Mitsubishi MR-J4-70A Servo Amplifier

MELSERVO-J4-Serie, 750W (0.75 kW), 200-V class general-purpose pulse-input Servoverstärker

Modelldefinition

MR-J4: Mitsubishi 4th-generation servo series

70: Matched motor power: 750 W

A: General-purpose interface (Impuls + analoger Eingang). Not SSCNET fiber-bus type. Accepts pulse commands from SPS. The -B variant is equipped with SSCNET III/H fiber optic bus interface.

Grundlegende elektrische Spezifikationen

Mechanische Spezifikationen

Abmessungen: W 60 × H 168 × D 185 mm

Gewicht: 1.4 kg

Montage: Vertical DIN-rail mounting inside cabinet, IP20

Betriebstemperatur: 0-55 °C, keine kondensation

Compatible Motors (Standard Combinations)

HG-KR73: 750 W, geringe Trägheit, ohne Bremse

HG-KR73B: 750 W, geringe Trägheit, mit elektromagnetischer Bremse

HG-SR73: 750 W, mittlere Trägheit

Notiz: Amplifier and motor encoder must be matched. MR-J4 drives cannot directly run MR-J3 series motors.

Connector Overview

1. CN1: Digital I/O signals, STO safety inputs
2. CN2: Servo-motor encoder interface
3. CN3: Impuls / analog command input (for host PLC)
4. CN4: USB debug port for PC parameter setup
5. CN5: Analog monitor output
6. U/V/W: Power output to servo motor

Ersatzkompatibilität

1. Upgrade within same product family

MR-J4-70A → MR-J5-70A (New-generation pulse-type servo). Hardware pin-out is incompatible; program retuning is required.

2. Replacement for legacy unit

MR-J3-70A retrofit: MR-J4-70A offers functional compatibility, but mounting dimensions and wiring are not fully interchangeable; cables must be replaced.

3. Bus-type comparison

MR-J4-70A: Impuls / analog interface; MR-J4-70B: SSCNET fiber bus. Not direct pin-for-pin replacements.

Typische Anwendungen

Engraving machines, Etikettierer, material handling mechanisms, Verpackungsausrüstung, machine-tool feed axes. Suitable for PLC systems with pulse-output capability.

Fehlerbehebung & Wartungshinweise

1. ALM 32: Überstrom. Inspect U/V-W motor short-circuit or ground leakage.
2. ALM 50: Überlast. Check for mechanical jamming or poor inertia matching.
3. AL.E6: Encoder communication failure. Inspect CN2 encoder cable.
4. Regenerative overload: Frequent fast acceleration/deceleration requires external regenerative resistor.

Customs HS-code: 8501520000

Complete Installation Guide for Mitsubishi MR-J4-70A

⚠️Sicherheitswarnung: All wiring and disassembly must be performed with full power removed. Wait at least 15 minutes until the charge lamp extinguishes. Verify no high-voltage residual exists between P+-N- terminals with multimeter to avoid electric shock. Die Arbeiten müssen von qualifizierten Elektrikern durchgeführt werden.

MR-J4-70A: 750 W, 200-V pulse-input servo amplifier, supports single-phase or three-phase AC200-240 V supply.

1. Cabinet Mechanical Installation

1.1 Installationsumgebung

Mount vertically upright inside control cabinet. Do NOT lay flat or install upside-down.

Umgebungstemperatur: 0-55 °C, keine kondensation; Altitude ≤ 1000 m; Free from dust, oil mist and corrosive gas.

Montagemethode: Screw fastening or DIN-rail mounting.

1.2 Cooling Clearances (Kritisch)

Top clearance ≥ 50 mm; Bottom clearance ≥ 50 mm; Side clearance ≥ 10 mm

When multiple amplifiers are mounted side-by-side, reserve sufficient cooling space. Keep away from heat-generating components such as contactors and resistors.

Do not block intake and exhaust vents with cables or trunking.

1.3 Fastening Procedure

1. Ensure cabinet back-plate is flat and burr-free.
2. Fit amplifier against back-plate and tighten four mounting screws.
3. Avoid heavy impact on the housing to prevent internal component damage.
4. Step-by-Step Wiring

Terminal definitions for MR-J4-70A

L1, L2, L3: Main-circuit power input. For single-phase 220 V operation: connect L1 & L2; leave L3 unconnected.

L11, L21: Control-circuit power AC200-240 V

U/V/W: Power output to servo motor

P+, N-: Regenerative resistor terminals; factory short-circuit jumper fitted for built-in resistor

PE: Schutzerde

CN1: Digital I/O and STO safety signals

CN2: Encoder plug for HG-KR73 / HG-SR73 motor

CN3: Pulse command I/O connected to PLC pulse output

CN4: Mini-USB debug port for MR-Configurator2 PC software

Schritt 1: Schutzerde (PE)

Connect amplifier PE terminal and motor PE to cabinet protective earth busbar. Earth resistance ≤ 10 Ω. Perform earthing first.

Schritt 2: Power-circuit Wiring

1. Main-circuit power L1/L2/L3

Three-phase AC200-240 V: Wire L1, L2 und L3.

Single-phase AC200-240 V: Connect L1 and L2; L3 must remain open.

Install circuit-breaker and contactor upstream. Never feed mains voltage into U/V-W output terminals.

2. Control-circuit power L11, L21: AC200-240 V. May share supply with main circuit.

Notiz: Main circuit and control circuit can be supplied separately. For signal-only debugging, energize only L11/L21; amplifier powers up without main motor voltage.

3. Regenerative resistor configuration:

Normal start-stop duty: Retain factory short-circuit jumper between P+-D to use internal regenerative resistor.

Frequent rapid acceleration/deceleration: Remove jumper and fit external regenerative resistor between P+ and N-, select correct resistance and power rating.

Schritt 3: Motor Power Cable U/V/W

Connect amplifier U-motor U; V-motor V; W-motor W one-to-one. Do NOT swap phases. Do not insert contactor, capacitor or surge suppressor between amplifier and motor.

Motors with electromagnetic brake: Brake coil requires independent 24 VDC supply. Brake release logic shall be controlled via external relay. Do not power brake from servo drive.

Schritt 4: Encoder Cable CN2

Use dedicated MR-J4 encoder cable. Fully insert CN2 connector and lock latch. Route encoder cable away from power cables. Avoid sharp bending or pulling. MR-J3 encoder cables are NOT compatible with MR-J4 drives.

Schritt 5: Digital I/O CN1 & Pulse Interface CN3 (Position-pulse control)

1. EM2 (Forced stop / Nothalt): Hardware safety signal. Hard-wire emergency stop for operational machines. Short-circuit only for temporary bench testing.
2. SON (Servo-On), RES (Alarm reset), LSP (Forward stroke limit), LSN (Reverse stroke limit).
3. CN3 pulse command: Select PULSE+SIGN format to match PLC output configuration.

Separate signal cables from power cables by ≥ 10 cm to reduce noise interference. Use shielded signal cables with single-end shield grounding.

Schritt 6: Debug Interface CN4-USB

Connect Mini-USB cable between PC and CN4. Install MR-Configurator2 software for parameter backup, JOG operation and alarm diagnostics.

3. Mandatory Pre-Power-On Check-List (Perform with power OFF)
4. Multimeter measurements:

No short-circuit between L1-L2-L3 and L11-L21.

Good insulation; no short-circuit phase-to-phase or phase-to-ground on U/V-W motor output.

No short-circuit across P+ and N- Terminals.

2. Überprüfung der Verkabelung:

Confirm mains supply is NOT connected to U/V-W output terminals.

U/V-W phases correctly matched; encoder connector latched; PE earthing solid.

Regenerative resistor jumper / external resistor fitted correctly; brake wiring verified.

3. Mechanical inspection:

Coupling securely tightened; no mechanical binding; no mechanical collision risk. Implement anti-fall protection for vertical axes.

4. Safety loop: Emergency-stop circuit confirmed functional.
5. Power-Up Sequence
6. Keep personnel clear of moving mechanisms; position machine at safe location.
7. Energize control power L11/L21 first. Confirm amplifier powers on without alarms.
8. Close main-circuit power L1/L2/L3.
9. If alarms appear: Troubleshoot according to alarm codes (AL 32 over-current, AL.E6 encoder error, AL 50 overload).
10. Connect PC software and back-up factory parameter set.
11. Debug workflow:
12. Run low-speed JOG via software, verify motor rotation direction.
13. Validate forward / reverse limit signals.
14. Configure pulse format and electronic gear ratio to match PLC.
15. Test positioning with small-volume pulse commands; gradually increase travel.
16. Run full-cycle motion and execute One-Touch-Tuning for servo gain optimization.
17. Häufige Fallstricke bei der Installation
18. Single-phase supply: Do not connect voltage to L3 terminal.
19. Applying AC220 V power to U/V-W will permanently destroy amplifier.
20. Loose encoder CN2 connector causes intermittent AL.E6 encoder fault.
21. Powering motor brake directly from servo drive results in brake-release failure.
22. Insufficient cooling clearance leads to thermal alarm AL 51 under continuous operation.
23. EM2 emergency-stop left un-wired prevents servo-on operation.
24. Parallel routing of power and signal cables causes pulse noise and positioning loss.
25. Wartung

Periodically re-tighten terminal screws; keep cabinet dust-free. Export and save servo parameter files annually.

Storage conditions: -20 ~ +65 °C, keine kondensation.

Complete Parameter Tuning Procedure for Mitsubishi MR-J4-70A

MR-J4-70A pulse-input servo amplifier. Tuning tool: MR-Konfigurator2 (Mini-USB cable connected to CN4).

⚠️Before tuning: Confirm machine is mechanically free of jamming; keep personnel clear of moving parts. After parameter modification, write parameters to EEPROM for non-volatile storage. Parameters groups: PA-Basic parameters, PB-Gain & Filter, PC-Extended parameters, PD-I/O assignment parameters.

1. Software Connection & Vorbereitungen
2. Connect PC Mini-USB to CN4. Power on drive. Launch MR-Configurator2, go online, read all parameters and save parameter backup file.
3. Factory reset (optional): Unlock write-protection via PA19, perform parameter reset, cycle power for changes to take effect.
4. Confirm motor identification: Verify connected motor HG-KR73 / HG-SR73 is correctly recognized in software monitor screen; no motor-mismatch alarm.
5. Basic Control Parameters (Position Pulse Mode Most-Used)

PA-Group (Basic Setting Parameters)

✅Electronic-gear example: Ball-screw lead 10 mm, direct motor coupling. Require 10000 PLC pulses per full motor rotation.

Encoder-Auflösung: 4194304 (22-bisschen)

CMX/CDV = 4194304 / 10000 → CMX=4194304, CDV=10000

Hardware note: Differential input max. 4 Mpps; open-collector max. 200 kpps. Use differential signaling for high-speed operation.

3. PD-Group Digital I/O Parameters
4. PD01-PD14: Input terminal assignment (CN1)

SON (Servo-On), LSP (Forward stroke limit), LSN (Reverse stroke limit), RES (Zurücksetzen), EM2 (Nothalt).

EM2 hardware emergency-stop must be hard-wired. Short-circuit connection permitted only for temporary bench-test; never for production equipment.

2. PD20-PD27: Output terminal assignment: ALM (Alarm), RD (Servo Ready), INP (In-position complete).
3. Power-On & JOG Test (PLC connection not required, motor validation first)
4. Software → Test Operation → JOG operation.
5. Set low speed 50-200 r/min, jog forward and reverse.
6. Confirm rotation direction. If direction reversed: invert setting of PA14 Rotation direction selection.
7. Check for abnormal noise, vibration and mechanical binding.

Complete JOG validation before connecting PLC pulse commands.

5. Servo Gain Tuning (Critical for vibration, overshoot and positioning time)

Three tuning methods for MR-J4: One-Touch Tuning (Recommended first-choice), Real-Time Auto-Tuning, Manual PB-parameter fine-tuning.

Methode1: One-Touch Tuning (Recommended for commissioning)

1. Complete mechanical assembly with real-world load fitted.
2. Software menu Tuning → One-Touch Tuning.
3. Set target response level: 1-15

High-rigidity light-load machine: 8-12

Timing-belt / low-rigidity mechanism: 3-7

4. Execute procedure; servo performs reciprocating test motion to estimate load inertia and auto-set gains and filters.
5. Write result to EEPROM after completion.
6. Run positioning cycles; evaluate vibration, over-shoot and acoustic noise.

Methode2: Real-Time Auto-Tuning

Set PA08 tuning mode to `_ _ _1`. Servo continuously estimates load inertia and dynamically adjusts gain during actual machine operation. Suitable for variable-load conditions.

Methode3: Manual PB-Parameter Fine-Tuning (Refine when One-Touch result is unsatisfactory)

Manual tuning sequence: Tune speed-loop parameters first, then position-loop. If oscillation occurs, immediately reduce gain values; do not increase gain blindly.

Symptom-based correction table

1. Buzzing vibration at stand-still: Reduce PB07 position-loop gain; enable PB01 adaptive filter, configure notch filter.
2. Position over-shoot: Lower position-loop gain; increase speed-loop integral time.
3. Slow response and long settling time: Moderately raise PG1 and VG1.
4. Fixed-frequency abnormal noise: Use software Machine Analyzer function to scan resonance frequency and configure notch filter.
5. Limit, Home-Return & Torque-Limit Parameters
6. PA12 Torque limit: Range 0-100%. Set to 50% during commissioning to prevent mechanical collision damage.
7. PC01-PC06: Homing parameters; home-return mode, homing speed, creep speed, home offset value.
8. PC13, PC14: Soft-limit position thresholds (Einheit: command pulses).
9. Parameter Upload / Herunterladen & Saving
10. After modification, execute Write to EEPROM in software. Changes stored in RAM only will be lost on power-cycle.
11. Upload: Read servo parameters and save project file. For amplifier replacement, download saved parameter file for fast commissioning.
12. Standard Commissioning Test Sequence
13. JOG jog test; confirm rotation direction and no mechanical binding.
14. Send small-volume pulse commands from PLC, verify travel distance via electronic-gear ratio calculation.
15. Low-speed reciprocating motion; check for noise and vibration.
16. Execute One-Touch-Tuning.
17. Mid-speed and full-speed positioning cycles; monitor in-position status, over-shoot and residual vibration.
18. Functional test of travel limits, emergency-stop and alarm-reset.
19. After full validation, save complete parameter backup.
20. Common Commissioning Faults
21. Motor does not rotate, RD (Servo Ready) output ON: Check SON (Servo-On) Signal, EM2 emergency-stop loop and PA01 operation-mode setting.
22. Motor rotates but travel distance is incorrect: Verify PA13 pulse-input format and CMX/CDV electronic-gear ratio calculation.
23. Vibrationen und ungewöhnliche Geräusche während des Betriebs: Incorrect inertia-ratio setting, excessive gain, mechanical resonance. Prioritize One-Touch-Tuning plus Machine-Analyzer tool.
24. AL 50 Overload alarm: Excessive load-inertia ratio, high mechanical friction, gain values too high.
25. AL.E6 Encoder alarm: Damaged or poorly-seated CN2 encoder cable.

HS-code for customs: 8501520000