General-Purpose AC Servo M R General-Purpose Interface AC Servo - J MODEL E - MR-JE-_A _ A S SERVO AMPLIFIER E R INSTRUCTION MANUAL V O A M P L I F I E R I N S T R U C T I O N M A N U A L MR-JE-A SERVOAMPLIFIER MODEL INSTRUCTIONMANUAL MODEL 1CW706 CODE HEAD OFFICE : TOKYO BLDG MARUNOUCHI TOKYO 100-8310 C C This Instruction Manual uses recycled paper. SH (NA) 030128-C (1401) MEE Printed in Japan Specifications are subject to change without notice. Safety Instructions Please read the instructions carefully before using the equipment. To use the equipment correctly, do not attempt to install, operate, maintain, or inspect the equipment until you have read through this Instruction Manual, Installation guide, and appended documents carefully. Do not use the equipment until you have a full knowledge of the equipment, safety information and instructions. In this Instruction Manual, the safety instruction levels are classified into "WARNING" and "CAUTION". WARNING 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, keep it accessible to the operator. A - 1 1. To prevent electric shock, note the following WARNING Before wiring and inspections, turn off the power and wait for 15 minutes or more until the charge lamp turns off. Otherwise, an electric shock may occur. In addition, when confirming whether the charge lamp is off or not, always confirm it from the front of the servo amplifier. Ground the servo amplifier and servo motor securely. Any person who is involved in wiring and inspection should be fully competent to do the work. Do not attempt to wire the servo amplifier and servo motor until they have been installed. Otherwise, it may cause an electric shock. Do not operate switches with wet hands. Otherwise, it may cause an electric shock. The cables should not be damaged, stressed, loaded, or pinched. Otherwise, it may cause an electric shock. To prevent an electric shock, always connect the protective earth (PE) terminal (marked ) of the servo amplifier to the protective earth (PE) of the cabinet. When using an earth-leakage current breaker (RCD), select the type B. To avoid an electric shock, insulate the connections of the power supply terminals. 2. To prevent fire, note the following CAUTION Install the servo amplifier, servo motor, and regenerative resistor on incombustible material. Installing them directly or close to combustibles will lead to a fire. Always connect a magnetic contactor between the power supply and the power supply (L1, L2, and L3) of the servo amplifier, in order to configure a circuit that shuts down the power supply on the side of the servo amplifier’s power supply. If a magnetic contactor is not connected, continuous flow of a large current may cause a fire when the servo amplifier malfunctions. When using the regenerative resistor, switch power off with the alarm signal. Not doing so may cause a fire when a regenerative transistor malfunctions or the like may overheat the regenerative resistor. When you use a regenerative option with an MR-JE-40A to MR-JE-100A, remove the built-in regenerative resistor and wiring from the servo amplifier. Provide adequate protection to prevent screws and other conductive matter, oil and other combustible matter from entering the servo amplifier and servo motor. Always connect a molded-case circuit breaker to the power supply of the servo amplifier. 3. To prevent injury, note the following CAUTION Only the voltage specified in the Instruction Manual should be applied to each terminal. Otherwise, a burst, damage, etc. may occur. Connect cables to the correct terminals. Otherwise, a burst, damage, etc. may occur. Ensure that polarity (+/-) is correct. Otherwise, a burst, damage, etc. may occur. The servo amplifier heat sink, regenerative resistor, servo motor, etc. may be hot while power is on or for some time after power-off. Take safety measures, e.g. provide covers, to avoid accidentally touching the parts (cables, etc.) by hand. A - 2 4. Additional instructions The following instructions should also be fully noted. Incorrect handling may cause a malfunction, injury, electric shock, etc. (1) Transportation and installation CAUTION Transport the products correctly according to their mass. Stacking in excess of the specified number of product packages is not allowed. Do not hold the lead wire of the regenerative resistor when transporting the servo amplifier. Install the servo amplifier and the servo motor in a load-bearing place in accordance with the Instruction Manual. Do not get on or put heavy load on the equipment. The equipment must be installed in the specified direction. Leave specified clearances between the servo amplifier and the cabinet walls or other equipment. Do not install or operate the servo amplifier and servo motor which have been damaged or have any parts missing. Do not block the intake and exhaust areas of the servo amplifier. Otherwise, it may cause a malfunction. Do not drop or strike the servo amplifier and servo motor. Isolate them from all impact loads. When you keep or use the equipment, please fulfill the following environment. Item Environment Ambient Operation 0 ˚C to 55 ˚C (non-freezing) temperature Storage -20 ˚C to 65 ˚C (non-freezing) Ambient Operation 90 %RH or less (non-condensing) humidity Storage Ambience Indoors (no direct sunlight), free from corrosive gas, flammable gas, oil mist, dust, and dirt Altitude 1000 m or less above sea level Vibration resistance 5.9 m/s2, at 10 Hz to 55 Hz (directions of X, Y and Z axes) When the product has been stored for an extended period of time, contact your local sales office. When handling the servo amplifier, be careful about the edged parts such as corners of the servo amplifier. The servo amplifier must be installed in a metal cabinet. When fumigants that contain halogen materials such as fluorine, chlorine, bromine, and iodine are used for disinfecting and protecting wooden packaging from insects, they cause malfunction when entering our products. Please take necessary precautions to ensure that remaining materials from fumigant do not enter our products, or treat packaging with methods other than fumigation (heat method). Additionally, disinfect and protect wood from insects before packing products. A - 3 (2) Wiring CAUTION Before removing the CNP1 connector of MR-JE-40A to MR-JE-100A, disconnect the lead wires of the regenerative resistor from the CNP1 connector. Wire the equipment correctly and securely. Otherwise, the servo motor may operate unexpectedly. Do not install a power capacitor, surge killer, or radio noise filter (optional FR-BIF) on the servo amplifier output side. To avoid a malfunction, connect the wires to the correct phase terminals (U, V, and W) of the servo amplifier and servo motor. Connect the servo amplifier power output (U, V, and W) to the servo motor power input (U, V, and W) directly. Do not let a magnetic contactor, etc. intervene. Otherwise, it may cause a malfunction. Servo amplifier Servo motor Servo amplifier Servo motor U U U U V V V M V M W W W W The connection diagrams in this instruction manual are shown for sink interfaces, unless stated otherwise. The surge absorbing diode installed to the DC relay for control output should be fitted in the specified direction. Otherwise, the emergency stop and other protective circuits may not operate. Servo amplifier Servo amplifier 24 V DC 24 V DC DOCOM DOCOM Control output Control output signal RA signal RA For sink output interface For source output interface When the cable is not tightened enough to the terminal block, the cable or terminal block may generate heat because of the poor contact. Be sure to tighten the cable with specified torque. Connecting a servo motor of the wrong axis to U, V, W, or CN2 of the servo amplifier may cause a malfunction. (3) Test run and adjustment CAUTION Before operation, check the parameter settings. Improper settings may cause some machines to operate unexpectedly. Never make a drastic adjustment or change to the parameter values as doing so will make the operation unstable. Do not get close to moving parts during the servo-on status. A - 4 (4) Usage CAUTION When it is assumed that a hazardous condition may occur due to a power failure or product malfunction, use a servo motor with an external brake to prevent the condition. Do not disassemble, repair, or modify the equipment. Before resetting an alarm, make sure that the run signal of the servo amplifier is off in order to prevent a sudden restart. Otherwise, it may cause an accident. Use a noise filter, etc. to minimize the influence of electromagnetic interference. Electromagnetic interference may be given to the electronic equipment used near the servo amplifier. Burning or breaking a servo amplifier may cause a toxic gas. Do not burn or break it. Use the servo amplifier with the specified servo motor. The electromagnetic brake on the servo motor is designed to hold the motor shaft and should not be used for ordinary braking. For such reasons as service life and mechanical structure (e.g. where a ball screw and the servo motor are coupled via a timing belt), the electromagnetic brake may not hold the motor shaft. To ensure safety, install a stopper on the machine side. (5) Corrective actions CAUTION When it is assumed that a hazardous condition may occur due to a power failure or product malfunction, use a servo motor with an electromagnetic brake or external brake to prevent the condition. Configure an electromagnetic brake circuit so that it is activated also by an external EMG stop switch. Contacts must be opened when ALM Contacts must be opened (Malfunction) or MBR (Electromagnetic with the EMG stop switch. brake interlock) turns off. Servo motor RA B 24 V DC Electromagnetic brake When any alarm has occurred, eliminate its cause, ensure safety, and deactivate the alarm before restarting operation. Provide an adequate protection to prevent unexpected restart after an instantaneous power failure. (6) Maintenance, inspection and parts replacement CAUTION With age, the electrolytic capacitor of the servo amplifier will deteriorate. To prevent a secondary accident due to a malfunction, it is recommend that the electrolytic capacitor be replaced every 10 years when it is used in general environment. For replacement, please contact your local sales office. A - 5 (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. DISPOSAL OF WASTE Please dispose a servo amplifier and other options according to your local laws and regulations. EEP-ROM life The number of write times to the EEP-ROM, which stores parameter settings, etc., is limited to 100,000. If the total number of the following operations exceeds 100,000, the servo amplifier may malfunction when the EEP-ROM reaches the end of its useful life. Write to the EEP-ROM due to parameter setting changes Write to the EEP-ROM due to device changes Compliance with global standards Refer to appendix 2 for the compliance with global standard. «About the manual» You must have this Instruction Manual and the following manuals to use this servo. Ensure to prepare them to use the servo safely. Relevant manuals Manual name Manual No. MELSERVO-JE Series Instructions and Cautions for Safe Use of AC Servos (packed with the IB(NA)0300194 servo amplifier) MELSERVO HF-KN/HF-SN Servo Motor Instruction Manual SH(NA)030123 EMC Installation Guidelines IB(NA)67310 «Cables used for wiring» Wires mentioned in this Instruction Manual are selected based on the ambient temperature of 40 ˚C. A - 6 CONTENTS 1. FUNCTIONS AND CONFIGURATION 1- 1 to 1-12 1.1 Summary...........................................................................................................................................1- 1 1.2 Function block diagram.....................................................................................................................1- 2 1.3 Servo amplifier standard specifications............................................................................................1- 4 1.4 Combinations of servo amplifiers and servo motors........................................................................1- 6 1.5 Function list.......................................................................................................................................1- 6 1.6 Model designation.............................................................................................................................1- 8 1.7 Structure...........................................................................................................................................1- 9 1.7.1 Parts identification......................................................................................................................1- 9 1.8 Configuration including peripheral equipment.................................................................................1-11 2. INSTALLATION 2- 1 to 2- 6 2.1 Installation direction and clearances................................................................................................2- 2 2.2 Keep out foreign materials................................................................................................................2- 3 2.3 Encoder cable stress........................................................................................................................2- 4 2.4 Inspection items................................................................................................................................2- 4 2.5 Parts having service lives.................................................................................................................2- 5 3. SIGNALS AND WIRING 3- 1 to 3-62 3.1 Input power supply circuit.................................................................................................................3- 2 3.2 I/O signal connection example..........................................................................................................3- 6 3.2.1 Position control mode.................................................................................................................3- 6 3.2.2 Speed control mode..................................................................................................................3-11 3.2.3 Torque control mode.................................................................................................................3-13 3.3 Explanation of power supply system...............................................................................................3-15 3.3.1 Signal explanations...................................................................................................................3-15 3.3.2 Power-on sequence..................................................................................................................3-16 3.3.3 Wiring CNP1 and CNP2............................................................................................................3-17 3.4 Connectors and pin assignment......................................................................................................3-19 3.5 Signal (device) explanations............................................................................................................3-21 3.6 Detailed explanation of signals........................................................................................................3-29 3.6.1 Position control mode................................................................................................................3-29 3.6.2 Speed control mode..................................................................................................................3-34 3.6.3 Torque control mode.................................................................................................................3-36 3.6.4 Position/speed control switching mode.....................................................................................3-39 3.6.5 Speed/torque control switching mode.......................................................................................3-41 3.6.6 Torque/position control switching mode....................................................................................3-43 3.7 Forced stop deceleration function...................................................................................................3-44 3.7.1 Forced stop deceleration function.............................................................................................3-44 3.7.2 Base circuit shut-off delay time function...................................................................................3-46 3.7.3 Vertical axis freefall prevention function...................................................................................3-47 3.7.4 Residual risks of the forced stop function (EM2)......................................................................3-47 3.8 Alarm occurrence timing chart.........................................................................................................3-48 3.8.1 When you use the forced stop deceleration function................................................................3-48 3.8.2 When you do not use the forced stop deceleration function.....................................................3-49 1 3.9 Interfaces.........................................................................................................................................3-50 3.9.1 Internal connection diagram......................................................................................................3-50 3.9.2 Detailed explanation of interfaces.............................................................................................3-52 3.9.3 Source I/O interfaces................................................................................................................3-56 3.10 Servo motor with an electromagnetic brake..................................................................................3-57 3.10.1 Safety precautions..................................................................................................................3-57 3.10.2 Timing chart............................................................................................................................3-58 3.11 Grounding......................................................................................................................................3-61 4. STARTUP 4- 1 to 4-36 4.1 Switching power on for the first time.................................................................................................4- 1 4.1.1 Startup procedure......................................................................................................................4- 1 4.1.2 Wiring check...............................................................................................................................4- 2 4.1.3 Surrounding environment...........................................................................................................4- 3 4.2 Startup in position control mode.......................................................................................................4- 4 4.2.1 Power on and off procedures.....................................................................................................4- 4 4.2.2 Stop............................................................................................................................................4- 4 4.2.3 Test operation............................................................................................................................4- 5 4.2.4 Parameter setting.......................................................................................................................4- 6 4.2.5 Actual operation.........................................................................................................................4- 6 4.2.6 Trouble at start-up......................................................................................................................4- 7 4.3 Startup in speed control mode..........................................................................................................4- 9 4.3.1 Power on and off procedures.....................................................................................................4- 9 4.3.2 Stop............................................................................................................................................4- 9 4.3.3 Test operation...........................................................................................................................4-10 4.3.4 Parameter setting......................................................................................................................4-11 4.3.5 Actual operation........................................................................................................................4-12 4.3.6 Trouble at start-up.....................................................................................................................4-12 4.4 Startup in torque control mode........................................................................................................4-13 4.4.1 Power on and off procedures....................................................................................................4-13 4.4.2 Stop...........................................................................................................................................4-13 4.4.3 Test operation...........................................................................................................................4-14 4.4.4 Parameter setting......................................................................................................................4-15 4.4.5 Actual operation........................................................................................................................4-15 4.4.6 Trouble at start-up.....................................................................................................................4-16 4.5 Display and operation sections........................................................................................................4-17 4.5.1 Summary...................................................................................................................................4-17 4.5.2 Display flowchart.......................................................................................................................4-18 4.5.3 Status display mode..................................................................................................................4-19 4.5.4 Diagnostic mode.......................................................................................................................4-23 4.5.5 Alarm mode...............................................................................................................................4-25 4.5.6 Parameter mode.......................................................................................................................4-26 4.5.7 External I/O signal display.........................................................................................................4-28 4.5.8 Output signal (DO) forced output..............................................................................................4-31 4.5.9 Test operation mode.................................................................................................................4-32 5. PARAMETERS 5- 1 to 5-44 5.1 Parameter list....................................................................................................................................5- 1 5.1.1 Basic setting parameters ([Pr. PA_ _ ])......................................................................................5- 1 2 5.1.2 Gain/filter setting parameters ([Pr. PB_ _ ])...............................................................................5- 2 5.1.3 Extension setting parameters ([Pr. PC_ _ ])..............................................................................5- 3 5.1.4 I/O setting parameters ([Pr. PD_ _ ]).........................................................................................5- 5 5.1.5 Extension setting 2 parameters ([Pr. PE_ _ ])............................................................................5- 6 5.1.6 Extension setting 3 parameters ([Pr. PF_ _ ])............................................................................5- 7 5.2 Detailed list of parameters................................................................................................................5- 8 5.2.1 Basic setting parameters ([Pr. PA_ _ ])......................................................................................5- 8 5.2.2 Gain/filter setting parameters ([Pr. PB_ _ ])..............................................................................5-17 5.2.3 Extension setting parameters ([Pr. PC_ _ ]).............................................................................5-28 5.2.4 I/O setting parameters ([Pr. PD_ _ ])........................................................................................5-38 5.2.5 Extension setting 2 parameters ([Pr. PE_ _ ])...........................................................................5-42 5.2.6 Extension setting 3 parameters ([Pr. PF_ _ ])...........................................................................5-43 6. NORMAL GAIN ADJUSTMENT 6- 1 to 6-24 6.1 Different adjustment methods...........................................................................................................6- 1 6.1.1 Adjustment on a single servo amplifier......................................................................................6- 1 6.1.2 Adjustment using MR Configurator2..........................................................................................6- 2 6.2 One-touch tuning..............................................................................................................................6- 3 6.2.1 One-touch tuning flowchart........................................................................................................6- 3 6.2.2 Display transition and operation procedure of one-touch tuning...............................................6- 5 6.2.3 Caution for one-touch tuning.....................................................................................................6-13 6.3 Auto tuning.......................................................................................................................................6-14 6.3.1 Auto tuning mode......................................................................................................................6-14 6.3.2 Auto tuning mode basis.............................................................................................................6-15 6.3.3 Adjustment procedure by auto tuning.......................................................................................6-16 6.3.4 Response level setting in auto tuning mode.............................................................................6-17 6.4 Manual mode...................................................................................................................................6-18 6.5 2 gain adjustment mode..................................................................................................................6-22 7. SPECIAL ADJUSTMENT FUNCTIONS 7- 1 to 7-26 7.1 Filter setting......................................................................................................................................7- 1 7.1.1 Machine resonance suppression filter.......................................................................................7- 1 7.1.2 Adaptive filter II...........................................................................................................................7- 4 7.1.3 Shaft resonance suppression filter.............................................................................................7- 6 7.1.4 Low-pass filter............................................................................................................................7- 7 7.1.5 Advanced vibration suppression control II.................................................................................7- 7 7.1.6 Command notch filter................................................................................................................7-12 7.2 Gain switching function....................................................................................................................7-13 7.2.1 Applications...............................................................................................................................7-13 7.2.2 Function block diagram.............................................................................................................7-14 7.2.3 Parameter..................................................................................................................................7-15 7.2.4 Gain switching procedure.........................................................................................................7-17 7.3 Tough drive function........................................................................................................................7-20 7.3.1 Vibration tough drive function....................................................................................................7-20 7.3.2 Instantaneous power failure tough drive function.....................................................................7-22 8. TROUBLESHOOTING 8- 1 to 8-28 8.1 Alarm and warning list......................................................................................................................8- 1 3