Contents

Safety Instructions
DISPOSAL OF WASTE
STO function of the servo amplifier
Compliance with global standards
About the manuals
Wiring
U.S. customary units
CONTENTS
1. FUNCTIONS AND CONFIGURATION
- 1.1 Summary
- 1.2 Function block diagram
- 1.3 Servo amplifier standard specifications
- 1.4 Combinations of servo amplifiers and servo motors
- 1.5 Function list
- 1.6 Model designation
- 1.7 Structure
  - 1.7.1 Parts identification
  - 1.7.2 Removal and reinstallation of the front cover
- 1.8 Configuration including peripheral equipment
2. INSTALLATION
- 2.1 Installation direction and clearances
- 2.2 Keeping out of foreign materials
- 2.3 Encoder cable stress
- 2.4 Inspection items
- 2.5 Parts having service life
- 2.6 Restrictions when using this product at altitude exceeding 1000 m and up to 2000 m above sea level
3. SIGNALS AND WIRING
- 3.1 Input power supply circuit
  - 3.1.1 200 V class
  - 3.1.2 400 V class
  - 3.1.3 100 V class
- 3.2 I/O signal connection example
  - 3.2.1 Position control mode
  - 3.2.2 Speed control mode
  - 3.2.3 Torque control mode
- 3.3 Explanation of power supply system
  - 3.3.1 Signal explanations
  - 3.3.2 Power-on sequence
  - 3.3.3 Wiring CNP1, CNP2, and CNP3
- 3.4 Connectors and pin assignment
- 3.5 Signal (device) explanations
- 3.6 Detailed explanation of signals
  - 3.6.1 Position control mode
  - 3.6.2 Speed control mode
  - 3.6.3 Torque control mode
  - 3.6.4 Position/speed control switching mode
  - 3.6.5 Speed/torque control switching mode
  - 3.6.6 Torque/position control switching mode
- 3.7 Forced stop deceleration function
  - 3.7.1 Forced stop deceleration function
  - 3.7.2 Base circuit shut-off delay time function
  - 3.7.3 Vertical axis freefall prevention function
  - 3.7.4 Residual risks of the forced stop function (EM2)
- 3.8 Alarm occurrence timing chart
  - 3.8.1 When you use the forced stop deceleration function
  - 3.8.2 When you do not use the forced stop deceleration function
- 3.9 Interfaces
  - 3.9.1 Internal connection diagram
  - 3.9.2 Detailed explanation of interfaces
  - 3.9.3 Source I/O interfaces
- 3.10 Servo motor with an electromagnetic brake
  - 3.10.1 Safety precautions
  - 3.10.2 Timing chart
- 3.11 Grounding
4. STARTUP
- 4.1 Switching power on for the first time
  - 4.1.1 Startup procedure
  - 4.1.2 Wiring check
  - 4.1.3 Surrounding environment
- 4.2 Startup in position control mode
  - 4.2.1 Power on and off procedures
  - 4.2.2 Stop
  - 4.2.3 Test operation
  - 4.2.4 Parameter setting
  - 4.2.5 Actual operation
  - 4.2.6 Trouble at start-up
- 4.3 Startup in speed control mode
  - 4.3.1 Power on and off procedures
  - 4.3.2 Stop
  - 4.3.3 Test operation
  - 4.3.4 Parameter setting
  - 4.3.5 Actual operation
  - 4.3.6 Trouble at start-up
- 4.4 Startup in torque control mode
  - 4.4.1 Power on and off procedures
  - 4.4.2 Stop
  - 4.4.3 Test operation
  - 4.4.4 Parameter setting
  - 4.4.5 Actual operation
  - 4.4.6 Trouble at start-up
- 4.5 Display and operation sections
  - 4.5.1 Summary
  - 4.5.2 Display flowchart
  - 4.5.3 Status display mode
  - 4.5.4 Diagnostic mode
  - 4.5.5 Alarm mode
  - 4.5.6 Parameter mode
  - 4.5.7 External I/O signal display
  - 4.5.8 Output signal (DO) forced output
  - 4.5.9 Test operation mode
5. PARAMETERS
- 5.1 Parameter list
  - 5.1.1 Basic setting parameters ([Pr. PA_ _ ])
  - 5.1.2 Gain/filter setting parameters ([Pr. PB_ _ ])
  - 5.1.3 Extension setting parameters ([Pr. PC_ _ ])
  - 5.1.4 I/O setting parameters ([Pr. PD_ _ ])
  - 5.1.5 Extension setting 2 parameters ([Pr. PE_ _ ])
  - 5.1.6 Extension setting 3 parameters ([Pr. PF_ _ ])
  - 5.1.7 Linear servo motor/DD motor setting parameters ([Pr. PL_ _ ])
  - 5.1.8 Option setting parameters ([Pr. Po_ _ ])
- 5.2 Detailed list of parameters
  - 5.2.1 Basic setting parameters ([Pr. PA_ _ ])
  - 5.2.2 Gain/filter setting parameters ([Pr. PB_ _ ])
  - 5.2.3 Extension setting parameters ([Pr. PC_ _ ])
  - 5.2.4 I/O setting parameters ([Pr. PD_ _ ])
  - 5.2.5 Extension setting 2 parameters ([Pr. PE_ _ ])
  - 5.2.6 Extension setting 3 parameters ([Pr. PF_ _ ])
  - 5.2.7 Linear servo motor/DD motor setting parameters ([Pr. PL_ _ ])
  - 5.2.8 Option setting parameters ([Pr. Po_ _ ])
- 5.3 Stop system when LSP (Forward rotation stroke end) or LSN (Reverse rotation stroke end) is turned off
6. NORMAL GAIN ADJUSTMENT
- 6.1 Different adjustment methods
  - 6.1.1 Adjustment on a single servo amplifier
  - 6.1.2 Adjustment using MR Configurator2
- 6.2 One-touch tuning
  - 6.2.1 One-touch tuning flowchart
  - 6.2.2 Display transition and operation procedure of one-touch tuning
  - 6.2.3 Caution for one-touch tuning
- 6.3 Auto tuning
  - 6.3.1 Auto tuning mode
  - 6.3.2 Auto tuning mode basis
  - 6.3.3 Adjustment procedure by auto tuning
  - 6.3.4 Response level setting in auto tuning mode
- 6.4 Manual mode
- 6.5 2 gain adjustment mode
7. SPECIAL ADJUSTMENT FUNCTIONS
- 7.1 Filter setting
  - 7.1.1 Machine resonance suppression filter
  - 7.1.2 Adaptive filter II
  - 7.1.3 Shaft resonance suppression filter
  - 7.1.4 Low-pass filter
  - 7.1.5 Advanced vibration suppression control II
  - 7.1.6 Command notch filter
- 7.2 Gain switching function
  - 7.2.1 Applications
  - 7.2.2 Function block diagram
  - 7.2.3 Parameter
  - 7.2.4 Gain switching procedure
- 7.3 Tough drive function
  - 7.3.1 Vibration tough drive function
  - 7.3.2 Instantaneous power failure tough drive function
- 7.4 Compliance with SEMI-F47 standard
- 7.5 Model adaptive control disabled
- 7.6 Lost motion compensation function
- 7.7 Super trace control
8. TROUBLESHOOTING
- 8.1 Explanation for the lists
- 8.2 Alarm list
- 8.3 Warning list
9. DIMENSIONS
- 9.1 Servo amplifier
- 9.2 Connector
10. CHARACTERISTICS
- 10.1 Overload protection characteristics
- 10.2 Power supply capacity and generated loss
- 10.3 Dynamic brake characteristics
  - 10.3.1 Dynamic brake operation
  - 10.3.2 Permissible load to motor inertia when the dynamic brake is used
- 10.4 Cable bending life
- 10.5 Inrush currents at power-on of main circuit and control circuit
11. OPTIONS AND PERIPHERAL EQUIPMENT
- 11.1 Cable/connector sets
  - 11.1.1 Combinations of cable/connector sets
  - 11.1.2 MR-D05UDL3M-B STO cable
  - 11.1.3 Battery cable/junction battery cable
- 11.2 Regenerative options
  - 11.2.1 Combination and regenerative power
  - 11.2.2 Selection of regenerative option
  - 11.2.3 Parameter setting
  - 11.2.4 Connection of regenerative option
  - 11.2.5 Mounting direction
  - 11.2.6 Dimensions
- 11.3 FR-BU2-(H) Brake unit
  - 11.3.1 Selection
  - 11.3.2 Brake unit parameter setting
  - 11.3.3 Connection example
  - 11.3.4 Dimensions
- 11.4 FR-RC-(H) power regeneration converter
- 11.5 FR-CV-(H) power regeneration common converter
  - 11.5.1 Model designation
  - 11.5.2 Selection example
- 11.6 Junction terminal block MR-TB50
- 11.7 MR Configurator2
  - 11.7.1 Engineering software
  - 11.7.2 Precautions for using USB communication function
- 11.8 Battery
  - 11.8.1 Selection of battery
  - 11.8.2 MR-BAT6V1SET battery
  - 11.8.3 MR-BAT6V1BJ battery for junction battery cable
  - 11.8.4 MR-BAT6V1SET-A battery
  - 11.8.5 MR-BT6VCASE battery case
  - 11.8.6 MR-BAT6V1 battery
- 11.9 Selection example of wires
- 11.10 Molded-case circuit breakers, fuses, magnetic contactors
- 11.11 Power factor improving DC reactors
- 11.12 Power factor improving AC reactors
- 11.13 Relays (recommended)
- 11.14 Noise reduction techniques
- 11.15 Earth-leakage current breaker
- 11.16 EMC filter (recommended)
- 11.17 External dynamic brake
- 11.18 Panel through attachment (MR-J4ACN15K/MR-J3ACN)
- 11.19 Multifunction regeneration converter FR-XC-(H)
  - 11.19.1 Multifunction regeneration converters and dedicated stand-alone reactors
  - 11.19.2 Precautions
  - 11.19.3 Servo amplifier settings
  - 11.19.4 Capacity selection
  - 11.19.5 Connection diagrams
  - 11.19.6 Wiring and peripheral options
12. ABSOLUTE POSITION DETECTION SYSTEM
- 12.1 Summary
  - 12.1.1 Features
  - 12.1.2 Restrictions
  - 12.1.3 Structure
  - 12.1.4 Parameter setting
  - 12.1.5 Confirmation of absolute position detection data
- 12.2 Battery
  - 12.2.1 Using MR-BAT6V1SET battery or MR-BAT6V1SET-A battery
  - 12.2.2 Using MR-BAT6V1BJ battery for junction battery cable
  - 12.2.3 Using MR-BT6VCASE battery case
- 12.3 Standard connection example
- 12.4 Signal explanation
- 12.5 Startup procedure
- 12.6 Absolute position data transfer protocol
  - 12.6.1 Data transfer procedure
  - 12.6.2 Transfer method
  - 12.6.3 Home position setting
  - 12.6.4 Use of servo motor with an electromagnetic brake
  - 12.6.5 How to process the absolute position data at detection of stroke end
- 12.7 Absolute position data transfer errors
- 12.8 Communication-based absolute position transfer system
  - 12.8.1 Serial communication command
  - 12.8.2 Absolute position data transfer protocol
13. USING STO FUNCTION
- 13.1 Introduction
  - 13.1.1 Summary
  - 13.1.2 Terms related to safety
  - 13.1.3 Cautions
  - 13.1.4 Residual risks of the STO function
  - 13.1.5 Specifications
  - 13.1.6 Maintenance
- 13.2 STO I/O signal connector (CN8) and signal layouts
  - 13.2.1 Signal layouts
  - 13.2.2 Signal (device) explanations
  - 13.2.3 How to pull out the STO cable
- 13.3 Connection example
  - 13.3.1 Connection example for CN8 connector
  - 13.3.2 External I/O signal connection example using an MR-J3-D05 safety logic unit
  - 13.3.3 External I/O signal connection example using an external safety relay unit
- 13.4 Detailed description of interfaces
  - 13.4.1 Sink I/O interface
  - 13.4.2 Source I/O interface
14. COMMUNICATION FUNCTION (MITSUBISHI ELECTRIC GENERAL-PURPOSE AC SERVO PROTOCOL)
- 14.1 Structure
  - 14.1.1 Configuration diagram
  - 14.1.2 Precautions for using RS-422/RS-232C/USB communication function
- 14.2 Communication specifications
  - 14.2.1 Outline of communication
  - 14.2.2 Parameter setting
- 14.3 Protocol
  - 14.3.1 Transmission data configuration
  - 14.3.2 Character codes
  - 14.3.3 Error codes
  - 14.3.4 Checksum
  - 14.3.5 Time-out processing
  - 14.3.6 Retry processing
  - 14.3.7 Initialization
  - 14.3.8 Communication procedure example
- 14.4 Command and data No. list
  - 14.4.1 Reading command
  - 14.4.2 Writing commands
- 14.5 Detailed explanations of commands
  - 14.5.1 Data processing
  - 14.5.2 Status display mode
  - 14.5.3 Parameter
  - 14.5.4 External I/O signal status (DIO diagnosis)
  - 14.5.5 Input device on/off
  - 14.5.6 Disabling/enabling I/O devices (DIO)
  - 14.5.7 Input devices on/off (test operation)
  - 14.5.8 Test operation mode
  - 14.5.9 Output signal pin on/off (output signal (DO) forced output)
  - 14.5.10 Alarm history
  - 14.5.11 Current alarm
  - 14.5.12 Specifying servo amplifier groups
  - 14.5.13 Machine diagnosis/service life diagnosis
  - 14.5.14 Other commands
15. USING A LINEAR SERVO MOTOR
- 15.1 Functions and configuration
  - 15.1.1 Summary
  - 15.1.2 Configuration including peripheral equipment
- 15.2 Signals and wiring
- 15.3 Operation and functions
  - 15.3.1 Startup
  - 15.3.2 Magnetic pole detection
  - 15.3.3 Home position return
  - 15.3.4 Test operation mode in MR Configurator2
  - 15.3.5 Function
  - 15.3.6 Absolute position detection system
- 15.4 Characteristics
  - 15.4.1 Overload protection characteristics
  - 15.4.2 Power supply capacity and generated loss
  - 15.4.3 Dynamic brake characteristics
  - 15.4.4 Permissible load to motor mass ratio when the dynamic brake is used
16. USING A DIRECT DRIVE MOTOR
- 16.1 Functions and configuration
  - 16.1.1 Summary
  - 16.1.2 Configuration including peripheral equipment
- 16.2 Signals and wiring
- 16.3 Operation and functions
  - 16.3.1 Startup procedure
  - 16.3.2 Magnetic pole detection
  - 16.3.3 Function
- 16.4 Absolute position detection system
- 16.5 Characteristics
  - 16.5.1 Overload protection characteristics
  - 16.5.2 Power supply capacity and generated loss
  - 16.5.3 Dynamic brake characteristics
17. FULLY CLOSED LOOP SYSTEM
- 17.1 Functions and configuration
  - 17.1.1 Function block diagram
  - 17.1.2 Selecting procedure of control mode
  - 17.1.3 System configuration
- 17.2 Load-side encoder
  - 17.2.1 Linear encoder
  - 17.2.2 Rotary encoder
  - 17.2.3 Configuration diagram of encoder cable
  - 17.2.4 MR-J4FCCBL03M branch cable
- 17.3 Operation and functions
  - 17.3.1 Startup
  - 17.3.2 Home position return
  - 17.3.3 Fully closed loop control error detection functions
  - 17.3.4 Auto tuning function
  - 17.3.5 Machine analyzer function
  - 17.3.6 Test operation mode
  - 17.3.7 Absolute position detection system under fully closed loop system
  - 17.3.8 About MR Configurator2
18. MR-J4-03A6(-RJ) SERVO AMPLIFIER
- 18.1 Functions and configuration
  - 18.1.1 Summary
  - 18.1.2 Function block diagram
  - 18.1 3 Servo amplifier standard specifications
  - 18.1.4 Combinations of servo amplifiers and servo motors
  - 18.1.5 Function list
  - 18.1.6 Model definition
  - 18.1.7 Parts identification
  - 18.1.8 Configuration including peripheral equipment
- 18.2 Installation
  - 18.2.1 Installation direction and clearances
  - 18.2.2 Installation by DIN rail
- 18.3 Signals and wiring
  - 18.3.1 Input power supply circuit
  - 18.3.2 Explanation of power supply system
  - 18.3.3 Selection of main circuit power supply/control circuit power supply
  - 18.3.4 Power-on sequence
  - 18.3.5 I/O signal connection example
  - 18.3.6 Connectors and pin assignment
  - 18.3.7 Signal (device) explanations
  - 18.3.8 Alarm occurrence timing chart
  - 18.3.9 Interfaces (Internal connection diagram)
  - 18.3.10 Grounding
- 18.4 Startup
  - 18.4.1 Startup procedure
  - 18.4.2 Troubleshooting when "24 V ERROR" lamp turns on
  - 18.4.3 Wiring check
  - 18.4.4 Surrounding environment
- 18.5 Display and operation sections
  - 18.5.1 Summary
  - 18.5.2 Display flowchart
  - 18.5.3 Status display mode
  - 18.5.4 One-touch tuning
  - 18.5.5 Diagnostic mode
  - 18.5.6 Alarm mode
  - 18.5.7 Parameter mode
  - 18.5.8 External I/O signal display
  - 18.5.9 Output signal (DO) forced output
  - 18.5.10 Test operation mode
- 18.6 Dimensions
- 18.7 Characteristics
  - 18.7.1 Overload protection characteristics
  - 18.7.2 Power supply capacity and generated loss
  - 18.7.3 Dynamic brake characteristics
  - 18.7.4 Inrush currents at power-on of main circuit and control circuit
- 18.8 Options and peripheral equipment
  - 18.8.1 Cable/connector sets
  - 18.8.2 Combinations of cable/connector sets
  - 18.8.3 Selection example of wires
  - 18.8.4 Circuit protector
- 18.9 Communication function (Mitsubishi Electric general-purpose AC servo protocol)
19. MR-D01 EXTENSION I/O UNIT
- 19.1 Function block diagram
- 19.2 Structure
  - 19.2.1 Parts identification
  - 19.2.2 Installation and removal of the MR-D01 extension I/O unit
- 19.3 Configuration including peripheral equipment
- 19.4 Installation direction and clearances
- 19.5 Signals and wiring
  - 19.5.1 I/O Signal Connection Example
  - 19.5.2 Connectors and pin assignment
  - 19.5.3 Signal (device) explanations
  - 19.5.4 Interface
- 19.6 Monitor display with MR Configurator2
- 19.7 Dimensions
  - 19.7.1 MR-D01 extension I/O unit
  - 19.7.2 When an MR-D01 extension IO unit is connected to a servo amplifier
- 19.8 Options peripheral equipment
  - 19.8.1 Combinations of cable/connector sets
  - 19.8.2 PS7DW-20V14B-F (Junction terminal block) (recommended)
  - 19.8.3 MR-TB50 (Junction terminal block)
APPENDIX
- App. 1 Peripheral equipment manufacturer (for reference)
- App. 2 Handling of AC servo amplifier batteries for the United Nations Recommendations on the Transport of Dangerous Goods
- App. 3 Symbol for the new EU Battery Directive
- App. 4 Compliance with global standards
- App. 5 MR-J3-D05 Safety logic unit
- App. 6 EC declaration of conformity
- App. 7 Analog monitor
- App. 8 Two-wire type encoder cable for HG-MR/HG-KR
- App. 9 How to replace servo amplifier without magnetic pole detection
- App. 10 Special specification
- App. 11 Driving on/off of main circuit power supply with DC power supply
- App. 12 STO function with SIL 3 certification
- App. 13 When using the servo amplifier with the DC power supply input
- App. 14 Status of general-purpose AC servo products for compliance with the China RoHS directive
- App. 15 Encoder output pulse setting method
- App. 16 How to adjust the error excessive alarm level
REVISIONS
Warranty

Mitsubishi MR-J4-03A6 Instruction Manual

Mitsubishi MR-J4-03A6 Servo Amplifier manual cover

Pages 930

Year 2021

Language(s)

of 930

Mitsubishi MR-J4-03A6 Servo Amplifier Specification

The Mitsubishi MR-J4-03A6 Servo Amplifier is a cutting-edge component in the MR-J4 series, designed to provide precision control and high performance for a variety of industrial automation applications. It features a compact design that simplifies installation and integration into existing systems while delivering robust functionality to meet demanding operational requirements. This servo amplifier supports a power output of 0.3 kW, making it suitable for driving small to medium-sized servo motors with high efficiency and reliability.

The MR-J4-03A6 is equipped with advanced control algorithms, including real-time auto-tuning and vibration suppression capabilities, ensuring optimized performance and reduced mechanical stress. It supports high-resolution encoders, facilitating precise positioning and speed control. The amplifier features seamless connectivity options, including compatibility with various fieldbus networks such as CC-Link IE Field, EtherCAT, and SSCNET III/H, enabling integration into complex automation systems.

Safety is a key consideration in the design of the MR-J4-03A6, incorporating features such as Safe Torque Off (STO) to meet international safety standards, enhancing operator protection and reducing the risk of accidents during operation. The amplifier also offers diagnostic functions and easy-to-use software tools for monitoring and configuration, providing maintenance support and reducing downtime.

Energy efficiency is enhanced through regenerative energy feedback capabilities, minimizing power consumption and operational costs. The MR-J4-03A6 Servo Amplifier stands out for its reliability, precision, and ease of use, making it a valuable asset in applications ranging from manufacturing to robotics. Its robust construction ensures longevity and consistent performance, making it a preferred choice for industries seeking advanced motion control solutions.

Mitsubishi MR-J4-03A6 Servo Amplifier F.A.Q.

How can I set up the Mitsubishi MR-J4-03A6 Servo Amplifier for initial operation?

To set up the MR-J4-03A6 Servo Amplifier for initial operation, connect the power supply, encoder, and motor cables. Then, use the MR Configurator2 software to configure the initial parameters such as motor type, control mode, and tuning settings. Refer to the user manual for detailed step-by-step instructions.

What are the common causes of alarm codes appearing on the MR-J4-03A6 Servo Amplifier?

Common causes of alarm codes include incorrect parameter settings, faulty wiring, overloading, and environmental factors like overheating. Each alarm code corresponds to a specific issue, which can be resolved by consulting the troubleshooting section of the manual.

How do I perform regular maintenance on the MR-J4-03A6 Servo Amplifier?

Regular maintenance involves checking for loose connections, cleaning the cooling vents, inspecting for signs of wear or damage, and verifying parameter settings. It's recommended to perform these checks at regular intervals as specified in the maintenance section of the user manual.

What is the procedure for tuning the servo motor connected to the MR-J4-03A6 Servo Amplifier?

Tuning the servo motor involves using the auto-tuning function in the MR Configurator2 software, which adjusts parameters for optimal performance. Manual tuning can be done by adjusting gain settings such as position, speed, and torque gains. Follow the detailed guidelines in the software manual for precise tuning.

How can I resolve communication issues between the MR-J4-03A6 and the PLC?

To resolve communication issues, ensure that the correct communication protocol is selected and that all cables are securely connected. Check the parameter settings related to communication and verify the network configuration on both the servo amplifier and the PLC.

What steps should be taken if the MR-J4-03A6 Servo Amplifier does not power up?

If the servo amplifier does not power up, first check the power supply and ensure that the input voltage matches the specifications. Inspect all wiring for any faults or disconnections. If the issue persists, consult the troubleshooting guide or contact technical support.

How do I update the firmware on the MR-J4-03A6 Servo Amplifier?

To update the firmware, download the latest firmware version from the Mitsubishi Electric website. Connect the servo amplifier to a computer using the USB interface and use the MR Configurator2 software to perform the update. Follow the on-screen instructions carefully to complete the process.

What safety precautions should be observed when handling the MR-J4-03A6 Servo Amplifier?

Always turn off the power supply before performing any installation or maintenance tasks. Use appropriate personal protective equipment and ensure that the servo amplifier is properly grounded to prevent electrical shocks. Refer to the installation manual for detailed safety guidelines.

How can I extend the lifespan of the MR-J4-03A6 Servo Amplifier?

To extend the lifespan, ensure proper ventilation and avoid operating the amplifier in extreme environmental conditions. Regularly perform maintenance checks and promptly address any warning or alarm codes. Use the amplifier within the specified load and temperature limits.

What are the advantages of using the MR-J4-03A6 Servo Amplifier with a compatible Mitsubishi servo motor?

The MR-J4-03A6 Servo Amplifier offers seamless integration with Mitsubishi servo motors, providing precise control and high efficiency. It supports advanced features like real-time auto-tuning and vibration suppression, which enhance performance and reliability in various industrial applications.