Encoder output pulses) of the corresponding slots are output in the differential line driver system. In CCW rotation of the servo motor, the encoder B-phase pulse lags the encoder A-phase pulse by a phase angle of /2. The relationships between rotation direction and phase difference of the Aand B-phase pulses can be changed using DRU parameter No. 54 (Function selection 9). As LZ and LZR the zero-point signals of the encoders of the corresponding slots are output. One pulse is output per servo motor revolution. The same signals as OP are output in the differential line driver system. Encoder pulse outputs for slot 1 Encoder A-phase pulse 2 LA2 CN4A-47 LAR2 CN4A-22 Encoder B-phase pulse 2 LB2 LBR2 CN4A-46 CN4A-21 Encoder Z-phase pulse 2 LZ2 CN4A-45 LZR2 CN4A-20 LA3 CN4A-44 Encoder B-phase pulse 3 LAR3 LB3 LBR3 CN4A-19 CN4A-43 CN4A-18 Encoder A-phase pulse 1 Encoder B-phase pulse 1 Encoder Z-phase pulse 1 Encoder Z-phase pulse 3 LZ3 CN4A-42 Encoder pulse outputs for slot 2 LZR3 CN4A-17 LA4 LAR4 LB4 CN4A-41 CN4A-16 CN4A-40 Encoder A-phase pulse 2 Encoder B-phase pulse 2 Encoder Z-phase pulse 2 LBR4 CN4A-15 Encoder pulse outputs for slot 3 LZ4 CN4A-39 Encoder A-phase pulse 5 LZR4 LA5 LAR5 CN4A-14 CN4B-50 CN4B-25 Encoder A-phase pulse 3 Encoder B-phase pulse 3 Encoder Z-phase pulse 3 Encoder B-phase pulse 5 LB5 CN4B-49 Encoder pulse outputs for slot 4 LBR5 CN4B-24 LZ5 LZR5 LA6 CN4B-48 CN4B-23 CN4B-47 Encoder A-phase pulse 4 Encoder B-phase pulse 4 Encoder Z-phase pulse 4 LAR6 CN4B-22 Encoder pulse outputs for slot 5 LB6 CN4B-46 Encoder Z-phase pulse 6 LBR6 LZ6 LZR6 CN4B-21 CN4B-45 CN4B-20 Encoder A-phase pulse 5 Encoder B-phase pulse 5 Encoder Z-phase pulse 5 Encoder A-phase pulse 7 LA7 CN4B-44 Encoder pulse outputs for slot 6 LAR7 CN4B-19 LB7 LBR7 LZ7 CN4B-43 CN4B-18 CN4B-42 Encoder A-phase pulse 6 Encoder B-phase pulse 6 Encoder Z-phase pulse 6 LZR7 CN4B-17 Encoder pulse outputs for slot 7 LA8 CN4B-41 Encoder B-phase pulse 8 LAR8 LB8 LBR8 CN4B-16 CN4B-40 CN4B-15 Encoder A-phase pulse 7 Encoder B-phase pulse 7 Encoder Z-phase pulse 7 Encoder Z-phase pulse 8 LZ8 CN4B-39 Encoder pulse outputs for slot 8 LZR8 CN4B-14 Encoder A-phase pulse 3 Encoder A-phase pulse 4 Encoder B-phase pulse 4 Encoder Z-phase pulse 4 Encoder Z-phase pulse 5 Encoder A-phase pulse 6 Encoder B-phase pulse 6 Encoder B-phase pulse 7 Encoder Z-phase pulse 7 Encoder A-phase pulse 8 Signal Symbol LA1 LAR1 LB1 LBR1 LZ1 LZR1 Signal Symbol LA2 LAR2 LB2 LBR2 LZ2 LZR2 Signal Symbol LA3 LAR3 LB3 LBR3 LZ3 LZR3 Signal Symbol LA4 LAR4 LB4 LBR4 LZ4 LZR4 Signal Symbol LA5 LAR5 LB5 LBR5 LZ5 LZR5 Signal Symbol LA6 LAR6 LB6 LBR6 LZ6 LZR6 Signal Signal Encoder A-phase pulse 8 Encoder B-phase pulse 8 Encoder Z-phase pulse 8 3 - 24 Symbol LA7 LAR7 LB7 LBR7 LZ7 LZR7 Symbol LA8 LAR8 LB8 LBR8 LZ8 LZR8 I/O division DO-2 3. SIGNALS AND WIRING (3) Power supply Signal Power input for Symbol VIN digital interface Common for SG digital interface Connector Functions/Applications pin No. CN4A-11 Driver power input terminal for digital interface. CN4A-36 Used to input 24VDC (200mA or more) for input interface. CN4B-11 24VDC 10% CN4B-36 Not connected to VIN of the interface unit. CN4A-12 Common terminal to VIN. Pins are connected internally. CN4A-37 Separated from LG. CN4B-12 Not connected to SG of the interface unit. CN4B-37 Control common LG CN4A-13 Common terminal to MO1, MO2 and MO3. CN4A-38 CN4B-13 CN4B-38 Shield SD Plate Connect the external conductor of the shield cable. 3 - 25 3. SIGNALS AND WIRING 3.3.4 Device explanations (1) Input device Using the MR Configurator (servo configuration software), you can assign the devices given in this section to the pins of connectors CN4A and CN4B of the MR-J2M-D01 extension IO unit. Device name Symbol Functions/Applications Internal torque limit selection 1 TL11 TL11: Internal torque limit selection device for slot 1 Internal torque limit selection 2 TL12 TL12: Internal torque limit selection device for slot 2 Internal torque limit selection 3 TL13 TL13: Internal torque limit selection device for slot 3 Internal torque limit selection 4 TL14 TL14: Internal torque limit selection device for slot 4 Internal torque limit selection 5 TL15 TL15: Internal torque limit selection device for slot 5 Internal torque limit selection 6 TL16 Internal torque limit selection 7 TL17 Internal torque limit selection 8 TL18 Proportion control 1 PC1 PC1: Proportion control device for slot 1 Proportion control 2 PC2 PC2: Proportion control device for slot 2 Proportion control 3 PC3 PC3: Proportion control device for slot 3 Proportion control 4 PC4 PC4: Proportion control device for slot 4 Proportion control 5 PC5 PC5: Proportion control device for slot 5 Proportion control 6 PC6 Proportion control 7 PC7 Proportion control 8 PC8 TL16: Internal torque limit selection device for slot 6 TL17: Internal torque limit selection device for slot 7 TL18: Internal torque limit selection device for slot 8 Refer to Section 3.3.5 (2) for details. PC6: Proportion control device for slot 6 PC7: Proportion control device for slot 7 PC8: Proportion control device for slot 8 Short PC -SG to switch the speed amplifier from the proportional integral type to the proportional type. If the servo motor at a stop is rotated even one pulse due to any external factor, it generates torque to compensate for a position shift. When the servo motor shaft is to be locked mechanically after positioning completion (stop), switching on the proportion control (PC ) upon positioning completion will suppress the unnecessary torque generated to compensate for a position shift. 3 - 26 3. SIGNALS AND WIRING Device name Symbol Functions/Applications Electronic gear selection 11 CM11 CM11: Electronic gear selection 1 device for slot 1 Electronic gear selection 12 CM12 CM12: Electronic gear selection 1 device for slot 2 Electronic gear selection 13 CM13 CM13: Electronic gear selection 1 device for slot 3 Electronic gear selection 14 CM14 CM14: Electronic gear selection 1 device for slot 4 Electronic gear selection 15 CM15 CM15: Electronic gear selection 1 device for slot 5 Electronic gear selection 16 CM16 Electronic gear selection 17 CM17 Electronic gear selection 18 CM18 Electronic gear selection 21 CM21 Electronic gear selection 22 CM22 Electronic gear selection 23 CM23 Electronic gear selection 24 CM24 Electronic gear selection 25 CM25 Electronic gear selection 26 CM26 CM27: Electronic gear selection 2 device for slot 7 Electronic gear selection 27 CM27 CM28: Electronic gear selection 2 device for slot 8 Electronic gear selection 28 CM28 CM16: Electronic gear selection 1 device for slot 6 CM17: Electronic gear selection 1 device for slot 7 CM18: Electronic gear selection 1 device for slot 8 CM21: Electronic gear selection 2 device for slot 1 CM22: Electronic gear selection 2 device for slot 2 CM23: Electronic gear selection 2 device for slot 3 CM24: Electronic gear selection 2 device for slot 4 CM25: Electronic gear selection 2 device for slot 5 CM26: Electronic gear selection 2 device for slot 6 The combination of CM1 -SG and CM2 -SG gives you a choice of four different electronic gear numerators set in the DRU parameters. and CM2 CM1 cannot be used in the absolute position detection system. (Note) Input signal Electronic gear numerator CM2 CM1 0 0 DRU parameter No.3 0 1 DRU parameter No.69 1 0 DRU parameter No.70 1 1 DRU parameter No.71 Note. 0: Off across terminal-SG (open) 1: On across terminal-SG (shorted) Gain switching 1 CDP1 CDP1: Gain switching device for slot 1 Gain switching 2 CDP2 CDP2: Gain switching device for slot 2 Gain switching 3 CDP3 CDP3: Gain switching device for slot 3 Gain switching 4 CDP4 CDP4: Gain switching device for slot 4 Gain switching 5 CDP5 CDP5: Gain switching device for slot 5 Gain switching 6 CDP6 Gain switching 7 CDP7 Gain switching 8 CDP8 CDP6: Gain switching device for slot 6 CDP7: Gain switching device for slot 7 CDP8: Gain switching device for slot 8 Connect CDP -SG to change the load inertia moment ratio into the DRU parameter No. 61 setting and the gain values into the values multiplied by the DRU parameter No. 62 to 64 settings. 3 - 27 3. SIGNALS AND WIRING (2) Output device Device name Symbol Functions/Applications Ready 1 RD1 RD1: Ready device for slot 1 Ready 2 RD2 RD2: Ready device for slot 2 Ready 3 RD3 RD3: Ready device for slot 3 Ready 4 RD4 RD4: Ready device for slot 4 Ready 5 RD5 RD5: Ready device for slot 5 Ready 6 RD6 Ready 7 RD7 Ready 8 RD8 In position 1 INP1 INP1: In position device for slot 1 In position 2 INP2 INP2: In position device for slot 2 In position 3 INP3 INP3: In position device for slot 3 In position 4 INP4 INP4: In position device for slot 4 In position 5 INP5 INP5: In position device for slot 5 In position 6 INP6 In position 7 INP7 In position 8 INP8 RD6: Ready device for slot 6 RD7: Ready device for slot 7 RD8: Ready device for slot 8 RD -SG are connected when the servo is switched on and the servo amplifier is ready to operate. INP6: In position device for slot 6 INP7: In position device for slot 7 INP8: In position device for slot 8 INP -SG are connected when the number of droop pulses is in the preset in- position range. The in-position range can be changed using DRU parameter No. 5. When the in-position range is increased, INP -SG may be kept connected during low-speed rotation. Limiting torque 1 TLC1 TLC1: Limiting torque device for slot 1 Limiting torque 2 TLC2 TLC2: Limiting torque device for slot 2 Limiting torque 3 TLC3 TLC3: Limiting torque device for slot 3 Limiting torque 4 TLC4 TLC4: Limiting torque device for slot 4 Limiting torque 5 TLC5 TLC5: Limiting torque device for slot 5 Limiting torque 6 TLC6 Limiting torque 7 TLC7 Limiting torque 8 TLC8 TLC6: Limiting torque device for slot 6 TLC7: Limiting torque device for slot 7 TLC8: Limiting torque device for slot 8 TLC -SG are connected when the torque generated reaches the value set to the internal torque limit 1 (DRU parameter No. 28) or internal torque limit 2(DRU parameter No. 76). Zero speed detection 1 ZSP1 ZSP1: Zero speed detection device for slot 1 Zero speed detection 2 ZSP2 ZSP2: Zero speed detection device for slot 2 Zero speed detection 3 ZSP3 ZSP3: Zero speed detection device for slot 3 Zero speed detection 4 ZSP4 Zero speed detection 5 ZSP5 Zero speed detection 6 ZSP6 Zero speed detection 7 ZSP7 Zero speed detection 8 ZSP8 ZSP4: Zero speed detection device for slot 4 ZSP5: Zero speed detection device for slot 5 ZSP6: Zero speed detection device for slot 6 ZSP7: Zero speed detection device for slot 7 ZSP8: Zero speed detection device for slot 8 ZSP -SG are connected when the servo motor speed is zero speed (50r/min) or less. Zero speed can be changed using DRU parameter No. 24. Electromagnetic brake interlock 1 MBR1 MBR1: Electromagnetic brake interlock device for slot 1 Electromagnetic brake interlock 2 MBR2 MBR2: Electromagnetic brake interlock device for slot 2 Electromagnetic brake interlock 3 MBR3 MBR3: Electromagnetic brake interlock device for slot 3 Electromagnetic brake interlock 4 MBR4 MBR4: Electromagnetic brake interlock device for slot 4 Electromagnetic brake interlock 5 MBR5 MBR5: Electromagnetic brake interlock device for slot 5 Electromagnetic brake interlock 6 MBR6 Electromagnetic brake interlock 7 MBR7 Electromagnetic brake interlock 8 MBR8 MBR6: Electromagnetic brake interlock device for slot 6 MBR7: Electromagnetic brake interlock device for slot 7 MBR8: Electromagnetic brake interlock device for slot 8 In the servo-off or alarm status, MBR -SG are disconnected. 3 - 28 3. SIGNALS AND WIRING Device name Symbol Functions/Applications Warning 1 WNG1 WNG1: Warning device for slot 1 Warning 2 WNG2 WNG2: Warning device for slot 2 Warning 3 WNG3 WNG3: Warning device for slot 3 Warning 4 WNG4 WNG4: Warning device for slot 4 Warning 5 WNG5 WNG5: Warning device for slot 5 Warning 6 WNG6 Warning 7 WNG7 Warning 8 WNG8 WNG6: Warning device for slot 6 WNG7: Warning device for slot 7 WNG8: Warning device for slot 8 When warning has occurred, WNG -SG are connected. When there is no warning, WNG -SG are disconnected within about 3 second after power-on. Battery warning 1 BWNG1 BWNG1: Battery warning device for slot 1 Battery warning 2 BWNG2 BWNG2: Battery warning device for slot 2 Battery warning 3 BWNG3 BWNG3: Battery warning device for slot 3 Battery warning 4 BWNG4 BWNG4: Battery warning device for slot 4 Battery warning 5 BWNG5 BWNG5: Battery warning device for slot 5 Battery warning 6 BWNG6 Battery warning 7 BWNG7 Battery warning 8 BWNG8 BWNG6: Battery warning device for slot 6 BWNG7: Battery warning device for slot 7 BWNG8: Battery warning device for slot 8 BWNG -SG are connected when battery cable breakage warning (A.92) or battery warning (A.9F) has occurred. When there is no battery warning, BWNG -SG are disconnected within about 3 second after power-on 3 - 29 3. SIGNALS AND WIRING 3.3.5 Detailed description of the device (1) Electronic gear switching The combination of CM1 -SG and CM2 -SG gives you a choice of four different electronic gear numerators set in the DRU parameters. As soon as Electronic gear selection (CM1 ) / Electronic gear selection 2 (CM2 ) is turned ON or OFF, the denominator of the electronic gear changes. Therefore, if any shock occurs at this change, use position smoothing (DRU parameter No. 7) to relieve shock. (Note) External input signal Electronic gear numerator CM2 CM1 0 0 DRU parameter No. 3 0 1 DRU parameter No. 69 1 0 DRU parameter No. 70 1 1 DRU parameter No. 71 Note. 0: CM1 /CM2 -SG off(open) 1: CM1 /CM2 -SG on(short) (2) Torque limit CAUTION Releasing the torque limit during servo lock may cause the servo motor to suddenly rotate according to the position deviation from the instructed position. (a) Torque limit and torque By setting DRU parameter No. 28 (internal torque limit 1), and DRU parameter No. 76 (internal torque limit 2), torque is always limited to the maximum value during operation. A relationship between the limit value and servo motor torque is shown below. Generated torque Max. torque 0 0 100 Torque limit value [%] (b) Torque limit value selection By making internal torque limit selection (TL1 ) usable, you can select the torque limit value as indicated below. (Note 1) External input signals TL1 0 1 Note 1. 0: TL1 -SG off (open) 1: TL1 -SG on (short) (Note 2) Torque limit value made valid Internal torque limit 1 (DRU parameter No. 28) DRU parameter No. 76 DRU parameter No. 28: DRU parameter No. 28 DRU parameter No. 76 DRU parameter No. 28: DRU parameter No. 76 2. Releasing the torque limit during servo lock may cause the servo motor to suddenly rotate according to the position deviation from the instructed position. (c) Limiting torque (TLC ) TLC-SG are connected when the torque by the servo motor reaches the torque set to internal torque limit 1 or internal torque limit 2. 3 - 30 3. SIGNALS AND WIRING 3.3.6 Device assignment method POINT When using the device setting, preset "000E" in IFU parameter No. 19. (1) How to open the setting screen Click "Parameters" on the menu bar and click "Device setting" in the menu. Making selection displays the following window. Click "Yes" button reads and displays the function assigned to each pin from the interface unit and extension IO unit. Click "No" button displays the initial status of the interface unit and extension IO unit. Click "Cancel" button terminates the processing. Click "Yes" button or "No" button displays the following two windows. 3 - 31 3. SIGNALS AND WIRING (2) Screen explanation (a) DIDO device setting window screen This is the device assignment screen of the interface unit/option unit. In Dev. selection, choose the IFU (interface unit) or D01 (extension IO unit). Making selection displays the pin assignment status per unit. a) b) d) c) 1) Read of function assignment ( a)) Click the "Read" button reads and displays all functions assigned to the pins from the interface unit and extension IO unit. 2) Write of function assignment ( b)) Click the "Write" button writes all pins that are assigned the functions to the interface unit and extension IO unit. 3) Verify of function assignment ( c)) Click the "Verify" button verifies the function assignment in the interface unit and extension IO unit with the device information on the screen. 4) Initial setting of function assignment ( d)) Click the "Set to Default" button initializes the function assignment. 3 - 32 3. SIGNALS AND WIRING (b) DIDO function display window screen This screen is used to select the slot numbers and functions assigned to the pins. Choose the slot numbers in Input device slot selection and Output device slot selection. The functions displayed below Input device function and Output device function are assignable. a) b) In the DIDO function display window, choose the slot numbers where you want to assign the functions. Move the pointer to the place of the function to be assigned. Drag and drop it as-is to the pin you want to assign in the DIDO device setting window. 1) Assignment check/auto ON setting ( a)) Press this button to display the screen that shows the slot-by-slot assignment list and enables auto ON setting. Refer to this section (4) for more information. 2) Quitting Click "Close" button to exit from the window. ( b)) 3 - 33 3. SIGNALS AND WIRING (C) Function device assignment check/auto ON setting display Click the "Function device assignment check/auto ON setting" button in the DIDO function display window displays the following window. a) b) c) d) e) The assigned functions are indicated by . The functions assigned by auto ON are grayed. When you want to set auto ON to the function that is enabled for auto ON, click the corresponding cell. Clicking it again disables auto ON. 1) Auto ON read of function assignment ( a)) Click "Auto ON read" button reads the functions set for auto ON from the interface unit and extension IO unit. 2) Auto ON write of function assignment ( b)) Click "Auto ON write" button writes the functions currently set for auto ON to the interface unit and extension IO unit. 3) Auto ON verify of function assignment ( c)) Click "Auto ON verify" button verifies the current auto ON setting in the interface unit and extension IO unit with the auto ON setting on the screen. 4) Auto ON initial setting of function assignment ( d)) Click "Auto ON initial setting" button initializes the auto ON setting. 5) Quitting the function device assignment checking/auto ON setting window ( e)) Click "Close" button exits from the window. 3 - 34 3. SIGNALS AND WIRING 3.4 Signals and wiring for base unit When each unit has become faulty, switch power off on the servo amplifier power side. Continuous flow of a large current may cause a fire. Use the trouble (ALM_ ) to switch power off. Otherwise, a regenerative brake transistor fault or the like may overheat the regenerative brake resistor, causing a fire. Fabricate the cables noting the shapes of the CNP1A housing (X type) and CNP1B housing (Y type). CAUTION 3.4.1 Connection example for power line circuit Wire the power supply and main circuit as shown below so that the servo-on (SON ) turns off as soon as alarm occurrence, or a servo forced stop is made valid is detected and power is shut off. A no-fuse breaker (NFB) must be used with the input cables of the power supply. (1) For 3-phase 200 to 230VAC power supply Forced Trouble A Trouble B stop A RA1 RA2 Forced stop B OFF ON MC MC SK NFB Power supply 3-phase 200 to 230VAC MELSERVO-J2M CNP3 MC L1 1 L2 2 L3 3 CNP1B CN1A L11 1 27 ALM_A L21 2 26 RA1 Trouble A VIN CN5 Forced stop A Forced stop B EMG_A 20 CN1B EMG_B 19 27 ALM_B 26 VIN SG 8 24VDC 3 - 35 RA2 Trouble B 3. SIGNALS AND WIRING (2) For 1-phase 200 to 230 VAC power supply Forced Trouble A Trouble B stop A RA1 RA2 Forced stop B OFF ON MC MC SK NFB (Note) Power supply 1-phase 200 to 230VAC MELSERVO-J2M MC CNP3 L1 1 L2 2 L3 3 CNP1B CN1A L11 1 27 ALM_A L21 2 26 RA1 Trouble A VIN CN5 Forced stop A Forced stop B EMG_A 20 EMG_B 19 SG 8 CN1B 27 ALM_B 26 VIN 24VDC Note. Connect a 1-phase 200 to 230VAC power supply to L1/L2 and keep L3 open. 3 - 36 RA2 Trouble B 3. SIGNALS AND WIRING 3.4.2 Connectors and signal configurations POINT The pin configurations of the connectors are as viewed from the cable connector wiring section. CNP1B (Y type) CNP1A (X type) 1 1 Base unit N L11 2 2 P L21 3 3 C CNP3 3 L3 2 L2 1 L1 The connector frames are connected to the PE (earth) terminal of the base unit. Cable side connector Connector Model Maker Housing: 1-178128-3 (X type) CNP1A Contact: 917511-2 (max. sheath OD: 353717-2 (max. sheath OD: 2.8[mm] ( 0.11[in])) 3.4[mm] ( 0.13[in])) (Note) Tyco Housing: 2-178128-3 (Y type) CNP1B Contact: 917511-2 (max. sheath OD: 353717-2 (max. sheath OD: CNP3 2.8[mm] ( 0.11[in])) 3.4[mm] ( 0.13[in])) (Note) Housing: 1-179958-3 Contact: 316041-2 Note. This contact is not included in the option (MR-J2MCNM). 3 - 37 Electronics 3. SIGNALS AND WIRING 3.4.3 Terminals Refer to Section 10.2 for the layouts and signal configurations of the terminal blocks. Connector CNP3 CNP1B Pin No. Code 1 L1 2 L2 3 L3 1 L11 2 L21 Connection target (1) When using a three -phase power supply Supply L1, L2 and L3 with three-phase, 200 to 230VAC, 50/60Hz Main circuit power 1 N 2 P 3 C (Earth) power. (2) When using a signal -phase power supply Supply L1 and L2 with signal-phase, 200 to 230VAC, 50/60Hz power. Control circuit power 3 CNP1A Description (Application) Regenerative brake option Supply L11 and L21 with single-phase, 200 to 230VAC, 50/60Hz power. Connect the regenerative brake option across P-C. Accidental connection of the regenerative brake option to P-N may cause burning (Refer to Section 12.1.1) Protective earth (PE) Connect this terminal to the protective earth (PE) terminals of the servo motor and control box for grounding. 3.4.4 Power-on sequence (1) Power-on procedure 1) Always wire the power supply as shown in above Section 3.7.1 using the magnetic contactor with the main circuit power supply (three-phase 200V: L1, L2, L3). Configure up an external sequence to switch off the magnetic contactor as soon as an alarm occurs. 2) Switch on the control circuit power supply L11, L21 simultaneously with the main circuit power supply or before switching on the main circuit power supply. If the main circuit power supply is not on, the display shows the corresponding warning. However, by switching on the main circuit power supply, the warning disappears and the servo amplifier will operate properly. 3) The servo amplifier can accept the servo-on (SON ) about 3s after the main circuit power supply is switched on. Therefore, when SON is switched on simultaneously with the main circuit power supply, the base circuit will switch on in about 1 to 2s, and the ready (RD ) will switch on in further about 20ms, making the servo amplifier ready to operate. (Refer to paragraph (2) in this section.) 4) When the reset (RES ) is switched on, the base circuit is shut off and the servo motor shaft coasts. (2) Timing chart SON accepted (3s) Main circuit power ON control circuit OFF Base circuit ON OFF Servo-on (SON ) ON OFF Reset (RES ) ON OFF Ready (RD ) ON OFF 10ms 10ms 100ms 10ms 20ms 100ms 20ms 10ms 3 - 38 20ms 10ms 3. SIGNALS AND WIRING (3) Forced stop CAUTION Install an forced stop circuit externally to ensure that operation can be stopped and power shut off immediately. Make up a circuit which shuts off main circuit power as soon as EMG_ -SG are opened at a forced stop. To ensure safety, always install a forced stop switch across EMG_ -SG. By disconnecting EMG_ -SG, the dynamic brake is operated to bring the servo motor to a stop. At this time, the display shows the servo forced stop warning (A.E6). During ordinary operation, do not use forced stop (EMG_ ) to alternate stop and run. The service life of each drive unit may be shortened. Interface unit 24VDC VIN EMG_A EMG_B SG 3.5 Connection of drive unit and servo motor 3.5.1 Connection instructions CAUTION Connect the wires to the correct phase terminals (U, V, W) of the drive unit and servo motor. Otherwise, the servo motor will operate improperly. Do not connect AC power supply directly to the servo motor. Otherwise, a fault may occur. POINT Do not apply the test lead bars or like of a tester directly to the pins of the connectors supplied with the servo motor. Doing so will deform the pins, causing poor contact. The connection method differs according to the series and capacity of the servo motor and whether or not the servo motor has the electromagnetic brake. Perform wiring in accordance with this section. (1) The protective earth of the servo motor joins to the base unit via the drive unit mounting screw. Connect the protective earth terminal of the base unit to the protective earth of the control box to discharge electricity to the earth. (2) The power supply for the electromagnetic brake should not be used as the 24VDC power supply for interface. Always use the power supply for electromagnetic brake only. 3 - 39 3. SIGNALS AND WIRING 3.5.2 Connection diagram The following table lists wiring methods according to the servo motor types. Use the connection diagram which conforms to the servo motor used. For cables required for wiring, refer to Section 12.2.1. For encoder cable connection, refer to Section 12.1.2. For the signal layouts of the connectors, refer to Section 3.5.3. For the servo motor connector, refer to Chapter 3 of the Servo Motor Instruction Manual. Servo motor Connection diagram Base unit Servo motor Drive unit CNP2 U (Red) U V (White) V W (Black) W (Note 1) (Note 3) 24VDC B1 B2 HC-KFS053 (B) to 73 (B) EM1 HC-MFS053 (B) to 73 (B) Motor (Green) (Earth) (Note 2) Electromagnetic brake To be shut off when servoon (SON ) switches off or by trouble (ALM_ ) HC-UFS13 (B) to 73 (B) CN2 Encoder Encoder cable Note 1. To prevent an electric shock, always connect the protective earth (PE) terminal of the base unit to the protective earth (PE) of the control box. 2. This circuit applies to the servo motor with electromagnetic brake. 3. The protective earth of the servo motor is connected to the base unit via the drive unit mounting screw. 3 - 40 3. SIGNALS AND WIRING 3.5.3 I/O terminals (1) Drive unit POINT The pin configurations of the connectors are as viewed from the cable connector wiring section. CN2 20 19 P5 17 MRR 15 P5 18 P5 16 MDR 10 9 Drive unit BAT 8 7 MR 5 MD 14 13 4 3 12 11 CNP2 2 4 V 1 3 U W 6 LG LG 2 1 LG Cable side connector Connector LG CN2 CNP2 Model Maker 1. Soldering type Connector: 10120-3000VE Shell kit: 10320-52F0-008 2. Insulation displacement type Connector: 10120-6000EL Shell kit: 10320-3210-000 Housing: 5557-04R-210 Terminal: 5556PBT3L 3M molex (2) Servo motor (HC-KFS HC-MFS HC-UFS3000r/min series) Encoder connector signal arrangement Power supply lead 4-AWG19 0.3m(0.98ft) Encoder cable 0.3m(0.98ft) With connector 1-172169-9 (Tyco Electronics) Power supply connector 5557-04R-210 1 3 2 4 Pin 1 2 3 4 Signal U V W Power supply connector (molex) Without electromagnetic brake 5557-04R-210 (receptacle) 5556PBTL (Female terminal) With electromagnetic brake 5557-06R-210 (receptacle) 5556PBTL (Female terminal) Power supply connector 5557-06R-210 (Earth) 1 4 2 5 3 6 Pin 1 2 3 4 (Note) 5 (Note) 6 1 2 3 MR MRR BAT 4 5 6 MD MDR 7 8 9 P5 LG SHD Signal U V W (Earth) B1 B2 Note. Supply electromagnetic brake power (24VDC). There is no polarity. 3 - 41 3. SIGNALS AND WIRING 3.6 Alarm occurrence timing chart CAUTION When an alarm has occurred, remove its cause, make sure that the operation signal is not being input, ensure safety, and reset the alarm before restarting operation. As soon as an alarm occurs, turn off Servo-on (SON ) and power off the main circuit. When an alarm occurs in the MELSERVO-J2M, the base circuit is shut off and the servo motor is coated to a stop. Switch off the main circuit power supply in the external sequence. To reset the alarm, switch the control circuit power supply from off to on, or turn the reset (RES ) from off to on. However, the alarm cannot be reset unless its cause is removed. (Note) Main circuit control circuit power supply ON OFF Power off ON OFF Valid Dynamic brake Invalid Power on Base circuit Servo-on (SON ) ON OFF Ready (RD ) ON OFF Trouble (ALM_ ) ON OFF Reset (RES ) ON OFF Brake operation Brake operation 3s 50ms or more 30ms or more Alarm occurs. Remove cause of trouble. Note. Switch off the main circuit power as soon as an alarm occurs. (1) Overcurrent, overload 1 or overload 2 If operation is repeated by switching control circuit power off, then on to reset the overcurrent (A.32), overload 1 (A.50) or overload 2 (A.51) alarm after its occurrence, without removing its cause, the servo amplifier and servo motor may become faulty due to temperature rise. Securely remove the cause of the alarm and also allow about 30 minutes for cooling before resuming operation. (2) Regenerative alarm If operation is repeated by switching control circuit power off, then on to reset the regenerative (A.30) alarm after its occurrence, the external regenerative brake resistor will generate heat, resulting in an accident. (3) Instantaneous power failure Undervoltage (A.10) occurs when the input power is in either of the following statuses. A power failure of the control circuit power supply continues for 30ms or longer and the control circuit is not completely off. The bus voltage dropped to 200VDC or less. (4) Incremental When an alarm occurs, the home position is lost. When resuming operation after deactivating the alarm, make a home position return. 3 - 42 3. SIGNALS AND WIRING 3.7 Servo motor with electromagnetic brake Configure the electromagnetic brake operation circuit so that it is activated not only by the interface unit signals but also by an external forced stop (EMG_ ). Contacts must be open when Circuit must be servo-on (SON ) is off, when an opened during trouble (ALM_ ) is present and forced stop when an electromagnetic brake (EMG_ ). interlock (MBR ). Servo motor RA EMG_ CAUTION 24VDC Electromagnetic brake The electromagnetic brake is provided for holding purpose and must not be used for ordinary braking. Before performing the operation, be sure to confirm that the electromagnetic brake operates properly. POINT Refer to the Servo Motor Instruction Manual for specifications such as the power supply capacity and operation delay time of the electromagnetic brake. Note the following when the servo motor equipped with electromagnetic brake is used: 1) Using the MR Configurator (servo configuration software), make the electromagnetic brake interlock (MBR ) valid. 2) Do not share the 24VDC interface power supply between the interface and electromagnetic brake. Always use the power supply designed exclusively for the electromagnetic brake. 3) The brake will operate when the power (24VDC) switches off. 4) While the reset (RES ) is on, the base circuit is shut off. When using the servo motor with a vertical shaft, use the electromagnetic brake interlock (MBR ). 5) Switch off the servo-on (SON ) command after the servo motor has stopped. (1) Connection diagram Interface unit or extension IO unit Forced stop A or RA Forced stop B B1 24VDC Servo motor SG 24VDC MBR RA B2 (2) Setting 1) Using the MR Configurator (servo configuration software), make the electromagnetic brake interlock (MBR ) valid. 2) In DRU parameter No.33 (electromagnetic brake sequence output), set the delay time (Tb) from electromagnetic brake operation to base circuit shut-off at a servo off time as in the timing chart in (3) in this section. 3 - 43 3. SIGNALS AND WIRING (3) Timing charts (a) Servo-on (SON ) command (from controller) ON/OFF Tb [ms] after the servo-on (SON ) is switched off, the servo lock is released and the servo motor coasts. If the electromagnetic brake is made valid in the servo lock status, the brake life may be shorter. Therefore, when using the electromagnetic brake in a vertical lift application or the like, set delay time (Tb) to about the same as the electromagnetic brake operation delay time to prevent a drop. Coasting 0 r/min Servo motor speed (100ms) ON Base circuit OFF Tb (120ms) Electromagnetic brake operation delay time Invalid(ON) Electromagnetic brake(MBR ) Valid(OFF) ON Servo-on(SON ) OFF (b) Forced stop (EMG_ ) ON/OFF Dynamic brake Dynamic brake Electromagnetic brake Electromagnetic brake Electromagnetic brake release Servo motor speed (10ms) (180ms) ON Base circuit OFF Forced stop (EMG_ Electromagnetic brake operation delay time Invalid (ON) Electromagnetic brake interlock (MBR ) Valid (OFF) ) (180ms) Invalid (ON) Valid (OFF) (c) Alarm occurrence Dynamic brake Dynamic brake Electromagnetic brake Servo motor speed Electromagnetic brake (10ms) ON Base circuit OFF Electromagnetic brake interlock (MBR Trouble (ALM_ ) Invalid(ON) ) Valid(OFF) No(ON) Yes(OFF) 3 - 44 Electromagnetic brake operation delay time 3. SIGNALS AND WIRING (d) Both main and control circuit power supplies off (10ms) Servo motor speed Dynamic brake Dynamic brake Electromagnetic brake Electromagnetic brake (Note)15 to 100ms ON Base circuit OFF Invalid(ON) Electromagnetic brake interlock(MBR Trouble (ALM_ ) Valid(OFF) Electromagnetic brake operation delay time No(ON) ) Yes(OFF) ON Main circuit power Control circuit OFF Note. Changes with the operating status. (e) Only main circuit power supply off (control circuit power supply remains on) (10ms) Servo motor speed Dynamic brake Dynamic brake Electromagnetic brake Electromagnetic brake (Note 1)15ms or more ON Base circuit OFF Invalid(ON) Electromagnetic brake interlock (MBR ) Trouble (ALM_ Valid(OFF) ) Electromagnetic brake operation delay time (Note 2) No(ON) Yes(OFF) ON Main circuit power OFF supply Note 1. Changes with the operating status. 2. When the main circuit power supply is off in a motor stop status, the main circuit off warning (A.E9) occurs and the trouble (ALM_ 3 - 45 ) does not turn off. 3. SIGNALS AND WIRING 3.8 Grounding Ground the base unit and servo motor securely. To prevent an electric shock, always connect the protective earth (PE) terminal of the base unit with the protective earth (PE) of the control box. WARNING The base unit switches the power transistor on-off to supply power to the servo motor. Depending on the wiring and ground cablerouting, MELSERVO-J2M may be affected by the switching noise (due to di/dt and dv/dt) of the transistor. To prevent such a fault, refer to the following diagram and always ground. To conform to the EMC Directive, refer to the EMC Installation Guidelines (IB(NA)67310). Control box Base unit NFB MC Drive unit FR-BAL CN2 L1 Line filter Power supply 3-phase 200 to 230VAC (Note4) 1-phase 200 to 230VAC Servo motor Encoder L2 L3 L11 L21 CNP2 (Note 2) U U V V W W M (Earth) (Note 3) Drive unit CN2 Servo motor Encoder CNP2 (Note2) U U V V W W M (Earth) (Note 3) Interface unit CN1A Programmable controller (Note 1) Protective earth(PE) Note 1. To reduce the influence of external noise, we recommend you to ground the bus cable near the controller using a cable clamping fixture or to connect three or four data line filters in series. 2. The mounting screw of the drive unit is also used for PE connection of the servo motor. 3. Ensure to connect it to PE terminal of the drive unit. Do not connect it directly to the protective earth of the control panel. 4. For 1-phase 230VAC, connect the power supply to L1 L2 and leave L3 open. 3 - 46 3. SIGNALS AND WIRING 3.9 Instructions for the 3M connector When fabricating an encoder cable or the like, securely connect the shielded external conductor of the cable to the ground plate as shown in this section and fix it to the connector shell. External conductor Sheath Core Sheath External conductor Pull back the external conductor to cover the sheath Strip the sheath. Screw Cable Screw Ground plate 3 - 47 3. SIGNALS AND WIRING MEMO 3 - 48 4. OPERATION AND DISPLAY 4. OPERATION AND DISPLAY On the interface unit display (5-digit, seven-segment display), check the status of communication with the servo system controller at power-on, check the slot number, and diagnose a fault at occurrence of an alarm. 4.1 Display flowchart When powered on, the MELSERVO-J2M is placed in the automatic scroll mode in which the statuses of the interface unit/drive units installed on the base unit appear at intervals of 2 seconds in due order. At this time, open slot numbers do not appear. In the initial status, the indication is in the automatic scroll mode. Pressing the "SET" button switches the automatic scroll mode to the fixed mode. In the fixed mode, pressing the "UP" or "DOWN" button displays the status of the subsequent-slot drive unit. If an alarm/warning occurs in the interface unit/drive units, the alarm/warning number of the interface unit/drive unit appears. (Refer to Section 4.1.2) Automatic scroll or button UP DOWN IFU status indication DRU status indication DRU status indication (Slot 2) (Slot 1) DRU status indication DRU status indication (Slot 7) (Slot 8) In the automatic scroll mode, pressing the "MODE" button for 2s or more switches between the normal indication and the corresponding unit-related display screen. (Refer to Section 4.2/ Section 4.3.) 4- 1 4. OPERATION AND DISPLAY 4.1.1 Normal indication The normal indication shows the interface unit status or the slot number and current status (during servo ON or during servo OFF) of the corresponding drive unit to allow you to diagnose faults at alarm occurrence. The following are the drive unit status display data in the normal indication. (Note 1)Indication @ C@ @ d@ (Note 2) @A**@ Status Description Servo off Servo off status. Servo-on Servo on status. Alarm/Warning The encountered alarm/warning number is displayed. Test operation mode Test operation mode status using the MR Configurator (Refer to Section 9.1.) @T d@. @T C@. (servo configuration software). Displayed for JOG operation, positioning operation, motor-less operation or D0 forced output. The indication varies with the current condition. Note 1. @ denotes the slot number of the base unit. 2. ** indicates the warning/alarm No. (1) When the drive unit is during servo off 1. C 1 Slot number Indicates servo OFF. Slot number (2) When the drive unit is during servo on 1. d 1 Slot number Indicates servo ON. Slot number (3) When the interface unit is normal F. Indicates the interface unit. 4- 2 4. OPERATION AND DISPLAY 4.1.2 If alarm/warning occurs (1) If alarm/warning occurs in drive unit An alarm/warning which occurred in the drive unit is represented by the following indication. The following indication example assumes that an encoder error (A.16) occurred in the drive unit of installed on slot 1. During alarm occurrence digits flicker. 1. A 1 6. 1 Slot number Alarm/warning number Denotes alarm/warning indication. Slot number (2) If alarm/warning occurs in interface unit An alarm/warning which occurred in the interface unit is represented by the following indication. The following indication example assumes that interface unit undervoltage (A.10) occurred. During alarm occurrence digits flicker. F. A 1 0. Alarm/warning number Denotes alarm/warning indication. Denotes interface unit. 4- 3 4. OPERATION AND DISPLAY 4.1.3 If test operation POINT Test operation can be performed using the MR Configurator (servo configuration software). (1) When test operation is being performed Test operation being performed is indicated as follows. @. T C @. Slot number. Test operation being performed is indicated as follows. Indicates the current status. Refer to the following table for below. Denotes test operation indication. Slot number Indication Current Status @T C@. Servo off status @T d@. Servo on status (2) When alarm occurs during test operation Any alarm that occurred during test operation is indicated as follows. @. A 1 6. @. Slot number. The decimal point is lit during test operation. Alarm display Slot number 4- 4 4. OPERATION AND DISPLAY 4.2 Interface unit display 4.2.1 Display flowchart of interface unit Use the display (5-digit, 7-segment LED) on the front panel of the interface unit for status display, parameter setting, etc. Set the parameters before operation, diagnose an alarm, confirm external sequences, and/or confirm the operation status. The automatic scroll mode is selected at power-on. Before starting use, therefore, press the "UP" or "DOWN" button to change the fifth digit to "F" and press the "MODE" button for 2s or more to change the indication. Press the "MODE" "UP" or "DOWN" button once to move to the next screen. button MODE Status display Diagnosis Alarm Basic IFU parameters Expansion IFU parameters Regenerative load ratio [%] Interface unit external input signal Current alarm IFU parameter No. 0 IFU parameter No. 20 Bus voltage [V] Interface unit external output signal Last alarm IFU parameter No. 1 IFU parameter No. 21 Peak bus voltage [V] Interface unit output signal (DO) forced output Second alarm in past UP DOWN Software version Low Third alarm in past Software version High Fourth alarm in past IFU parameter No. 18 IFU parameter No. 28 Fifth alarm in past IFU parameter No. 19 IFU parameter No. 29 Sixth alarm in past Parameter error No. Note. The parameter display range varies with the parameter write inhibit. 4- 5 4. OPERATION AND DISPLAY 4.2.2 Status display of interface unit MELSERVO-J2M status during operation is shown on the 5-digit, 7-segment LED display. Press the "UP" or "DOWN" button to change display data as desired. When the required data is selected, the corresponding symbol appears. Press the "SET" button to display its data. (1) Display examples The following table lists display examples: Item Displayed data Status Regenerative load ratio 60% Bus voltage 270V Peak bus voltage 350V Interface unit display (2) Interface unit status display list The following table indicates the MELSERVO-J2M statuses that can be shown. After it has been selected, each status display changes to a symbol display. Press the "SET" button to show the definition of the status display. Refer to Appendix 1 for the measurement point. Pressing the "MODE" button during a status definition display returns to a symbol display. Name Symbol Unit Description Display range Regenerative load ratio F.L % The ratio of regenerative power to permissible regenerative power is displayed in %. 0 to 100 Bus voltage F.Pn V The voltage (across P-N) of the main circuit converter is displayed. 0 to 450 Peak bus voltage F.PnP V Shows the maximum voltage of the main circuit converter (across P-N). The maximum value during past 15s is displayed. 4- 6 0 to 450 4. OPERATION AND DISPLAY 4.2.3 Diagnostic mode of interface unit Name Display Description 2) 1) 2) 1) Interface unit external input signal Interface unit external output signal Interface unit output signal (DO) forced output Shows the ON/OFF states of the external input signals. 1) Forced stop A (EMG_A) ON: On OFF: Off 2) Forced stop B (EMG_B) ON: On OFF: Off Shows the ON/OFF states of the external output signals. 1) Trouble A (ALM_A) ON: On OFF: Off 2) Trouble B (ALM_B) ON: On OFF: Off The digital output signal can be forced on/off. For more information, refer to section 4.2.6. During output signal (DO) forced output, the decimal point in the first digit is lit. Software version Low Indicates the version of the software. Software version High Indicates the system number of the software. 4- 7 4. OPERATION AND DISPLAY 4.2.4 Alarm mode of interface unit The current alarm, past alarm history and parameter error are displayed. The lower 2 digits on the display indicate the alarm number that has occurred or the parameter number in error. Display examples are shown below. Name Display Description Indicates no occurrence of an alarm in the interface unit. Current alarm Indicates the occurrence of overvoltage (A.10) in the interface unit. Flickers at occurrence of the alarm. Indicates that the last alarm is base unit error (A.1C) in the interface unit. Indicates that the second alarm in the past is overvoltage (A.33) in the interface unit. Indicates that the third alarm in the past is undervoltage (A.10) in the interface unit. Alarm history Indicates that the fourth alarm in the past is over regenerative (A.30) in the interface unit. Indicates that there is no fifth alarm in the past of the interface unit. Indicates that there is no sixth alarm in the past of the interface unit. Indicates no occurrence of parameter error (A.37) of the interface unit. Parameter error No. Indicates that the data of parameter No. 1 is faulty of the interface unit. Functions at occurrence of an alarm (1) Any mode screen displays the current alarm. (2) The other screen is visible during occurrence of an alarm. At this time, the decimal point in the fourth digit flickers. (3) For any alarm, remove its cause and clear it in any of the following: (for clearable alarms, refer to Section 9.2) (a) Switch power OFF, then ON. (b) Press the "SET" button on the current alarm screen. (4) Use IFU parameter No. 0 to clear the alarm history. (5) Pressing "SET" button on the alarm history display screen for 2s or longer shows the following detailed information display screen. Note that this is provided for maintenance by the manufacturer. (6) Press "UP" or "DOWN" button to move to the next history. (7) Pressing the "MODE" button on the alarm detail display screen returns to the alarm history display. 4- 8 4. OPERATION AND DISPLAY 4.2.5 Interface unit parameter mode The parameters whose abbreviations are marked* are made valid by changing the setting and then switching power off once and switching it on again. Refer to Section 5.2.2. The following example shows the operation procedure performed after power-on to change the regenerative brake resistor (IFU parameter No. 1) to 0005 (MR-RB15). Using the "MODE" button, show the basic parameter screen. The parameter number is displayed. Press UP or DOWN button to change the number. Press SET twice. The set value of the specified parameter number flickers. Press UP fifth. During flickering, the set value can be changed. Use ( or button . UP DOWN 5: regenerative brake option MR-RB14) Press SET to enter. Pressing the "MODE" button during a parameter setting display or setting change display cancels the processing and returns to a parameter number display. To shift to the next parameter, press the "UP" or "DOWN" button. 4- 9 4. OPERATION AND DISPLAY 4.2.6 Interface unit output signal (DO) forced output POINT This function is available during test operation. The output signal can be forced on/off independently of the servo status. This function is used for output signal wiring check, etc. This operation must be performed in the servo off state (SON off). Call the display screen shown after power-on. Using the "MODE" button, show the diagnostic screen. Press UP button twice. Press SET button for more than 2s. ALM_A ALM_B Turns on/off the signal under the lit LED. Always lit. Indicates whether the output signal is ON or OFF. The signals are the same as the external output signals. (On: ON, Off: OFF) Pressing MODE button once moves the lit LED to the left. Press UP button once. The ALM_A turns on. (There will be continuity across ALM_A-SG.) Press DOWN button once. The ALM_A turns off. Press SET button for more than 2s. 4 - 10 4. OPERATION AND DISPLAY 4.3 Drive unit display 4.3.1 Drive unit display sequence Use the display (5-digit, 7-segment LED) on the front panel of the servo amplifier for status display, parameter setting, etc. Set the parameters before operation, diagnose an alarm, confirm external sequences, and/or confirm the operation status. The automatic scroll mode is selected at power-on. Before starting use, therefore, press the "UP" or "DOWN" button to change the fifth digit to the necessary slot number "1" to "8" and press the "MODE" button for 2s or more to change the indication. Press the "MODE" "UP" or "DOWN" button once to move to the next screen. To refer to or set the expansion parameters, make them valid with DRU parameter No. 19 (parameter write disable). button MODE Status display @ (Note) Cumulative feedback pulses [pulse] Diagnosis @ @ Drive unit external input signal Current alarm @ @ @ Motor speed [r/min] Drive unit external output signal Last alarm @ @ Droop pulses [pulse] Drive unit output signal (DO) forced output Software version Low Third alarm in past @ @ @ Command pulse frequency [kpps] Software version High Fourth alarm in past @ @ @ Effective load ratio [%] Motor series ID Fifth alarm in past @ @ @ Peak load ratio [%] Motor type ID Sixth alarm in past @ Instantaneous torque [%] @ DRU parameter No. 21 @ DRU parameter No. 50 @ DRU parameter No. 51 @ @ Cumulative command pulses [pulse] @ DRU parameter No. 1 @ DRU parameter No. 20 Second alarm in past @ @ @ DRU parameter No. 0 Expansion DRU parameters 2 Expansion DRU parameters 1 Basic DRU parameters Alarm @ @ Encoder ID Parameter error No. UP @ DRU parameter No. 18 @ DRU parameter No. 19 @ DRU parameter No. 48 @ DRU parameter No. 49 @ Within one-revolution position low [pulse] @ Within one-revolution position, high [100 pulses] @ ABS counter [rev] @ Load inertia moment ratio [times] Note 1. @ indicates the slot number. 2. The parameter display range varies with the parameter write inhibit. 4 - 11 @ DRU parameter No. 83 @ DRU parameter No. 84 DOWN 4. OPERATION AND DISPLAY 4.3.2 Status display of drive unit The servo status during operation is shown on the 5-digit, 7-segment LED display. Press the "UP" or "DOWN" button to change display data as desired. When the required data is selected, the corresponding symbol appears. Press the "SET" button to display its data. (1) Display examples The following table lists display examples: Item Displayed data Status Servo amplifier display Forward rotation at 3000r/min Motor speed Reverse rotation at 3000r/min Reverse rotation is indicated by " ". 11252pulse Multirevolution counter 12566pulse Lit Negative value is indicated by the lit decimal points in the upper four digits. Load inertia moment 15.5 times 4 - 12 4. OPERATION AND DISPLAY (2) Drive unit status display list The following table lists the servo statuses that may be shown: Refer to Appendix 2 for the measurement point. Name Symbol Unit Description Cumulative feedback pulses @.C pulse Servo motor speed @.r r/min Feedback pulses from the servo motor encoder are counted and displayed. The value in excess of 99999 is counted, bus since the interface display is five digits, it shows the lower five digits of the actual value. Press the "SET" button to reset the display value to zero. Reverse rotation is indicated by the lit decimal points in the upper four digits. The servo motor speed is displayed. The value rounded off is displayed in 0.1r/min. Droop pulses @.E pulse Cumulative command pulses @.P pulse Command pulse frequency @.n kpps Effective load ratio @.J % Peak load ratio @.b % Instantaneous torque @.T % Within one-revolution position Low @.CY1 pulse Within one-revolution @.CY2 position High 100 pulse The number of droop pulses in the deviation counter is displayed. When the servo motor is rotating in the reverse direction, the decimal points in the upper four digits are lit. Since the servo amplifier display is five digits, it shows the lower five digits of the actual value. The number of pulses displayed is not yet multiplied by the electronic gear. The position command input pulses are counted and displayed. As the value displayed is not yet multiplied by the electronic gear (CMX/CDV), it may not match the indication of the cumulative feedback pulses. The value in excess of 99999 is counted, but since the interface display is five digits, it shows the lower five digits of the actual value. Press the "SET" button to reset the display value to zero. When the servo motor is rotating in the reverse direction, the decimal points in the upper four digits are lit. The frequency of the position command input pulses is displayed. The value displayed is not multiplied by the electronic gear (CMX/CDV). The continuous effective load torque is displayed. The effective value in the past 15 seconds is displayed relative to the rated torque of 100%. The maximum torque generated during acceleration/deceleration, etc. The highest value in the past 15 seconds is displayed relative to the rated torque of 100%. Torque that occurred instantaneously is displayed. The value of the torque that occurred is displayed in real time relative to the rate torque of 100%. Position within one revolution is displayed in encoder pulses. The value returns to "0" when it exceeds the maximum number of pulses. The value is incremented in the "CCW" direction of rotation. Display range 99999 to 99999 5400 to 5400 99999 to 99999 99999 to 99999 800 to 800 0 to 300 0 to 400 0 to 400 0 to 99999 The within one-revolution position is displayed in 100 pulse 0 increments of the encoder. to The value returns to "0" when it exceeds the maximum number of 13107 pulses. The value is incremented in the "CCW" direction of rotation. ABS counter @.LS rev Travel value from the home position in the absolute position detection systems is displayed in terms of the absolute position detectors counter value. Load inertia moment ratio @.dC 0.1 Times The estimated ratio of the load inertia moment to the servo motor shaft inertia moment is displayed. 32768 to 32768 0.0 to 300.0 4 - 13 4. OPERATION AND DISPLAY 4.3.3 Diagnostic mode of drive unit Name (Note) Display Drive unit external Refer to section 4.3.6. input signal Drive unit external Refer to section 4.3.6. output signal Drive unit output Description Shows the ON/OFF statuses of the external input signals. Each signal corresponds to the function assignment. (The corresponding segment is lit when the function-assigned signal turns on.) Shows the ON/OFF statuses of the external output signals. When the corresponding segment is lit, the output is provided to the assigned signal. @ The digital output signal can be forced on/off. For more information, refer to section 4.3.8. Software version Low @ Indicates the version of the drive unit software. Software version High @ Indicates the system number of the drive unit software. Motor series ID @ signal (DO) forced output Press the "SET" button to show the motor series ID of the servo motor currently connected. For indication details, refer to the optional MELSERVO Servo Motor Instruction Manual. Press the "SET" button to show the motor type ID of the servo Motor type ID @ motor currently connected. For indication details, refer to the optional MELSERVO Servo Motor Instruction Manual. Press the "SET" button to show the encoder ID of the servo motor Encoder ID @ currently connected. For indication details, refer to the optional MELSERVO Servo Motor Instruction Manual. Note. @ indicates the slot number. 4 - 14 4. OPERATION AND DISPLAY 4.3.4 Alarm mode of drive unit Name (Note) Display @ Description Indicates no occurrence of an alarm in the drive unit. Current alarm @ @ Indicates the occurrence of overvoltage (A.33) in the drive unit. Flickers at occurrence of the alarm. Indicates that the last alarm is overload 1 (A.50) in the drive unit. @ Indicates that the second alarm in the past is overvoltage (A.33) in the @ Indicates that the third alarm in the past is undervoltage (A.52) in the @ Indicates that the fourth alarm in the past is encoder error (A.20) in the drive unit. drive unit. Alarm history drive unit. @ Indicates that there is no fifth alarm in the past in the drive unit. @ Indicates that there is no sixth alarm in the past in the drive unit. @ Indicates no occurrence of parameter error (A.37) in the drive unit. @ Indicates that the data of parameter No. 1 is faulty in the drive unit. Parameter error No. Note. @ indicates the slot number. Functions at occurrence of an alarm (1) Any mode screen displays the current alarm. (2) The other screen is visible during occurrence of an alarm. At this time, the decimal point in the fourth digit flickers. (3) For any alarm, remove its cause and clear it in any of the following methods: (for clearable alarms, refer to Section 9.2) (a) Switch power OFF, then ON. (b) Turn on the reset (RES ). (4) Use DRU parameter No. 16 to clear the alarm history. (5) Pressing "SET" button on the alarm history display screen for 2s or longer shows the following detailed information display screen. Note that this is provided for maintenance by the manufacturer. @ (6) Press "UP" or "DOWN" button to move to the next history. 4 - 15 4. OPERATION AND DISPLAY 4.3.5 Drive unit parameter mode The parameter setting of the drive unit is the same as that of the interface unit. Refer to Section 4.2.5. To use the expansion parameters, change the setting of DRU parameter No. 19 (parameter write disable). Refer to section 5.1.1. 4.3.6 Drive unit external input signal display The ON/OFF states of the digital input signals connected to the servo amplifier can be confirmed. (1) Operation Call the display screen shown after power-on. Using the "MODE" button, show the diagnostic screen. @ External input signal display screen (2) Display definition Corresponds to the signals of the seven-segment LED. Slot number TL1 PC CR RES SON LSN LSP Always lit CM2 CM1 CDP Lit: ON Extinguished: OFF The 7-segment LED shown above indicates ON/OFF. Each segment at top indicates the input signal and each segment at bottom indicates the output signal. The following table indicates the signal names. Signal Name List Signal Signal Name Signal Signal Name LSP Forward rotation stroke end PC Proportion control LSN Reverse rotation stroke end TL1 Internal torque limit selection SON Servo-on CM1 Electronic gear 1 selection RES Reset CM2 Electronic gear 2 selection CR Clear CDP Gain switch selection 4 - 16 4. OPERATION AND DISPLAY 4.3.7 Drive unit external output signal display The ON/OFF states of the digital output signals connected to the servo amplifier can be confirmed. (1) Operation Call the display screen shown after power-on. Using the "MODE" button, show the diagnostic screen. @ Press UP button once. @ External output signal display screen (2) Display definition Slot number Always lit WNG BWNG ALM_ ZSP TLC INP OP MBR RD Lit: ON Extinguished: OFF The 7-segment LED shown above indicates ON/OFF. Each segment at top indicates the input signal and each segment at bottom indicates the output signal. The following table indicates the signal names. Signal Name List Signal RD MBR Signal Name Ready Signal TLC Signal Name Limiting torque Electromagnetic brake sequence output ALM_ Trouble OP Encoder Z-phase pulse WNG Warning INP In position ZSP Zero speed BWNG 4 - 17 Battery warning 4. OPERATION AND DISPLAY 4.3.8 Drive unit output signal (DO) forced output POINT This function is usable during test operation only. The output signal can be forced on/off independently of the servo status. This function is used for output signal wiring check, etc. This operation must be performed in the servo off state (SON off). Call the display screen shown after power-on. Using the "MODE" button, show the diagnostic screen. @ Press UP button twice. @ Press SET button for more than 2 seconds. @ ZSP OP WNG BWNG TLC INP MBR ALM_ RD Switch on/off the signal below the lit segment. Always lit Indicates the ON/OFF of the output signal. The correspondences between segments and signals are as in the external output signal display. (Lit: ON, extinguished: OFF) Press the MODE button once to shift the lit LED to the left. @ @ Press UP button once. RD (RD is switched on. -SG conduct.) Press DOWN button once. RD is switched off. Press SET button for more than 2 seconds. 4 - 18 5. PARAMETERS 5. PARAMETERS CAUTION Never adjust or change the parameter values extremely as it will make operation instable. 5.1 DRU parameter list 5.1.1 DRU parameter write inhibit POINT After setting the DRU parameter No. 19 value, switch power off, then on to make that setting valid. In the MELSERVO-J2M servo amplifier, its parameters are classified into the DRU basic parameters (No. 0 to 19), DRU expansion parameters 1 (No. 20 to 49) and DRU expansion parameters 2 (No.50 to 84) according to their safety aspects and frequencies of use. In the factory setting condition, the customer can change the basic parameter values but cannot change the DRU expansion parameter values. When fine adjustment, e.g. gain adjustment, is required, change the DRU parameter No. 19 setting to make the expansion parameters write-enabled. The following table indicates the parameters which are enabled for reference and write by the setting of DRU parameter No. 19. Operation can be performed for the DRU parameters marked . DRU parameter No. 19 setting Operation 0000 Reference (initial value) Write 000A 000B 000C 000E 100B 100C 100E DRU basic parameters DRU expansion parameters 1 DRU expansion parameters 2 No. 0 to 19 Reference No. 19 only Write No. 19 only Reference Write Reference Write Reference Write Reference Write No. 19 only Reference Write No. 19 only Reference Write No. 19 only 5- 1 No. 20 to 49 No. 50 to 84 5. PARAMETERS 5.1.2 Lists POINT For any DRU parameter whose symbol is preceded by *, set the DRU parameter value and switch power off once, then switch it on again to make that DRU parameter setting valid. (1) Item list No. Symbol Basic DRU parameters 0 Name Initial value For manufacturer setting 0000 1 *OP1 Function selection 1 0000 2 ATU Auto tuning 0105 3 CMX 4 CDV Electronic gear numerator (Command pulse multiplying factor numerator) Electronic gear denominator (Command pulse multiplying factor denominator) Unit 1 1 5 INP In-position range 100 pulse 6 PG1 Position loop gain 1 35 rad/s 3 ms 7 PST Position command acceleration/deceleration time constant (Position smoothing) 100 For manufacturer setting 8 9 500 10 1000 11 0 12 0 13 0 14 0 15 16 0 *BPS 17 Alarm history clear 0000 For manufacturer setting 0100 DRU parameter write inhibit 0000 18 19 0000 *BLK 5- 2 Customer setting 5. PARAMETERS No. Symbol Name 20 *OP2 Function selection 2 0000 21 *OP3 Function selection 3 (Command pulse selection) 0000 22 *OP4 Function selection 4 0000 23 FFC Feed forward gain 0 % 24 ZSP Zero speed 50 r/min For manufacturer setting 25 100 27 *ENR Encoder output pulses 4000 28 TL1 Internal torque limit 1 100 For manufacturer setting 29 pulse /rev % 0 30 0 31 0 32 33 Unit 0 26 Expansion DRU parameters 1 Initial value 0 MBR Electromagnetic brake sequence output 100 ms 0.1 34 GD2 Ratio of load inertia moment to servo motor inertia moment 70 35 PG2 Position loop gain 2 35 rad/s 36 VG1 Speed loop gain 1 177 rad/s 37 VG2 Speed loop gain 2 817 rad/s 38 VIC Speed integral compensation 48 ms 39 VDC Speed differential compensation 980 40 41 *DIA 42 *DI1 43 0 For manufacturer setting 0000 Input signal selection 1 0003 For manufacturer setting 0000 44 0000 45 0000 46 0000 47 0000 48 0000 49 0000 5- 3 times Customer setting 5. PARAMETERS No. Symbol 50 51 *OP6 52 Name For manufacturer setting 0000 Function selection 6 0000 For manufacturer setting 0000 Function selection 9 0000 Function selection A 0000 53 Unit 0000 54 *OP9 55 *OPA For manufacturer setting 56 0 57 Expansion DRU parameters 2 Initial value 10 58 NH1 Machine resonance suppression filter 1 59 NH2 Machine resonance suppression filter 2 0000 60 LPF Low-pass filter, adaptive vibration suppression control 0000 61 GD2B Ratio of load inertia moment to Servo motor inertia moment 2 70 62 PG2B Position control gain 2 changing ratio 100 63 VG2B Speed control gain 2 changing ratio 100 % 64 VICB Speed integral compensation changing ratio 100 % 65 *CDP Gain changing selection 0000 66 CDS Gain changing condition 10 (Note) 67 CDT Gain changing time constant 1 ms 68 0000 For manufacturer setting 0 69 CMX2 Command pulse multiplying factor numerator 2 1 70 CMX3 Command pulse multiplying factor numerator 3 1 71 CMX4 Command pulse multiplying factor numerator 4 For manufacturer setting 72 1 300 74 500 75 77 % 200 73 76 0.1 times 800 TL2 Internal torque limit 2 100 100 For manufacturer setting 78 10000 79 10 80 10 81 100 82 100 83 100 84 0 Note. Depends on the parameter No. 65 setting. 5- 4 % Customer setting 5. PARAMETERS (2) Details list Class No. Symbol 0 Name and function For manufacturer setting Initial value Unit Setting range 0000 Do not change this value any means. 1 *OP1 Function selection 1 0000 Used to select the absolute position detection system. Name and 0 0 0 function column. Selection of absolute position detection system (Refer to Chapter 15) 0: Used in incremental system 1: Used in absolute position detection system (Serial communication) 2 ATU Auto tuning 0105 Refer to Used to selection the response level, etc. for execution of auto tuning. Name Refer to Chapter 6. and 0 function 0 column. Auto tuning response level setting Set value Basic DRU parameters Refer to Response level Low response Machine resonance frequency guideline 1 15Hz 2 20Hz 3 25Hz 4 30Hz 5 35Hz 6 45Hz 7 55Hz Middle 8 70Hz response 9 85Hz A 105Hz B 130Hz C 160Hz 200Hz D High E 240Hz response F 300Hz If the machine hunts or generates large gear sound, decrease the set value. To improve performance, e.g. shorten the settling time, increase the set value. Gain adjustment mode selection (For more information, refer to Section 6.1.1.) Set Description Gain adjustment mode value Interpolation mode Fixes position control gain 1 0 (DRU parameter No. 6). Auto tuning mode 1 Ordinary auto tuning. 1 Auto tuning mode 2 Fixes the load inertia moment 2 ratio set in DRU parameter No. 34. Response level setting can be changed. Manual mode 1 3 Simple manual adjustment. Manual mode 2 4 Manual adjustment of all gains. 5- 5 5. PARAMETERS Class No. Symbol 3 CMX Initial value Name and function Electronic gear numerator (Command pulse multiplying factor numerator) Used to set the electronic gear numerator value. Unit Setting range 1 0 1 to 65535 1 1 to 65535 For the setting, refer to Section 5.2.1. Setting "0" automatically sets the resolution of the servo motor connected. For the HC-MFS series, 131072 pulses are set for example. 4 CDV 5 INP Electronic gear denominator (Command pulse multiplying factor denominator) Used to set the electronic gear denominator value. For the setting, refer to Section 5.2.1. In-position range Set the in-position (INP 100 pulse 0 to 10000 35 red/s 4 to 2000 3 ms 0 to 20000 ) output range in the command pulse unit that was used before electronic gear calculation. For example, when you want to set 100 m when the ballscrew is directly coupled, the lead is 10mm, the feedback pulse count is 131072 pulses/rev, and the electronic gear numerator (CMX)/electronic gear denominator (CDV) is 16384/125 (setting in units of 10 m per pulse), set "10" as indicated by the following expression. 100[ m] 10[mm] 6 PG1 10 6 10 3 131072[pulse/rev] 125 16384 10 Position loop gain 1 Used to set the gain of position loop. Increase the gain to improve trackability in response to the position command. Basic DRU parameters When auto turning mode 1,2 is selected, the result of auto turning is automatically used. 7 PST Position command acceleration/deceleration time constant (position smoothing) Used to set the time constant of a low pass filter in response to the position command. You can use DRU parameter No. 55 to choose the primary delay or linear acceleration/deceleration control system. When you choose linear acceleration/deceleration, the setting range is 0 to 10ms. Setting of longer than 10ms is recognized as 10ms. Example: When a command is given from a synchronizing detector, synchronous operation can be started smoothly if started during line operation. Synchronizing detector Start Without time constant setting Servo motor speed Start Servo motor Servo amplifier With time constant setting ON OFF t 5- 6 5. PARAMETERS Class No. Symbol 8 9 10 11 12 13 14 15 16 *BPS Basic DRU parameters value For manufacturer setting Do not change this value any means. 100 500 1000 0 0 0 0 0 Alarm history clear Clear the alarm history. 0000 0 0 17 18 19 *BLK 000A 000B 000C 000E 100B 100C 100E 20 *OP2 Operation Setting range Refer to and 0 function For manufacturer setting Do not change this value any means. DRU parameter write inhibit Used to select the reference and write ranges of the parameters. Operation can be performed for the parameters marked . Set value Unit Name Alarm history clear 0: Invalid 1: Valid When alarm history clear is made valid, the alarm history is cleared at next power-on. After the alarm history is cleared, the setting is automatically made invalid (reset to 0). 0000 (Initial value) Expansion DRU parameters 1 Initial Name and function Basic DRU Expansion DRU parameters parameters 1 No. 0 to No. 19 No. 20 to No. 49 column. 0100 0000 0000 Expansion DRU parameters 2 No. 50 to No. 84 Refer to Name and function column. Reference Write Reference Write Reference Write Reference Write Reference Write Reference Write Reference Write Reference Write No. 19 only No. 19 only No. 19 only No. 19 only No. 19 only Function selection 2 Used to select slight vibration suppression control. 0 0 Slight vibration suppression control Made valid when auto tuning selection is set to "0400" in DRU parameter No. 2. Used to suppress vibration at a stop. 0: Invalid 1: Valid Encoder cable selection 0: 2-wire type (when MR-JCCBL M-L/H is used) 1: 4-wire type (when MR-JC4CBL M-H is used) 5- 7 0000 Refer to Name and function column. 5. PARAMETERS Class No. Symbol 21 *OP3 Name and function Function selection 3 (Command pulse selection) Used to select the input form of the pulse train input signal. (Refer to Section 3.2.3.) Initial value 0000 Unit Setting range Refer to Name and function column. 0 0 Command pulse train input form 0: Forward/reverse rotation pulse train 1: Signed pulse train 2: A/B phase pulse train Pulse train logic selection 0: Positive logic 1: Negative logic 22 *OP4 Function selection 4 Used to select stop processing at the forward rotation stroke end (LSP ) reveres rotation stroke end (LSN ) off. Refer to Name and function column. 0000 0 0 0 Expansion DRU parameters 1 How to make a stop when the forward rotation stroke end (LSP ) reveres rotation stroke end (LSN ) is valid. 0: Sudden stop 1: Slow stop 23 FFC 24 ZSP 25 26 27 *ENR Feed forward gain Set the feed forward gain. When the setting is 100%, the droop pulses during operation at constant speed are nearly zero. However, sudden acceleration/deceleration will increase the overshoot. As a guideline, when the feed forward gain setting is 100%, set 1s or more as the acceleration/deceleration time constant up to the rated speed. Zero speed Used to set the output range of the zero speed (ZSP ). For manufacturer setting Do not change this value any means. Encoder output pulses POINT The MR-J2M-D01 extension IO unit is required to output the encoder pulses (A phase, B phase, Z phase). Used to set the encoder pulses (A-phase, B-phase) output by the servo amplifier. Set the value 4 times greater than the A-phase or B-phase pulses. You can use DRU parameter No. 54 to choose the output pulse setting or output division ratio setting. The number of A/B-phase pulses actually output is 1/4 times greater than the preset number of pulses. The maximum output frequency is 1.3Mpps (after multiplication by 4). Use this parameter within this range. For output pulse designation Set " 0 " (initial value) in DRU parameter No. 54. Set the number of pulses per servo motor revolution. Output pulse set value [pulses/rev] At the setting of 5600, for example, the actually output A/B-phase pulses are as indicated below: 5600 A B-phase output pulses 1400[pulse/rev] 4 For output division ratio setting " in DRU parameter No. 54. Set " 1 The number of pulses per servo motor revolution is divided by the set value. Resolution per servo motor revolution Output pulse [pulses/rev] Set value At the setting of 8, for example, the actually output A/B-phase pulses are as indicated below: 131072 1 A B-phase output pulses 4096[pulse/rev] 8 4 5- 8 0 % 0 to 100 50 r/min 0 to 10000 pulse/ rev 1 to 65535 0 100 4000 5. PARAMETERS Class No. Symbol Expansion DRU parameters 1 28 TL1 29 30 31 32 33 MBR 34 GD2 35 PG2 36 VG1 37 VG2 38 VIC 39 VDC 40 41 42 *DI1 Name and function Internal torque limit 1 Set this parameter to limit servo motor torque on the assumption that the maximum torque is 100[%]. When 0 is set, torque is not produced. When torque is output in analog monitor, this set value is the maximum output voltage ( 4V). (Refer to Section 3.3.5 (2)) For manufacturer setting Do not change this value any means. Electromagnetic brake sequence output Used to set the delay time (Tb) between electronic brake interlock (MBR ) and the base drive circuit is shut-off. Ratio of load inertia moment to servo motor inertia moment Used to set the ratio of the load inertia moment to the servo motor shaft inertia moment. When auto tuning mode 1 and interpolation mode is selected, the result of auto tuning is automatically used. (Refer to section 6.2.1) In this case, it varies between 0 and 1000. Position loop gain 2 Used to set the gain of the position loop. Set this parameter to increase the position response to level load disturbance. Higher setting increases the response level but is liable to generate vibration and/or noise. When auto tuning mode 1 2 and interpolation mode is selected, the result of auto tuning is automatically used. Speed loop gain 1 Normally this parameter setting need not be changed. Higher setting increases the response level but is liable to generate vibration and/or noise. When auto tuning mode 1 2, manual mode and interpolation mode is selected, the result of auto tuning is automatically used. Speed loop gain 2 Set this parameter when vibration occurs on machines of low rigidity or large backlash. Higher setting increases the response level but is liable to generate vibration and/or noise. When auto tuning mode 1 2 and interpolation mode is selected, the result of auto tuning is automatically used. Speed integral compensation Used to set the integral time constant of the speed loop. Lower setting increases the response level but is liable to generate vibration and/or noise. When auto tuning mode 1 2 and interpolation mode is selected, the result of auto tuning is automatically used. Speed differential compensation Used to set the differential compensation. Made valid when the proportion control (PC ) is switched on. For manufacturer setting Do not change this value any means. Input signal selection 1 Used to set the clear (CR ). 0 0 Initial value Unit 100 % Setting range 0 to 100 0 0 0 0 100 ms 0 to 1000 0 to 3000 70 0.1 times 35 rad/s 1 to 1000 177 rad/s 20 to 8000 817 rad/s 20 to 20000 48 ms 1 to 1000 980 0 0000 0003 0 to 1000 Refer to Name and 3 function column. Clear (CR ) selection 0: Droop pulses are cleared on the leading edge. 1: While on, droop pulses are always cleared. 5- 9 5. PARAMETERS Class No. Symbol Initial value Name and function 43 For manufacturer setting 0000 44 Do not change this value any means. 0000 45 0000 46 0000 47 0000 48 0000 49 0000 50 0000 51 *OP6 Function selection 6 0000 Unit Setting range Refer to Used to select the operation to be performed when the reset (RES ) Name switches on. and 0 function 0 0 column. Expansion DRU parameters 2 Operation to be performed when the reset (RES ) switches on 0: Base drive circuit is shut-off 1: Base drive circuit is not shut-off 52 For manufacturer setting 0000 53 Do not change this value any means. 0000 Function selection 9 0000 54 *OP9 Refer to Use to select the command pulse rotation direction, encoder output pulse Name direction and encoder pulse output setting. and function 0 column. Servo motor rotation direction changing Changes the servo motor rotation direction for the input pulse train. Set value Servo motor rotation direction At forward rotation At reverse rotation pulse input (Note) pulse input (Note) 0 CCW CW 1 CW CCW Note. Refer to Section 3.1.5 . Encoder pulse output phase changing Changes the phases of A B-phase encoder pulses output . Servo motor rotation direction Set value 0 1 CCW CW A phase A phase B phase B phase A phase A phase B phase B phase Encoder output pulse setting selection (refer to DRU parameter No. 27) 0: Output pulse designation 1: Division ratio setting 5 - 10 5. PARAMETERS Class No. Symbol 55 *OPA Initial value Name and function Function selection A 0000 Unit Setting range Refer to Used to select the position command acceleration/deceleration time Name constant (DRU parameter No. 7) control system. and 0 0 function 0 column. Position command acceleration/deceleration time constant control 0: Primary delay 1: Linear acceleration/deceleration 56 For manufacturer setting 0 57 Do not change this value any means. 10 58 NH1 Machine resonance suppression filter 1 0000 Refer to Used to selection the machine resonance suppression filter. Name (Refer to Section 7.2.) and function 0 column. Expansion DRU parameters 2 Notch frequency selection Set "00" when you have set adaptive vibration suppression control to be "valid" or "held" (DRU parameter No. 60: 1 or 2 ). Setting Frequency Setting Frequency Setting Frequency Setting Frequency value value value value 00 Invalid 08 562.5 10 281.3 18 187.5 01 4500 09 500 11 264.7 19 180 02 2250 0A 450 12 250 1A 173.1 03 1500 0B 409.1 13 236.8 1B 166.7 04 1125 0C 375 14 225 1C 160.1 05 900 0D 346.2 15 214.3 1D 155.2 06 750 0E 321.4 16 204.5 1E 150 07 642.9 0F 300 17 195.7 1F 145.2 Notch depth selection 59 NH2 Setting value Depth Gain 0 Deep 40dB 1 to 14dB 2 3 Shallow 8dB 4dB Machine resonance suppression filter 2 Used to set the machine resonance suppression filter. 0000 Refer to Name and 0 function column. Notch frequency Same setting as in DRU parameter No. 58 However, you need not set "00" if you have set adaptive vibration suppression control to be "valid" or "held". Notch depth Same setting as in DRU parameter No. 58 5 - 11 5. PARAMETERS Class No. Symbol 60 LPF Name and function Low-pass filter/adaptive vibration suppression control Used to selection the low-pass filter and adaptive vibration suppression Initial value 0000 Unit Setting range Refer to Name and function column. control. (Refer to Chapter 7.) 0 Low-pass filter selection 0: Valid (Automatic adjustment) 1: Invalid VG2 setting 10 When you choose "valid", 2 (1 GD2 setting 0.1) [Hz] bandwidth filter is set automatically. Expansion DRU parameters 2 Adaptive vibration suppression control selection Choosing "valid" or "held" in adaptive vibration suppression control selection makes the machine resonance control filter 1 (DRU parameter No. 58) invalid. 0: Invalid 1: Valid Machine resonance frequency is always detected and the filter is generated in response to resonance to suppress machine vibration. 2: Held The characteristics of the filter generated so far are held, and detection of machine resonance is stopped. Adaptive vibration suppression control sensitivity selection Used to set the sensitivity of machine resonance detection. 0: Normal 1: Large sensitivity 61 GD2B Ratio of load inertia moment to servo motor inertia moment 2 Used to set the ratio of load inertia moment to servo motor inertia moment 70 0.1 times 0 to 3000 100 % 10 to 200 100 % 10 to 200 % 50 to 1000 when gain changing is valid. 62 PG2B Made valid when auto tuning is invalid. Position control gain 2 changing ratio Used to set the ratio of changing the position control gain 2 when gain changing is valid. 63 VG2B Made valid when auto tuning is invalid. Speed control gain 2 changing ratio Used to set the ratio of changing the speed control gain 2 when gain changing is valid. 64 VICB Made valid when auto tuning is invalid. Speed integral compensation changing ratio Used to set the ratio of changing the speed integral compensation when 100 65 *CDP gain changing is valid. Made valid when auto tuning is invalid. Gain changing selection Used to select the gain changing condition. (Refer to Section 7.5.) 0000 0 0 0 Gain changing selection Gains are changed in accordance with the settings of DRU parameters No. 61 to 64 under any of the following conditions: 0: Invalid 1: Gain changing (CDP ) is ON 2: Command frequency is equal to higher than DRU parameter No. 66 setting 3: Droop pulse value is equal to higher than DRU parameter No. 66 setting 4: Servo motor speed is equal to higher than DRU parameter No. 66 setting 5 - 12 Refer to Name and function column. 5. PARAMETERS Class No. Symbol 66 CDS Name and function Initial value 10 Gain changing condition Unit Setting range kpps 10 Used to set the value of gain changing condition (command frequency, droop pulse to pulses, servo motor speed) selected in parameter No. 65 (Gain changing r/min 9999 selection). The set value unit changes with the changing condition item. (Refer to Section 7.5.) 67 CDT 1 Gain changing time constant ms 0 to Used to set the time constant at which the gains will change in response to 100 the conditions set in parameters No. 65 and 66. (Refer to Section 7.5.) 68 For manufacturer setting 0 Do not change this value any means. 69 CMX2 Command pulse multiplying factor numerator 2 1 0 1 Used to set the multiplier for the command pulse. to Expansion DRU parameters 2 Setting "0" automatically sets the connected motor resolution. 70 CMX3 Command pulse multiplying factor numerator 3 65535 1 0 1 Used to set the multiplier for the command pulse. to Setting "0" automatically sets the connected motor resolution. 71 CMX4 Command pulse multiplying factor numerator 4 65535 1 0 1 Used to set the multiplier for the command pulse. to Setting "0" automatically sets the connected motor resolution. 65535 72 For manufacturer setting 200 73 Do not change this value any means. 300 74 500 800 75 76 TL2 100 Internal torque limit 2 When 0 is set, torque is not produced. When torque is output in analog monitor, this set value is the maximum output voltage ( 4V). (Refer to Section 3.3.5 (2)) For manufacturer setting 78 Do not change this value any means. 0 100 maximum torque is 100[%]. 77 % to Set this parameter to limit servo motor torque on the assumption that the 100 10000 79 10 80 10 81 100 82 100 83 100 84 0 5 - 13 5. PARAMETERS 5.2 Interface unit 5.2.1 IFU parameter write inhibit POINT Use the unit operation section pushbutton switches or MR Configurator (servo configuration software) to set the IFU parameters of the interface unit. Use the unit pushbutton switches or MR Configurator (servo configuration software) to set the interface unit parameters. When assigning the devices, change the setting to "000E". The following table indicates the IFU parameters which are made valid for reference and write by setting the IFU parameter No. 19. Setting 0000 (initial value) 000A 000B 000C 000E 100B 100C Setting operation Expansion IFU basic parameter IFU parameter I/O assignment Reference Write Reference IFU parameter No. 19 Write IFU parameter No. 19 Reference Write Reference Write Reference Write Reference Write IFU parameter No. 19 Reference Write IFU parameter No. 19 5.2.2 Lists POINT For any parameter whose symbol is preceded by *, set the IFU parameter value and switch power off once, then switch it on again to make that parameter setting valid. 5 - 14 5. PARAMETERS (1) Item list Classifi- Expansion IFU parameter Basic IFU parameters cation No. Symbol 0 *BPS Name Serial communication function selection, alarm history clear Unit 0000 1 SIC 2 *OP1 Function selection 1 0000 3 MD1 Analog monitor 1 output 0000 4 MD2 Analog monitor 2 output 0000 5 MD3 Analog monitor 3 output 0000 6 MO1 Analog monitor 1 offset 0 mV 7 MO2 Analog monitor 2 offset 0 mV 8 MO3 Analog monitor 3 offset 0 mV 9 *OP2 Function selection 2 10 *ISN Interface unit serial communication station number selection 0 11 *SL1 1 slot serial communication station number selection 0 12 *SL2 2 slot serial communication station number selection 1 13 *SL3 3 slot serial communication station number selection 2 14 *SL4 4 slot serial communication station number selection 3 15 *SL5 5 slot serial communication station number selection 4 16 *SL6 6 slot serial communication station number selection 5 17 *SL7 7 slot serial communication station number selection 6 18 *SL8 8 slot serial communication station number selection 19 *BLK IFU parameter write inhibit 20 SIC 21 Regenerative brake option selection Initial Value 0 0020 7 0000 Serial communication time-out selection 0 For manufacturer setting 0 22 0 23 0 24 0 25 0 26 0 27 0 28 0 29 0 5 - 15 s Customer setting 5. PARAMETERS (2) Details list Classification No. Symbol 0 *BPS Name and Function Serial communication function selection, alarm history clear Initial Value 0000 Unit Setting Range Refer to Used to select the serial communication baudrate function selection, name select various communication conditions, and clear the alarm and history. function column. Serial communication baudrate selection 0: 9600 [bps] 1: 19200[bps] 2: 38400[bps] 3: 57600[bps] Basic IFU parameters Alarm history clear 0: Invalid 1: valid When alarm history clear is made valid, the alarm history is cleared at next power-on. After the alarm history is cleared, the setting is automatically made invalid (reset to 0). Serial communication I/F selection 0: RS-232C 1: RS-422 Communication response delay time selection 0: Invalid 1: valid, reply sent after time of 888 s or more 1 *REG Regenerative brake option selection 0000 Used to select the regenerative brake option. Refer to Name and function 0 0 column. Selection of regenerative brake option 00: Not used 01: Spare (do not set) 02: MR-RB032 05: MR-RB14 06: MR-RB34 07: MR-RB54 2 *OP1 Function selection 1 0000 Used to select the protocol of serial communication. 0 0 Refer to name and 0 function column. Protocol checksum selection 0: Yes (checksum added) 1: No (checksum not added) 5 - 16 5. PARAMETERS Classification No. Symbol 3 MD1 Name and Function Analog monitor 1 output Initial Value 0000 Choose the signal to be output to analog monitor 1. Unit Setting Range Refer to name and 0 0 function column. Basic IFU parameters Analog monitor 1 selection 0: Servo motor speed ( 4V/max. Servo motor speed) 1: Torque ( 4V/max. Torque) 2: Servo motor speed ( 4V/max. Servo motor speed) 3: Torque ( 4V/max. Torque) 4: Current command ( 4V/max. Current command) 5: Command pulse frequency( 4V/500kpps) 6: Droop pulses ( 4V/128pulse) 7: Droop pulses ( 4V/2048pulse) 8: Droop pulses ( 4V/8192pulse) 9: Droop pulses ( 4V/32768pulse) A: Droop pulses ( 4V/131072pulse) B: Bus voltage ( 4V/400V) C: In position ( 4V/ON) D: Ready ( 4V/ON) E: Trouble ( 4V/ON) Slot number of analog monitor 1 Choose the slot number output to analog monitor 1. Slot number set value. Selecting "0" disables output. 4 *MD2 Analog monitor 2 output 0000 Choose the signal to be output to analog monitor 2. Refer to name and 0 0 function column. Analog monitor 2 selection 0: Servo motor speed ( 4V/max. Servo motor speed) 1: Torque ( 4V/max. Torque) 2: Servo motor speed ( 4V/max. Servo motor speed) 3: Torque ( 4V/max. Torque) 4: Current command ( 4V/max. Current command) 5: Command pulse frequency ( 4V/500kpps) 6: Droop pulses ( 4V/128pulse) 7: Droop pulses ( 4V/2048pulse) 8: Droop pulses ( 4V/8192pulse) 9: Droop pulses ( 4V/32768pulse) A: Droop pulses ( 4V/131072pulse) B: Bus voltage ( 4V/400V) C: In position ( 4V/ON) D: Ready ( 4V/ON) E: Trouble ( 4V/ON) Slot number of analog monitor 2 Choose the slot number output to analog monitor 2. Slot number set value. Selecting "0" disables output. 5 - 17 5. PARAMETERS Classification No. Symbol 5 *MD3 Name and Function Analog monitor 3 output Initial Value Unit 0000 Setting Range Refer to Choose the signal to be output to analog monitor 3. name and 0 0 function Basic IFU parameters column. Analog monitor 3 selection 0: Servo motor speed ( 4V/max. Servo motor speed) 1: Torque ( 4V/max. Torque) 2: Servo motor speed ( 4V/max. Servo motor speed) 3: Torque ( 4V/max. Torque) 4: Current command ( 4V/max. Current command) 5: Command pulse frequency ( 4V/500kpps) 6: Droop pulses ( 4V/128pulse) 7: Droop pulses ( 4V/2048pulse) 8: Droop pulses ( 4V/8192pulse) 9: Droop pulses ( 4V/32768pulse) A: Droop pulses ( 4V/131072pulse) B: Bus voltage ( 4V/400V) C: In position ( 4V/ON) D: Ready ( 4V/ON) E: Trouble ( 4V/ON) Slot number of analog monitor 3 Choose the slot number output to analog monitor 3. Slot number set value. Selecting "0" disables output. 6 MO1 Analog monitor 1 offset Used to set the offset voltage of the analog monitor 1 (MO1). 0 mV 7 MO2 Analog monitor 2 offset Used to set the offset voltage of the analog monitor 2 (MO2). 0 mV 8 MO3 Analog monitor 3 offset Used to set the offset voltage of the analog monitor 3 (MO2). 0 mV 9 *OP2 Function selection 2 0200 Used to select the input signal filter. 999 to 999 999 to 999 999 to 999 Refer to name and 0 0 2 0 function Input signal filter 0 : None 1 : 1.777ms 2 : 3.555ms 5 - 18 column. 5. PARAMETERS Classification No. Symbol 10 *INS Name and Function Interface unit serial communication Initial Value 0 Unit Setting Range 0 Choose the serial communication station number of the interface to unit. 31 When making selection, avoid setting the station number used by any other unit. 11 *SL1 1 slot serial communication station number selection 1 0 Choose the station number of the drive unit connected to the first to slot of the base unit. 31 When making selection, avoid setting the station number used by any other unit. Basic IFU parameters 12 *SL2 2 slot serial communication station number selection 2 0 Choose the station number of the drive unit connected to the second to slot of the base unit. 31 When making selection, avoid setting the station number used by any other unit. 13 *SL3 3 slot serial communication station number selection 3 0 Choose the station number of the drive unit connected to the third to slot of the base unit. 31 When making selection, avoid setting the station number used by any other unit. 14 *SL4 4 slot serial communication station number selection 4 0 Choose the station number of the drive unit connected to the fourth to slot of the base unit. 31 When making selection, avoid setting the station number used by any other unit. 15 *SL5 5 slot serial communication station number selection 5 0 Choose the station number of the drive unit connected to the fifth to slot of the base unit. 31 When making selection, avoid setting the station number used by any other unit. 5 - 19 5. PARAMETERS Classification No. Symbol 16 *SL6 Initial Name and Function Value Unit Setting Range 6 6 slot serial communication station number selection 0 Choose the station number of the drive unit connected to the sixth to slot of the base unit. 31 When making selection, avoid setting the station number used by any other unit. 17 *SL7 7 7 slot serial communication station number selection 0 Choose the station number of the drive unit connected to the seventh to slot of the base unit. 31 When making selection, avoid setting the station number used by any other unit. 18 *SL8 8 8 slot serial communication station number selection 0 Choose the station number of the drive unit connected to the eighth to slot of the base unit. 31 Basic IFU parameters When making selection, avoid setting the station number used by any other unit. 19 *BLK Parameter write inhibit 0000 Setting 0000 (initial value) 000A 000B 000C 000E 100B 100C 20 SIC Setting operation IFU basic parameter Expansion IFU parameter name and I/O assignment function column. Reference Write Reference IFU parameter No. 19 Write IFU parameter No. 19 Reference Write Reference Write Reference Write Reference Write IFU parameter No. 19 Reference Write IFU parameter No. 19 Serial communication time-out selection 0 For manufacturer setting 22 Do not change this value any means. 0 23 24 25 26 27 28 29 5 - 20 0 60 Setting "0" disables time-out checking. 21 s to Set the time-out period of the communication protocol in the [s] unit. Expansion IFU parameter Refer to Used to select reference and write ranges of the parameters. 5. PARAMETERS 5.3 Detailed description 5.3.1 Electronic gear CAUTION Wrong setting can lead to unexpected fast rotation, causing injury. POINT 1 CMX 500. 50 CDV If the set value is outside this range, noise may be generated during acceleration/ deceleration or operation may not be performed at the preset speed and/or acceleration/deceleration time constants. The following specification symbols are required to calculate the electronic gear. The guideline of the electronic gear setting range is (1) Concept of electronic gear The machine can be moved at any multiplication factor to input pulses. CMX CDV Input pulse train Motor DRU parameter No.3 DRU parameter No.4 Deviation counter CMX CDV Feedback pulse Electronic gear Encoder The following setting examples are used to explain how to calculate the electronic gear: POINT The following specification symbols are required to calculate the electronic gear Pb : Ballscrew lead [mm] n : Reduction ratio Pt : Servo motor resolution [pulses/rev] 0: Travel per command pulse [mm/pulse] S : Travel per servo motor revolution [mm/rev] : Angle per pulse [ /pulse] : Angle per revolution [ /rev] (a) For motion in increments of 10 m per pulse n n NL/NM 1/2 NL Machine specifications Ballscrew lead Pb 10 [mm] Reduction ratio: n 1/2 Servo motor resolution: Pt 131072 [pulses/rev] CMX CDV 0 Pt S 0 Pt n Pb 10 10 3 131072 1/2 10 Hence, set 32768 to CMX and 125 to CDV. 5 - 21 NM Servo motor 131072 [pulse/rev] 262144 1000 32768 125 Pb 10[mm] 5. PARAMETERS (b) Conveyor setting example For rotation in increments of 0.01 per pulse Servo motor 131072 [pulse/rev] Machine specifications Table Table : 360 /rev Reduction ratio: n 4/64 Servo motor resolution: Pt CMX CDV Pt 0.01 131072 [pulses/rev] 131072 4/64 360 Timing belt : 4/64 65536 ................................................................................. (5.1) 1125 Since CMX is not within the setting range in this status, it must be reduced to the lowest term. When CMX has been reduced to a value within the setting range, round off the value to the nearest unit. 26214.4 26214 CMX 65536 1125 450 450 CDV Hence, set 26214 to CMX and 450 to CDV. POINT When “0” is set to parameter No.3 (CMX), CMX is automatically set to the servo motor resolution. Therefore, in the case of Expression (5.1), setting 0 to CMX and 2250 to CDX concludes in the following expression: CMX/CDV=131072/2250, and electric gear can be set without the necessity to reduce the fraction to the lowest term. For unlimited one-way rotation, e.g. an index table, indexing positions will be missed due to cumulative error produced by rounding off. For example, entering a command of 36000 pulses in the above example causes the table to rotate only: 26214 1 4 360 359.995 450 131072 64 Therefore, indexing cannot be done in the same position on the table. 36000 (2) Instructions for reduction The calculated value before reduction must be as near as possible to the calculated value after reduction. In the case of (1), (b) in this section, an error will be smaller if reduction is made to provide no fraction for CDV. The fraction of Expression (5.1) before reduction is calculated as follows. CMX CDV 65536 1125 58.25422 ................................................................................................................... (5.2) The result of reduction to provide no fraction for CMX is as follows. CMX CDV 65536 1125 32768 562.5 32768 563 58.20249 .................................................................................... (5.3) The result of reduction to provide no fraction for CDV is as follows. CMX CDV 65536 1125 26214.4 450 26214 450 58.25333 .................................................................................. (5.4) As a result, it is understood that the value nearer to the calculation result of Expression (5.2) is the result of Expression (5.4). Accordingly, the set values of (1), (b) in this section are CMX 26214, CDV 450. 5 - 22 5. PARAMETERS (3) Setting for use of AD75P The AD75P also has the following electronic gear parameters. Normally, the servo amplifier side electronic gear must also be set due to the restriction on the command pulse frequency (differential 400kpulse/s, open collector 200kpulse/s). AP: Number of pulses per motor revolution AL: Moving distance per motor revolution AM: Unit scale factor AP75P Command value Servo amplifier Control unit AL AP AM Electronic gear Command pulse CMX CDV Electronic gear Deviation counter Feedback pulse Servo motor The resolution of the servo motor is 131072 pulses/rev. For example, the pulse command needed to rotate the servo motor is as follows Servo motor speed [r/min] Required pulse command 2000 131072 2000/60 4369066 pulse/s 3000 131072 3000/60 6553600 pulse/s For the AD75P, the maximum value of the pulse command that may be output is 200kpulse/s in the open collector system or 400kpulse/s in the differential line driver system. Hence, either of the servo motor speeds exceeds the maximum output pulse command of the AD75P. Use the electronic gear of the servo amplifier to run the servo motor under the maximum output pulse command of the AD75P. 5 - 23 5. PARAMETERS To rotate the servo motor at 3000r/min in the open collector system (200kpulse/s), set the electronic gear as follows f CMX CDV f : N0 : Pt : N0 60 pt Input pulses [pulse/s] Servo motor speed [r/min] Servo motor resolution [pulse/rev] 200 103 CMX CDV CMX CDV 3000 131072 60 3000 60 131072 200 3 3000 131072 60 200000 4096 125 The following table indicates the electronic gear setting example (ballscrew lead AD75P is used in this way. Rated servo motor speed 3000r/min Input system Servo amplifier Max. input pulse frequency [kpulse/s] Differential Open Differential collector line driver collector line driver 200 500 200 500 131072 Electronic gear (CMX/CDV) 2048/125 8192/375 4096/375 200 400 200 400 4000 8000 6000 12000 AP 1 1 1 1 AL 1 1 1 1 AM 1 1 1 1 Number of pulses per servo motor revolution as viewed from AD75P[pulse/rev] Minimum command unit 1pulse Electronic gear Minimum command unit 131072 4096/125 Command pulse frequency [kpulse/s] (Note) 0.1 m 2000r/min Open Feedback pulse/revolution [pulse/rev] AD75P 10mm) when the AP 4000 8000 6000 12000 AL 1000.0 [ m] 1000.0 [ m] 1000.0 [ m] 1000.0 [ m] AM 10 10 10 10 Note. Command pulse frequency at rated speed 5 - 24 5. PARAMETERS 5.3.2 Analog monitor The servo status can be output to 3 channels in terms of voltage. Using an ammeter enables monitoring the servo status. (1) Setting Change the following digits of IFU parameter No.3 to 5: IFU parameter No. 3 Analog monitor 1 selection (Signal output to across MO1-LG) Slot number of analog monitor 1 IFU parameter No. 4 Analog monitor 2 selection (Signal output to across MO2-LG) Slot number of analog monitor 2 IFU parameter No. 5 Analog monitor 3 selection (Signal output to across MO3-LG) Slot number of analog monitor 3 IFU parameters No.6 to 8 can be used to set the offset voltages to the analog output voltages. The setting range is between 999 and 999mV. IFU parameter No. 6 7 8 Description Setting range [mV] Used to set the offset voltage for the analog monitor 1. Used to set the offset voltage for the analog monitor 2. Used to set the offset voltage for the analog monitor 3. 999 to 999 (2) Settings The three channels are all factory-set to output servo motor speeds. By changing the IFU parameter No. 3 to 5 values, you can change the data as shown in the following tale. Refer to (3) for measurement points. Setting 0 Output item Data Servo motor speed Setting 1 CCW direction Data 4[V] 4[V] Max. speed Driving in CCW direction Max. torque 0 CW direction Output item Torque (Note) 0 Max. torque Max. speed 4[V] Driving in CW direction 5 - 25 4[V] 5. PARAMETERS Setting 2 Output item Servo motor speed Data CW direction 4[V] Setting 9 CCW direction Output item Data Droop pulses 4[V] ( 4V/32768pulse) CCW direction 32768[pulse] 0 Max. speed 0 Max. speed 4[V] CW direction 3 Torque (Note) A Driving in CW direction 4[V] Driving in CCW direction Droop pulses 4[V] ( 4V/131072pulse) 32768[pulse] CCW direction 131072[pulse] 0 Max. torque 0 Max. torque CW direction 4 Current command Max. current command CCW direction 4[V] B 131072[pulse] 4[V] Bus voltage 4[V] 0 Max. current command 0 CW direction 5 Command pulse frequency 400[V] 4[V] CCW direction C 4[V] In-position 4[V] 500[kpps] 0 500[kpps] OFF ON OFF ON 0 4[V] CW direction 6 Droop pulses ( 4V/128pulse) 4[V] CCW direction D Ready 4[V] 128[pulse] 0 128[pulse] 0 4[V] CW direction 7 Droop pulses ( 4V/2048pulse) 4[V] CCW direction E Failure 4[V] Alarm provided 2048[pulse] 0 2048[pulse] Alarm not provided 0 4[V] CW direction 8 Droop pulses ( 4V/8192pulse) 4[V] CCW direction 8192[pulse] 0 CW direction 8192[pulse] 4[V] Note. 4V is outputted at the maximum torque. However, when DRU parameter No. 28 76 are set to limit torque, 4V is outputted at the torque highly limited. 5 - 26 Command pulse PP,NP Command pulse frequency 5 - 27 Cumulative feedback pulse CDV CMX Electronic gear Cumulative command pulse Position control Load inertia moment ratio Auto tuning section Droop pulse Speed control Differential Current control Low Within onerevolution position High Current position calculation Speed feedback Servo motor speed Instantaneously occurring torque ABS counter Absolute position encoder M Servo motor Within onerevolution position ABS counter PWM Peak hold Effective value calculation Bus voltage Peak load ratio Effective load torque 5. PARAMETERS (3) Analog monitor block diagram 5. PARAMETERS 5.3.3 Using forward rotation stroke end (LSP ) reverse rotation stroke end (LSN ) to change the stopping pattern The stopping pattern is factory-set to make a sudden stop when the forward rotation stroke end (LSP ) reverse rotation stroke end (LSN ) is made valid. A slow stop can be made by changing the DRU parameter No. 22 (Function selection 2) value. DRU parameter No.22 Setting 0 (initial value) Stopping method Sudden stop Motor stops with droop pulses cleared. Slow stop 1 The motor is decelerated to a stop in accordance with the DRU parameter No. 7 value. (Position command acceleration/deceleration time constant) 5.3.4 Alarm history clear The servo amplifier stores one current alarm and five past alarms from when its power is switched on first. To control alarms which will occur during operation, clear the alarm history using DRU parameter No.16 or IFU parameter No.0 before starting operation. These parameters are made valid when you switch power off, then on after setting their values. DRU parameter No. 16 and IFU parameter No. 0 return to " 0 " automatically when the alarm history is cleared. DRU parameter No.16 Alarm history clear 0: Invalid 1: Valid IFU parameter No.0 Alarm history clear 0: Invalid 1: Valid 5 - 28 5. PARAMETERS 5.3.5 Position smoothing By setting the position command acceleration/deceleration time constant (DRU parameter No.7), you can run the servo motor smoothly in response to a sudden position command. The following diagrams show the operation patterns of the servo motor in response to a position command when you have set the position command acceleration/deceleration time constant. Choose the primary delay or linear acceleration/deceleration in DRU parameter No. 55 according to the machine used. (1) For step input Command : Input position command t t : Position command after filtering for primary delay : Position command after filtering for linear acceleration/deceleration : Position command acceleration/ deceleration time constant (DRU parameter No. 7) t Time (3t) (2) For trapezoidal input (3t) t : Input position command Command : Position command after filtering for linear acceleration/deceleration : Position command after filtering for primary delay t t (3t) 5 - 29 Time : Position command acceleration/ deceleration time constant (DRU parameter No. 7) 5. PARAMETERS MEMO 5 - 30 6. GENERAL GAIN ADJUSTMENT 6. GENERAL GAIN ADJUSTMENT 6.1 Different adjustment methods 6.1.1 Adjustment on a MELSERVO-J2M The gain adjustment in this section can be made on the MELSERVO-J2M. For gain adjustment, first execute auto tuning mode 1. If you are not satisfied with the results, execute auto tuning mode 2, manual mode 1 and manual mode 2 in this order. (1) Gain adjustment mode explanation Gain adjustment DRU parameter Estimation of load Automatically set Manually set mode No. 2 setting inertia moment ratio DRU parameters DRU parameters Auto tuning mode 1 010 Always estimated (initial value) PG1 (DRU parameter No. 6) Response level setting of DRU GD2 (DRU parameter No. 34) parameter No. 2 PG2 (DRU parameter No. 35) VG1 (DRU parameter No. 36) VG2 (DRU parameter No. 37) VIC (DRU parameter No. 38) Auto tuning mode 2 020 Fixed to parameter PG1 (DRU parameter No. 6) GD2 (DRU parameter No. 34) No. 34 value PG2 (DRU parameter No. 35) Response level setting of VG1 (DRU parameter No. 36) parameter No. 2 VG2 (DRU parameter No. 37) VIC (DRU parameter No. 38) Manual mode 1 030 PG2 (DRU parameter No. 35) PG1 (DRU parameter No. 6) VG1 (DRU parameter No. 36) GD2 (DRU parameter No. 34) VG2 (DRU parameter No. 37) VIC (DRU parameter No. 38) Manual mode 2 PG1 (DRU parameter No. 6) 040 GD2 (DRU parameter No. 34) PG2 (DRU parameter No. 35) VG1 (DRU parameter No. 36) VG2 (DRU parameter No. 37) VIC (DRU parameter No. 38) Interpolation mode 000 Always estimated GD2 (DRU parameter No. 34) PG1 (DRU parameter No. 6) PG2 (DRU parameter No. 35) VG1 (DRU parameter No. 36) VG2 (DRU parameter No. 37) VIC (DRU parameter No. 38) 6- 1 6. GENERAL GAIN ADJUSTMENT (2) Adjustment sequence and mode usage START Usage Interpolation made for 2 or more axes? Used when you want to Yes match the position gain 1 Interpolation mode No (PG1) between 2 or more axes. Normally not used for Operation Allows adjustment by Auto tuning mode 1 merely changing the response level setting. Operation Yes other purposes. First use this mode to make No OK? adjustment. OK? Used when the conditions of auto tuning mode 1 are not No Yes Auto tuning mode 2 met and the load inertia moment ratio could not be estimated properly, for Operation Yes example. OK? This mode permits No adjustment easily with three gains if you were not Manual mode 1 satisfied with auto tuning results. Operation Yes OK? You can adjust all gains No manually when you want to Manual mode 2 do fast settling or the like. END 6.1.2 Adjustment using MR Configurator (servo configuration software) This section gives the functions and adjustment that may be performed by using the servo amplifier with the MR Configurator (servo configuration software) which operates on a personal computer. Function Description Adjustment Machine analyzer With the machine and servo motor coupled, the characteristic of the mechanical system can be measured by giving a random vibration command from the personal computer to the servo and measuring the machine response. Gain search Executing gain search under to-and-fro positioning command measures settling characteristic while simultaneously changing gains, and automatically searches for gains which make settling time shortest. Response at positioning settling of a machine can be simulated from machine analyzer results on personal computer. Machine simulation 6- 2 You can grasp the machine resonance frequency and determine the notch frequency of the machine resonance suppression filter. You can automatically set the optimum gains in response to the machine characteristic. This simple adjustment is suitable for a machine which has large machine resonance and does not require much settling time. You can automatically set gains which make positioning settling time shortest. You can optimize gain adjustment and command pattern on personal computer. 6. GENERAL GAIN ADJUSTMENT 6.2 Auto tuning 6.2.1 Auto tuning mode The MELSERVO-J2M has a real-time auto tuning function which estimates the machine characteristic (load inertia moment ratio) in real time and automatically sets the optimum gains according to that value. This function permits ease of gain adjustment of the MELSERVO-J2M. (1) Auto tuning mode 1 The MELSERVO-J2M is factory-set to the auto tuning mode 1. In this mode, the load inertia moment ratio of a machine is always estimated to set the optimum gains automatically. The following DRU parameters are automatically adjusted in the auto tuning mode 1. DRU parameter No. Abbreviation 6 PG1 Position control gain 1 Name 34 GD2 Ratio of load inertia moment to servo motor inertia moment 35 PG2 Position control gain 2 36 VG1 Speed control gain 1 37 VG2 Speed control gain 2 38 VIC Speed integral compensation POINT The auto tuning mode 1 may not be performed properly if the following conditions are not satisfied. Time to reach 2000r/min is the acceleration/deceleration time constant of 5s or less. Speed is 150r/min or higher. The ratio of load inertia moment to servo motor is not more than 100 times. The acceleration/deceleration torque is 10% or more of the rated torque. Under operating conditions which will impose sudden disturbance torque during acceleration/deceleration or on a machine which is extremely loose, auto tuning may not function properly, either. In such cases, use the auto tuning mode 2 or manual mode 1 2 to make gain adjustment. (2) Auto tuning mode 2 Use the auto tuning mode 2 when proper gain adjustment cannot be made by auto tuning mode 1. Since the load inertia moment ratio is not estimated in this mode, set the value of a correct load inertia moment ratio (DRU parameter No. 34). The following DRU parameters are automatically adjusted in the auto tuning mode 2. DRU parameter No. Abbreviation 6 PG1 Position control gain 1 Name 35 PG2 Position control gain 2 36 VG1 Speed control gain 1 37 VG2 Speed control gain 2 38 VIC Speed integral compensation 6- 3 6. GENERAL GAIN ADJUSTMENT 6.2.2 Auto tuning mode operation The block diagram of real-time auto tuning is shown below. Load inertia moment Automatic setting Command Control gains PG1,VG1 PG2,VG2,VIC Current control Servo motor Encoder Current feedback Set 0 or 1 to turn on. Gain table Real-time auto tuning section Switch Load inertia moment ratio estimation section Position/speed feedback Speed feedback DRU parameter No. 34 Load inertia moment ratio estimation value DRU parameter No. 2 Third digit First digit Auto tuning Response level setting selection When a servo motor is accelerated/decelerated, the load inertia moment ratio estimation section always estimates the load inertia moment ratio from the current and speed of the servo motor. The results of estimation are written to DRU parameter No. 34 (the ratio of load inertia moment to servo motor). These results can be confirmed on the status display screen of the servo amplifier display section. If the value of the load inertia moment ratio is already known or if estimation cannot be made properly, chose the "auto tuning mode 2" (DRU parameter No.2: 2 ) to stop the estimation of the load inertia moment ratio (Switch in above diagram turned off), and set the load inertia moment ratio (DRU parameter No. 34) manually. From the preset load inertia moment ratio (DRU parameter No. 34) value and response level (The first digit of DRU parameter No. 2), the optimum control gains are automatically set on the basis of the internal gain tale. The auto tuning results are saved in the EEP-ROM of the servo amplifier every 60 minutes since poweron. At power-on, auto tuning is performed with the value of each control gain saved in the EEP-ROM being used as an initial value. POINT If sudden disturbance torque is imposed during operation, the estimation of the inertia moment ratio may malfunction temporarily. In such a case, choose the "auto tuning mode 2" (DRU parameter No. 2: 020 ) and set the correct load inertia moment ratio in DRU parameter No. 34. When any of the auto tuning mode 1, auto tuning mode 2 and manual mode 1 settings is changed to the manual mode 2 setting, the current control gains and load inertia moment ratio estimation value are saved in the EEP-ROM. 6- 4 6. GENERAL GAIN ADJUSTMENT 6.2.3 Adjustment procedure by auto tuning Since auto tuning is made valid before shipment from the factory, simply running the servo motor automatically sets the optimum gains that match the machine. Merely changing the response level setting value as required completes the adjustment. The adjustment procedure is as follows. Auto tuning adjustment Acceleration/deceleration repeated Yes Load inertia moment ratio estimation value stable? No Auto tuning conditions not satisfied. (Estimation of load inertia moment ratio is difficult) No Yes Choose the auto tuning mode 2 (DRU parameter No.2 : 020 )and set the load inertia moment ratio (DRU parameter No.34) manually. Adjust response level setting so that desired response level is achieved on vibration-free level. Acceleration/deceleration repeated Requested performance satisfied? No Yes END To manual mode 6- 5 6. GENERAL GAIN ADJUSTMENT 6.2.4 Response level setting in auto tuning mode Set the response (The first digit of DRU parameter No.2) of the whole servo system. As the response level setting is increased, the trackability and settling time for a command decreases, but a too high response level will generate vibration. Hence, make setting until desired response is obtained within the vibrationfree range. If the response level setting cannot be increased up to the desired response because of machine resonance beyond 100Hz, adaptive vibration suppression control (DRU parameter No. 60) or machine resonance suppression filter (DRU parameter No. 58 59) may be used to suppress machine resonance. Suppressing machine resonance may allow the response level setting to increase. Refer to Section 7.2 for adaptive vibration suppression control and machine resonance suppression filter. DRU parameter No. 2 Response level setting Auto tuning selection Machine characteristic Response level setting 1 Machine rigidity Low Machine resonance frequency guideline 15Hz 2 20Hz 3 25Hz 4 30Hz 5 35Hz 6 45Hz 7 55Hz 8 Middle 85Hz A 105Hz B 130Hz C 160Hz D 200Hz E 240Hz High Large conveyor Arm robot General machine tool conveyor 70Hz 9 F Guideline of corresponding machine 300Hz 6- 6 Precision working machine Inserter Mounter Bonder 6. GENERAL GAIN ADJUSTMENT 6.3 Manual mode 1 (simple manual adjustment) If you are not satisfied with the adjustment of auto tuning, you can make simple manual adjustment with three DRU parameters. 6.3.1 Operation of manual mode 1 In this mode, setting the three gains of position control gain 1 (PG1), speed control gain 2 (VG2) and speed integral compensation (VIC) automatically sets the other gains to the optimum values according to these gains. GD2 User setting PG1 VG2 VIC Automatic setting PG2 VG1 Therefore, you can adjust the model adaptive control system in the same image as the general PI control system (position gain, speed gain, speed integral time constant). Here, the position gain corresponds to PG1, the speed gain to VG2 and the speed integral time constant to VIC. When making gain adjustment in this mode, set the load inertia moment ratio (DRU parameter No. 34) correctly. 6.3.2 Adjustment by manual mode 1 POINT If machine resonance occurs, adaptive vibration suppression control (DRU parameter No. 60) or machine resonance suppression filter (DRU parameter No. 58 59) may be used to suppress machine resonance. (Refer to Section 7.1.) (1) DRU parameters The following parameters are used for gain adjustment: DRU parameter No. Abbreviation 6 PG1 Position control gain 1 Name 34 GD2 Ratio of load inertia moment to servo motor inertia moment 37 VG2 Speed control gain 2 38 VIC Speed integral compensation (2) Adjustment procedure Step 1 2 Operation Description Set an estimated value to the ratio of load inertia moment to servo motor inertia moment (DRU parameter No. 34). Set a slightly smaller value to the position control gain 1 (DRU parameter No. 6). Increase the speed control gain 2 (DRU parameter No. 37) within the 3 Increase the speed control gain. vibration- and unusual noise-free range, and return slightly if vibration takes place. 4 5 6 Decrease the speed integral compensation (DRU parameter No. 38) within the Decrease the time constant of the vibration-free range, and return slightly if vibration takes place. speed integral compensation. Increase the position control gain 1 (DRU parameter No. 6). Increase the position control gain. If the gains cannot be increased due to mechanical system resonance or the Suppression of machine resonance. like and the desired response cannot be achieved, response may be increased Refer to Section 7.1. by suppressing resonance with adaptive vibration suppression control or machine resonance suppression filter and then executing steps 3 to 5. 7 While checking the settling characteristic and rotational status, fine-adjust each gain. 6- 7 Fine adjustment 6. GENERAL GAIN ADJUSTMENT (3) Adjustment description (a) Position control gain 1 (DRU parameter No. 6) This parameter determines the response level of the position control loop. Increasing position control gain 1 improves trackability to a position command but a too high value will make overshooting liable to occur at the time of settling. Position control gain 1 guideline Speed control gain 2 setting (1 ratio of load inertia moment to servo motor inertia moment) ( 13 to 15 ) (b) Speed control gain 2 (VG2: DRU parameter No. 37) This parameter determines the response level of the speed control loop. Increasing this value enhances response but a too high value will make the mechanical system liable to vibrate. The actual response frequency of the speed loop is as indicated in the following expression: Speed loop response frequency(Hz) Speed control gain 2 setting (1 ratio of load inertia moment to servo motor inertia moment) 2 (c) Speed integral compensation (DRU parameter No. 38) To eliminate stationary deviation against a command, the speed control loop is under proportional integral control. For the speed integral compensation, set the time constant of this integral control. Increasing the setting lowers the response level. However, if the load inertia moment ratio is large or the mechanical system has any vibratory element, the mechanical system is liable to vibrate unless the setting is increased to some degree. The guideline is as indicated in the following expression: Speed integral compensation setting(ms) 2000 to 3000 Speed control gain 2 setting/ (1 ratio of load inertia moment to servo motor inertia moment setting 0.1) 6- 8 6. GENERAL GAIN ADJUSTMENT 6.4 Interpolation mode The interpolation mode is used to match the position control gains of the axes when performing the interpolation operation of servo motors of two or more axes for an X-Y table or the like. In this mode, the position control gain 2 and speed control gain 2 which determine command trackability are set manually and the other parameter for gain adjustment are set automatically. (1) Parameter (a) Automatically adjusted parameters The following parameters are automatically adjusted by auto tuning. DRU parameter No. Abbreviation 34 35 GD2 PG2 Ratio of load inertia moment to servo motor inertia moment Position control gain 2 Name 37 VG2 Speed control gain 2 38 VIC Speed integral compensation (b) Manually adjusted parameters The following parameters are adjustable manually. DRU parameter No. Abbreviation Name 6 PG1 Position control gain 1 36 VG1 Speed control gain 1 (2) Adjustment procedure Step Operation Description 1 Set 15Hz (DRU parameter No. 2: 010 ) as the machine resonance frequency of response in the auto tuning mode 1. Select the auto tuning mode 1. 2 During operation, increase the response level setting (DRU parameter No. 2), and return the setting if vibration occurs. Adjustment in auto tuning mode 1. 3 Check the values of position control gain 1 (DRU parameter No. 6) and speed control gain 1 (DRU parameter No. 36). Check the upper setting limits. 4 Set the interpolation mode (DRU parameter No. 2: 000 Select the interpolation mode. 5 Using the position control gain 1 value checked in step 3 as the guideline of the upper limit, set in PG1 the value identical to the position loop gain of the axis to be interpolated. Set position control gain 1. 6 Using the speed control gain 1 value checked in step 3 as the guideline of the upper limit, look at the rotation status and set in speed control gain 1 the value three or more times greater than the position control gain 1 setting. Set speed control gain 1. 7 Looking at the interpolation characteristic and rotation status, fine-adjust the gains and response level setting. Fine adjustment. ). (3) Adjustment description (a) Position control gain 1 (DRU parameter No.6) This parameter determines the response level of the position control loop. Increasing position control gain 1 improves trackability to a position command but a too high value will make overshooting liable to occur at the time of settling. The droop pulse value is determined by the following expression. Droop pulse value (pulse) Rotation speed (r/min) 131072(pulse) 60 Position control gain set value (b) Speed control gain 1 (DRU parameter No. 36) Set the response level of the speed loop of the model. Make setting using the following expression as a guideline. Speed control gain 1 setting Position control gain 1 setting 3 6- 9 6. GENERAL GAIN ADJUSTMENT MEMO 6 - 10 7. SPECIAL ADJUSTMENT FUNCTIONS 7. SPECIAL ADJUSTMENT FUNCTIONS POINT The functions given in this chapter need not be used generally. Use them if you are not satisfied with the machine status after making adjustment in the methods in Chapter 6. If a mechanical system has a natural resonance point, increasing the servo system response level may cause the mechanical system to produce resonance (vibration or unusual noise) at that resonance frequency. Using the machine resonance suppression filter and adaptive vibration suppression control functions can suppress the resonance of the mechanical system. 7.1 Function block diagram Speed control DRU parameter No.58 00 Machine resonance suppression filter 1 DRU parameter No.60 DRU parameter No.59 00 0 except Machine resonance suppression filter 2 00 DRU parameter Current No.60 command Low-pass filter 0 Servo motor 1 except Encoder 00 Adaptive vibration suppression control 1 or 2 7.2 Machine resonance suppression filter (1) Function 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. You can set the gain decreasing frequency (notch frequency) and gain decreasing depth. Mechanical system response level Machine resonance point Frequency Notch depth Notch frequency 7- 1 Frequency 7. SPECIAL ADJUSTMENT FUNCTIONS You can use the machine resonance suppression filter 1 (DRU parameter No. 58) and machine resonance suppression filter 2 (DRU parameter No. 59) to suppress the vibration of two resonance frequencies. Note that if adaptive vibration suppression control is made valid, the machine resonance suppression filter 1 (DRU parameter No. 58) is made invalid. Machine resonance point Mechanical system response level Frequency Notch depth Frequency DRU parameter No. 58 DRU parameter No. 59 POINT The machine resonance suppression filter is a delay factor for the servo system. Hence, vibration may increase if you set a wrong resonance frequency or a too deep notch. (2) Parameters (a) Machine resonance suppression filter 1 (DRU parameter No. 58) Set the notch frequency and notch depth of the machine resonance suppression filter 1 (DRU parameter No. 58) When you have made adaptive vibration suppression control selection (DRU parameter No. 60) "valid" or "held", make the machine resonance suppression filter 1 invalid (DRU parameter No. 58: 0000). DRU parameter No. 58 0 Notch frequency Setting Setting Setting Frequency Frequency Frequency value value value Setting Frequency value 00 Invalid 08 562.5 10 281.3 18 01 4500 09 500 11 264.7 19 180 02 2250 0A 450 12 250 1A 173.1 03 1500 0B 409.1 13 236.8 1B 166.7 04 1125 0C 375 14 225 1C 160.1 05 900 0D 346.2 15 214.3 1D 155.2 06 750 0E 321.4 16 204.5 1E 150 07 642.9 0F 300 17 195.7 1F 145.2 Notch depth Setting value Depth (Gain) 0 1 2 3 Deep ( 40dB) ( 14dB) ( 8dB) Shallow( 4dB) 7- 2 187.5 7. SPECIAL ADJUSTMENT FUNCTIONS POINT If the frequency of machine resonance is unknown, decrease the notch frequency from higher to lower ones in order. The optimum notch frequency is set at the point where vibration is minimal. A deeper notch has a higher effect on machine resonance suppression but increases a phase delay and may increase vibration. The machine characteristic can be grasped beforehand by the machine analyzer on the MR Configurator (servo configuration software). This allows the required notch frequency and depth to be determined. Resonance may occur if DRU parameter No. 58 59 is used to select a close notch frequency and set a deep notch. (b) Machine resonance suppression filter 2 (DRU parameter No. 59) The setting method of machine resonance suppression filter 2 (DRU parameter No. 59) is the same as that of machine resonance suppression filter 1 (DRU parameter No. 58). However, the machine resonance suppression filter 2 can be set independently of whether adaptive vibration suppression control is valid or invalid. 7.3 Adaptive vibration suppression control (1) Function Adaptive vibration suppression control is a function in which the drive unit detects machine resonance and sets the filter characteristics automatically to suppress mechanical system vibration. Since the filter characteristics (frequency, depth) are set automatically, you need not be conscious of the resonance frequency of a mechanical system. Also, while adaptive vibration suppression control is valid, the servo amplifier always detects machine resonance, and if the resonance frequency changes, it changes the filter characteristics in response to that frequency. Mechanical system response level Machine resonance point Frequency Mechanical system response level Notch depth Machine resonance point Frequency Notch depth Notch frequency Frequency When machine resonance is large and frequency is low Notch frequency Frequency When machine resonance is small and frequency is high POINT The machine resonance frequency which adaptive vibration suppression control can respond to is about 150 to 500Hz. Adaptive vibration suppression control has no effect on the resonance frequency outside this range. Use the machine resonance suppression filter for the machine resonance of such frequency. Adaptive vibration suppression control may provide no effect on a mechanical system which has complex resonance characteristics or which has too large resonance. Under operating conditions in which sudden disturbance torque is imposed during operation, the detection of the resonance frequency may malfunction temporarily, causing machine vibration. In such a case, set adaptive vibration suppression control to be "held" (DRU parameter No. 60: 2 ) to fix the characteristics of the adaptive vibration suppression control filter. 7- 3 7. SPECIAL ADJUSTMENT FUNCTIONS (2) Parameters The operation of adaptive vibration suppression control selection (DRU parameter No.60). DRU parameter No. 60 Adaptive vibration suppression control selection Choosing "valid" or "held" in adaptive vibration suppression control selection makes the machine resonance suppression filter 1 (DRU parameter No. 58) invalid. 0: Invalid 1: Valid Machine resonance frequency is always detected to generate the filter in response to resonance, suppressing machine vibration. 2: Held Filter characteristics generated so far is held, and detection of machine resonance is stopped. Adaptive vibration suppression control sensitivity selection Select the sensitivity at which machine resonance is detected. 0: Normal 1: Large sensitivity POINT Adaptive vibration suppression control is factory-set to be invalid (DRU parameter No. 60: 0000). The filter characteristics generated are saved in the EEP-ROM every 60 minutes since power-on. At next power-on, vibration suppression control is performed with this data saved in the EEP-ROM being used as an initial value. Setting the adaptive vibration suppression control sensitivity can change the sensitivity of detecting machine resonance. Setting of "large sensitivity" detects smaller machine resonance and generates a filter to suppress machine vibration. However, since a phase delay will also increase, the response of the servo system may not increase. 7.4 Low-pass filter (1) Function When a ballscrew or the like is used, resonance of high frequency may occur as the response level of the servo system is increased. To prevent this, the low-pass filter is factory-set to be valid for a torque command. The filter frequency of this low-pass filter is automatically adjusted to the value in the following expression: Filter frequency(Hz) 2 Speed control gain 2 setting 10 (1 Ratio of load inertia moment to servo motor inertia moment setting 0.1) (2) Parameter Set the operation of the low-pass filter (DRU parameter No. 60.) DRU parameter No. 60 Low-pass filter selection 0: Valid (automatic adjustment) 1: Invalid initial value POINT In a mechanical system where rigidity is extremely high and resonance is difficult to occur, setting the low-pass filter to be "invalid" may increase the servo system response to shorten the settling time. 7- 4 7. SPECIAL ADJUSTMENT FUNCTIONS 7.5 Gain changing function This function can change the gains. You can change between gains during rotation and gains during stop or can use an external signal to change gains during operation. 7.5.1 Applications This function is used when: (1) You want to increase the gains during servo lock but decrease the gains to reduce noise during rotation. (2) You want to increase the gains during settling to shorten the stop settling time. (3) You want to change the gains using an external signal to ensure stability of the servo system since the load inertia moment ratio varies greatly during a stop (e.g. a large load is mounted on a carrier). 7.5.2 Function block diagram The valid control gains PG2, VG2, VIC and GD2 of the actual loop are changed according to the conditions selected by gain changing selection (DRU parameter No. 65) and gain changing condition (DRU parameter No. 66). CDP DRU parameter No.65 External signal CDP Command pulse frequency Droop pulses Changing Model speed CDS DRU parameter No.66 Comparator GD2 DRU parameter No.34 GD2B DRU parameter No.61 PG2 DRU parameter No.35 PG2 PG2B 100 VG2 DRU parameter No.37 VG2 VG2B 100 VIC DRU parameter No.38 VIC VICB 100 7- 5 Valid GD2 value Valid PG2 value Valid VG2 value Valid VIC value 7. SPECIAL ADJUSTMENT FUNCTIONS 7.5.3 Parameters 4 " in DRU parameter No.2 (auto tuning) to When using the gain changing function, always set " choose the manual mode of the gain adjustment modes. The gain changing function cannot be used in the auto tuning mode. DRU Abbrevi- parameter No. ation Name Unit Description 6 PG1 Position control gain 1 rad/s Position and speed gains of a model used to set the 36 VG1 Speed control gain 1 rad/s response level to a command. Always valid. 34 GD2 Ratio of load inertia moment to 0.1 servo motor inertia moment times 35 PG2 Position control gain 2 rad/s 37 VG2 Speed control gain 2 rad/s 38 VIC Speed integral compensation ms Ratio of load inertia moment to 0.1 61 GD2B 62 PG2B 63 VG2B servo motor inertia moment 2 Position control gain 2 changing ratio Speed control gain 2 changing ratio Speed integral compensation 64 VICB 65 CDP Gain changing selection 66 CDS Gain changing condition changing ratio times % % % Control parameters before changing Used to set the ratio of load inertia moment to servo motor inertia moment after changing. Used to set the ratio (%) of the after-changing position control gain 2 to position control gain 2. Used to set the ratio (%) of the after-changing speed control gain 2 to speed control gain 2. Used to set the ratio (%) of the after-changing speed integral compensation to speed integral compensation. Used to select the changing condition. kpps Used to set the changing condition values. pulse r/min 67 CDT Gain changing time constant ms 7- 6 You can set the filter time constant for a gain change at changing. 7. SPECIAL ADJUSTMENT FUNCTIONS (1) DRU parameters No. 6 34 to 38 These parameters are the same as in ordinary manual adjustment. Gain changing allows the values of ratio of load inertia moment to servo motor inertia moment, position control gain 2, speed control gain 2 and speed integral compensation to be changed. (2) Ratio of load inertia moment to servo motor inertia moment 2 (GD2B: DRU parameter No. 61) Set the ratio of load inertia moment to servo motor inertia moment after changing. If the load inertia moment ratio does not change, set it to the same value as ratio of load inertia moment to servo motor inertia moment (DRU parameter No. 34). (3) Position control gain 2 changing ratio (DRU parameter No. 62), speed control gain 2 changing ratio (DRU parameter No. 63), speed integral compensation changing ratio (DRU parameter No. 64) Set the values of after-changing position control gain 2, speed control gain 2 and speed integral compensation in ratio (%). 100% setting means no gain change. For example, at the setting of position control gain 2 100, speed control gain 2 2000, speed integral compensation 20 and position control gain 2 changing ratio 180%, speed control gain 2 changing ratio 150% and speed integral compensation changing ratio 80%, the after-changing values are as follows: Position control gain 2 Position control gain 2 Position control gain 2 changing ratio /100 180rad/s Speed control gain 2 Speed control gain 2 Speed control gain 2 changing ratio /100 3000rad/s Speed integral compensation Speed integral compensation Speed integral compensation changing ratio /100 16ms (4) Gain changing selection (DRU parameter No. 65) Used to set the gain changing condition. Choose the changing condition in the first digit. If you set "1" here, you can use the gain changing (CDP ) external input signal for gain changing. The gain changing (CDP ) can be assigned to the pins using DRU parameters No. 43 to 48. DRU parameter No. 65 Gain changing (CDP ) selection Gains are changed in accordance with the settings of DRU parameters No. 61 to 64 under any of the following conditions: 0: Invalid 1: Gain changing (CDP ) is ON 2: Command frequency is equal to higher than DRU parameter No. 66 setting 3: Droop pulse value is equal to higher than DRU parameter No. 66 setting 4: Servo motor speed is equal to higher than DRU parameter No. 66 setting (5) Gain changing condition (DRU parameter No. 66) When you selected "command frequency", "droop pulses" or "servo motor speed" in gain changing selection (DRU parameter No.65), set the gain changing level. The setting unit is as follows: Gain changing condition Unit Command frequency kpps Droop pulses pulse Servo motor speed r/min (6) Gain changing time constant (DRU parameter No. 67) You can set the primary delay filter to each gain at gain changing. This parameter is used to suppress shock given to the machine if the gain difference is large at gain changing, for example. 7- 7 7. SPECIAL ADJUSTMENT FUNCTIONS 7.5.4 Gain changing operation This operation will be described by way of setting examples. (1) When you choose changing by external input (a) Setting DRU parameter No. Abbreviation Name Setting Unit 6 PG1 Position control gain 1 100 rad/s 36 VG1 Speed control gain 1 1000 rad/s 4 0.1 times Ratio of load inertia moment to 34 GD2 35 PG2 Position control gain 2 120 rad/s 37 VG2 Speed control gain 2 3000 rad/s 38 VIC Speed integral compensation 20 ms 100 0.1 times 70 % 133 % 250 % servo motor inertia moment Ratio of load inertia moment to 61 GD2B 62 PG2B 63 VG2B 64 VICB 65 CDP Gain changing selection 67 CDT Gain changing time constant servo motor inertia moment 2 Position control gain 2 changing ratio Speed control gain 2 changing ratio Speed integral compensation changing ratio 0001 (Changed by ON/OFF of pin CN1A-8) 100 (b) Changing operation OFF Gain changing (CDP ) Change of each gain ON After-changing gain Before-changing gain CDT 100ms Position control gain 1 100 Speed control gain 1 1000 Ratio of load inertia moment to servo motor inertia moment OFF 10.0 4.0 4.0 Position control gain 2 120 84 120 Speed control gain 2 3000 4000 3000 20 50 20 Speed integral compensation 7- 8 ms 7. SPECIAL ADJUSTMENT FUNCTIONS (2) When you choose changing by droop pulses (a) Setting DRU parameter No. Abbreviation Setting Unit 6 PG1 Position control gain 1 Name 100 rad/s 36 VG1 Speed control gain 1 1000 rad/s 34 GD2 40 0.1 times Ratio of load inertia moment to servo motor inertia moment 35 PG2 Position control gain 2 120 rad/s 37 VG2 Speed control gain 2 3000 rad/s 38 VIC Speed integral compensation 20 ms 100 0.1 times 70 % 133 % 250 % Ratio of load inertia moment to 61 GD2B 62 PG2B 63 VG2B 64 VICB 65 CDP Gain changing selection 66 CDS Gain changing condition 50 pulse 67 CDT Gain changing time constant 100 ms servo motor inertia moment 2 Position control gain 2 changing ratio Speed control gain 2 changing ratio Speed integral compensation changing ratio 0003 (Changed by droop pulses) (b) Changing operation Command pulse Droop pulses [pulses] 0 Droop pulses CDS CDS After-changing gain Change of each gain Before-changing gain CDT 100ms Position control gain 1 100 Speed control gain 1 1000 Ratio of load inertia moment to servo motor inertia moment 4.0 10.0 4.0 10.0 Position control gain 2 120 84 120 84 Speed control gain 2 3000 4000 3000 4000 20 50 20 50 Speed integral compensation 7- 9 7. SPECIAL ADJUSTMENT FUNCTIONS MEMO 7 - 10 8. INSPECTION 8. INSPECTION WARNING Before starting maintenance and/or inspection, make sure that the charge lamp is off more than 15 minutes after power-off. Then, confirm that the voltage is safe in the tester or the like. Otherwise, you may get an electric shock. Any person who is involved in inspection should be fully competent to do the work. Otherwise, you may get an electric shock. For repair and parts replacement, contact your safes representative. POINT Do not test MELSERVO-J2M with a megger (measure insulation resistance), or it may become faulty. Do not disassemble and/or repair the equipment on customer side. (1) Inspection It is recommended to make the following checks periodically: (a) Check for loose terminal block screws. Retighten any loose screws. (b) Check the cables and the like for scratches and cracks. Perform periodic inspection according to operating conditions. (2) Life The following parts must be changed periodically as listed below. If any part is found faulty, it must be changed immediately even when it has not yet reached the end of its life, which depends on the operating method and environmental conditions. For parts replacement, please contact your sales representative. Part name Smoothing capacitor Relay Life guideline 10 years Number of power-on and number of forced Stop times:100,000times. Cooling fan 10,000 to 30,000hours (2 to 3 years) Absolute position battery unit Refer to Section 13.2 (a) Smoothing capacitor Affected by ripple currents, etc. and deteriorates in characteristic. The life of the capacitor greatly depends on ambient temperature and operating conditions. The capacitor will reach the end of its life in 10 years of continuous operation in normal air-conditioned environment. (b) Relays Their contacts will wear due to switching currents and contact faults occur. Relays reach the end of their life when the cumulative number of power-on and forced stop times is 100,000, which depends on the power supply capacity. (c) Drive unit cooling fan The cooling fan bearings reach the end of their life in 10,000 to 30,000 hours. Normally, therefore, the fan must be changed in a few years of continuous operation as a guideline. It must also be changed if unusual noise or vibration is found during inspection. 8- 1 8. INSPECTION MEMO 8- 2 9. TROUBLESHOOTING 9. TROUBLESHOOTING 9.1 Trouble at start-up CAUTION Excessive adjustment or change of parameter setting must not be made as it will make operation instable. POINT Using the optional MR Configurator (servo configuration software), you can refer to unrotated servo motor reasons, etc. The following faults may occur at start-up. If any of such faults occurs, take the corresponding action. (1) Troubleshooting No. 1 Start-up sequence Power on Fault Investigation Possible cause LED is not lit. Not improved if connectors LED flickers. CN1A, CN1B, CN2 and CN3 2. MELSERVO-J2M is faulty. Reference 1. Power supply voltage fault are disconnected. Improved when connectors Power supply of CNP1 cabling CN1A and CN1B are is shorted. disconnected. Improved when connector CN2 is disconnected. 1. Power supply of encoder cabling is shorted. 2. Encoder is faulty. 2 Improved when connector Power supply of CN3 cabling is CN3 is disconnected. shorted. Alarm occurs. Refer to Section 9.2 and remove cause. Switch on servo-on Alarm occurs. Refer to Section 9.2 and remove cause. (SON ). Servo motor shaft is 1. Check the display to see if 1. Servo-on (SON ) is not not servo-locked the servo amplifier is (is free). ready to operate. 2. Check the external I/O Section 9.2 Section 9.2 Section 4.3.6 input. (Wiring mistake) 2. 24VDC power is not supplied to VIN. signal indication to see if the servo-on (SON ) is ON. 3 Enter input Servo motor does Check cumulative command 1. Wiring mistake command. not rotate. pulses. Section 4.3.2 (a) For open collector pulse (Test operation) train input, 24VDC power is not supplied to OPC. (b) LSP /LSN -SG are not connected. 2. No pulses is input. Servo motor run in 1. Mistake in wiring to reverse direction. controller. 2. Mistake in setting of DRU parameter No. 54. 9- 1 Chapter 5 9. TROUBLESHOOTING No. 4 Start-up sequence Gain adjustment Possible cause Reference Rotation ripples Fault Make gain adjustment in the Gain adjustment fault Chapter 6 (speed fluctuations) following procedure: are large at low 1. Increase the auto tuning speed. Investigation response level. 2. Repeat acceleration and deceleration several times to complete auto tuning. Large load inertia If the servo motor may be moment causes the run with safety, repeat servo motor shaft to acceleration and Gain adjustment fault Chapter 6 oscillate side to side. deceleration several times to complete auto tuning. 5 Cyclic operation Position shift occurs Confirm the cumulative Pulse counting error, etc. command pulses, cumulative due to noise. feedback pulses and actual servo motor position. 9- 2 (2) in this section 9. TROUBLESHOOTING (2) How to find the cause of position shift Positioning unit MELSERVO-J2M (a) Output pulse counter Electronic gear (DRU parameters No. 3, 4) Q (A) (C) Servo-on (SON ), forward rotation stroke end (LSP ) reverse rotation stroke end (LSD ) input Machine Servo motor P CMX M CDV L (d) Machine stop position M (B) (b) Cumulative command pulses C Encoder (c) Cumulative feedback pulses When a position shift occurs, check (a) output pulse counter, (b) cumulative command pulse display, (c) cumulative feedback pulse display, and (d) machine stop position in the above diagram. (A), (B) and (C) indicate position shift causes. For example, (A) indicates that noise entered the wiring between positioning unit and servo amplifier, causing pulses to be mis-counted. In a normal status without position shift, there are the following relationships: 1) Q P (positioning unit's output counter servo amplifier's cumulative command pulses) CMX(parameter No.3) 2) P CDV(parameter No.4) C (cumulative command pulses electronic gear cumulative feedback pulses) M (cumulative feedback pulses travel per pulse machine position) 3) C Check for a position shift in the following sequence: 1) When Q P Noise entered the pulse train signal wiring between positioning unit and servo amplifier, causing pulses to be miss-counted. (Cause A) Make the following check or take the following measures: Check how the shielding is done. Change the open collector system to the differential line driver system. Run wiring away from the power circuit. Install a data line filter. (Refer to (2)(a) Section 12.2.6.) CMX 2) When P C CDV During operation, the servo-on (SON ) or forward rotation stroke end (LSP ) reverse rotation stroke end (LSN ) was switched off or the clear (CR ) and the reset (RES ) switched on. (Cause C) If a malfunction may occur due to much noise, increase the input filter setting (DRU parameter No. 1). 3) When C M Mechanical slip occurred between the servo motor and machine. (Cause B) 9- 3 9. TROUBLESHOOTING 9.2 Alarms and warning list POINT The alarm/warning whose indication is not given does not exist in that unit. When a fault occurs during operation, the corresponding alarm or warning is displayed. If any alarm or warning has occurred, refer to Section 9.3 or 9.4 and take the appropriate action. When an alarm occurs in any of slots 1 to 4, ALM_A-SG open. When an alarm occurs in any of slots 5 to 8, ALM_B-SG open. The alarm can be canceled by turning the power OFF to ON. After its cause has been removed, the alarm can be deactivated in any of the methods marked alarm deactivation column. in the When an alarm/warning occurs, the interface unit display shows the corresponding unit and alarm number. Interface unit display Slot number Alarm/warning number Symbol F 1 2 3 4 5 6 7 8 9- 4 Definition (Slot) Interface unit First slot Second slot Third slot Fourth slot Fifth slot Sixth slot Seventh slot Eight slot 9. TROUBLESHOOTING Alarms Display A.10 A.12 A.13 A.15 A.16 A.17 A.19 A.1A A.1C A.1D A.1E A.20 A.24 A.25 A.30 A.31 A.32 A.33 A.35 Warnings A.37 A.45 A.46 A.50 A.51 A.52 A.53 A.54 A.78 A.79 A.8A A.8E 88888 A.92 A.96 A.9F A.E0 A.E1 A.E3 A.E6 A.E9 Name Undervoltage Memory error 1 Clock error Memory error 2 Encoder error 1 Board error Memory error 3 Servo motor combination error Base unit bus error 1 Base unit bus error 2 Drive unit mounting error Encoder error 2 Main circuit error Absolute position erase Regenerative error Overspeed Overcurrent Overvoltage Command pulse frequency error IFU parameter error DRU parameter error Main circuit device overheat Servo motor overheat Overload 1 Overload 2 Error excessive Multiple axis overload Drive unit alarm Option slot fault Option slot loading error Serial communication time-out Serial communication error Watchdog Open battery cable warning Home position setting warning Battery warning Excessive regenerative warning Overload warning Absolute position counter warning Servo forced stop warning Main circuit off warning Power OFF ON (Note 1) Alarm deactivation Press “SET” on current alarm screen. (Note 1) (Note 1) (Note 1) (Note 1) (Note 1) (Note 2) (Note 2) Note 1. Deactivate the alarm about 30 minutes of cooling time after removing the cause of occurrence. 9- 5 (Note 1) (Note 1) (Note 1) (Note 1) (Note 1) Removing the cause of occurrence deactivates the alarm automatically. 2. Automatically deactivated when the alarm of the drive unit is reset. Reset (RES) (Note 2) 9. TROUBLESHOOTING 9.3 Remedies for alarms CAUTION When any alarm has occurred, eliminate its cause, ensure safety, then reset the alarm, and restart operation. Otherwise, injury may occur. If an absolute position erase (A.25) occurred, always make home position setting again. Otherwise, misoperation may occur. As soon as an alarm occurs, turn off Servo-on (SON ) and power off the main circuit. POINT When any of the following alarms has occurred, always remove its cause and allow about 30 minutes for cooling before resuming operation. If operation is resumed by switching control circuit power off, then on to reset the alarm, each unit and servo motor may become faulty. Regenerative error (A.30) Overload 2 (A.51) Overload 1 (A.50) The alarm can be deactivated by switching power off, then on press the “SET” button on the interface unit current alarm screen or by turning on the reset (RES ). For details, refer to Section 9.2. When an alarm occurs, the dynamic brake is operated to stop the servo motor. At this time, the display indicates the alarm No. The servo motor comes to a stop. Remove the cause of the alarm in accordance with this section. The optional MR Configurator (servo configuration software) may be used to refer to the cause. @ in the Indication field denotes the slot number of the base unit. Display IFU DRU FA.10 Name Undervoltage Definition Power supply voltage fell to or below 160VAC. Cause Action 1. Power supply voltage is low. Review the power supply. 2. There was an instantaneous control circuit power failure of 30ms or longer. 3. Shortage of power supply capacity caused the power supply voltage to drop at start, etc. 4. Power was restored after the bus voltage had dropped to 200VDC. (Main circuit power switched on within 5s after it had switched off.) 5. Faulty parts in the base unit. Change the base unit. Checking method Alarm (A.10) occurs if interface unit is changed. 6. Faulty parts in interface unit. Change the interface unit. Checking method Alarm (A.10) occurs if base unit is changed. FA.12 Memory error 1 RAM, memory fault FA.13 Clock error FA.15 Memory error 2 EEP-ROM fault Printed board fault. 7. CNP3 or CNP1B connector unplugged. Faulty parts in the interface unit. Checking method Alarm (any of A.11 and 13) occurs if power is switched on after disconnection of all cables but the control circuit power supply cables. 9- 6 Connect properly. Change the interface unit. 9. TROUBLESHOOTING Display IFU DRU Name Definition @A.12@ Memory error 1 RAM, memory fault @A.13@ Clock error Printed board fault. @A.15@ Memory error 2 EEP-ROM fault Cause 1. Faulty parts in the drive unit Action Change the drive unit. Checking method Alarm (A.15) occurs if power is switched on after disconnection of all cables but the control circuit power supply cables. 2. The number of write times to EEPROM exceeded 100,000. @A.16@ Encoder error 1 Communication error 1. Encoder connector (CN2) occurred between disconnected. encoder and servo 2. Encoder fault. amplifier. 3. Encoder cable faulty. (Wire breakage or shorted) @A.17@ Board error 2 CPU/parts fault 1. Faulty parts in the drive unit. Connect correctly. Change the servo motor. Repair or change cable. Change the drive unit. Checking method Alarm (A.17) occurs if power is switched on after disconnection of all cables but the control circuit power supply cables. The output terminals 2. The wiring of U, V, W is U, V, W of the drive disconnected or not connected. unit and the input terminals U, V, W of the servo motor are not connected. FA.19 @A.19@ Memory error 3 ROM memory fault Faulty parts in the interface unit or drive unit. Correctly connect the output terminals U, V, W of the drive unit and the input terminals U, V, W of the servo motor. Change the interface unit or drive unit. Checking method Alarm (A.19) occurs if power is switched on after disconnection of all cables but the control circuit power supply cables. @A.1A@ Servo motor combination error FA.1C Base unit bus error 1 FA.1D FA.1E Base unit bus error 2 Wrong combination of drive unit and servo motor. There is error in communication between interface unit and drive unit. Wrong combination of drive unit and servo motor connected. Use correct combination. 1. Interface unit connection fault. Connect the interface unit to the base unit properly. Change the interface unit. Change the base unit. Connect the drive unit to the base unit properly. Change the drive unit. Change the base unit. Connect the drive unit to the base unit properly. Change the base unit. Change the drive unit. 2. Interface unit failure. 3. Base unit failure. 1. Drive unit connection fault. There is error in communication between interface unit 2. Drive unit failure. and drive unit. 3. Base unit failure. Drive unit Drive unit came off 1. Drive unit connection fault. mounting error the base unit after initialization. 2. Base unit failure. 3. Faulty parts in drive unit. Checking method Alarm (A.1E) occurs if power is switched on after disconnection of the U, V, W power cables. @A.20@ Encoder error 2 Communication error 1. Encoder connector (CN2) disconnected. Connect correctly. occurred between 2. Encoder fault. Change the servo motor. encoder and drive 3. Encoder cable faulty. Repair or change cable. unit. (Wire breakage or shorted) 9- 7 9. TROUBLESHOOTING Display IFU DRU Name @A.24@ Main circuit error Definition Cause Ground fault occurred 1. Power input wires and servo motor at the servo motor outputs (U,V and W phases) of the drive unit. Action Connect correctly. output wires are in contact at CNP2. 2. Sheathes of servo motor power Change the cable. cables deteriorated, resulting in ground fault. 3. Main circuit of drive unit failed. Change the drive unit. Checking method Alarm (A.24) occurs if power is switched on after disconnection of the U, V, W power cables. @A.25@ Absolute position erase Absolute position data 1. Battery voltage low. Change battery. in error. 2. Battery cable or battery is faulty. Always make home position Power was switched 3. Super capacitor of the absolute After leaving the alarm occurring setting again. on for the first time in position encoder is not charged. the absolute position off, then on again. Always make detection system. FA.30 Regenerative Permissible alarm regenerative power of the regenerative brake option is exceeded. for a few minutes, switch power home position setting again. 1. Mismatch between used Set correctly. regenerative brake option and IFU parameter No. 1 setting. 2. Regenerative brake option is not Connect correctly. connected. 3. High-duty operation or continuous regenerative operation caused the permissible regenerative power of the regenerative brake option to be exceeded. 1. Reduce the frequency of positioning. 2. Use the regenerative brake option of larger capacity. 3. Reduce the load. Checking method Call the status display and check the regenerative load ratio. 4. Power supply voltage rose to or Review power supply. above 260VAC. 5. Regenerative brake option faulty. Change regenerative brake option. Regenerative transistor fault 6. Regenerative transistor faulty. Checking method 1) The regenerative brake option has overheated abnormally. 2) The alarm occurs even after removal of the built-in regenerative brake resistor or regenerative brake option. 9- 8 Change the drive unit. 9. TROUBLESHOOTING Display IFU DRU Name @A.31@ Overspeed Definition Speed has exceeded the instantaneous permissible speed. Cause Action 1. Input command pulse frequency is Set the command pulse correctly. too high. 2. Small acceleration/deceleration time Increase acceleration/ constant caused overshoot to be deceleration time constant. large. 3. Servo system is instable to cause overshoot. 1. Reset servo gain to proper value. 2. If servo gain cannot be set to proper value: 1) Reduce load inertia moment ratio; or 2) Reexamine acceleration/ deceleration time constant. 4. Electronic gear ratio is large. Set correctly. (DRU parameter No. 3 4) @A.32@ Overcurrent Current that flew is higher than the 5. Encoder faulty. Change the servo motor. 1. Short occurred in drive unit output Correct the wiring. phases U, V and W. permissible current of 2. Transistor of the servo drive unit the drive unit. faulty. Change the drive unit. Checking method Alarm (A.32) occurs if power is switched on after disconnection of the U, V, W power cables. 3. Ground fault occurred in servo Correct the wiring. amplifier output phases U, V and W. 4. External noise caused the overcurrent detection circuit to Take noise suppression measures. misoperate. FA.33 Overvoltage Converter bus voltage 1. Regenerative brake option is not Use the regenerative brake exceeded 400VDC. option. used. 2. Though the regenerative brake Make correct setting. option is used, the IFU parameter No. 1 setting is " 00 (not used)". 3. Regenerative brake option is open or 1. Change lead. disconnected. 4. Regenerative transistor faulty. 2. Connect correctly. Change drive unit. 5. Wire breakage of regenerative brake For wire breakage of regenerative option. brake option, change regenerative brake option. 6. Power supply voltage high. @A.35@ Command pulse Input frequency of frequency error command pulse is too high. Review the power supply. 1. Command given is greater than the Review operation program. maximum speed of the servo motor. 2. Noise entered bus cable. 3. Servo system controller failure. Take action against noise. Change the servo system controller. 9- 9 9. TROUBLESHOOTING Display IFU DRU FA.37 Name IFU parameter error Definition IFU parameter setting is wrong. @A.37@ DRU parameter DRU parameter error setting is wrong. @A.45@ Main circuit Main circuit device device overheat overheat. @A.46@ Servo motor overheat @A.50@ Overload 1 Cause 1. Interface unit fault caused the IFU parameter setting to be rewritten. 2. The number of write times to EEPROM exceeded 100,000 due to parameter write, program write, etc. 1. Drive unit fault caused the DRU parameter setting to be rewritten. 2. The number of write times to EEPROM exceeded 100,000 due to parameter write, program write, etc. 1. Drive unit faulty. 2. The power supply was turned on and off continuously by overloaded status. 3. Air cooling fan of drive unit stops. Action Change the interface unit. Change the interface unit Change the drive unit. Change the drive unit. Change the drive unit. The drive method is reviewed. 1. Change the drive unit or cooling fan. 2. Reduce ambient temperature. Servo motor 1. Ambient temperature of servo motor Review environment so that temperature rise is over 40 . ambient temperature is 0 to actuated the thermal 40 . sensor. 2. Servo motor is overloaded. 1. Reduce load. 2. Review operation pattern. 3. Use servo motor that provides larger output. 3. Thermal sensor in encoder is faulty. Change servo motor. Load exceeded 1. Drive unit is used in excess of its 1. Reduce load. overload protection continuous output current. 2. Review operation pattern. characteristic of servo 3. Use servo motor that provides amplifier. larger output. 2. Servo system is instable and 1. Repeat acceleration/ hunting. deceleration to execute auto tuning. 2. Change auto tuning response level setting. 3. Set auto tuning to OFF and make gain adjustment manually. 3. Machine struck something. 1. Review operation pattern. 2. Install limit switches. 4. Wrong connection of servo motor. Connect correctly. Drive unit's output U, V, W do not match servo motor's input U, V, W. 5. Encoder faulty. Change the servo motor. Checking method When the servo motor shaft is rotated with the servo off, the cumulative feedback pulses do not vary in proportion to the rotary angle of the shaft but the indication skips or returns midway. 9 - 10 9. TROUBLESHOOTING Display IFU DRU Name @A.51@ Overload 2 Definition Machine collision or Cause 1. Machine struck something. Action 1. Review operation pattern. the like caused max. 2. Install limit switches. output current to flow 2. Wrong connection of servo motor. successively for Drive unit's output terminals U, V, Connect correctly. several seconds. W do not match servo motor's input Servo motor locked: terminals U, V, W. 0.3s or more 3. Servo system is instable and During rotation: hunting. 2.5s or more 1. Repeat acceleration/ deceleration to execute auto tuning. 2. Change auto tuning response setting. 3. Set auto tuning to OFF and make gain adjustment manually. 4. Encoder faulty. Change the servo motor. Checking method When the servo motor shaft is rotated with the servo off, the cumulative feedback pulses do not vary in proportion to the rotary angle of the shaft but the indication skips or returns midway. @A.52@ Error excessive The difference between the model position and the actual servo motor position exceeds 2.5 1. Acceleration/deceleration time constant is too small. deceleration time constant. 2. Torque limit value (DRU parameter Increase the torque limit value. No.28) is too small. 3. Motor cannot be started due to rotations. (Refer to torque shortage caused by power the function block supply voltage drop. diagram in Section 1.2) Increase the acceleration/ 1. Review the power supply capacity. 2. Use servo motor which provides larger output. 4. Position control gain 1 (DRU parameter No.36) value is small. 5. Servo motor shaft was rotated by external force. Increase set value and adjust to ensure proper operation. 1. When torque is limited, increase the limit value. 2. Reduce load. 3. Use servo motor that provides larger output. 6. Machine struck something. 1. Review operation pattern. 2. Install limit switches. 7. Encoder faulty. Change the servo motor. 8. Wrong connection of servo motor. Connect correctly. Drive unit's output U, V, W do not match servo motor's input U, V, W. 9 - 11 9. TROUBLESHOOTING Display IFU DRU FA.53 Name Definition Multiple axis Drive unit whose overload effective load factor is Cause 1. Drive unit having large load is adjacent. Action 1. Change the slot of the drive unit whose load is large. 85% or more is 2. Reduce the load. adjacent. 3. Reexamine the operation pattern. 4. Use a servo motor whose output is large. 2. Servo system is instable and hunting. 1. Repeat acceleration/ deceleration and perform auto tuning. 2. Change the response setting of auto tuning. 3. Turn off auto tuning and make gain adjustment manually. 3. Encoder cable and power cable (U, Make correct connection. V, W) coming out of one drive unit are connected to the incorrect servo motor. FA.54 Drive unit Alarm occurred in one Alarm occurred in one or more axes of Remove the alarm causes of all alarm or more axes of drive drive units installed to the base unit. drive units where alarm has units installed to the occurred. base unit. FA.78 Option slot fault Extension IO unit is faulty. 1. Extension IO unit is not inserted Insert correctly. properly. 2. Incompatibility with the extension IO unit. Change the interface unit for the one compatible with the extension IO unit. 3. Extension IO unit is faulty. FA.79 FA.8A 4. Base unit is faulty. Change the base unit. Extension IO unit is disconnected. Switch power off and reinsert the Option slot Extension IO unit is loading error connected improperly. Serial Serial communication 1. Communication cable fault. communication stopped for longer time-out than the time set in IFU parameter No.20. Change the extension IO unit. extension IO unit. Repair or change the cable. (Wire break or short circuit) 2. Communication cycle is longer than Set the IFU parameter value the IFU parameter No.20 setting. 3. Protocol is incorrect. correctly. Correct the protocol. FA.8E Serial communication 1. Communication cable fault. Serial Repair or change the cable. communication error occurred (Open cable or short circuit) between interface unit error 2. Communication device (e.g. personal Change the communication and communication device (e.g. personal computer) faulty. device (e.g. personal computer). computer). 88888 Watchdog CPU, parts faulty Fault of parts in interface unit. Checking method Alarm (8888) occurs if power is switched on after disconnection of all cables but the control circuit power supply cables. 9 - 12 Change interface unit. 9. TROUBLESHOOTING 9.4 Remedies for warnings If an absolute position counter warning (A.E3) occurred, always make home position setting again. Otherwise, misoperation may occur. CAUTION POINT When any of the following alarms has occurred, do not resume operation by switching power of the servo amplifier OFF/ON repeatedly. The servo amplifier and servo motor may become faulty. If the power of the servo amplifier is switched OFF/ON during the alarms, allow more than 30 minutes for cooling before resuming operation. Excessive regenerative warning (A.E0) Overload warning 1 (A.E1) If servo forced stop warning (A.E6) or main circuit off warning (A.E9) occurs, the servo off status is established. If any other warning occurs, operation can be continued but an alarm may take place or proper operation may not be performed. Eliminate the cause of the warning according to this section. Use the optional MR Configurator (servo configuration software) to refer to the cause of warning. @ in the Indication field denotes the slot number of the base unit. Display IFU DRU Name @A.92@ Open battery cable warning Definition Cause 1. Battery cable is open. Absolute position 2. Battery voltage supplied from the detection system battery unit to the encoder fell to battery voltage is low. about 3.2V or less. (Detected with the encoder) 3. Encoder cable is open. @A.96@ Home position Home position return 1. Droop pulses remaining are greater setting warning could not be made in than the in-position range setting. the precise position. 2. Home position return was executed during operation command. 3. Creep speed high. Battery Voltage of battery for Battery voltage fell to 3.2V or less. FA.9F warning absolute position (Detected with the servo amplifier) detection system reduced. FA.E0 Excessive regenerative warning @A.E1@ Overload warning There is a possibility that regenerative power may exceed permissible regenerative power of regenerative brake option. There is a possibility that overload alarm 1 or 2 may occur. @A.E3@ Absolute Absolute position position counter encoder pulses faulty. warning The multi-revolution counter value of the absolute position encoder exceeded the maximum revolution range. Servo forced EMG_ -SG are open. FA.E6 stop warning Main circuit off Servo-on (SON ) was FA.E9 warning turned on with main circuit power off. Regenerative power increased to 85% or more of permissible regenerative power of regenerative brake option. Checking method Call the status display and check regenerative load ratio. Action Repair cable or changed. Change battery unit. Change the encoder cable. Remove the cause of droop pulse occurrence. Reduce creep speed. Change the battery unit. 1. Reduce frequency of positioning. 2. Change regenerative brake option for the one with larger capacity. 3. Reduce load. Load increased to 85% or more of Refer to A.50, A.51. overload alarm 1 or 2 occurrence level. Cause, checking method Refer to A.50, A.51. 1. Noise entered the encoder. 2. Encoder faulty. 3. The movement amount from the home position exceeded a 32767 rotation or -37268 rotation in succession. External forced stop was made valid. (EMG_ -SG opened.) 9 - 13 Take noise suppression measures. Change servo motor. Make home position setting again. Ensure safety and deactivate forced stop. Switch on main circuit power. 9. TROUBLESHOOTING MEMO 9 - 14 10. OUTLINE DRAWINGS 10. OUTLINE DRAWINGS 10.1 MELSERVO-J2M configuration example The following diagram shows the MR-J2M-BU8 base unit where one interface unit and eight drive units are installed. 158 (6.22) 130 (5.12) 28 (1.10) [Unit: mm] ([Unit: in]) 35 (1.38) 30 (1.12) 50 (1.67) 25 (0.98) 240 (9.45) 350 (13.78) 6 (0.24) 27 (1.06) 6 (0.24) 86 (3.39) 27 (1.06) CC NN PP 11 AB C N 1 A C N 1 B C N 5 C N 3 CHARGE SON ALM SON ALM SON ALM SON ALM SON ALM SON ALM SON ALM ALM MELSERVO MELSERVO MELSERVO MELSERVO MELSERVO MELSERVO MELSERVO MELSERVO MITSUBISHI ELECTRIC MITSUBISHI ELECTRIC MITSUBISHI ELECTRIC MITSUBISHI ELECTRIC MITSUBISHI ELECTRIC MITSUBISHI ELECTRIC MITSUBISHI ELECTRIC MITSUBISHI ELECTRIC C N 2 C N 2 C N 2 C N 2 C N 2 C N 2 C N 2 C N 2 C N P 2 C N P 2 C N P 2 C N P 2 C N P 2 C N P 2 C N P 2 C N P 2 CON4 CON5 (70 (2.76)) 130 (5.12) 130 (5.12) (80 (3.15)) 10 (0.39) 10 (0.39) 140 (5.51) SON MELSERVO MITSUBISHI MR-J2M-J2M C N P 3 NAME PLATE 6 (0.24) 338 (13.31) 10 - 1 NAME PLATE 10. OUTLINE DRAWINGS 10.2 Unit outline drawings 10.2.1 Base unit (MR-J2M-BU ) [Unit: mm] ([Unit: in]) Variable Dimensions Mass [kg]([lb]) B A 1.1 (2.43) MR-J2M-BU4 230 (9.06) 218 (8.58) MR-J2M-BU6 290 (11.42) 278 (10.95) 1.3 (2.87) MR-J2M-BU8 350 (13.78) 338 (13.307) 1.5 (3.31) Base Unit A B 6 (0.24) 27 (1.06) 6 (0.24) Connector layout CNP1A, CNP1B A B 1 N L11 2 P L21 3 C 6 (0.24) 86 (3.39) 140 (5.51) NAME PLATE CC NN PP 11 AB 27 (1.06) C N P 3 CNP3 PE 3 L3 2 L2 1 L1 Terminal screw : M4 Tightening torque : 3.24 [N m] (28.7 [lb in]) 2 (0.08) 32 (1.26) 28 (1.10) 2- 6 ( 0.24) mounting hole Mounting screw : M5 Tightening torque : 3.24 [N m] (28.7 [lb in]) 10.2.2 Interface unit (MR-J2M-P8A) [Unit: mm] ([Unit: in]) 50 (1.97) 8.5 (0.34) 130 (5.12) 6.5 (0.26) Display/setting cover MELSERVO C N 1 B C N 5 C N 3 128 (5.04) C N 1 A 130 (5.12) MITSUBISHI MR-J2M-J2M NAME PLATE Approx.80 (3.15) 25 (0.98) 5 (0.20) 139 (5.47) 1(0.04) 5 (0.2) mounting hole NAME PLATE CHARG Mounting screw : M4 Tightening torque : 1.5 [N m] (13.3 [lb in]) Mass: 0.5kg (1.10lb) 10 - 2 10. OUTLINE DRAWINGS 10.2.3 Drive unit (MR-J2M- DU) (1) MR-J2M-10DU to MR-J2M-40DU Approx.70 (2.76) 138.5 (5.45) 130 (4.72) 6.5 (0.26) 5 (0.20) Connector layout 4.5 ( 0.18) mounting hole CNP2 5 (0.20) 30 (1.18) (1 (0.04)) [Unit: mm] ([Unit: in]) 2 4 V SON ALM MITSUBISHI 3 U W PLATE MITSUBISHI C N 2 120 (4.72) 1 NAME 130 (5.12) MELSERVO Mounting screw : M4 Tightening torque : 1.5 [N m] (13.3 [lb in]) NAME PLATE C N P 2 Mass: 0.4kg (0.88lb) (2) MR-J2M-70DU [Unit: mm] ([Unit: in]) 1 (0.04) 60 (2.36) Approx.70 (2.76) 138.5 (5.47) 130 (4.72) 6.5 (0.26) 5 (0.20) 2- 5 ( 0.2) mounting hole Connector layout 30 (1.18) CNP2 5 (0.20) 2 SON ALM MITSUBISHI MITSUBISHI C N 2 120 (4.72) NAME PLATE 130 (5.12) MELSERVO NAME PLATE 4 V 1 3 U W Mounting screw : M4 Tightening torque : 1.5 [N m] (13.3 [lb in]) C N P 2 Mass: 0.7kg (1.54lb) 10 - 3 10. OUTLINE DRAWINGS 10.2.4 Extension IO unit (MR-J2M-D01) [Unit: mm] ([Unit: in]) (1 (0.04)) Approx.80 (3.15) 130 (4.72) 6.5 (0.26) 5 (0.20) 25 (0.89) 138.5 (5.45) 5 (0.20) 2- 4.5 ( 0.18) mounting hole Mounting screw : M4 Tightening torque : 1.5 [N m] (13.3 [lb in]) C N 4 B 120 (4.72) 120 (4.72) 130 (5.12) C N 4 A 5 (0.20) NAME PLATE Mass: 0.2kg (1.10lb) 10.2.5 Battery unit (MR-J2M-BT) [Unit: mm] ([Unit: in]) 130 (5.45) 6.5 (0.26) 5 (0.20) Approx.70 (2.76) (1 (0.04)) 25(0.89) 5 (0.20) 2- 4.5 ( 0.18) mounting hole 120 (4.72) 120 (4.72) NAME PLATE 5 (0.20) C N 1 C 130 (5.12) Mounting screw : M4 Tightening torque : 1.5 [N m] (13.3 [lb in]) Mass: 0.3kg (0.66lb) 10 - 4 10. OUTLINE DRAWINGS 10.3 Connectors (1) CN1A CN1B CN4A CN4B connector <3M> (a) Soldered type Model Connector : 10150-3000VE Shell kit : 10350-52F0-008 [Unit: mm] ([Unit: in]) 14.0 (0.55) 17.0 (0.67) 18.0 (0.71) 52.4 (2.06) 12.7 (0.50) 46.5 (1.83) Logo, etc. are indicated here. 39.0 (1.54) 23.8 (0.94) 41.1 (1.62) (b) Threaded type Model Connector Shell kit : 10150-3000VE : 10350-52A0-008 Note. This is not available as option and should be user-prepared. [Unit: mm] ([Unit: in]) 14.0 (0.55) 17.0 (0.67) 39.0 (1.54) 5.2 (0.21) 23.8 ( 0.94) 41.1 (1.62) 52.4 (2.06) 18.0 (0.71) 12.7 (0.50) 10 - 5 46.5 (1.83) Logo, etc. are indicated here. 10. OUTLINE DRAWINGS (2) CN2 CN3 connector <3M> (a) Soldered type Model Connector Shell kit : 10120-3000VE : 10320-52F0-008 [Unit: mm] ([Unit: in]) 10.0 39.0 (1.54) 14.0 (0.55) 33.3 (1.31) 12.7 (0.50) Logo, etc. are indicated here. 23.8 (0.98) 22.0 (0.87) (0.39) 12.0 (0.47) (b) Threaded type Model Connector Shell kit : 10120-3000VE : 10320-52A0-008 Note. This is not available as option and should be user-prepared. [Unit: mm] ([Unit: in]) 10.0 (0.39) 12.0 (0.47) 39.0 (1.54) 5.7 (0.22) 23.8 (0.94) 22.0 (0.87) 33.3 (1.31) 14.0 (0.55) 12.7 (0.50) 10 - 6 27.4 (1.08) Logo, etc. are indicated here. 10. OUTLINE DRAWINGS (c) Insulation displacement type Model Connector : 10120-6000EL Shell kit : 10320-3210-000 [Unit: mm] ([Unit: in]) 11.5 42.0 (1.65) 20.9 (0.82) Logo, etc. are indicated here. 33.0 (1.3) 2- 0.5 ( 0.02) (0.45) 6.7 ( 0.26) 29.7 (1.17) (3) CN5 connector <3M> [Unit: mm] ([Unit: in]) 10.0 27.4 (1.08) 14.0 (0.55) Logo, etc. are indicated here. 3.0 (0.12) R 4.0 (0.16) 4.0 (0.16) A 4.0 (0.16) 7.6 (0.3) 10.7 12.7 (0.42 (0.50) 23.35 (0.92) 0.2 0.08) .R 0. 3 33.3 (1.31) M AX 38.0 (1.5) 22.8 (0.9) 22.0 (0.87) (0.39) 12.0 (0.47) Details A 10 - 7 R 3.0 (0.12) 10. OUTLINE DRAWINGS (4) CNP1A/CNP1B connector Model CNP1A housing CNP1B housing Contact : 1-178128-3 : 2-178128-3 : 917511-2 (max. sheath OD: 2.8 [mm] ( 0.11 [in])) 353717-2 (max. sheath OD: 3.4 [mm] ( 0.13 [in])) : 91560-1 (for 917511-2) 937315-1 (for 353717-2) Applicable tool [Unit: mm] ([Unit: in]) 5.08 (0.2) 7.15 (0.28) 29.7 (0.12) 1 2 3 AMP 22.8 (0.90) 0-3 16.3 (0.06) X 19.24 (0.76) 6.55 (0.26) (5) CNP3 connector Model Housing Contact Applicable tool : 1-179958-3 : 316041-2 : 234171-1 [Unit: mm] ([Unit: in) 10.16 (0.4) 9.8 (0.39) 45.29 (1.79) 29 (1.14) 21.2 (0.84) 1 0-5 2 3 AMP Y 33.92 (1.33) 10 - 8 10. OUTLINE DRAWINGS (6) Connectors for CNP2 [Unit: mm] 0.6 (0.024) 0.6 (0.024) ([Unit: in]) 5 4 3 R0.3 1.2 Circuit number (0.047) 10 8.5 (0.335) 11.6 (0.457) 6 3.3 (0.13) 6.3 (0.248) 4.2 (0.165) 2.5 (0.098) 9.6 (0.378) 3 (0.118) 1.5 (0.059) 19.6 (0.772) 7 1 5.4 (0.213) Layout diagrams classified by the number of poles 10.7 (0.421) 9 2 3 (0.118) 5.4 (0.213) 1 2 3 4 4 poles 3.5 (0.138) Variable Dimensions Model 5557-04R A B 4.2 (0.165) 9.6 (0.378) 4.2 (Pitch) (0.165) A B 2.7 (0.106) 2.7 (0.106) Terminal Model: 5556 [Unit: mm] 1.7 1.9 (0.075) 5.5 (0.217) 4.3 (0.169) 1.2 (0.047) 1 OMIN 14.7 (0.579) 6.6 (0.26) (0.067) 2.9 (0.114) ([Unit: in]) 2.6 (0.102) (0.039) 2 2.15 (0.085) 2.55 (0.1) (0.067) 1.7 (0.079) Applicable wire Core size : AWG#18 to #24 (5556-PBTL) AWG28 (5556-PBT2L) Sheath OD: 3.1mm ( 0.122 in) max. Strip length: 3.0 to 3.5 [mm] (0.118 to 0.138 [in]) Exclusive tools Terminal 5556-PBL Wire specifications Core size AWG18 to AWG24 Sheath OD [mm(inch)] Tool number 1.5 to 2.2 (0.06 to 0.09) 57026-5000 2.3 to 3.1 (0.06 to 0.12) 57027-5000 5556-PBT2L AWG28 57064-5000 5556-PBT3L AWG16 57022-5300 10 - 9 10. OUTLINE DRAWINGS MEMO 10 - 10 11. CHARACTERISTICS 11. CHARACTERISTICS 11.1 Overload protection characteristics 1000 1000 100 100 During rotation During rotation 10 Operation time [s] Operation time [s] An electronic thermal relay is built in the drive unit to protect the servo motor and drive unit from overloads. Overload 1 alarm (A.50) occurs if overload operation performed is above the electronic thermal relay protection curve shown in any of Figs 11.1. Overload 2 alarm (A.51) occurs if the maximum current flows continuously for several seconds due to machine collision, etc. Use the equipment on the left-hand side area of the continuous or broken line in the graph. In a machine like the one for vertical lift application where unbalanced torque will be produced, it is recommended to use the machine so that the unbalanced torque is 70% or less of the rated torque. The overload protection characteristic is about 20% lower than that of the MELSERVO-J2-Super series. However, operation at the 100% continuous rating can be performed. During servo lock 1 During servo lock 1 0.1 0 10 50 100 150 200 250 300 Load ratio [%] 0.1 0 50 100 150 200 250 300 Load ratio [%] a. MR-J2M-10DU to MR-J2M-40DU b. MR-J2M-70DU Fig 11.1 Electronic thermal relay protection characteristics Note. If operation that generates torque more than 100% of the rating is performed with an abnormally high frequency in a servo motor stop status (servo lock status) or in a 30r/min or less low-speed operation status, the servo amplifier may fail even when the electronic thermal relay protection is not activated. 11 - 1 11. CHARACTERISTICS 11.2 Power supply equipment capacity and generated loss (1) Amount of heat generated by the drive unit Table 11.1 indicates drive unit's power supply capacities and losses generated under rated load. For thermal design of an enclosure, use the values in Table 11.1 in consideration for the worst operating conditions. The actual amount of generated heat will be intermediate between values at rated torque and servo off according to the duty used during operation. When the servo motor is run at less than the maximum speed, the power supply capacity will be smaller than the value in the table, but the drive unit's generated heat will not change. Table 11.1 Power supply capacity and generated heat at rated output Unit MR-J2M-10DU Servo motor MR-J2M-40DU MR-J2M-70DU (Note 2) Generated heat[W] Area required for heat dissipation capacity[kVA] At rated torque At servo off [m2] [ft2] HC-KFS053 13 0.3 11 6 0.2 2.16 HC-MFS053 13 0.3 11 6 0.2 2.16 0.3 11 6 0.2 2.16 HC-UFS13 MR-J2M-20DU (Note 1) Power supply HC-KFS23 0.5 14 6 0.3 3.24 HC-MFS23 0.5 14 6 0.3 3.24 3.24 HC-UFS23 0.5 14 6 0.3 HC-KFS43 0.9 20 6 0.4 4.32 HC-MFS43 0.9 20 6 0.4 4.32 HC-KFS73 1.3 40 6 0.7 7.54 HC-MFS73 1.3 40 6 0.7 7.54 1.3 40 6 0.7 7.54 MR-J2M-P8A HC-UFS73 0.1 9 9 0.2 2.16 MR-J2M-BU4 0 4 4 0.1 1.08 MR-J2M-BU6 0 4 4 0.1 1.08 MR-J2M-BU8 0 4 4 0.1 1.08 Note 1. Note that the power supply capacity will vary according to the power supply impedance. This value applies to the case where the power factor improving reactor is not used. 2. Heat generated during regeneration is not included in the drive unit-generated heat. To calculate heat generated by the regenerative brake option, use Equation 12.1 in Section 12.1.1. 11 - 2 11. CHARACTERISTICS (2) Heat dissipation area for enclosed drive unit The enclosed control box (hereafter called the control box) which will contain the drive unit should be designed to ensure that its temperature rise is within 10 (50 ) at the ambient temperature of 40 . (With a 5 (41 ) safety margin, the system should operate within a maximum 55 (131 ) limit.) The necessary enclosure heat dissipation area can be calculated by Equation 11.1: P ............................................................................................................................................. (11.1) K T where, A : Heat dissipation area [m2] P : Loss generated in the control box [W] T : Difference between internal and ambient temperatures [ ] K : Heat dissipation coefficient [5 to 6] A When calculating the heat dissipation area with Equation 11.1, assume that P is the sum of all losses generated in the enclosure. Refer to Table 11.1 for heat generated by the drive unit. "A" indicates the effective area for heat dissipation, but if the enclosure is directly installed on an insulated wall, that extra amount must be added to the enclosure's surface area. The required heat dissipation area will vary wit the conditions in the enclosure. If convection in the enclosure is poor and heat builds up, effective heat dissipation will not be possible. Therefore, arrangement of the equipment in the enclosure and the use of a fan should be considered. Table 11.1 lists the enclosure dissipation area for each drive unit when the drive unit is operated at the ambient temperature of 40 (104 ) under rated load. (Outside) (Inside) Air flow Fig. 11.2 Temperature distribution in enclosure When air flows along the outer wall of the enclosure, effective heat exchange will be possible, because the temperature slope inside and outside the enclosure will be steeper. 11 - 3 11. CHARACTERISTICS 11.3 Dynamic brake characteristics Fig. 11.4 shows the pattern in which the servo motor comes to a stop when the dynamic brake is operated. Use Equation 11.2 to calculate an approximate coasting distance to a stop. The dynamic brake time constant varies with the servo motor and machine operation speeds. (Refer to Fig. 11.4) Forced stop(EMG_ ) ON OFF Time constant V0 Machine speed te Time Fig. 11.3 Dynamic brake operation diagram Lmax Lmax Vo JM JL te JL V0 te 1 ....................................................................................................................... (11.2) 60 JM : Maximum coasting distance .................................................................................................[mm][in] : Machine rapid feedrate ......................................................................................... [mm/min][in/min] : Servo motor inertial moment................................................................................. [kg cm2][oz in2] : Load inertia moment converted into equivalent value on servo motor shaft..... [kg cm2][oz in2] : Brake time constant ........................................................................................................................ [s] : Delay time of control section .......................................................................................................... [s] (There is internal relay delay time of about 30ms.) 11 - 4 16 14 12 23 10 8 6 053 4 2 0 0 Time constant [s] Time constant [ms] 11. CHARACTERISTICS 73 43 13 500 1000 1500 2000 2500 3000 Speed [r/min] 0.02 0.018 0.016 0.014 0.012 0.01 0.008 0.006 0.004 0.002 0 0 a. HC-KFS series 23 43 053 73 13 500 1000 1500 2000 2500 3000 Speed [r/min] b. HC-MFS series 0.07 73 0.06 Time constant [s] 0.05 0.04 0.03 43 0.02 23 13 0.01 0 0 50 500 1000 1500 2000 2500 3000 Speed [r/min] c. HC-UFS3000r/min series Fig. 11.4 Dynamic brake time constant Use the dynamic brake at the load inertia moment indicated in the following table. If the load inertia moment is higher than this value, the built-in dynamic brake may burn. If there is a possibility that the load inertia moment may exceed the value, contact Mitsubishi. Drive unit Load inertia moment ratio [times] MR-J2M-10DU MR-J2M-20DU 30 MR-J2M-40DU MR-J2M-70DU 11 - 5 11. CHARACTERISTICS 11.4 Encoder cable flexing life The flexing life of the cables is shown below. This graph calculated values. Since they are not guaranteed values, provide a little allowance for these values. 1 108 5 107 a 1 107 a : Long flexing-life encoder cable MR-JCCBL M-H MR-JC4CBL M-H 5 106 1 106 b : Standard encoder cable MR-JCCBL M-L Flexing life [times] 5 105 1 105 5 104 1 104 b 5 103 1 103 4 7 10 20 40 70 100 Flexing radius [mm] 11 - 6 200 12. OPTIONS AND AUXILIARY EQUIPMENT 12. OPTIONS AND AUXILIARY EQUIPMENT WARNING Before connecting any option or auxiliary equipment, make sure that the charge lamp is off more than 15 minutes after power-off, then confirm the voltage with a tester or the like. Otherwise, you may get an electric shock. CAUTION Use the specified auxiliary equipment and options. Unspecified ones may lead to a fault or fire. 12.1 Options 12.1.1 Regenerative brake options The specified combinations of regenerative brake options and base units may only be used. Otherwise, a fire may occur. CAUTION (1) Combinations and regenerative powers The power values in the table are resistor-generated powers and not rated powers. Regenerative power [W] Base unit MR-RB032 MR-RB14 MR-RB34 MR-RB54 [40 ] [26 ] [26 ] [26 ] 30 100 300 500 MR-J2M-BU4 MR-J2M-BU6 MR-J2M-BU8 (2) Selection of regenerative brake option (a) Simple judgment of regenerative brake option necessity The MELSERVO-J2M series does not contain a regenerative brake resistor. Check whether the regenerative brake option is needed or not in the following method. 1) Requirements The drive units mounted to the same base unit are all horizontal axes. The operation pattern is clear and the load inertia moments of the axes to be decelerated simultaneously are clear. 2) Checking method The following table gives the permissible load inertia moment that does not require the regenerative brake option when speed is reduced from 3000r/min. Drive unit Permissible Load Inertia Moment MR-J2M-10DU MR-J2M-20DU 1.42kg cm2 4.94kg cm2 MR-J2M-40DU MR-J2M-70DU Calculate the 3000r/min-equivalent inertia moment of each drive unit. (Load inertia moment equivalent for 3000r/min) 12 - 1 (JL JM) (running speed/3000)2 12. OPTIONS AND AUXILIARY EQUIPMENT Calculate the total of the 3000r/min-equivalent inertia moments of the axes to be decelerated simultaneously, and find the maximum total of 3000r/min-equivalent inertia moments. Also find the sum total of permissible load inertia moments of the drive units installed on the same base unit. (Maximum total of 3000r/min-equivalent inertia moments) inertia moments of drive units) 1.42 (Sum total of permissible load Regenerative brake option is unnecessary. (Maximum total of 3000r/min-equivalent inertia moments) inertia moments of drive units) 1.42 (Sum total of permissible load Regenerative brake option is necessary. 3) Confirmation example In the following 8-axis system, the total 3000r/min-equivalent inertia moment is maximum (9.75kg cm2) at the timing of 7). The permissible inertia moment of this 8-axis system is 11.36[kg cm2] as indicated by the following expression. 8 [axes] 1.42[kg cm2] 11.36[kg cm2] Hence, (Maximum total of 3000r/min-equivalent load inertia moments 9.75) 11.36[kg cm2] The regenerative brake option is unnecessary. Speed 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) First slot Second slot Third slot Operation pattern Fourth slot Fifth slot Sixth slot Seventh slot Eighth slot Servo Motor Inertia Moment kg cm2 Load Inertia Moment (Servo motor shaft equivalent) kg cm2 Total inertia moment kg cm2 r/min 3000r/minequivalent Total Inertia Moment kg cm2 First slot HC-KFS13 0.084 1.3 1.384 3000 1.38 1.38 1.38 1.38 Second slot HC-KFS23 0.42 2.1 2.52 3000 2.52 2.52 2.52 2.52 Third slot HC-KFS43 0.67 2.0 2.67 3000 2.67 2.67 2.67 2.67 Fourth slot HC-KFS13 0.084 0.8 0.884 2500 0.61 0.61 Fifth slot HC-MFS13 0.03 0.9 0.93 2500 0.65 0.65 Sixth slot HC-MFS23 0.088 2.5 2.588 3000 2.59 2.59 Seventh slot HC-KFS13 0.084 0.4 0.484 3300 0.59 0.59 Eighth slot HC-KFS43 0.67 5.83 6.5 3000 6.5 Axis No. Servo Motor Model 3000r/min-equivalent total inertia moment Running speed 0.65 6.5 6.57 1.26 kg cm2 0.61 9.75 6.5 6.57 1.26 Simultaneous deceleration total inertia moment maximum value 12 - 2 12. OPTIONS AND AUXILIARY EQUIPMENT (b) To make selection according to regenerative energy Use the following method when regeneration occurs continuously in vertical motion applications or when it is desired to make an in-depth selection of the regenerative brake option: 1) Regenerative energy calculation Use the following table to calculate the regenerative energy. Formulas for calculating torque and energy in operation Regenerative power 1) T1 2) T2 3) T3 4), 8) T4 5) T5 6) T6 7) T7 Torque applied to servo motor [N m] (JL JM) No 1 TU TF 4 T psa1 9.55 10 TU TF (JL JM) No 9.55 104 TU (JL JM) No 4 9.55 10 TU TF (JL JM) No 9.55 104 E1 E2 1 Tpsd1 1 Tpsa2 E3 TF E4 0 (No regeneration) 0.1047 E5 No T5 Tpsa2 2 E6 1 Tpsd2 TU 0.1047 No T2 t1 0.1047 No T3 Tpsd1 2 TF TU TU Energy [J] 0.1047 No T1 Tpsa1 2 TF E7 0.1047 No T6 t3 0.1047 No T7 Tpsd2 2 From the calculation results in 1) to 8), find the absolute value (Es) of the sum total of negative energies. 2) Losses of servo motor and drive unit in regenerative mode The following table lists the efficiencies and other data of the servo motor and drive unit in the regenerative mode. Drive unit Inverse efficiency [%] MR-J2M-10DU 55 MR-J2M-20DU 70 MR-J2M-40DU 85 MR-J2M-70DU 80 C charging [J] 5.5 18 Using the following expression, find the total of C charging [J] of the MELSERVO-J2M. Number of drive unit axes 5.5J Then, find the energy at each timing in a single-cycle operation pattern. The energy is positive in the driving mode and negative in the regenerative mode. Enter signed driving/regenerative energy values into the following calculation table. The shaded areas indicate negative values. 12 - 3 12. OPTIONS AND AUXILIARY EQUIPMENT Timing 1) 2) 3) 4) 5) 6) 7) 8) First slot E1 E2 E3 E4 E1 E2 E3 E4 Second slot E1 E2 E3 E4 E1 E2 E3 E4 Third slot E1 E2 E3 E4 E5 E6 E7 E8 Fourth slot E4 E4 E1 E2 E3 E4 E4 E4 Fifth slot E4 E4 E4 E4 E4 E1 E2 E3 Sixth slot E1 E2 E2 E3 E4 E4 E1 E2 Seventh slot E1 E2 E2 E3 E4 E4 E1 E2 Eighth slot E1 E2 E2 E3 E4 E4 E1 E2 Total E 1) E 2) E 3) E 4) E 5) E 6) E 7) E 8) Regenerative ES ES 3) ES 4) |ES|-EC ER ER PR(W) ER/tf Calculate the total of energies at each timing. Only when the total is negative (timings 3, 4 in the example), use the following expression for calculation. Energy total ER regenerative energy ES (absolute value) C charging total (EC) If the subtraction results are negative at all timings, the regenerative brake option is not needed. From the total of ER's whose subtraction results are positive and a single-cycle period, the power consumption of the regenerative brake option can be calculated with the following expression. Power consumption PR [W] (total of positive ER's)/1-cycle operation period (tf) 12 - 4 12. OPTIONS AND AUXILIARY EQUIPMENT (3) Connection of the regenerative brake option POINT When using the MR-RB54, cooling by a fan is required. Please obtain a cooling fan at your discretion. Set IFU parameter No.1 according to the option to be used. The regenerative brake option will generate heat of about 100 (212 ). Fully examine heat dissipation, installation position, used cables, etc. before installing the option. For wiring, use flame-resistant cables and keep them clear of the regenerative brake option body. Always use twisted cables of max. 5m(16.4ft) length for connection with the base unit. The G3 and G4 terminals act as a thermal sensor. G3-G4 are disconnected when the regenerative brake option overheats abnormally. DRU parameter No.2 Selection of regenerative 0: Not used. 2: MR-RB032 5: MR-RB14 6: MR-RB34 7: MR-RB54 Base unit CNP1A 2 P 3 C Regenerative brake option P C (Note) G3 G4 5m (16.4 ft) max. Note. Make up a sequence which will switch off the magnetic contactor (MC) when abnormal heating occurs. G3-G4 contact specifications Maximum voltage: 120V AC/DC Maximum current: 0.5V/4.8VDC Maximum capacity: 2.4VA 12 - 5 12. OPTIONS AND AUXILIARY EQUIPMENT (4) Outline drawing (a) MR-RB032 MR-RB14 [Unit: mm (in)] LA 12 (0.47) 6 (0.23) 6 (0.24) mounting hole LB 144 (5.67) TE1 Terminal block 5 (0.20) G3 G4 P C 6 (0.23) 12 (0.47) G3 G4 P C 6 (0.23) TE1 168 (6.61) 156 (6.14) MR-RB Terminal screw: M3 1.6 (0.06) 20 (0.79) LD LC Regenerative brake option MR-RB032 MR-RB14 LA 30 (1.18) 40 (1.57) Tightening torque: 0.5 to 0.6 [N m](4 to 5 [lb in]) Mounting screw Screw size: M5 Tightening torque: 3.2 [N m](28.32 [lb in]) Variable dimensions Mass LB LC LD [kg] [lb] 15 (0.59) 119 (4.69) 99 (3.9) 0.5 1.1 15 (0.59) 169 (6.69) 149 (5.87) 1.1 2.4 (b) MR-RB34 10 (0.39) 142 (5.59) 150 (5.91) G4 G3 C P P C Terminal screw: M4 G3 Tightening torque: 1.2 [N m] (10.6 [lb in]) G4 318 (12.52) 7(0.28) 90 (3.54) Terminal block 17 (0.67) 335 (13.19) 100 (3.94) Mounting screw Screw : M6 Tightening torque: 5.4 [N m](47.79 [lb in]) 79 (7.05) 8.5 (0.34) 125 (4.92) 8.5 (0.34) [Unit: mm (in)] 12 - 6 Regenerative Brake Option Mass [kg(lb)] MR-RB34 2.9 (6.393) 12. OPTIONS AND AUXILIARY EQUIPMENT (c) MR-RB54 200 (7.87) 223 (8.78) 17 (0.67) 12.5 (0.49) 12.5 (0.49) 82.5 (3.25) 133 (5.24) 2.3 (0.09) 12 (0.47) Mounting screw Screw : M6 Wind blows in the arrow direction. 7 (0.28) 108 (4.25) 120 (4.73) [Unit: mm (in)] P C Terminal screw: M4 G3 Tightening torque: 1.2 [N m](10.6 [lb in]) G4 G4 G3 C P 162.5 (6.39) 14 slot 350 (13.78) 7 Terminal block 162.5(6.39) 82.5 49 (1.93) (3.25) Fan mounting screw (2-M3 screw) On opposite side Tightening torque: 5.4 [N m](47.79 [lb in]) Approx.30 (1.18) 8 (0.32) 12 - 7 Regenerative Brake Option Mass [kg(lb)] MR-RB54 5.6 (12.346) 12. OPTIONS AND AUXILIARY EQUIPMENT 12.1.2 Cables and connectors (1) Cable make-up The following cables are used for connection with the servo motor and other models. The broken line areas in the diagram are not options. 5) Operation panel 5) 16) Programmable controller ‡N 14) BU Programmable controller ‡L IFU Battery unit MR-J2M-BT Inhancin IO unit DRU MR-J2M-D01 DRU CNP1A CNP1B To regenerative brake option 12) Operation panel CN1C CN4A CN1A CN1B To control circuit power supply CN2 CN3 To main circuit power supply CN2 CN4B CN5 CN3 CNP2 CON5 CNP2 13) Supplied with interface unit 17) 10) 9) 10) HC-KFS HC-MFS HC-UFS 3000r/min 15) Programmable controller 1) 2) 3) Personal computer 8) 7) 4) 6) 12 - 8 12. OPTIONS AND AUXILIARY EQUIPMENT No. Product Model 1) Standard encoder MR-JCCBL M-L cable Refer to (2) (a) in this section. 2) Long flexing life encoder cable 3) Description Connector: 10120-3000VE Shell kit: 10320-52F0-008 (3M or equivalent) Application Housing: 1-172161-9 Standard Pin: 170359-1 flexing life (Tyco Electronics or equivalent) IP20 Cable clamp: MTI-0002 (Toa Electric Industry) MR-JCCBL M-H Refer to (2) (a) in this section. Long flexing life IP20 MR-JC4CBL M-H Refer to (2) (b) in this section. 4 line type Long flexing life IP20 4) Encoder connector set MR-J2CNM Connector: 10120-3000VE Shell kit: 10320-52F0-008 (3M or equivalent) 5) Connector set MR-J2MCN1 Connector: 10150-3000VE Shell kit: 10350-52F0-008 (3M or equivalent) IP20 Housing: 1-172161-9 Pin: 170359-1 (Tyco Electronics or equivalent) Cable clamp: MTI-0002 (Toa Electric Industry) Qty: 2 each 6) Bus cable MR-J2HBUS M Refer to section 12.1.4 (4). Connector: 10120-6000EL Shell kit: 10320-3210-000 (3M or equivalent) 7) Maintenance junction card MR-J2CN3TM Refer to Section 12.1.4. 8) Communication cable MR-CPCATCBL3M Connector: DE-9SF-N Refer to (3) in this Case: DE-C1-J6-S6 section. (Japan Aviation Electronics) 9) Power supply connector set MR-PWCNK1 Plug: 5559-04P-210 Terminal: 5558PBT3L (For AWG16)(6 pcs.) (Molex) IP20 10) Power supply connector set MR-PWCNK2 Plug: 5559-06P-210 Terminal: 5558PBT3L (For AWG16)(8 pcs.) (Molex) For motor with brake IP20 12 - 9 Connector: 10120-6000EL Shell kit: 10320-3210-000 (3M or equivalent) Connector: 10120-6000EL Shell kit: 10320-3210-000 (3M or equivalent) For connection with PC-ATcompatible personal computer 12. OPTIONS AND AUXILIARY EQUIPMENT No. Product 11) Power supply Model MR-PWCNK3 connector Description Application Plug: 5557-04R-210 Servo motor Terminal: 5556PBT3L (for AWG16) (6 pcs.) power cable (Molex) 12) Base unit MR-J2MCNM For CNP1B Housing: 2-178128-3 (5 pcs.) connector set Y Contact: 917511-2 (max. sheath OD ( 2.8 [mm] 0.11[in]) 15 pcs.) (Tyco Electronics) For CNP1A Housing: 1-178128-3 (5 pcs.) X Contact: 917511-2 (max. sheath OD ( 2.8 [mm] 0.11[in]) 15 pcs.) (Tyco Electronics) Housing: 1-179958-3 (5 pcs.) For CNP3 Contact: 316041-2 (20 pcs.) (Tyco Electronics) 13) Battery cable MR-J2MBTCBL M Housing: 51030-0230 14) Junction terminal MR-J2M-CN1TBL block cable Shell kit: 10320-52F0-008 (molex) (3M or equivalent) M Junction terminal block connector Cable length 0.5, 1m D7950-B500FL (connector) MR-J2TBL 10150-6000EL(connector) Interface unit connector (3M or equivalent) (3M) 0.5, 1m D7920-B500FL (connector) 10120-6000EL(connector) 10320-52F0-F08-M1A(shell kit) (1.64, 3.28ft) 16) Junction terminal MR-TB50 Refer to Section 12.1.3 17) Refer to Section 12.1.4 MR-TB20 For MR-TB50 10350-3210-000(shell kit) M-1A Junction terminal block connector Cable length Interface unit connector (3M or equivalent) (3M) (1.64, 3.28ft) 15) Connector: 10120-3000VE Terminal: 50083-8160 12 - 10 For MR-TB20 12. OPTIONS AND AUXILIARY EQUIPMENT (2) Encoder cable CAUTION If you have fabricated the encoder cable, connect it correctly. Otherwise, misoperation or explosion may occur. POINT The encoder cable is not oil resistant. Refer to Section 11.4 for the flexing life of the encoder cable. When the encoder cable is used, the sum of the resistance values of the cable used for P5 and the cable used for LG should be within 2.4 . When soldering the wire to the connector pin, insulate and protect the connection portion using heat-shrinkable tubing. Generally use the encoder cable available as our options. If the required length is not found in the options, fabricate the cable on the customer side. (a) MR-JCCBL M-L/H 1) Model explanation Model: MR-JCCBL MSymbol Specifications L Standard flexing life H Long flexing life Symbol Cable length [m(ft)] 2 5 10 20 2 (6.56) 5 (16.4) 10 (32.8) 20 (65.6) 2) Connection diagram The signal assignment of the encoder connector is as viewed from the pin side. For the pin assignment on the drive unit side, refer to Section 3.5.3 Encoder cable supplied to servo motor Drive unit Encoder connector Encoder cable (option or fabricated) Servo motor Encoder connector 1-172169-9 (Tyco Electronics) 1 Encoder CN2 Less than 30m(98ft) 30cm (0.98ft) 12 - 11 MR 4 MD 7 P5 2 3 MRR BAT 5 6 MDR 8 9 LG SHD 12. OPTIONS AND AUXILIARY EQUIPMENT MR-JCCBL2M-L MR-JCCBL5M-L MR-JCCBL2M-H MR-JCCBL5M-H Drive unit side P5 LG P5 LG P5 LG 19 11 20 12 18 2 MR MRR MD MDR BAT LG 7 17 6 16 9 1 Encoder side 7 8 1 2 4 5 3 MR-JCCBL10M-L MR-JCCBL10M-H MR-JCCBL20M-L MR-JCCBL20M-H Drive unit side Encoder side P5 LG P5 LG P5 LG 19 11 20 12 18 2 7 MR MRR MD MDR BAT LG 7 17 6 16 9 1 (Note) SD Plate 8 1 2 4 5 3 Drive unit side Encoder side P5 LG P5 LG P5 LG 19 11 20 12 18 2 7 MR MRR MD MDR BAT LG 7 17 6 16 9 1 (Note) 9 SD Plate 8 1 2 4 5 3 (Note) 9 SD Plate 9 Note. Always make connection for use in an absolute position detection system. This wiring is not needed for use in an incremental system. When fabricating an encoder cable, use the recommended wires given in Section 12.2.1 and the MR-J2CNM connector set for encoder cable fabrication, and fabricate an encoder cable as shown in the following wiring diagram. Referring to this wiring diagram, you can fabricate an encoder cable of less than 30m(98ft) length including the length of the encoder cable supplied to the servo motor. When the encoder cable is to be fabricated by the customer, the wiring of MD and MDR is not required. Refer to Chapter 3 of the servo motor instruction manual and choose the encode side connector according to the servo motor installation environment. For use of AWG22 Drive unit side Encoder side (3M) P5 LG P5 LG P5 LG 19 11 20 12 18 2 MR MRR 7 17 BAT LG 9 1 SD Plate 7 8 1 2 3 (Note) 9 Note. Always make connection for use in an absolute position detection system. This wiring is not needed for use in an incremental system. 12 - 12 12. OPTIONS AND AUXILIARY EQUIPMENT (b) MR-JC4CBL M-H POINT When using this encoder cable, set "1 " in DRU parameter No. 20. 1) Model explanation Model: MR-JC4CBL M- H Long flexing life Symbol Cable length [m(ft)] 30 40 50 30 (98.4) 40 (131.2) 50 (164.0) 2) Connection diagram The signal assignment of the encoder connector is as viewed from the pin side. For the pin assignment on the drive unit side, refer to Section 3.5.3. Encoder cable supplied to servo motor Drive unit Encoder connector Encoder cable (option or fabricated) Servo motor Encoder connector 1-172169-9 (Tyco Electronics) 1 Encoder CN2 50m(164ft) max. 30cm (0.98ft) 12 - 13 MR 4 MD 7 P5 2 3 MRR BAT 5 6 MDR CNT 8 9 LG SHD 12. OPTIONS AND AUXILIARY EQUIPMENT MR-JC4CBL30M-H to MR-JC4CBL50M-H Encoder side Drive unit side P5 LG P5 LG P5 LG 19 11 20 12 18 2 MR MRR MD MDR BAT LG 7 17 6 16 9 1 7 8 1 2 4 5 3 (Note) SD Plate 9 Note. Always make connection for use in an absolute position detection system. This wiring is not needed for use in an incremental system. When fabricating an encoder cable, use the recommended wires given in Section 12.2.1 and the MR-J2CNM connector set for encoder cable fabrication, and fabricate an encoder cable as shown in the following wiring diagram. Referring to this wiring diagram, you can fabricate an encoder cable of up to 50m(164.0ft) length. When the encoder cable is to be fabricated by the customer, the wiring of MD and MDR is not required. Refer to Chapter 3 of the servo motor instruction manual and choose the encode side connector according to the servo motor installation environment. For use of AWG22 Drive unit side Encoder side (3M) P5 LG P5 LG P5 LG 7 19 11 20 12 18 2 MR MRR 7 17 BAT LG 9 1 SD Plate 6 8 1 2 3 (Note) 9 Note. Always make connection for use in an absolute position detection system. This wiring is not needed for use in an incremental system. 12 - 14 12. OPTIONS AND AUXILIARY EQUIPMENT (3) Communication cable POINT This cable may not be used with some personal computers. After fully examining the signals of the RS-232C connector, refer to this section and fabricate the cable. (a) Model definition Model : MR-CPCATCBL3M Cable length 3[m](10[ft]) (b) Connection diagram MR-CPCATCBL3M Personal computer side Interface unit side Plate FG TXD 3 2 RXD RXD 2 1 12 LG TXD GND RTS 5 7 11 LG CTS 8 DSR DTR 6 4 D-SUB9 pins Half-pitch 20 pins When fabricating the cable, refer to the connection diagram in this section. The following must be observed in fabrication: 1) Always use a shielded, multi-core cable and connect the shield with FG securely. 2) The optional communication cable is 3m(10ft) long. When the cable is fabricated, its maximum length is 15m(49ft) in offices of good environment with minimal noise. 12 - 15 12. OPTIONS AND AUXILIARY EQUIPMENT (4) Battery cable When fabricating, use the recommended wire given in Section 12.2.1 and fabricate as in the connection diagram shown in this section. (a) Definition of model Model: MR-J2MBTCBL M Symbol 03 1 Cable Length L [m(ft)] 0.3 (0.1) 1 (3.28) 10 20 11 L 1 (b) Outline drawing (c) Connection diagram Base unit side Housing: 51030-0230 Terminal: 50083-8160 Battery unit side Connector: 10120-3000VE Shell kit: 10320-52F0-008 LG 1 1 LG BAT 2 9 BAT Plate SD 12 - 16 12. OPTIONS AND AUXILIARY EQUIPMENT 12.1.3 Junction terminal block (MR-TB50) (1) How to use the junction terminal block Always use the junction terminal block (MR-TB50) with the junction terminal block cable (MR-J2MCN1TBL M) as a set. A connection example is shown below: Interface unit Junction terminal block MR-TB50 CN1A or CN1B Junction terminal block cable (MR-J2M-CN1TBL M) Ground the junction terminal block cable on the junction terminal block side with the standard accessory cable clamp fitting (AERSBAN-ESET). For the use of the cable clamp fitting, refer to Section 12.2.6, (2)(c). (2) Terminal labels Use the following junction terminal block labels. (a) For CN1A OP_ ALM SG INP4 SON4 CR3 RES2 RD1 PP4 PP3 PP2 PP1 LG OP3 OP1 _A CR4 RES3 RD2 INP1 SON1 NG4 NG3 NG2 NG1 VIN P5 OP_ OPC RES4 RD3 INP2 SON2 CR1 NP4 NP3 NP2 NP1 OP4 OP2 VIN RD4 INP3 SON3 CR2 RES1 PG4 PG3 PG2 PG1 LG COM (b) For CN1B OP_ ALM SG INP8 SON8 CR7 RES6 RD5 PP8 PP7 PP6 PP5 LG OP7 OP5 _B CR8 RES7 RD6 INP5 SON5 NG8 NG7 NG6 NG5 VIN P5 OPC RES8 RD7 INP6 SON6 CR5 NP8 NP7 NP6 NP5 OP8 OP6 VIN RD8 INP7 SON7 CR6 RES5 PG8 PG7 PG6 PG5 LG OP_ COM (3) Outline drawing 50 49 244(9.61) (1.97) MITSUBISHI MR-TB50 2.5 (0.09) 2 1 9 (0.35) 25 (25) (0.98) 50 (0.98) [Unit: mm] ([Unit: in.]) 2- 4.5(0.18) 235(9.25) 46.5(1.83) Terminal screw: M3.5 Applicable cable: 2mm 2 Crimping terminal width: 7.2mm (0.283 in) max. 12 - 17 12. OPTIONS AND AUXILIARY EQUIPMENT (4) Junction terminal block cable (MR-J2M-CN1TBL M) (a) Model explanation Model: MR-J2M-CN1TBL M Symbol Cable length[m(ft)] 05 0.5 (1.64) 1 1 (3.28) (b) Connection diagram PCR-S50FS(Servo amplifier side) Symbol Pin No. CN1A CN1B SG SG 1 OPC OPC 2 INP4 INP8 3 RES4 RES8 4 SON4 SON8 5 6 RD3 RD7 CR3 CR7 7 INP2 INP6 8 RES2 RES6 9 SON2 SON6 10 RD1 RD5 11 CR1 CR5 12 PP4 PP8 13 NP4 NP8 14 PP3 PP7 15 NP3 NP7 16 PP2 PP6 17 NP2 NP6 18 PP1 PP5 19 NP1 NP5 20 LG LG 21 OP4 OP8 22 OP3 OP7 23 OP2 OP6 24 OP1 OP5 25 VIN VIN 26 ALM_A ALM_B 27 RD4 RD8 28 CR4 CR8 29 INP3 INP7 30 RES3 RES7 31 SON3 SON7 32 RD2 RD6 33 CR2 CR6 34 INP1 INP5 35 RES1 RES5 36 SON1 SON5 37 PG4 PG8 38 NG4 NG8 39 PG3 PG7 40 NG3 NG7 41 PG2 PG6 42 NG2 NG6 43 PG1 PG5 44 NG1 NG5 45 LG LG 46 OP_VIN OP_VIN 47 OP_COM OP_COM 48 P5 P5 49 LG LG 50 plate SD SD JE1S-501(Junction terminal side) 12 - 18 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 12. OPTIONS AND AUXILIARY EQUIPMENT 12.1.4 Junction terminal block (MR-TB20) (1) How to use the junction terminal block Always use the junction terminal block (MR-TB20) with the junction terminal block cable (MRJ2TBL M-1A) as a set. A connection example is shown below: Servo amplifier Junction terminal block Cable clamp MR-TB20 (AERSBAN-ESET) CN5 Junction terminal block cable (MR-J2TBL M-1A) Ground the junction terminal block cable on the junction terminal block side with the standard accessory cable clamp fitting (AERSBAN-ESET). For the use of the cable clamp fitting, refer to Section 13.2.6, (2)(c). (2) Terminal labels Use the following junction terminal block label designed for CN5. When changing the input signals in parameters No. 43 to 48, refer to (4) in this section and Section 3.2.1 and apply the accessory signal seals to the labels. 19 18 17 16 15 LSP5 LSP6 LSP7 LSP8 EMG_B SD 14 SG 13 12 11 10 LSN1 LSN2 LSN3 9 8 7 6 5 4 3 2 1 0 LSP1 LSP2 LSP3 LSP4 LSN4 LSN5 LSN6 LSN7 LSN8 EMG_A (3) Outline drawing 19 9 2- 4.5(0.18) 46.2(1.82) 0 50(1.97) 10 7 MITSUBISHI MR-TB20 12 - 19 (0.28) 126(4.96) 117(4.61) 60(2.36) [Unit: mm] ([Unit: in.]) Terminal screw: M3.5 Applicable cable: Max. 2mm 2 (Crimping terminal width: 7.2mm (0.283 in) max.) 12. OPTIONS AND AUXILIARY EQUIPMENT (4) Junction terminal block cable (MR-J2TBL M-1A) (a) Model explanation Model: MR-J2TBL M-1A Symbol Cable length[m(ft)] 05 0.5 (1.64) 1 1 (3.28) (b) Connection diagram Junction terminal block side connector(3M) D7920-B500FL(Connector) Symbol CN5 Junction Terminal Pin No. Block No. LSP1 LSN1 LSP2 LSN2 LSP3 LSN3 LSP4 SG 0 10 1 11 2 12 3 13 1 2 3 4 5 6 7 8 LSN4 LSP5 LSN5 LSP6 LSN6 LSP7 LSN7 LSP8 LSN8 4 14 5 15 6 16 7 17 8 18 9 19 9 10 11 12 13 14 15 16 17 18 19 20 EMG_B EMG_A SD Servo amplifierside(CN5)connector(3M) 10120-6000EL(Connector) 10320-52F0-R08-M1A(Shell kit) Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 plate 12 - 20 12. OPTIONS AND AUXILIARY EQUIPMENT 12.1.5 Maintenance junction card (MR-J2CN3TM) (1) Usage The maintenance junction card (MR-J2CN3TM) is designed for use when a personal computer and analog monitor are used at the same time. Interface unit Communication cable Maintenance junction card (MR-J2CN3TM) Bus cable MR-J2HBUS M CN3B CN3A CN3 CN3C A1 A2 A3 A4 B4 B3 B2 B1 B5 B6 A5 A6 TRE RDP P5 SDN LG LG PE LG LG MO1 MO2 Analog monitor 2 Not used. Analog monitor 1 (2) Connection diagram TE1 B5 B6 CN3A LG 1 RXD 2 LG 3 MO1 4 RDP 5 6 MO3 7 8 SDP 9 TRE 10 11 LG TXD 12 13 LG MO2 14 15 16 17 18 SDN 19 20 P5 CN3B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Shell CN3C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Shell 1 A5 3 4 5 A6 10 A1 A2 13 14 15 A3 A4 B4 19 20 LG LG MO1 MO2 TRE RDP P5 SDN LG Not used. B3 B2 Shell B1 LG PE (3) Outline drawing [Unit: mm] ([Unit: in.]) CN3A CN3B CN3C 75 (2.95) MR-J2CN3TM 2- 5.3(0.21)(mounting hole) A1 A6 B1 B6 TE1 3 (0.12) 88 (3.47) 100 (3.94) 12 - 21 41.5 (1.63) Mass: 110g (0.24lb) 12. OPTIONS AND AUXILIARY EQUIPMENT (4) Bus cable (MR-J2HBUS (a) Model explanation M) Model: MR-J2HBUS M Symbol Cable length [m(ft)] 05 1 5 0.5 (1.64) 1 (3.28) 5 (16.4) (b) Connection diagram MR-J2HBUS05M MR-J2HBUS1M MR-J2HBUS5M 10120-6000EL (connector) 10320-3210-000 (shell kit) 10120-6000EL (connector) 10320-3210-000 (shell kit) 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 Plate Plate 12 - 22 12. OPTIONS AND AUXILIARY EQUIPMENT 12.1.6 MR Configurator (servo configurations software) POINT Required to assign devices to the pins of CN4A and CN4B of the MRJ2M-D01 extension IO unit. The MR Configurator (servo configuration software) uses the communication function of the interface unit to perform parameter setting changes, graph display, test operation, etc. on a personal computer. (1) Specifications Item Communication signal Baudrate [bps] System Monitor Alarm Diagnostic Parameters Test operation Advanced function File operation Others Description Conforms to RS-232C. 57600, 38400, 19200, 9600 Station selection, automatic demo Display, high speed monitor, trend graph Minimum resolution changes with the processing speed of the personal computer. Display, history, amplifier data Digital I/O, function device display no motor rotation, total power-on time, amplifier version info, motor information, tuning data, absolute encoder data, Axis name setting, unit composition listing. Turning, change list, detailed information, IFU parameter, DRU parameter, device setting. Jog operation, positioning operation, operation w/o motor, forced output, demo mode. Machine analyzer, gain search, machine simulation. Data read, save, print Automatic demo, help display (2) System configuration (a) Components To use this software, the following components are required in addition to MELSERVO-J2M and servo motor: Model (Note 2) Personal computer OS Display Keyboard Mouse Printer Communication cable (Note 1) Description IBM PC-AT compatible where the English version of Windows® 95, Windows® 98, Windows® Me, Windows NT® Workstation 4.0 or Windows® 2000 Professional operates Processor: Pentium® 133MHz or more (Windows® 95, Windows® 98, Windows NT® Workstation 4.0, Windows® 2000 Professional) Pentium® 150MHz or more (Windows® Me) Memory: 16MB or more (Windows® 95), 24MB or more (Windows® 98) 32MB or more (Windows® Me, Windows NT® Workstation 4.0, Windows® 2000 Professional) Free hard disk space: 60MB or more Serial port used Windows® 95, Windows® 98, Windows® Me, Windows NT® Workstation 4.0, Windows® 2000 Professional (English version) One whose resolution is 800 600 or more and that can provide a high color (16 bit) display. Connectable with the above personal computer. Connectable with the above personal computer. Connectable with the above personal computer. Note that a serial mouse is not used. Connectable with the above personal computer. MR-CPCATCBL3M When this cannot be used, refer to (3) Section 12.1.2 and fabricate. Note 1. Windows and Windows NT are the registered trademarks of Microsoft Corporation in the United State and other countries. Pentium is the registered trademarks of Intel Corporation. 2. On some personal computers, this software may not run properly. (b) Configuration diagram Personal computer IFU Communication cable CN3 BU DRU (First slot) CN2 Servo motor To RS-232C connector DRU (Eighth slot) CN2 Servo motor 12 - 23 12. OPTIONS AND AUXILIARY EQUIPMENT 12.2 Auxiliary equipment Always use the devices indicated in this section or equivalent. To comply with the EN Standard or UL/CUL (CSA) Standard, use the products which conform to the corresponding standard. 12.2.1 Recommended wires (1) Wires for power supply wiring The following diagram shows the wires used for wiring. Use the wires given in this section or equivalent. 1) Main circuit power supply lead Base unit Power supply 3) Motor power supply lead Drive unit Servo motor L1 U U L2 V V L3 W W Motor (Earth) L11 5) Electromagnetic brake lead L21 2) Control circuit power supply lead Regenerative brake option C ElectroB1 magnetic B2 brake CN2 Encoder P Encoder cable (refer to Section 12.1.2(2)) 4) Regenerative brake option lead The following table lists wire sizes. The wires used assume that they are 600V vinyl wires and the wiring distance is 30m(98.4ft) max. If the wiring distance is over 30m(98.4ft), choose the wire size in consideration of voltage drop. The servo motor side connection method depends on the type and capacity of the servo motor. Refer to Section 3.5.3. To comply with the UL/C-UL (CSA) Standard, use UL-recognized copper wires rated at 60 (140 ) or more for wiring. Table 12.1 Recommended wires 2 Unit MR-J2M-BU4 MR-J2M-BU6 MR-J2M-BU8 MR-J2M-10DU MR-J2M-20DU MR-J2M-40DU MR-J2M-70DU Wires [mm ] 1) L1 L2 L3 2 (AWG14) 3.5 (AWG12) 5.5 (AWG10) 2) L11 L21 3) U V W 2 (AWG14) 4) P C 5) B1 B2 2 (AWG14) 1.25 (AWG16) 12 - 24 1.25 (AWG16) 12. OPTIONS AND AUXILIARY EQUIPMENT (2) Wires for cables When fabricating a cable, use the wire models given in the following table or equivalent: Table 12.2 Wires for option cables Type Length [m(ft)] Model 2 to 10 (6.56 to 32.8) 20 30 (65.6 98.4) 2 5 (6.56 16.4) 10 to 20 (32.8 to 65.6) 30 to 50 (98.4 to 164) MR-JCCBL M-L Encoder cable MR-JCCBL M-H MR-JC4CBL M-H Communication MR-CPCATCBL3M cable Bus cable MR-J2HBUS M Battery unit cable MR-J2MBATCBL M Core size Number of Cores [mm2] 0.08 0.3 0.2 0.2 0.2 12 (6 pairs) 12 (6 pairs) 12 (6 pairs) 14 (7 pairs) 14 (7 pairs) 6 (3 pairs) Characteristics of one core Structure Conductor [Wires/mm] resistance[ /mm] Insulation coating ODd[mm] (Note 1) (Note 3) Finishing OD [mm] 7/0.127 222 0.38 5.6 12/0.18 62 1.2 8.2 40/0.08 105 0.88 7.2 40/0.08 105 0.88 8.0 40/0.08 105 0.88 8.0 7/0.127 222 0.38 4.6 Wire model UL20276 AWG#28 6pair (BLACK) UL20276 AWG#22 6pair (BLACK) (Note 2) A14B2343 6P (Note 2) A14B0238 7P (Note 2) A14B0238 7P UL20276 AWG#28 3pair (BLACK) 3 (9.84) 0.08 0.5 to 5 (1.64 to 16.4) 0.08 20 (10 pairs) 7/0.127 222 0.38 6.1 UL20276 AWG#28 10pair (CREAM) 0.3 1 (0.98 3.28) 0.3 2 (1 pairs) 12/0.18 63 1.5 5.1 MVVS IP 0.3mm2 Note 1. d is as shown below: d Conductor Insulation sheath 2. Purchased from Toa Electric Industry 3. Standard OD. Max. OD is about 10% greater. 12 - 25 12. OPTIONS AND AUXILIARY EQUIPMENT 12.2.2 No-fuse breakers, fuses, magnetic contactors Always use one no-fuse breaker and one magnetic contactor with one drive unit. Make selection as indicated below according to the total output value of the servo motors connected to one base unit. When using a fuse instead of the no-fuse breaker, use the one having the specifications given in this section. (1) No-fuse breaker Servo motor output total No-fuse breaker 550W max. 30A frame 5A Rated current [A] 5 More than 550W to 1100W max. 30A frame 10A 10 More than 1100W to 1650W max. 30A frame 15A 15 More than 1650W to 2200W max. 30A frame 20A 20 More than 2200W to 3300W max. 30A frame 30A 30 (2) Fuse Servo motor output total Fuse Class Current [A] Voltage [V] 800W max. K5 15 AC250 More than 800W to 1100W max. K5 20 AC250 More than 1100W to 1650W max. K5 30 AC250 More than 1650W to 2200W max. K5 40 AC250 More than 2200W to 3300W max. K5 70 AC250 (3) Magnetic contactor Servo motor output total Magnetic contactor 1700W max. S-N10 More than 1700W to 2800W max. S-N18 More than 2800W to 3300W max. S-N20 12 - 26 12. OPTIONS AND AUXILIARY EQUIPMENT 12.2.3 Power factor improving reactors The input power factor is improved to be about 90%. Make selection as described below according to the sum of the outputs of the servo motors connected to one base unit. [Unit : mm] ([Unit : in]) H 5(0.2) NFB MC 3-phase 200 to 230VAC W R FR-BAL X S Y T Z L1 L2 L3 Base unit MR-J2M-BU D1 NFB Installation screw MC (Note) 1-plase 200 to 230VAC D 5(0.2) RX S Y T Z C Base unit MR-J2M-BU R FR-BAL X S Y T Z L1 L2 L3 W1 Note. Connect a 1-phase 200 to 230VAC power supply to L1/L2 and keep L3 open. Servo motor output total Model Dimensions [mm (in) ] W W1 H D D1 C 135 (5.31) 120 (4.72) 115 (4.53) 59 (2.32) 45 0 2.5 (1.77 0 0.098 More than 300W to FR-BAL-0.75K 135 (5.31) 120 (4.72) 115 (4.53) 69 (2.72) 57 450W max. 0 2.5 (2.24 0 0.098 More than 450W to FR-BAL-1.5K 750W max. 160 (6.30) 145 (5.71) 140 (5.51) 71 (2.79) 55 0 2.5 More than 750W to FR-BAL-2.2K 1100W max. 160 (6.30) 145 (5.71) 140 (5.51) 91 (3.58) 75 More than 1100W to FR-BAL-3.7K 1900W max. 300W max. FR-BAL-0.4K ) 7.5 (0.29) Mounting Terminal screw size screw size Mass [kg (lb)] M4 M3.5 2.0 (4.4) ) 7.5 (0.29) M4 M3.5 2.8 (6.17) 0 0.098 ) 7.5 (0.29) M4 M3.5 3.7 (8.16) 0 2.5 0 0.098 ) 7.5 (0.29) M4 M3.5 5.6 (12.35) 220 (8.66) 200 (7.87) 192 (7.56) 90 (3.54) 70 0 2.5 0 0.098 ) 10 (0.39) M5 M4 8.5 (18.74) More than 1900W to FR-BAL-5.5K 2500W max. 220 (8.66) 200 (7.87) 192 (7.56) 96 (3.78) 75 0 2.5 0 0.098 ) 10 (0.39) M5 M4 9.5 (20.94) More than 2500W to FR-BAL-7.5K 3800W max. 220 (8.66) 200 (7.87) 194 (7.64) 120 (4.72) 100 0 0.098 ) 10 (0.39) M5 M5 14.5 (32.0) 12 - 27 (2.17 (2.95 (2.76 (2.95 0 2.5 (3.94 12. OPTIONS AND AUXILIARY EQUIPMENT 12.2.4 Relays The following relays should be used with the interfaces: Interface Selection example Relay used for digital input signals (interface DI-1) To prevent defective contacts , use a relay for small signal (twin contacts). (Ex.) Omron : type G2A , MY Relay used for digital output signals (interface DO-1) Small relay with 12VDC or 24VDC of 40mA or less (Ex.) Omron : type MY 12.2.5 Surge absorbers A surge absorber is required for the electromagnetic brake. Use the following surge absorber or equivalent. Insulate the wiring as shown in the diagram. Static Maximum rating Permissible circuit Surge Energy Rated voltage immunity immunity power [A] [J] [W] AC[Vma] DC[V] 140 Note. 1 time 180 8 (Note) 5 500/time 0.4 Maximum capacity Varistor voltage limit voltage (reference rating (range) V1mA value) [A] 25 [V] [pF] 360 300 [V] 220 (198 to 242) 20 s (Example) ERZV10D221 (Matsushita Electric Industry) TNR-10V221K (Nippon Chemi-con) Outline drawing [mm] ( [in] ) (ERZ-C10DK221) 4.7 1.0 (0.19 0.04) Vinyl tube 30.0 (1.18) or more 0.8 (0.03) 3.0 (0.12) or less 16.5 (0.65) 13.5 (0.53) Crimping terminal for M4 screw 12.2.6 Noise reduction techniques Noises are classified into external noises which enter MELSERVO-J2M to cause it to malfunction and those radiated by MELSERVO-J2M to cause peripheral devices to malfunction. Since MELSERVO-J2M is an electronic device which handles small signals, the following general noise reduction techniques are required. Also, the drive unit can be a source of noise as its outputs are chopped by high carrier frequencies. If peripheral devices malfunction due to noises produced by the drive unit, noise suppression measures must be taken. The measures will vary slightly with the routes of noise transmission. (1) Noise reduction techniques (a) General reduction techniques Avoid laying power lines (input cables) and signal cables side by side or do not bundle them together. Separate power lines from signal cables. Use shielded, twisted pair cables for connection with the encoder and for control signal transmission, and connect the shield to the SD terminal. Ground the base unit, servo motor, etc. together at one point (refer to Section 3.8). 12 - 28 12. OPTIONS AND AUXILIARY EQUIPMENT (b) Reduction techniques for external noises that cause MELSERVO-J2M to malfunction If there are noise sources (such as a magnetic contactor, an electromagnetic brake, and many relays which make a large amount of noise) near MELSERVO-J2M and MELSERVO-J2M may malfunction, the following countermeasures are required. Provide surge absorbers on the noise sources to suppress noises. Attach data line filters to the signal cables. Ground the shields of the encoder connecting cable and the control signal cables with cable clamp fittings. (c) Techniques for noises radiated by MELSERVO-J2M that cause peripheral devices to malfunction Noises produced by MELSERVO-J2M are classified into those radiated from the cables connected to MELSERVO-J2M and its main circuits (input and output circuits), those induced electromagnetically or statically by the signal cables of the peripheral devices located near the main circuit cables, and those transmitted through the power supply cables. Noises produced by MELSERVO-J2M Noises transmitted in the air Noise radiated directly from MELSERVO-J2M Route 1) Noise radiated from the power supply cable Route 2) Noise radiated from servo motor cable Route 3) Magnetic induction noise Routes 4) and 5) Static induction noise Route 6) Noises transmitted through electric channels Noise transmitted through power supply cable Route 7) Noise sneaking from grounding cable due to leakage current Route 8) 5) 7) 7) Instrument 7) 2) Receiver Sensor power supply 1) MELSERVOJ2M 2) 3) 8) 6) Sensor 4) Servo motor 12 - 29 3) M 12. OPTIONS AND AUXILIARY EQUIPMENT Noise transmission route Suppression techniques When measuring instruments, receivers, sensors, etc. which handle weak signals and may malfunction due to noise and/or their signal cables are contained in a control box together with the MELSERVO-J2M or run near MELSERVO-J2M, such devices may malfunction due to noises transmitted through the air. The following techniques are required. 1. Provide maximum clearance between easily affected devices and MELSERVO-J2M. 2. Provide maximum clearance between easily affected signal cables and the I/O cables of 1) 2) 3) MELSERVO-J2M. 3. Avoid laying the power lines (I/O cables of MELSERVO-J2M) and signal cables side by side or bundling them together. 4. Insert a line noise filter to the I/O cables or a radio noise filter on the input line. 5. Use shielded wires for signal and power cables or put cables in separate metal conduits. When the power lines and the signal cables are laid side by side or bundled together, magnetic induction noise and static induction noise will be transmitted through the signal cables and malfunction may occur. The following techniques are required. 1. Provide maximum clearance between easily affected devices and MELSERVO-J2M. 2. Provide maximum clearance between easily affected signal cables and the I/O cables of 4) 5) 6) MELSERVO-J2M. 3. Avoid laying the power lines (I/O cables of MELSERVO-J2M) and signal cables side by side or bundling them together. 4. Use shielded wires for signal and power cables or put the cables in separate metal conduits. When the power supply of peripheral devices is connected to the power supply of MELSERVO-J2M system, noises produced by MELSERVO-J2M may be transmitted back through the power supply 7) cable and the devices may malfunction. The following techniques are required. 1. Insert the radio noise filter (FR-BIF) on the power cables (input cables) of MELSERVO-J2M. 2. Insert the line noise filter (FR-BSF01 FR-BLF) on the power cables of MELSERVO-J2M. When the cables of peripheral devices are connected to MELSERVO-J2M to make a closed loop 8) circuit, leakage current may flow to malfunction the peripheral devices. If so, malfunction may be prevented by disconnecting the grounding cable of the peripheral device. (2) Noise reduction products (a) Data line filter Noise can be prevented by installing a data line filter onto the encoder cable, etc. For example, the ZCAT3035-1330 of TDK and the ESD-SR-25 of NEC TOKIN are available as data line filters. As a reference example, the impedance specifications of the ZCAT3035-1330 (TDK) are indicated below. This impedances are reference values and not guaranteed values. 10 to 100MHZ 100 to 500MHZ 80 150 39 1(1.54 0.04) 34 1 (1.34 0.04) Loop for fixing the cable band TDK Product name Lot number Outline drawing (ZCAT3035-1330) 12 - 30 13 1 30 1 (0.51 0.04) (1.18 0.04) [Unit: mm]([Unit: in.]) Impedance[ ] 12. OPTIONS AND AUXILIARY EQUIPMENT (b) Surge suppressor The recommended surge suppressor for installation to an AC relay, AC valve, AC electromagnetic brake or the like near MELSERVO-J2M is shown below. Use this product or equivalent. MC Surge suppressor Relay Surge suppressor Surge suppressor This distance should be short (within 20cm(0.79 in.)). (Ex.) 972A.2003 50411 (Matsuo Electric Co.,Ltd. 200VAC rating) Outline drawing [Unit: mm] ([Unit: in.]) Rated voltage C [ F] R[ ] Test voltage AC[V] 50 Across (1W) T-C 1000(1 to 5s) AC[V] 200 0.5 Vinyl sheath Blue vinyl cord Red vinyl cord 10(0.39)or less 10 3 (0.39 0.12) 18 1.5 (0.71 0.06) 6(0.24) 10(0.39)or less 4(0.16) 10 3 (0.39 200(7.87) 0.15) 48 1.5 (1.89 0.06) or more 15 1(0.59 0.04) 200(7.87) or more Note that a diode should be installed to a DC relay, DC valve or the like. Maximum voltage: Not less than 4 times the drive voltage of the relay or the like Maximum current: Not less than twice the drive current of the relay or the like 31(1.22) RA Diode (c) Cable clamp fitting (AERSBAN -SET) Generally, the earth of the shielded cable may only be connected to the connector's SD terminal. However, the effect can be increased by directly connecting the cable to an earth plate as shown below. Install the earth plate near the drive unit for the encoder cable. Peel part of the cable sheath to expose the external conductor, and press that part against the earth plate with the cable clamp. If the cable is thin, clamp several cables in a bunch. The clamp comes as a set with the earth plate. Cable Strip the cable sheath of the clamped area. Earth plate 40(1.57) Cable clamp (A,B) cutter cable External conductor Clamp section diagram 12 - 31 12. OPTIONS AND AUXILIARY EQUIPMENT Outline drawing [Unit: mm] ([Unit: in]) Earth plate Clamp section diagram 2- 5(0.20) hole installation hole AERSBAN-DSET AERSBAN-ESET A B C 100 86 30 (3.94) (3.39) (1.18) 70 56 (2.76) (2.20) Accessory fittings Clamp fitting clamp A: 2pcs. A clamp B: 1pc. B 12 - 32 L 70 (2.76) 45 (1.77) (0.940) 0.3 0 24 Note. Screw hole for grounding. Connect it to the earth plate of the control box. Type 10(0.39) A 35(1.38) 11(0.43) (0.24) C 22(0.87) 6 (Note) M4 screw L or less 35 (1.38) 24 0 0.2 7 (0.28) (0.940) B 0.3(0.01) 3 (0.12) 6 (0.24) 30(1.18) 17.5(0.69) 12. OPTIONS AND AUXILIARY EQUIPMENT (d) Line noise filter (FR-BLF, FR-BSF01) This filter is effective in suppressing noises radiated from the power supply side and output side of MELSERVO-J2M and also in suppressing high-frequency leakage current side (zero-phase current) especially within 0.5MHz to 5MHz band. Connection diagram Outline drawing [Unit: mm] ([Unit: in]) Wind the 3-phase wires by the equal number of times in the FR-BSF01 same direction, and connect the filter to the power supply side 110 (4.33) 95 0.5 (3.74 0.02) and output side of the base unit. 22.5 (0.89) The effect of the filter on the power supply side is higher as the number of winds is larger. The number of turns is generally four. If the wires are too thick to be wound, use two or more filters and make the total number of turns as mentioned above. 2- 5 (0.20) 65 (2.56) On the output side, the number of turns must be four or less. 33 (1.3) Do not wind the grounding wire together with the 3-phase wires. Power supply NFB MC L1 L2 Line noise L3 filter (Number of turns: 4) Example 2 NFB MC Power supply Base unit 65 (2.56) Example 1 4.5 (0.18) The filter effect will decrease. Use a separate wire for grounding. Base unit L1 L2 Line noise L3 filter Two filters are used (Total number of turns: 4) (e) Radio noise filter (FR-BIF)...for the input side only This filter is effective in suppressing noises radiated from the power supply side of MELSERVOJ2M especially in 10MHz and lower radio frequency bands. The FR-BIF is designed for the input only. Connection diagram Outline drawing (Unit: mm) ([Unit: in]) Base unit L1 Power supply Green 29 (1.14) L2 L3 58 (2.28) Radio noise filter FR-BIF 5 (0.20) hole 29 (1.14) 44 (1.73) 12 - 33 4 (0.16) MC Red White Blue 42 (1.65) NFB Leakage current: 4mA About 300(11.81) Make the connection cables as short as possible. Grounding is always required. When using the FR-BIF with a single-phase wire, always insulate the wires that are not used for wiring. 7 (0.28) 12. OPTIONS AND AUXILIARY EQUIPMENT 12.2.7 Leakage current breaker (1) Selection method High-frequency chopper currents controlled by pulse width modulation flow in the AC servo circuits. Leakage currents containing harmonic contents are larger than those of the motor which is run with a commercial power supply. Select a leakage current breaker according to the following formula, and ground the base unit, servo motor, etc. securely. Make the input and output cables as short as possible, and also make the grounding cable as long as possible (about 30cm (11.8 in)) to minimize leakage currents. Rated sensitivity current 10 {Ig1 Ign Iga K (Ig2 Igm)} [mA] ..........(12.1) K: Constant considering the harmonic contents Cable Leakage current breaker NV Noise filter Mitsubishi Type MELSERVO -J2M Ig1 Ign Iga Cable M NV-SP Models provided with Ig2 Igm K products NV-SW harmonic and surge NV-CP reduction techniques NV-CW 1 NV-HW BV-C1 General models NFB 3 NV-L Ig1: Ig2: Ign: Iga: Igm: Leakage current on the electric channel from the leakage current breaker to the input terminals of the base unit (Found from Fig. 12.1.) Leakage current on the electric channel from the output terminals of the drive unit to the servo motor (Found from Fig. 12.1.) Leakage current when a filter is connected to the input side (4.4mA per one FR-BIF) Leakage current of the drive unit (Found from Table 12.4.) Leakage current of the servo motor (Found from Table 12.3.) Table 12.3 Servo motor's 120 Table 12.4 Drive unit's Leakage current leakage current [mA] 100 80 60 example (Iga) Servo motor Leakage Drive unit Leakage current output [kW] current [mA] capacity [kW] [mA] 0.05 to 0.4 0.1 0.1 to 0.4 0.3 0.75 0.6 40 20 0 leakage current example (Igm) 2 3.5 8 1422 38 80 150 5.5 30 60 100 Cable size[mm2] Fig. 12.1 Leakage current example (Ig1, Ig2) for CV cable run in metal conduit 12 - 34 12. OPTIONS AND AUXILIARY EQUIPMENT 12.2.8 EMC filter For compliance with the EMC directive of the EN standard, it is recommended to use the following filter: Some EMC filters are large in leakage current.: (1) Combination with the base unit Base unit Recommended filter Model Leakage current [mA] SF1253 57 Mass [kg(lb)] MR-J2M-BU4 MR-J2M-BU6 1.37 (3.02) MR-J2M-BU8 (2) Connection example EMC filter NFB LINE (Note 2) Power supply (Note 1) Base unit LOAD MC L1 L1 L1 L2 L2 L2 L3 L3 L3 L11 L21 Note 1. Connect when the power supply has earth. 2. Connect a 1-phase 200 to 230VAC power supply to L1/L2 and keep L3 open. (3) Outline drawing [Unit: mm(in)] SF1253 6.0(0.236) 209.5(8.248) 156.0(6.142) 140.0(5.512) LINE LINE (input side) LOAD LABEL 168.0(6.614) L1 L2 L3 LOAD (output side) L1' L2' L3' 8.5 (0.335) 12 - 35 23.0(0.906) 49.0 (1.929) 12. OPTIONS AND AUXILIARY EQUIPMENT MEMO 12 - 36 13. COMMUNICATION FUNCTIONS 13. COMMUNICATION FUNCTIONS MELSERVO-J2M has the RS-422 and RS-232C serial communication functions. These functions can be used to perform servo operation, parameter changing, monitor function, etc. However, the RS-422 and RS-232C communication functions cannot be used together. Select between RS422 and RS-232C with IFU parameter No.0. (Refer to Section 13.2.2.) 13.1 Configuration 13.1.1 RS-422 configuration (1) Outline (Example) The interface unit and drive units of stations 0 to 31 can be run/operated on the same bus. Similarly, any servo amplifiers that enable station number setting can be connected on the same bus. It should be noted that the commands/data should be handled without mistakes since they are specific to each servo amplifier. Controller such as personal computer RS-232C/ RS-422 converter Station StationStation Station Station Station Station Station Station 0 1 2 3 4 5 6 7 8 RS-422 To CN3 MELSERVO-J2M (General-purpose interface type) Unavailable as option. To be prepared by customer. MITSUBISHI RS-422 Station 9 To CN3 CHARGE MELSERVO-J2S-A Station Station Station Station Station Station Station 10 11 12 13 14 15 16 RS-422 To CN3 MELSERVO-J2M (General-purpose interface type) 13 - 1 13. COMMUNICATION FUNCTIONS (2) Cable connection diagram Wire as shown below: (Note 3) 30m(98.4ft) max. (Note 1) Interface unit or Servo amplifier CN3 connector Plate SD (Note 1) Interface unit or Servo amplifier CN3 connector Plate SD 9 SDP 9 SDP 19 SDN 19 5 RDP SDN 5 RDP (Note 1) Interface unit or Servo amplifier CN3 connector Plate SD 9 SDP 19 SDN 5 RDP 15 RDN 15 RDN 15 RDN 10 TRE 10 TRE 10 TRE (Note 2) 11 LG 11 LG 11 LG 1 LG 1 LG RS-422 output unit 1 LG RDP RDN SDP SDN GND GND Note 1. Connector set MR-J2CN1 (3M or equivalent) Connector: 10120-3000VE Shell kit: 10320-52F0-008 2. In the last axis, connect TRE and RDN. 3. 30m (98.4ft) max. in environment of little noise. 13 - 2 13. COMMUNICATION FUNCTIONS 13.1.2 RS-232C configuration (1) Outline (Example) Run/operate. MELSERVO-J2M Controller such as personal computer Station Station Station Station Station Station Station Station Station 0 1 2 3 4 5 6 7 8 To CN3 (2) Cable connection diagram Wire as shown below. The communication cable for connection with the personal computer (MRCPCATCBL3M) is available. (Refer to Section 12.1.2 (3)) Personal computer connector D-SUB9 (socket) TXD 3 RXD GND RTS CTS DSR DTR 2 5 7 8 6 4 (Note 2) 15m(49.2ft) max. (Note 1) Interface unit CN3 connector Plate 2 1 12 11 FG RXD GND TXD GND Note 1. For CN3 connector (3M) Connector: 10120-6000EL Shell kit: 10320-3210-000 2. 15m(49.2ft) max. in environment of little noise. However, this distance should be 3m(9.84ft) max. for use at 38400bps or more baudrate. 13 - 3 13. COMMUNICATION FUNCTIONS 13.2 Communication specifications 13.2.1 Communication overview This servo amplifier is designed to send a reply on receipt of an instruction. The device which gives this instruction (e.g. personal computer) is called a master station and the device which sends a reply in response to the instruction (drive unit) is called a slave station. When fetching data successively, the master station repeatedly commands the slave station to send data. Item Baudrate Description 9600/19200/38400/57600 asynchronous system Start bit : 1 bit Transfer code Data bit : 8 bits Parity bit: 1 bit (even) Stop bit : 1 bit Transfer protocol Character system, half-duplex communication system (LSB) Start 0 (MSB) 1 2 3 4 5 Data 1 frame (11bits) 13 - 4 6 7 Parity Stop Next start 13. COMMUNICATION FUNCTIONS 13.2.2 Parameter setting When the RS-422/RS-232C communication function is used to operate the servo, set the communication specifications of the servo amplifier in the corresponding parameters. After setting the values of these parameters, they are made valid by switching power off once, then on again. (1) Serial communication baudrate Choose the communication speed. Match this value to the communication speed of the sending end (master station). IFU parameter No. 0 Communication baudrate selection 0: 9600[bps] 1: 19200[bps] 2: 38400[bps] 3: 57600[bps] (2) Serial communication selection Select the RS-422 or RS-232C communication standard. RS-422 and RS-232C cannot be used together. IFU parameter No. 0 Serial communication standard selection 0: RS-232C used 1: RS-422 used (3) Serial communication response delay time Set the time from when the servo amplifier (slave station) receives communication data to when it sends back data. Set "0" to send back data in less than 800 s or "1" to send back data in 800 s or more. IFU parameter No. 0 Serial communication response delay time selection 0: Invalid 1: Valid, reply sent in 800 s or more (4) Station number setting In IFU parameter No. 10 to 18, set the station numbers of the units connected to the slots. Do not use the station numbers used by the other units. IFU parameter No. Slot Whose Station Number Is Set Default Station Number Usable Station Numbers 10 Interface unit slot 0 0 to 31 11 Slot 1 1 12 Slot 2 2 13 Slot 3 3 14 Slot 4 4 15 Slot 5 5 16 Slot 6 6 17 Slot 7 7 18 Slot 8 8 13 - 5 13. COMMUNICATION FUNCTIONS 13.3 Protocol POINT Whether station number setting will be made or not must be selected if the RS-232C communication function is used. Since up to 32 axes may be connected to the bus, add a station number to the command, data No., etc. to determine the destination unit of data communication. Set the station number per unit using the IFU parameters. Send data are valid for the unit of the specified station number. S O H Slave station 10 frames (data) S T X Data No. Data* E T X Check sum Station number Error code Master station Command (1) Transmission of data from the controller to the servo S T X Station number E T X Check sum 6 frames Positive response: Error code A Negative response: Error code other than A (2) Transmission of data request from the controller to the servo S O H S T X Data No. E T X Check sum Station number S T X Station number Slave station Error code Master station Command 10 frames Data* 6 frames (data) (3) Recovery of communication status by time-out Master station EOT causes the servo to return to the receive neutral status. E O T Slave station (4) Data frames The data length depends on the command. Data 4 frames or Data or 12 frames or 16 frames 8 frames 13 - 6 E T X Check sum 13. COMMUNICATION FUNCTIONS 13.4 Character codes (1) Control codes Hexadecimal Code name Personal computer terminal key operation Description (ASCII code) (General) SOH 01H start of head ctrl A STX 02H start of text ctrl B ETX 03H end of text ctrl C EOT 04H end of transmission ctrl D (2) Codes for data ASCII unit codes are used. b8 to b5 b8 0 0 0 0 0 0 0 0 b7 0 0 0 0 1 1 1 1 b6 0 0 1 1 0 0 1 1 b5 0 1 0 1 0 1 0 1 0 1 2 3 4 5 6 7 C b4 b3 b2 b1 0 0 0 0 0 NUL DLE Space 0 @ P ` p 0 0 0 1 1 SOH DC1 ! 1 A Q a q 0 0 1 0 2 STX DC2 “ 2 B R b r 0 0 1 1 3 ETX DC3 # 3 C S c s 0 1 0 0 4 $ 4 D T d t 0 1 0 1 5 % 5 E U e u 0 1 1 0 6 & 6 F V f v 0 1 1 1 7 ‘ 7 G W g w 1 0 0 0 8 ( 8 H X h x 1 0 0 1 9 ) 9 I Y i y 1 0 1 0 10 : J Z j z 1 0 1 1 11 ; K [ k { 1 1 0 0 12 l | 1 1 0 1 13 1 1 1 0 14 . 1 1 1 1 15 / R , L ? M ] m } N ^ n O _ o DEL (3) Station numbers You may set 32 station numbers from station 0 to station 31 and the ASCII unit codes are used to specify the stations. Station number 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 ASCII code 0 1 2 3 4 5 6 7 8 9 A B C D E F Station number 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 ASCII code G H I J K L M N O P Q R S T U V For example, "30H" is transmitted in hexadecimal for the station number of "0". 13 - 7 13. COMMUNICATION FUNCTIONS 13.5 Error codes Error codes are used in the following cases and an error code of single-code length is transmitted. On receipt of data from the master station, the slave station sends the error code corresponding to that data to the master station. The error code sent in upper case indicates that the MELSERVO-J2M is normal and the one in lower case indicates that an alarm occurred. Error code Error name Description Servo normal Servo alarm [A] [a] Normal operation Data transmitted was processed properly. [B] [b] Parity error Parity error occurred in the transmitted data. [C] [c] Checksum error [D] [d] Character error [E] [e] Command error [F] [f] Data No. error Remarks Positive response Checksum error occurred in the transmitted data. Character not existing in the specifications was transmitted. Negative response Command not existing in the specifications was transmitted. Data No. not existing in the specifications was transmitted. 13.6 Checksum The check sum is a ASCII-coded hexadecimal representing the lower two digits of the sum of ASCII-coded hexadecimal numbers up to ETX, with the exception of the first control code (STX or S0H). (Example) Station number STX or SOH ETX S T X Check [0] [A] [1] [2] [5] [F] E T X [5] [2] 02H 30H 41H 31H 32H 35H 46H 03H 30H 41H 31H 32H 35H 46H 03H 152H Checksum range Lower 2 digits 52 is sent after conversion into ASCII code [5][2]. 13 - 8 13. COMMUNICATION FUNCTIONS 13.7 Time-out operation The master station transmits EOT when the slave station does not start reply operation (STX is not received) 300[ms] after the master station has ended communication operation. 100[ms] after that, the master station retransmits the message. Time-out occurs if the slave station does not answer after the master station has performed the above operation three times. (Communication error) 100ms 300ms E O T 100ms *Time-out 300ms Message E O T 300ms Message 100ms Message Master station Message 300ms E O T Slave station 13.8 Retry operation Slave station S T X Station number *Communication error Message Message Master station Message When a fault occurs in communication between the master and slave stations, the error code in the response data from the slave station is a negative response code ([B] to [F], [b] to [f]). In this case, the master station retransmits the message which was sent at the occurrence of the fault (Retry operation). A communication error occurs if the above operation is repeated and results in the error three or more consecutive times. S T X Station number S T X Station number Similarly, when the master station detects a fault (e.g. checksum, parity) in the response data from the slave station, the master station retransmits the message which was sent at the occurrence of the fault. A communication error occurs if the retry operation is performed three times. 13 - 9 13. COMMUNICATION FUNCTIONS 13.9 Initialization After the slave station is switched on, it cannot reply to communication until the internal initialization processing terminates. Hence, at power-on, ordinary communication should be started after: (1) 1s or more time has elapsed after the slave station is switched on; and (2) Making sure that normal communication can be made by reading the parameter or other data which does not pose any safety problems. 13.10 Communication procedure example The following example reads the set value of DRU parameter No.2 "function selection 1" from the drive unit of station 0: Data item Value Description Station number 0 Command 05 Interface unit station 0 Read command Data No. 02 DRU parameter No.2 Axis No. Command Data No. Start Data [0] 0 5 Data make-up STX 02 ETX [0][0][5] STX [0][2] ETX Checksum 30H 30H 35H 02H 30H 32H 03H FCH Checksum calculation and addition Transmission data Addition of SOH to make up transmission data SOH 0 05 STX 02 ETX F C 46H 43H Master station slave station Master station slave station Master station slave station Data transmission Data receive No Is there receive data? Yes 300ms elapsed? No Yes 3 consecutive times? Yes Other than error code [A] [a]? No 3 consecutive times? No Yes No Yes 100ms after EOT transmission Error processing Receive data analysis Error processing End 13 - 10 13. COMMUNICATION FUNCTIONS 13.11 Command and data No. list POINT If the command/data No. is the same, its data may be different from the interface and drive units and other servo amplifiers. The commands/data No. of the respective interface unit and drive units are those marked field. in the Unit 13.11.1 Read commands (1) Status display (Command [0][1]) Command Data No. Description Display item Frame length [0][1] [8][0] Status display data value and regenerative load ratio 12 [0][1] [8][1] processing information Bus voltage 12 [0][1] [8][2] Peak Bus voltage 12 12 [0][1] [8][0] Status display data value and cumulative feedback pulses [0][1] [8][1] processing information Servo motor speed 12 [0][1] [8][2] droop pulses 12 [0][1] [8][3] cumulative command pulses 12 [0][1] [8][4] command pulse frequency 12 [0][1] [8][5] effective load ratio 12 [0][1] [8][6] peak load ratio 12 [0][1] [8][7] Instantaneous torque 12 [0][1] [8][8] within one-revolution position 12 [0][1] [8][9] ABS counter 12 [0][1] [8][A] load inertia moment ratio 12 Unit IFU DRU (2) Parameter (Command [0][5]) Command Data No. [0][5] [0][0] to [0][5] Description The decimal equivalent of the data No. value (hexadecimal) corresponds to the parameter number. [0][0] Current value of each parameter [5][4] Unit IFU DRU Current value of each parameter [1][D] to Frame length The decimal equivalent of the data No. value (hexadecimal) corresponds 8 8 to the parameter number. (3) External I/O signals (Command [1][2]) Description Frame length Command Data No. [1][2] [4][0] External input pin statuses 8 [1][2] [4][1] External input pin statuses 8 [1][2] [4][3] External input pin statuses 8 [1][2] [C][0] External output pin statuses 8 [1][2] [C][1] External output pin statuses 8 13 - 11 Unit IFU DRU 13. COMMUNICATION FUNCTIONS (4) Alarm history (Command [3][3]) Command Data No. [3][3] [1][0] Description Alarm occurrence sequence Alarm number in alarm history most recent alarm Frame length IFU DRU 4 [3][3] [1][1] first alarm in past 4 [3][3] [1][2] second alarm in past 4 [3][3] [1][3] third alarm in past 4 [3][3] [1][4] fourth alarm in past 4 [3][3] [1][5] fifth alarm in past 4 [3][3] [2][0] most recent alarm 4 Alarm occurrence time in alarm history Unit [3][3] [2][1] first alarm in past 4 [3][3] [2][2] second alarm in past 4 [3][3] [2][3] third alarm in past 4 [3][3] [2][4] fourth alarm in past 4 [3][3] [2][5] fifth alarm in past 4 (5) Current alarm (Command [0][2] [3][5]) Command Data No. [0][2] [0][0] Command Data No. Frame length Description Current alarm number DRU 4 Description Display item Frame length [3][5] [8][0] Status display data value and processing regenerative load ratio 12 [3][5] [8][1] information at alarm occurrence 12 [3][5] [8][2] [3][5] [8][0] Status display data value and processing cumulative feedback pulses 12 [3][5] [8][1] information at alarm occurrence 12 Bus voltage Peak Bus voltage Servo motor speed Unit IFU DRU 12 [3][5] [8][2] droop pulses 12 [3][5] [8][3] cumulative command pulses 12 [3][5] [8][4] command pulse frequency 12 [3][5] [8][5] effective load ratio 12 [3][5] [8][6] peak load ratio 12 [3][5] [8][7] Instantaneous torque 12 [3][5] [8][8] within one-revolution position 12 [3][5] [8][9] ABS counter 12 [8][A] load inertia moment ratio 12 [3][5] Unit IFU (6) Others Description Frame length Command Data No. [0][2] [9][0] Servo motor end pulse unit absolute position 8 [0][2] [9][1] Command unit absolute position 8 [0][2] [7][0] Software version 16 [0][0] [8][0] Read of slot connection status 8 13 - 12 Unit IFU DRU 13. COMMUNICATION FUNCTIONS 13.11.2 Write commands (1) Status display (Command [8][1]) Command Data No. [8][1] [0][0] Description Status display data clear Setting range Frame length 1EA5 4 Setting range Frame length Unit IFU DRU (2) Parameter (Command [8][4]) Command Data No. [8][4] [0][0] to [8][4] Description Each parameter write Depends on the The decimal equivalent of the data No. value parameter. [1][D] (hexadecimal) corresponds to the parameter number. [0][0] Each parameter write Depends on the The decimal equivalent of the data No. value parameter. to [5][4] (hexadecimal) corresponds to the parameter number. Unit IFU DRU 8 8 (3) Alarm history (Command [8][2]) Command Data No. [8][2] [2][0] Description Alarm history clear Setting range Frame length 1EA5 4 Setting range Frame length 1EA5 4 Setting range Frame length Unit IFU DRU (4) Current alarm (Command [8][2]) Command Data No. [8][2] [0][0] Description Alarm reset Unit IFU DRU (5) Operation mode selection (Command [8][B]) Command Data No. [8][B] [0][0] Description Exit from test operation mode 0000 Jog operation 0001 Positioning operation 0002 Motor-less operation 0003 Output signal (DO) forced output 0004 13 - 13 4 Unit IFU DRU 13. COMMUNICATION FUNCTIONS (6) External input signal disable (Command [9][0]) Command Data No. [9][0] [0][0] Description Setting range Frame length 1EA5 4 1EA5 4 1EA5 4 1EA5 4 Setting range Frame length Unit IFU DRU Turns off the external input signals (DI), external input signals and pulse train inputs with the exception of EMG_ LSP and LSN , , independently of the external ON/OFF statuses. [9][0] [0][3] Changes the external output signals (DO) into the value of data No. [0][1]. command [8][B] or command [A][0] [9][0] [1][0] Enables the disabled external input signals (DI), external input signals and pulse train inputs with the exception of EMG_ [9][0] [1][3] , LSP and LSN . Enables the disabled external output signals (DO). (7) Data for test operation mode (Command [9][2] [A][0]) Command Data No. [9][2] [0][0] Description Input signal for test operation Refer to section 13.12.6 [9][2] [A][0] Forced output from signal pin Refer to section 13.12.8 Command Data No. [A][0] [1][0] Description Writes the speed of the test operation mode (jog operation, positioning operation). Setting range Permissible 8 Frame length 4 speed [A][0] [1][1] Writes the acceleration/deceleration time constant of the test operation mode (jog operation, positioning operation). 00000000 to 8 20000 [A][0] [1][2] Clears the acceleration/deceleration time constant of the test operation mode (jog operation, positioning operation). [A][0] [1][3] Writes the moving distance (in pulses) of the test operation mode (jog operation, positioning operation). 1EA5 4 80000000 to 8 7FFFFFFF [A][0] [1][5] Temporary stop command of the test operation mode (jog operation, positioning operation) 13 - 14 1EA5 DRU 8 0000 to instantaneous Unit IFU 4 Unit IFU DRU 13. COMMUNICATION FUNCTIONS 13.12 Detailed explanations of commands 13.12.1 Data processing When the master station transmits a command data No. or a command data No. data to a slave station, a reply or data is returned from the slave station according to the purpose. When numerical values are represented in these send data and receive data, they are represented in decimal, hexadecimal, etc. Therefore, data must be processed according to the application. Since whether data must be processed or not and how to process data depend on the monitoring, parameters, etc., follow the detailed explanation of the corresponding command. The following methods are how to process send and receive data when reading and writing data. (1) Processing the read data When the display type is 0, the eight-character data is converted from hexadecimal to decimal and a decimal point is placed according to the decimal point position information. When the display type is 1, the eight-character data is used unchanged. The following example indicates how to process the receive data "003000000929" given to show. The receive data is as follows. 0 0 3 0 0 0 0 0 0 9 2 9 Data 32-bit length (hexadecimal representation) (Data conversion is required as indicated in the display type) Display type 0: Data must be converted into decimal. 1: Data is used unchanged in hexadecimal. Decimal point position 0: No decimal point 1: First least significant digit (normally not used) 2: Second least significant digit 3: Third least significant digit 4: Forth least significant digit 5: Fifth least significant digit 6: Sixth least significant digit Since the display type is "0" in this case, the hexadecimal data is converted into decimal. 00000929H 2345 As the decimal point position is "3", a decimal point is placed in the third least significant digit. Hence, "23.45" is displayed. 13 - 15 13. COMMUNICATION FUNCTIONS (2) Writing the processed data When the data to be written is handled as decimal, the decimal point position must be specified. If it is not specified, the data cannot be written. When the data is handled as hexadecimal, specify "0" as the decimal point position. The data to be sent is the following value. 0 Data is transferred in hexadecimal. Decimal point position 0: No decimal point 1: First least significant digit 2: Second least significant digit 3: Third least significant digit 4: Forth least significant digit 5: Fifth least significant digit By way of example, here is described how to process the set data when a value of "15.5" is sent. Since the decimal point position is the second digit, the decimal point position data is "2".As the data to be sent is hexadecimal, the decimal data is converted into hexadecimal. 155 9B Hence, "0200009B" is transmitted. 13 - 16 13. COMMUNICATION FUNCTIONS 13.12.2 Status display (1) Status display data read When the master station transmits the data No. (refer to the following table for assignment) to the slave station, the slave station sends back the data value and data processing information. 1) Transmission Transmit command [0][1] and the data No. corresponding to the status display item to be read. Refer to Section 13.11.1. 2) Reply The slave station sends back the status display data requested. 0 0 Data 32 bits long (represented in hexadecimal) (Data conversion into display type is required) Display type 0: Used unchanged in hexadecimal 1: Conversion into decimal required Decimal point position 0: No decimal point 1: Lower first digit (usually not used) 2: Lower second digit 3: Lower third digit 4: Lower fourth digit 5: Lower fifth digit 6: Lower sixth digit (2) Status display data clear The cumulative feedback pulse data of the status display is cleared. Send this command immediately after reading the status display item. The data of the status display item transmitted is cleared to zero. Command Data No. Data [8][1] [0][0] 1EA5 Unit IFU DRU For example, after sending command [0][1] and data No. [8][0] and receiving the status display data, send command [8][1], data No. [0][0] and data [1EA5] to clear the cumulative feedback pulse value to zero. 13 - 17 13. COMMUNICATION FUNCTIONS 13.12.3 Parameter (1) Parameter read Read the parameter setting. 1) Transmission Transmit command [0][5] and the data No. corresponding to the parameter No. The data No. is expressed in hexadecimal equivalent of the data No. value corresponds to the parameter number. Command Data No. [0][5] [0][0] to [0][5] [0][0] to Unit IFU DRU [1][D] [5][4] 2) Reply The slave station sends back the data and processing information of the requested parameter No. Data is transferred in hexadecimal. Decimal point position 0: No decimal point 1: Lower first digit 2: Lower second digit 3: Lower third digit 4: Lower fourth digit 5: Lower fifth digit 0 Display type 0: Used unchanged in hexadecimal 1: Conversion into decimal required Parameter write type 0: Valid after write 1: Valid when power is switched on again after write Read enable/disable 0: Read enable 1: Read disable Enable/disable information changes according to the setting of parameter No.19 "parameter write inhibit". When the enable/disable setting is read disable, ignore the parameter data part and process it as unreadable. 13 - 18 13. COMMUNICATION FUNCTIONS (2) Parameter write POINT The number of write times to the EEP-ROM is limited to 100,000. Write the parameter setting. Write the value within the setting range. Refer to Section 5.1 for the setting range. Transmit command [8][4], the data No., and the set data. The data No. is expressed in hexadecimal. The decimal equivalent of the data No. value corresponds to the parameter number. When the data to be written is handled as decimal, the decimal point position must be specified. If it is not specified, data cannot be written. When the data is handled as hexadecimal, specify "0" as the decimal point position. Write the data after making sure that it is within the upper/lower limit value range given in Section 5.1.2. Read the parameter data to be written, confirm the decimal point position, and create transmission data to prevent error occurrence. On completion of write, read the same parameter data to verify that data has been written correctly. Command Data No. Set data [8][4] [0][0] to See below. [8][4] [0][0] to Unit IFU DRU [1][D] [5][4] Data is transferred in hexadecimal. Decimal point position 0: No decimal point 1: Lower first digit 2: Lower second digit 3: Lower third digit 4: Lower forth digit 5: Lower fifth digit Write mode 0: Write to EEP-ROM 3: Write to RAM When the parameter data is changed frequently through communication, set "3" to the write mode to change only the RAM data in the servo amplifier. When changing data frequently (once or more within one hour), do not write it to the EEP-ROM. 13 - 19 13. COMMUNICATION FUNCTIONS 13.12.4 External I/O pin statuses (DIO diagnosis) (1) External input pin status read (CN1A CN1B) Read the ON/OFF statuses of the external input pins. (a) Transmission Transmit command [1][2] and data No. [4][0]. Command Data No. [1][2] [4][0] Unit IFU DRU (b) Reply The ON/OFF statuses of the input pins are sent back. b31 b1 b0 1: ON 0: OFF Command of each bit is transmitted to the master station as hexadecimal data. bit External input pin bit External input pin bit External input pin bit 0 CN1A-4 8 CN1A-32 16 CN1B-10 24 1 CN1A-5 9 CN1A-34 17 CN1B-12 25 2 CN1A-7 10 CN1A-36 18 CN1B-29 26 3 CN1A-9 11 CN1A-37 19 CN1B-31 27 4 CN1A-10 12 CN1B-4 20 CN1B-32 28 5 CN1A-12 13 CN1B-5 21 CN1B-34 29 6 CN1A-29 14 CN1B-7 22 CN1B-36 30 7 CN1A-31 15 CN1B-9 23 CN1B-37 31 External input pin (2) External input pin status read (CN5) Read the ON/OFF statuses of the external output pins. (a) Transmission Transmit command [1][2] and data No. [4][1]. Command Data No. [1][2] [4][1] Unit IFU DRU (b) Reply The slave station sends back the ON/OFF statuses of the output pins. b31 b1 b0 1: ON 0: OFF Command of each bit is transmitted to the master station as hexadecimal data. bit External input pin bit External input pin bit External input pin bit 0 CN5-1 8 CN5-11 16 CN5-20 24 1 CN5-2 9 CN5-12 17 CN5-19 25 2 CN5-3 10 CN5-13 18 26 3 CN5-4 11 CN5-14 19 27 4 CN5-5 12 CN5-15 20 28 5 CN5-6 13 CN5-16 21 29 6 CN5-7 14 CN5-17 22 30 7 CN5-10 15 CN5-18 23 31 13 - 20 External input pin 13. COMMUNICATION FUNCTIONS (3) External input pin status read (CN4A CN4B) Read the ON/OFF statuses of the external input pins. (a) Transmission Transmit command [1][2] and data No. [4][3]. Command Data No. [1][2] [4][3] Unit IFU DRU (b) Reply The slave station sends back the ON/OFF statuses of the output pins. b1b0 b31 1: ON 0: OFF Command of each bit is transmitted to the master station as hexadecimal date. bit External input pin bit External input pin bit External input pin bit External input pin 0 CN4A-1 8 CN4A-26 16 CN4B-1 24 CN4B-26 1 CN4A-2 9 CN4A-27 17 CN4B-2 25 CN4B-27 2 CN4A-3 10 CN4A-28 18 CN4B-3 26 CN4B-28 3 CN4A-4 11 CN4A-29 19 CN4B-4 27 CN4B-29 4 CN4A-5 12 CN4A-30 20 CN4B-5 28 CN4B-30 5 CN4A-6 13 CN4A-31 21 CN4B-6 29 CN4B-31 6 CN4A-7 14 CN4A-32 22 CN4B-7 30 CN4B-32 7 CN4A-8 15 CN4A-33 23 CN4B-8 31 CN4B-33 (4) External output pin status read (CN1A CN1B) Read the ON/OFF statuses of the external output pins. (a) Transmission Transmit command [1][2] and data No. [C][0]. Command Data No. [1][2] [C][0] Unit IFU DRU (b) Reply The slave station sends back the ON/OFF statuses of the output pins. b1b0 b31 1: ON 0: OFF Command of each bit is transmitted to the master station as hexadecimal date. bit External output pin bit External output pin bit External output pin bit External output pin 0 CN1A-3 8 CN1B-6 16 CN1A-27 24 CN1B-23 1 CN1A-6 9 CN1B-8 17 CN1B-27 25 CN1B-22 2 CN1A-8 10 CN1B-11 18 CN1A-25 26 3 CN1A-11 11 CN1A-11 19 CN1A-24 27 4 CN1A-28 12 CN1A-28 20 CN1A-23 28 5 CN1A-30 13 CN1A-30 21 CN1A-22 29 6 CN1A-33 14 CN1A-32 22 CN1B-25 30 7 CN1B-3 15 CN1A-35 23 CN1B-24 31 13 - 21 13. COMMUNICATION FUNCTIONS (5) External output pin status read (CN4A CN4B) Read the ON/OFF statuses of the external output pins. (a) Transmission Transmit command [1][2] and data No. [C][1]. Command Data No. [1][2] [C][1] Unit IFU DRU (b) Reply The slave station sends back the statuses of the output pins. b1b0 b31 1: ON 0: OFF Command of each bit is transmitted to the master station as hexadecimal date. bit External output pin bit 0 CN4A-9 8 External output pin 16 bit 24 1 CN4A-10 9 17 25 2 CN4A-34 10 18 26 3 CN4A-35 11 19 27 4 CN4B-9 12 20 28 5 CN4B-10 13 21 29 6 CN4B-34 14 22 30 7 CN4B-35 15 23 31 13 - 22 External output pin bit External output pin 13. COMMUNICATION FUNCTIONS 13.12.5 Disable/enable of external I/O signals (DIO) Inputs can be disabled independently of the external I/O signal ON/OFF. When inputs are disabled, the input signals are recognized as follows. Among the external input signals, forced stop (EMG_ ), forward rotation stroke end (LSP ) and reverse rotation stroke end (LSN ) cannot be disabled. Signal Status External input signals (DI) OFF Pulse train inputs None (1) Disabling/enabling the external input signals (DI), external analog input signals and pulse train inputs with the exception of forced stop (EMG_ ), forward rotation stroke end (LSP ) and reverse rotation stroke end (LSN ). Transmit the following communication commands: (a) Disable Command Data No. Data [9][0] [0][0] 1EA5 Command Data No. Data [9][0] [1][0] 1EA5 Unit IFU DRU (b) Enable Unit IFU DRU (2) Disabling/enabling the external output signals (DO) Transmit the following communication commands: (a) Disable Command Data No. Data [9][0] [0][3] 1EA5 Command Data No. Data [9][0] [1][3] 1EA5 Unit IFU DRU (b) Enable Unit IFU DRU 13 - 23 13. COMMUNICATION FUNCTIONS 13.12.6 External input signal ON/OFF (test operation) Each input signal can be turned on/off for test operation. Turn off the external input signals. Send command [9] [2], data No. [0] [0] and data. Command Data No. Data [9][2] [0][0] See below Unit IFU DRU b31 b1 b0 1: ON 0: OFF Command of each bit is transmitted to the slave station as hexadecimal data. bit 0 Signal abbreviation SON bit Signal abbreviation 8 bit 16 Signal abbreviation bit 24 1 LSP 9 17 25 2 LSN 10 18 26 3 TL 4 11 ST1 19 27 12 ST2 20 28 5 PC 13 21 29 6 RES 14 22 30 7 CR 15 23 31 13 - 24 Signal abbreviation 13. COMMUNICATION FUNCTIONS 13.12.7 Test operation mode (1) Instructions for test operation mode The test operation mode must be executed in the following procedure. If communication is interrupted for longer than 0.5s during test operation, the servo amplifier causes the motor to be decelerated to a stop and servo-locked. To prevent this, continue communication without a break, e.g. monitor the status display. (a) Execution of test operation 1) Turn off all external input signals. 2) Disable the external input signals. Command Data No. Data [9][2] [0][0] 1EA5 Unit IFU DRU 3) Choose the test operation mode. Command Data No. Transmission data Selection of test operation mode [8][B] [0][0] 0000 Test operation mode cancel [8][B] [0][0] 0001 Jog operation [8][B] [0][0] 0002 Positioning operation [8][B] [0][0] 0003 Motor-less operation [8][B] [0][0] 0004 DO forced output 4) Set the data needed for test operation. 5) Start. 6) Continue communication using the status display or other command. (b) Termination of test operation To terminate the test operation mode, complete the corresponding operation and: 1) Clear the test operation acceleration/deceleration time constant. Command Data No. Data [A][0] [1][2] 1EA5 Unit IFU DRU 2) Cancel the test operation mode. Command Data No. Data [8][B] [0][0] 0000 Unit IFU DRU 3) Enable the disabled external input signals. Command Data No. Data [9][0] [1][0] 1EA5 Unit IFU 13 - 25 DRU Unit IFU DRU 13. COMMUNICATION FUNCTIONS (2) Jog operation Transmit the following communication commands: (a) Setting of jog operation data Item Command Data No. Unit Data IFU Speed [A][0] [1][0] Write the speed [r/min] in hexadecimal. Acceleration/deceleration [A][0] [1][1] Write the acceleration/deceleration time constant time constant DRU [ms] in hexadecimal. (b) Start Turn on the external input signals servo-on (SON ) forward rotation stroke end (LSP ) reverse rotation stroke end (LSN ) and ST1/ST2 by using command [9][2] data No. [0][0]. Item Forward rotation start Command Data No. [9][2] [0][0] [9][2] [0][0] [9][2] [0][0] DRU LSP and ST1. 00001007: Turns on SON LSP and ST2. LSN Stop IFU 00000807: Turns on SON LSN Reverse rotation start Unit Data 00000007: Turns on SON and LSN LSP . (3) Positioning operation Transmit the following communication commands: (a) Setting of positioning operation data Item Unit Command Data No. Speed [A][0] [1][0] Write the speed [r/min] in hexadecimal. Acceleration/decelera-tion [A][0] [1][1] Write the acceleration/deceleration time constant time constant Moving distance Data IFU DRU [ms] in hexadecimal. [A][0] [1][3] Write the moving distance [pulse] in hexadecimal. (b) Input of servo-on stroke end Turn on the external input signals servo-on (SON ) forward rotation stroke end (LSP ) and reverse rotation stroke end (LSN ) by using command [9][2] data No. [0][0]. Item Servo-on Servo OFF Stroke end ON Servo-on Stroke end ON Command Data No. [9][2] [0][0] [9][2] [0][0] [9][2] [0][0] Unit Data IFU 00000001: Turns on SON 00000006: Turns off SON LSP LSN 00000007: Turns on SON 13 - 26 and turns on . LSP LSN . DRU 13. COMMUNICATION FUNCTIONS (c) Start of positioning operation Transmit the speed and acceleration/deceleration time constant, turn on the servo-on (SON ) and forward rotation stroke end (LSP ) reverse rotation stroke end (LSN ), and then send the moving distance to start positioning operation. After that, positioning operation will start every time the moving distance is transmitted. To start opposite rotation, send the moving distance of a negative value. When the servo-on (SON ) and forward rotation stroke end (LSP ) reverse rotation stroke end (LSN ) are off, the transmission of the moving distance is invalid. Therefore, positioning operation will not start if the servo-on (SON ) and forward rotation stroke end (LSP ) reverse rotation stroke end (LSN ) are turned on after the setting of the moving distance. (d) Temporary stop A temporary stop can be made during positioning operation. Command Data No. Data [A][0] [1][5] 1EA5 Unit IFU DRU Retransmit the same communication commands as at the start time to resume operation. To stop positioning operation after a temporary stop, retransmit the temporary stop communication command. The remaining moving distance is then cleared. 13 - 27 13. COMMUNICATION FUNCTIONS 13.12.8 Output signal pin ON/OFF (output signal (DO) forced output) In the test operation mode, the output signal pins can be turned on/off independently of the servo status. Using command [9][0], disable the output signals in advance. (1) Choosing DO forced output in test operation mode Transmit command [8][B] data No. [0][0] data "0004" to choose DO forced output. 0 0 0 4 Selection of test operation mode 4: DO forced output (output signal forced output) (2) External output signal ON/OFF Transmit the following communication commands: Command Data No. Setting data [9][2] [A][0] See below. b31 b1 b0 1: ON 0: OFF Command of each bit is sent to the slave station in hexadecimal. bit External output pin bit 0 CN1A-19 8 16 24 1 CN1A-18 9 17 25 2 CN1B-19 10 18 26 3 CN1B-6 11 19 27 4 CN1B-4 12 20 28 5 CN1B-18 13 21 29 6 CN1A-14 14 22 30 15 23 31 7 External output pin bit 13 - 28 External output pin bit External output pin 13. COMMUNICATION FUNCTIONS 13.12.9 Alarm history (1) Alarm No. read Read the alarm No. which occurred in the past. The alarm numbers and occurrence times of No. 0 (last alarm) to No. 5 (sixth alarm in the past) are read. (a) Transmission Send command [3][3] and data No. [1][0] to [1][5]. Refer to Section 13.11.1(4). (b) Reply The alarm No. corresponding to the data No. is provided. 0 0 Alarm No. is transferred in decimal. For example, “0032” means A.32 and “00FF” means A._ (no alarm). (2) Alarm occurrence time read Read the occurrence time of alarm which occurred in the past. The alarm occurrence time corresponding to the data No. is provided in terms of the total time beginning with operation start, with the minute unit omitted. (a) Transmission Send command [3][3] and data No. [2][0] to [2][5]. Refer to Section 13.11.1(4). (b) Reply The alarm occurrence time is transferred in decimal. Hexadecimal must be converted into decimal. For example, data “01F5” means that the alarm occurred in 501 hours after start of operation. (3) Alarm history clear Erase the alarm history. Send command [8][2] and data No. [2][0]. Command Data No. Data [8][2] [2][0] 1EA5 Unit IDU DRU 13 - 29 13. COMMUNICATION FUNCTIONS 13.12.10 Current alarm (1) Current alarm read Read the alarm No. which is occurring currently. (a) Transmission Send command [0][2] and data No. [0][0]. Command Data No. [0][2] [0][0] Unit IFU DRU (b) Reply The slave station sends back the alarm currently occurring. 0 0 Alarm No. is transferred in decimal. For example, “0032” means A.32 and “00FF” means A._ (no alarm). (2) Read of the status display at alarm occurrence Read the status display data at alarm occurrence. When the data No. corresponding to the status display item is transmitted, the data value and data processing information are sent back. (a) Transmission Send command [3][5] and any of data No. [8][0] to [8][A] corresponding to the status display item to be read. Refer to Section 13.11.1 (5). (b) Reply The slave station sends back the requested status display data at alarm occurrence. 0 0 Data 32 bits long (represented in hexadecimal) (Data conversion into display type is required) Display type 0: Conversion into decimal required 1: Used unchanged in hexadecimal Decimal point position 0: No decimal point 1: Lower first digit (usually not used) 2: Lower second digit 3: Lower third digit 4: Lower fourth digit 5: Lower fifth digit 6: Lower sixth digit (3) Current alarm clear As by the entry of the reset (RES ), reset the servo amplifier alarm to make the servo amplifier ready to operate. After removing the cause of the alarm, reset the alarm with no command entered. Command Data No. Data [8][2] [0][0] 1EA5 Unit IFU DRU 13 - 30 13. COMMUNICATION FUNCTIONS 13.12.11 Other commands (1) Servo motor end pulse unit absolute position Read the absolute position in the servo motor end pulse unit. Note that overflow will occur in the position of 16384 or more revolutions from the home position. (a) Transmission Send command [0][2] and data No. [9][0]. Command Data No. [0][2] [9][0] Unit IFU DRU (b) Reply The slave station sends back the requested servo motor end pulses. Absolute value is sent back in hexadecimal in the servo motor end pulse unit. (Must be converted into decimal) For example, data "000186A0" is 100000 [pulse] in the motor end pulse unit. (2) Command unit absolute position Read the absolute position in the command unit. (a) Transmission Send command [0][2] and data No. [9][1]. Command Data No. [0][2] [9][1] Unit IFU DRU (b) Reply The slave station sends back the requested command pulses. Absolute value is sent back in hexadecimal in the command unit. (Must be converted into decimal) For example, data "000186A0" is 100000 [pulse] in the command unit. (3) Software version Reads the software version of the servo amplifier. (a) Transmission Send command [0][2] and data No.[7][0]. Command Data No. [0][2] [7][0] Unit IFU DRU (b) Reply The slave station returns the software version requested. Space Software version (15 digits) 13 - 31 13. COMMUNICATION FUNCTIONS (4) Read of slot connection status Read the absolute position in the command unit. (a) Transmission Send command [0][0] and data No.[8][0]. Command Data No. [0][0] [8][0] Unit IFU DRU (b) Reply The slave stations send back the statuses of the units connected to the slots. b1b0 b31 1: Connected 0: Not connected Command of each bit is sent to the slave station in hexadecimal. bit Slot bit bit Slot bit 0 1 8 Slot 16 Option 24 1 2 9 17 25 2 3 10 18 26 3 4 11 19 27 4 5 12 20 28 5 6 13 21 29 6 7 14 22 30 7 8 15 23 31 13 - 32 Slot 14. ABSOLUTE POSITION DETECTION SYSTEM 14. ABSOLUTE POSITION DETECTION SYSTEM If an absolute position erase (A.25) or an absolute position counter warning (A E3) has occurred, always perform home position setting again. Not doing so can cause runaway. CAUTION 14.1 Outline 14.1.1 Features For normal operation, as shown below, the encoder consists of a detector designed to detect a position within one revolution and a cumulative revolution counter designed to detect the number of revolutions. The absolute position detection system always detects the absolute position of the machine and keeps it battery-backed, independently of whether the controller power is on or off. Therefore, once the home position is defined at the time of machine installation, home position return is not needed when power is switched on thereafter. If a power failure or a fault occurs, restoration is easy. Also, the absolute position data, which is battery-backed by the super capacitor in the encoder, can be retained within the specified period (cumulative revolution counter value retaining time) if the cable is unplugged or broken. Controller Drive unit Current position data Backed up in the case of power failure Changing the current position data LS Detecting the number of revolutions Serial communication 1X Detecting the position within one revolutions Battery EEP-ROM memory LSO 1XO Current position data RS-422/ RS-232C Home position data Position control Speed control Pulse train command Battery unit High speed serial communication Servo motor Within-one-revolution counter 1pulse/rev Accumulative revolution counter Super capacitor 14.1.2 Restrictions The absolute position detection system cannot be configured under the following conditions. Test operation cannot be performed in the absolute position detection system, either. To perform test operation, choose incremental in DRU parameter No.1. (1) Stroke-less coordinate system, e.g. rotary shaft, infinitely long positioning. (2) Changing of electronic gear after home position setting. 14 - 1 14. ABSOLUTE POSITION DETECTION SYSTEM 14.2 Specifications (1) Specification of battery unit MR-J2M-BT POINT The revision (Edition 44) of the Dangerous Goods Rule of the International Air Transport Association (IATA) went into effect on January 1, 2003 and was enforced immediately. In this rule, "provisions of the lithium and lithium ion batteries" were revised to tighten the restrictions on the air transportation of batteries. However, since this battery is dangerous goods (Class 9), requires packing compliant with the Packing Standard 903. When a self-certificate is necessary for battery safety tests, contact our branch or representative. For more information, consult our branch or representative. (As of October, 2005). Item Description Model MR-J2M-BT System Electronic battery backup system Battery unit Lithium battery (primary battery, nominal 3.6V) Maximum revolution range Home position (Note 1) Maximum speed at power failure 500r/min (Note 2) Battery backup time Approx. 10,000 hours (battery life with power off) (Note 3) Data holding time during battery replacement Battery storage period 32767 rev. 2 hours at delivery, 1 hour in 5 years after delivery 5 years from date of manufacture Note 1. Maximum speed available when the shaft is rotated by external force at the time of power failure or the like. 2. Time to hold data by a battery with power off. It is recommended to replace the battery in three years independently of whether power is kept on or off. 3. Period during which data can be held by the super capacitor in the encoder after power-off, with the battery voltage low or the battery removed, or during which data can be held with the encoder cable disconnected. Battery replacement should be finished within this period. (2) Configuration Controller Pulse train command IO RS-422 /RS-232C CN1A Interface unit Base unit Drive unit CN1B CN3 Servo motor Battery unit 14 - 2 14. ABSOLUTE POSITION DETECTION SYSTEM (3) DRU parameter setting " in DRU parameter No.1 to make the absolute position detection system valid. Set " 1 DRU parameter No. 1 Selection of absolute position detection system 0: Used in incremental system 1: Used in absolute position detection system 14.3 Signal explanation The following is the signal used in an absolute position detection system. For the I/O interfaces (symbols in the I/O category column in the table), refer to section 3.2.5. Signal name Clear (home position setting) Code CR Functions/Applications Shorting CR -SG clears the position control counter and stores the I/O category DI-1 home position data into the non-volatile memory (backup memory). 14.4 Serial communication command The following commands are available for reading absolute position data using the serial communication function. When reading data, take care to specify the correct station number of the drive unit from where the data will be read. When the master station sends the data No. to the slave station (drive unit), the slave station returns the data value to the master station. (1) Transmission Transmit command [0][2] and data No. [9][1]. (2) Reply The absolute position data in the command pulse unit is returned in hexadecimal. Data 32-bit length (hexadecimal representation) 14 - 3 14. ABSOLUTE POSITION DETECTION SYSTEM 14.5 Startup procedure (1) Connection of a battery unit (2) Parameter setting Set "1 "in DRU parameter No. 1 of the servo amplifier and switch power off, then on. (3) Resetting of absolute position erase (A.25) After connecting the encoder cable, the absolute position erase (A.25) occurs at first power-on. Leave the alarm as it is for a few minutes, then switch power off, then on to reset the alarm. (4) Confirmation of absolute position data transfer After making sure that the ready (RD ) output after the servo-on (SON ) had turned on has turned on, read the absolute value data with the serial communication function. (5) Home position setting The home position must be set if: (a) System setup is performed; (b) When the drive unit or interface unit is replaced; (c) The servo motor has been changed; or (d) The absolute position erase (A.25) occurred. In the absolute position system, the absolute position coordinates are made up by making home position setting at the time of system setup. The motor shaft may misoperate if positioning operation is performed without home position setting. Always make home position setting before starting operation. For the home position setting method and types, refer to Section 14.6.3. 14 - 4 14. ABSOLUTE POSITION DETECTION SYSTEM 14.6 Absolute position data transfer protocol 14.6.1 Data transfer procedure Every time the servo-on (SON ) turns on at power-on or like, the controller must read the current position data in the drive unit. Not performing this operation will cause a position shift. Time-out monitoring is performed by the controller. Controller MELSERVO-J2M SON RD ON ON Absolute position data command transmission Command [0][2] data No.[9][1] Absolute position data acquisition Watch dog timer Absolute position data return Current position acquisition Current value change Position command start 14 - 5 14. ABSOLUTE POSITION DETECTION SYSTEM 14.6.2 Transfer method The sequence in which the base circuit is turned ON (servo-on) when it is in the OFF state due to the servo-on (SON ) going OFF, a forced stop, or alarm, is explained below. In the absolute position detection system, always give the serial communication command to read the current position in the drive unit to the controller every time the ready (RD ) turns on. The drive unit sends the current position to the controller on receipt of the command. At the same time, this data is set as a position command value in the drive unit. (1) Sequence processing at power-on Power supply Servo-on (SON ) Base circuit Ready (RD ) ON OFF ON OFF 100ms ON OFF 20ms ON OFF Absolute position data command transmission Absolute position data receive Current position change Current position ABS data Pulse train command During this period, get absolute position data. 1) 100ms after the servo-on (SON ) has turned on, the base circuit turns on. 2) After the base circuit has turned on, the ready (RD ) turns on. 3) After the ready (RD ) turned on and the controller acquired the absolute position data, give command pulses to the drive unit. Providing command pulses before the acquisition of the absolute position data can cause a position shift. (2) Communication error If a communication error occurs between the controller and MELSERVO-J2M, the MELSERVO-J2M sends the error code. The definition of the error code is the same as that of the communication function. Refer to Section 13.5 for details. If a communication error has occurred, perform retry operation. If several retries do not result in a normal termination, perform error processing. 14 - 6 14. ABSOLUTE POSITION DETECTION SYSTEM (3) At the time of alarm reset If an alarm has occurred, detect the trouble (ALM_ ) and turn off the servo-on (SON ). After removing the alarm occurrence factor and deactivating the alarm, get the absolute position data again from the drive unit in accordance with the procedure in (1) of this section. Servo-on (SON ) ON Reset (RES ) ON Base circuit OFF OFF 100ms ON OFF Trouble (ALM_ ) ON Ready (RD ) ON OFF 20ms OFF Absolute position data command transmission Absolute position data receive Current position change ABS data Current position Pulse train command During this period, get absolute position data. 14 - 7 14. ABSOLUTE POSITION DETECTION SYSTEM (4) At the time of forced stop reset 200ms after the forced stop is deactivated, the base circuit turns on, and further 20ms after that, the ready (RD ) turns on. Always get the current position data from when the ready (RD ) is triggered until before the position command is issued. (a) When power is switched on in a forced stop status Power supply ON OFF Servo-on (SON ) ON Forced stop (EMG_ ) ON(Valid) Base circuit Ready (RD ) OFF OFF(Invalied) 200ms ON OFF 20ms ON OFF Absolute position data command transmission Absolute position data receive Current position change Current position ABS data Pulse train command During this period, get absolute position data. (b) When a forced stop is activated during servo on Servo-on (SON ) ON Forced stop (EMG_ ) ON(Valid) Base circuit Ready (RD ) OFF OFF(Invalid) 100ms ON OFF 20ms ON OFF Absolute position data command transmission Absolute position data receive Current position change Current position ABS data Pulse train command During this period, get absolute position data. 14 - 8 14. ABSOLUTE POSITION DETECTION SYSTEM 14.6.3 Home position setting (1) Dog type home position return Preset a home position return creep speed at which the machine will not be given impact. On detection of a zero pulse, the home position setting (CR ) is turned from off to on. At the same time, the servo amplifier clears the droop pulses, comes to a sudden stop, and stores the stop position into the nonvolatile memory as the home position ABS data. The home position setting (CR ) should be turned on after it has been confirmed that the in-position (INP ) is on. If this condition is not satisfied, the home position setting warning (A.96) will occur, but that warning will be reset automatically by making home position return correctly. The number of home position setting times is limited to 100,000 times. Servo motor Near-zero point dog Dog signal ON OFF Zero pulse signal Completion of positioning ON (INP ) OFF Home position setting (CR ) ON OFF 20ms or more Home position ABS data 20ms or more Update 14 - 9 14. ABSOLUTE POSITION DETECTION SYSTEM (2) Data set type home position return POINT Never make home position setting during command operation or servo motor rotation. It may cause home position sift. It is possible to execute data set type home position return when the servo off. Perform manual operation such as JOG operation to move to the position where the home position is to be set. When the home position setting (CR ) is on for longer than 20ms, the stop position is stored into the non-volatile memory as the home position ABS data. When the servo on, set home position setting (CR ) to ON after confirming that the in-position (INP ) is ON. If this condition is not satisfied, the home position setting warning (A.96) will occur, but that warning will be reset automatically by making home position return correctly. The number of home position setting times is limited to 100,000 times. Manual feed (JOG, etc.) (more than 1 revolution of the motor shaft) Servo Motor Completion of positioning ( INP ) Home position setting (CR ) ON OFF ON OFF 20 [ms] or more Home position ABS data Update 14.6.4 How to process the absolute position data at detection of stroke end The drive unit stops the acceptance of the command pulse when forward rotation stroke end (LSP ) reverse rotation stroke end (LSN ) is detected, clears the droop pulses to 0 at the same time, and stops the servo motor rapidly. At this time, the controller keeps outputting the command pulse. Since this causes a discrepancy between the absolute position data of the servo amplifier and the controller, a difference will occur between the position data of the servo amplifier and that of the controller. When the stroke end is detected, therefore, perform JOG operation or like to return to the position where stroke end detection can be deactivated, and read the current position data in the drive unit again. 14 - 10 14. ABSOLUTE POSITION DETECTION SYSTEM 14.7 Confirmation of absolute position detection data You can confirm the absolute position data with MR Configurator (servo configuration software MRZJW3SETUP151E). Clicking "Diagnostics" on the menu bar and click "Absolute encoder data" in the menu. (1) (2) By clicking "Absolute encoder data" in the sub-menu, the absolute encoder data display window appears. (3) Click the "Close" button to close the absolute encoder data display window. 14 - 11 14. ABSOLUTE POSITION DETECTION SYSTEM MEMO 14 - 12 Command pulse PP,NP Command pulse frequency App - 1 Cumulative feedback pulse CDV CMX Electronic gear Cumulative command pulse Position control Load inertia moment ratio Auto tuning section Droop pulse Speed control Differential Current control Low Within onerevolution position High Current position calculation Speed feedback Servo motor speed Instantaneously occurring torque ABS counter Absolute position encoder M Servo motor Within onerevolution position ABS counter PWM Peak hold Effective value calculation Bus voltage Peak load ratio Effective load torque APPENDIX App 1. Status indication block diagram APPENDIX MEMO App - 2 REVISIONS *The manual number is given on the bottom left of the back cover. Print Data *Manual Number Revision Jan., 2002 SH(NA)030014-A First edition Sep., 2002 SH(NA)030014-B Safety Instructions: Addition of Note to 4. (1) Deletion of (7) in 4. Additional instructions Addition of About processing of waste Addition of EEP-ROM life Section 1.5 (2) (a): Partial change of rating plate Section 2.7: Partial change of CAUTION sentences Section 2.7 (8): Change of POINT Section 3.1: Partial change of drawing Section 3.2.1: Partial change of drawing Section 3.2.2: Addition of forced stop B text Section 3.2.4: Partial change of drawing Section 3.3.1: Partial change of drawing Section 3.4.2: Change of table Section 3.5.1: Addition of POINT Section 3.6: Addition of NOTE Section 5.1.2: Partial change of DRU parameter No. 20 data Section 5.2.1: Partial addition of text, change of table Section 6.2.2: Addition of POINT sentences Section 6.4 (3) (a): Change of expression Section 9.2: Deletion of A. 7A Section 9.3: Deletion of 4. in A. 16A Deletion of A. 7A Section 10.3 (4): Partial addition of contacts and applicable tools Section 11.1: Reexamination Section 11.2: Partial addition of NOTE sentences Section 11.4: Addition of MR-JC4CBL M-H Section 12.1.1 (1): Addition of text Section 12.1.2: Addition of cable Section 12.1.2 (2): Addition of POINT sentences Section 12.1.2 (2) (a): Addition and change of items, partial change of drawing Section 12.1.2 (2) (b): Addition of item Section 12.1.3 (2): Change of text Section 12.1.4: Deletion of POINT Section 12.1.4 (2): Change of terminal label sketch Section 12.1.4 (4) (b): Partial change of connection diagram Section 12.1.6 (1): Reexamination of table Section 12.1.6 (2): Partial change of contents Section 12.2.1 (2): Addition of cable Section 12.2.8: Partial addition of text Section 13.10: Partial addition of drawing Section 13.12.3 (2): Partial change of drawing Mar., 2004 SH(NA)030014-C Section 14.7: Partial reexamination of text Reexamination of description on configuration software Safety Instructions 1. To prevent electric shock: Addition of sentence Print Data *Manual Number Mar., 2004 SH(NA)030014-C Revision 3. To prevent injury: Reexamination of sentence 4. Additional instructions (1): Addition of Note/Reexamination of sentence (5): Reexamination of wiring drawing COMPLIANCE WITH EC DIRECTIVES 2. PRECAUTIONS FOR COMPLIANCE: IEC664-1 is modified to IEC60664-1 in (3) and (4). CONFORMANCE WITH UL/C-UL STANDARD (2): Reexamination of sentence Section 1.3 (1): Addition of “Inrush current” Section 2.4 (2): Reexamination of sentence Section 2.7: Reexamination and addition of NOTE sentence Section 2.7 (8): Addition of POINT Section 3.1: The following modification is made to the diagram: CLEAR COMPULSE COM of positioning module QD70 is connected to SG (24G). Section 3.2.5 (1): Reexamination of diagram Section 3.2.5 (2) (c) 2): Reexamination of diagram Section 3.3.5 (2): Addition of NOTE Section 3.7 (3) (a): Partial change of diagram Section 5.3.1 (1) (b): Addition of POINT sentence Section 9.2: Reexamination of sentence Section 9.3: A.12 to 15: Reexamination of occurrence cause A.37: Addition of occurrence cause A.51: “Rotation: 2.5s or more” is added. A.52: Change of content Section 12.1.1 (4): Addition of terminal block and mounting screw Section 12.1.6 (2) (a): Reexamination of Windows trademark Section 12.1.6 (2) (b): Change of FR-BSF01 outline drawing Section 14.2 (1): Addition of POINT Section 14.6.2 (4): Reexamination of forced stop Feb., 2005 SH(NA)030014-D Section 14.2 (1): Error in writing correction of POINT Oct., 2005 SH(NA)030014-E Reexamination of description on configuration software Safety Instructions: 1. To prevent electric shock: Change of description from 10 minutes to 15 minutes 4. Additional instructions (2), (4): Addition of instructions COMPLIANCE WITH EC DIRECTIVES: Partial change of sentence CONFORMANCE WITH UL/C-UL STANDARD (4): Partial change of sentence Chapter 2: Addition of CAUTION sentence Chapter 3: Partial change of WARNING sentences Section 3.2.2 (4): Deletion of open collector power input Section 3.2.5 (2) (d) 2): Modification of servo motor CCW rotation Section 3.3.4 (2): Limiting torque: Partial change of sentences Warning Battery warning: Modification of description from within 3 seconds to after approximately 3 seconds Section 3.6: Addition of CAUTION sentences Section 3.6 (3): Change of sentences Section 3.7: Addition of CAUTION sentences Change of sentences Section 3.7(3): Modification of drawing (d), (e) Print Data *Manual Number Oct., 2005 SH(NA)030014-E Revision Section 5.1.2 (2): Correction of DRU parameter No.38 Section 5.3.2: Partial reexamination of sentences Section 5.3.2 (2): Addition of Note in table Chapter 8: Partial change of WARNING sentences Section 9.2: Alarm code No.A. 45 A.46: Addition of Note in table Section 9.3: Addition of CAUTION sentence DRU parameter No.@A.17@: Addition of contents Section 9.4: Addition of CAUTION sentence Addition of POINT DRU parameter No.@A.92@: Reexamination of Cause 2 IFU parameter No.FA.9F: Partial addition of Cause IFU parameter No.@A.E3@: Addition of contents Section 10.2: Addition of Mounting screw Tightening torque Section 11.1: Partial change of CAUTION sentences Chapter 12: Partial change of WARNING sentences Section 12.1.1 (3): Addition of POINT Section 12.1.1 (4): Reexamination of Outline drawing (b), (c) Section 12.1.6 (2) (a): Partial reexamination of table and Note Section 12.2.3: Correction of Dimensions for D1 in table Section 12.2.6 (2) (d): Reexamination of Outline drawing for FR-BSF01 Section 12.2.6 (2) (e): Addition of sentences Section 13.12.7 (3) (b): Correction in table Chapter 14: Reexamination of CAUTION sentences MEMO MODEL MODEL CODE HEAD OFFICE:TOKYO BLDG MARUNOUCHI TOKYO 100-8310 SH (NA) 030014-E (0510) MEE Printed in Japan This Instruction Manual uses recycled paper. Specifications subject to change without notice.
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