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Mitsubishi Electric -MR-CV User Manual

Power regeneration converter unit
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Mitsubishi Electric AC Servo System
MR-CV Power Regeneration Converter Unit
User's Manual
-MR-CV_

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Summary of Contents for Mitsubishi Electric -MR-CV

  • Page 1 Mitsubishi Electric AC Servo System MR-CV Power Regeneration Converter Unit User's Manual -MR-CV_...

  • Page 3: Safety Instructions

    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 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.
  • Page 4 [Transportation] CAUTION ● To prevent injury, transport the products correctly according to their mass. [Installation/wiring] Warning ● To prevent an electric shock, turn off the power and wait for 20 minutes or more before starting wiring and/or inspection. ● To prevent an electric shock, ground the converter unit. ●...

  • Page 5: Disposal Of Waste

    Please dispose of this product and other options according to your local laws and regulations. ABOUT THE MANUAL e-Manuals are Mitsubishi Electric FA electronic book manuals that can be browsed with a dedicated tool. e-Manuals enable the following: • Searching for desired information in multiple manuals at the same time (manual cross searching) •...

  • Page 6: Table Of Contents

    CONTENTS SAFETY INSTRUCTIONS..............1 DISPOSAL OF WASTE .
  • Page 7 When connecting multiple drive units and servo amplifiers to the converter unit ......55 Forced stop of the converter unit ............59 When combining one converter unit and one drive unit .
  • Page 8 [EB_Excessive regeneration Warning] ............83 [EC_Overload warning] .

  • Page 9: Chapter 1 Functions And Configuration

    FUNCTIONS AND CONFIGURATION Outline The MR-CV_ power regeneration converter unit can return the regenerative energy generated at servo motor deceleration to the power supply. The MR-CV_ power regeneration converter unit supports connections that share the bus voltage with multiple drive units and servo amplifiers, enabling energy conservation, less wiring, and space saving. Model designation Rating plate The following shows an example of the rating plate for explanation of each item.

  • Page 10: Standard Specifications

    Standard specifications 200 V class Model MR-CV_ Output Rated voltage 270 V DC to 324 V DC Rated current [A] Main circuit power Voltage/Frequency 3-phase 200 V AC to 240 V AC, 50 Hz/60 Hz supply input Rated current [A] Permissible voltage fluctuation 3-phase 170 V AC to 264 V AC Permissible frequency fluctuation...
  • Page 11 400 V class Model MR-CV_ 11K4 18K4 30K4 37K4 45K4 55K4 75K4 Output Rated voltage 513 V DC to 648 V DC Rated current [A] Main circuit power Voltage/Frequency 3-phase 380 V AC to 480 V AC, 50 Hz/60 Hz supply input Rated current [A] Permissible voltage fluctuation...

  • Page 12: Configuration Including Peripheral Equipment

    Configuration including peripheral equipment • Equipment other than the converter unit, drive unit and servo motor is optional or a recommended product. The following is an example using the MR-J5D1-100G4 and MR-CV11K4. The actual converter unit and drive unit are mounted closely together. R S T Power supply Molded-case...

  • Page 13: Chapter 2 Installation

    INSTALLATION Precautions • Install the converter unit on incombustible material. Installing them either directly on or near combustibles may lead to smoke or a fire. In addition, the converter unit must be installed in a metal cabinet. • Provide an adequate protection to prevent the following matter from entering the converter unit: conductive matter such as screws and metal fragments, and combustible matter such as oil.

  • Page 14: Mounting Direction And Clearances

    Mounting direction and clearances Precautions • The converter unit must be installed in the specified direction. • To prevent a malfunction, maintain the specified clearances between the converter unit and cabinet walls or other equipment. • Circulate air so that the air at the top and bottom of the converter unit does not stagnate. •...

  • Page 15: Keeping Out Foreign Materials

    Keeping out foreign materials When drilling the cabinet for assembly, prevent drill chips and wire fragments from entering the converter unit. Prevent foreign matter such as oil, water, and metallic dust from entering the converter unit through cooling fans installed in openings in the cabinet or on the ceiling.

  • Page 16: Parts With A Service Life

    Parts with a service life The service life of the following parts is listed below. In addition, the service life varies depending on the operating methods and environment. If any fault is found in a part, it is necessary to replace it immediately regardless of its service life. For parts replacement, please contact your local sales office.

  • Page 17: Restrictions When Using This Product At An Altitude Exceeding 1000 M And Up To 2000 M

    Restrictions when using this product at an altitude exceeding 1000 m and up to 2000 m For restrictions on the drive unit/servo amplifier, refer to the drive unit/servo amplifier user's manual and instruction manual. Effective load ratio and regenerative load ratio As heat dissipation effects decrease in proportion to decreasing air density, use the product within the effective load ratio and regenerative load ratio shown in the following figure.

  • Page 18: Chapter 3 Function Block Diagram

    FUNCTION BLOCK DIAGRAM This chapter shows the function block diagram of this servo. MR-CV_ Thyristor AC reactor MCCB To drive unit Power supply Charge lamp To drive unit Base amplifier Cooling fan MCCB Control Voltage Current circuit detection detection power supply CN23 CN24...
  • Page 19 MEMO 3 FUNCTION BLOCK DIAGRAM...

  • Page 20: Chapter 4 Structure (Parts Identification)

    STRUCTURE (PARTS IDENTIFICATION) Parts identification MR-CV18K(4) or lower This diagram shows the terminal cover in the open position. For how to open and close the terminal cover, refer to the following. Page 24 Opening and closing the terminal cover (1) Display section (2) Rotary switch for converter setting (SW1) (3) Protection coordination connector (CN4) (5) Manufacturer setting connector (CN41)
  • Page 21 Name Application Detailed explanation Display section The 1-digit, 7-segment LED indicator shows the converter unit status Page 28 Converter unit and alarm number. switch settings and operation panel Rotary switch for converter setting Set the function of the converter unit. (SW1) Protection coordination connector Connect it with CN40A of the drive unit.
  • Page 22 MR-CV30K(4)/MR-CV37K(4)/MR-CV45K(4) (1) Display section (2) Rotary switch for converter setting (SW1) (3) Protection coordination connector (CN4) (5) Manufacturer setting connector (CN41) (6) I/O signal connector (CN24) (4) Manufacturer setting connector (CN9) (11) Alarm output connector (CN25) (7) Magnetic contactor control connector (CN23) (14) Rating plate (8) Charge light (9) L+/L- terminal (TE2)
  • Page 23 Name Application Detailed explanation Display section The 1-digit, 7-segment LED indicator shows the converter unit status Page 28 Converter unit and alarm number. switch settings and operation panel Rotary switch for converter setting Set the function of the converter unit. (SW1) Protection coordination connector Connect it with CN40A of the drive unit.
  • Page 24 MR-CV55K(4)/MR-CV75K4/MR-CV55K The diagram shows the MR-CV55K4. (1) Display section (2) Rotary switch for converter setting (SW1) (6) I/O signal connector (CN24) (15) Rating plate (5) Manufacturer setting connector (CN41) (3) Protection coordination connector (CN4) (4) Manufacturer setting connector (CN9) (12) Alarm output connector (CN25) (8) Charge light (7) Magnetic contactor control connector (CN23) (9) Manufacturer setting terminal (TE2-1)
  • Page 25 Name Application Detailed explanation Display section The 1-digit, 7-segment LED indicator shows the converter unit status Page 28 Converter unit and alarm number. switch settings and operation panel Rotary switch for converter setting Set the function of the converter unit. (SW1) Protection coordination connector Connect it with CN40A of the drive unit.

  • Page 26: Opening And Closing The Terminal Cover

    Opening and closing the terminal cover This section describes how to open and close the terminal cover. Top terminal cover ■How to open Support point A) and pull up the cover. The cover is fixed when it is raised to the position shown in the figure. 4 STRUCTURE (PARTS IDENTIFICATION) 4.2 Opening and closing the terminal cover...
  • Page 27 ■How to close Support point A) and close the cover. Installation hooks Press the cover until the installation hooks click. Installation hooks 4 STRUCTURE (PARTS IDENTIFICATION) 4.2 Opening and closing the terminal cover...
  • Page 28 Bottom terminal cover ■How to open Hold the left and right sides of the bottom of the terminal cover with both hands. Support point B) and close the cover. The cover is fixed when it is raised to the top. 4 STRUCTURE (PARTS IDENTIFICATION) 4.2 Opening and closing the terminal cover...
  • Page 29 ■How to close Hold the left and right sides of the bottom of the terminal cover with both hands. Installation hooks Installation hooks Support point B) and close the cover. Press the cover until the installation hooks click. Installation hooks 4 STRUCTURE (PARTS IDENTIFICATION) 4.2 Opening and closing the terminal cover...

  • Page 30: Converter Unit Switch Settings And Operation Panel

    Converter unit switch settings and operation panel Forced stop, protection coordination, and magnetic contactor drive output can be configured by setting the converter unit switch. The converter unit status and alarm number can be displayed on the converter unit display (1-digit, 7-segment LED). Switches If a metal screw driver contacts with the conductive areas, the switches may malfunction.

  • Page 31: Scrolling Display

    Scrolling display Normal display When the power supply to the control section of the converter unit is turned on, the progress of the initial setting is displayed on the 1-digit, 7-segment LED. Normally, the 1-digit, 7-segment LED is always lit. During ready-on Initialization completed Contactor on...

  • Page 32: Display Sequence

    Display sequence Initializing When an alarm No. or warning No. is displayed Example: Example: Initialization completed When [61] has occurred When [6E.1] has occurred Blinking Blinking 1.5 s Ready-off (charging) When an alarm occurs, its alarm code appears. Blinking Blinking Ready-on 1.5 s (charging completed)

  • Page 33: Chapter 5 Signals And Wiring

    SIGNALS AND WIRING Precautions • Insulate the conductive parts of the terminals. • Turn off the power and wait for 20 minutes or more until the charge light of the unit turns off. Checking the voltage between L+ and L- using the tester, etc. is recommended. •...

  • Page 34: Example Power Circuit Connections

    Example power circuit connections Precautions • Connect a magnetic contactor between a power supply and the main circuit power supply (L1/L2/L3) of a converter unit to configure a circuit that shuts off the power supply on the converter unit side because failure of the converter unit may cause smoke and fire if a magnetic contactor is not connected.

  • Page 35: Magnetic Contactor Control Connector (Cn23)

    Magnetic contactor control connector (CN23) By enabling the magnetic contactor drive output, the main circuit power supply can be automatically shut off when an alarm occurs in the converter unit and drive unit. The magnetic contactor drive output can be enabled by setting the rotary switch for converter setting (SW1) of the converter unit to "0"...

  • Page 36: Wiring Diagram

    When the magnetic contactor drive output is disabled Even if an alarm occurs on the converter unit and drive unit, the main circuit power supply is not automatically turned off, so configure a circuit that detects the alarms externally and turns off the main circuit power supply. Wiring diagram When the magnetic contactor drive output is enabled Set the rotary switch for converter setting to "0"...
  • Page 37 ■400 V class Ready for Emergency operation stop switch Drive unit error off/on AC reactor MR-CV_ MCCB 3-phase To the drive unit 380 V AC to 480 V AC 50/60 Hz CN23 *3*4 Protection coordination cable To the drive unit *1 Use the magnetic contactor with an operation delay time (interval between current being applied to the coil until closure of contacts) of 80 ms or less.
  • Page 38 When the magnetic contactor drive output is disabled Set the rotary switch for converter setting to "1". The converter unit controls the magnetic contactor. Connect the converter unit and the drive unit adjacent to it with a protection coordination cable. Turn on/off the control circuit power supplies of the converter unit and drive unit at the same time.
  • Page 39 ■400 V class Ready for Converter unit Emergency operation Drive unit error alarm output stop switch off/on AC reactor MR-CV_ MCCB 3-phase To the drive unit 380 V AC to 480 V AC 50/60 Hz CN25 24 V DC *3*4 Protection coordination cable...

  • Page 40: Explanation Of Power Supply System

    Explanation of power supply system Explanation of signals For the layout of terminal blocks, refer to the following. Page 84 DIMENSIONS Connection destination Symbol Terminal Description (application) block MR-CV11K to MR-CV55K MR-CV11K4 to MR-CV75K4 Main circuit power supply L1/L2/L3 Supply 3-phase 200 V AC to 240 V AC, 50 Supply 3-phase 380 V AC to 480 V AC, 50 Hz/60 Hz power to L1, L2, and L3.

  • Page 41: Power-On Sequence

    Power-on sequence Power-on procedure Wire the power supply using a magnetic contactor between the power supply and the main circuit power supply (L1/L2/ L3) of a servo amplifier by referring to the following section. Configure the circuit to switch off the magnetic contactor as soon as an alarm occurs using an external sequence.
  • Page 42 • When the magnetic contactor drive output is enabled and returns to ready-off When in ready-off, the magnetic contactor of the converter unit is turned off and the main circuit power supply is shut off. Servo motor speed 0 r/min Drive unit control circuit power supply Converter unit control circuit power supply...
  • Page 43 • When the magnetic contactor drive output is disabled When an alarm occurs, turn off the magnetic contactor using an external sequence and shut off the main circuit power supply. Servo motor speed 0 r/min Drive unit control circuit power supply Converter unit control circuit power supply Main circuit power supply (3 s)
  • Page 44 ■When connecting multiple drive units and servo amplifiers to the converter unit • When the magnetic contactor drive output is enabled and remains ready-on Drive unit (axis the protection coordination cable is connected) 0 r/min Servo motor speed Drive unit (axis the protection coordination cable is not connected) or servo amplifier 0 r/min Servo motor speed...
  • Page 45 • When the magnetic contactor drive output is enabled and returns to ready-off When the axis connected by the protection coordination cable is in the servo-off status, the magnetic contactor of the converter unit is turned off and the main circuit power supply is shut off. The main circuit power supply is not shut off even if the axes that are not connected by protection coordination cables are in the servo-off status.
  • Page 46 • When the magnetic contactor drive output is disabled When an alarm occurs, turn off the magnetic contactor using an external sequence and shut off the main circuit power supply. Drive unit (axis the protection coordination cable is connected) 0 r/min Servo motor speed Drive unit (axis the protection coordination cable is not connected) or servo amplifier...

  • Page 47: Connectors And Pin Assignments

    Connectors and pin assignments The pin assignments of the connectors are as viewed from the cable connector wiring section. When using the CN24 connector, the MR-CVCN24S connector set and crimping tool are required. Converter unit connectors and pin assignments CN4 Used to connect CN40A of the drive unit. CN41 Leave this open.

  • Page 48: Connecting The Cn25

    Connecting the CN25 Use care not to damage the conductor when stripping wires. Using a damaged conductor may cause poor insulation, loose connection, and missing wires. After completing the connection, pull the wires lightly one by one to ensure that they cannot be easily pulled out. Not satisfying this requirement may lead to loose connection and missing wires.
  • Page 49 Inserting wire Insert one wire per wire insertion hole (round hole) of CN25. Insert a screwdriver diagonally into the operation slot (square hole). Insert the screwdriver fully while adjusting the angle to the upright position. If performed correctly, the screwdriver will hold this position even when released.
  • Page 50 Usable screwdrivers The following dedicated screwdrivers are recommended for installing the wires. Model number Type Brand 210-720 Standard type (made in Europe) WAGO 210-120J Standard type (made in Japan) 210-657J Mini type (made in Japan) When using a general-purpose screwdriver, use one with a blade width of 3.5 mm. Do not use a screwdriver that does not fit into the operation slot or that cannot properly release the spring.

  • Page 51: Signal (Device) Explanation

    Signal (device) explanation This section describes the signals (devices) of the converter unit. For the I/O interfaces (symbols in the column "I/O signal interface type" in the table), refer to the following. Page 61 Interface I/O signal connector (CN24) Signal (device) Symbol Connector Function and application...

  • Page 52: Magnetic Contactor Control Connector (Cn23)

    Magnetic contactor control connector (CN23) Signal (device) Symbol Connector Function and application I/O signal name pin No. interface type  Magnetic contactor CN23-1 Connect to the coil of the magnetic contactor and the power supply for magnetic drive output contactor control. CN23-3 When the converter unit receives a start command from the drive unit, a short circuit occurs between MC1 (CN23-1 pin) and MC2 (CN23-3 pin).

  • Page 53: Timing Chart At Alarm Occurrence

    Timing chart at alarm occurrence Precautions When an alarm occurs, remove its cause, check that the operation signal is not being inputted, ensure safety, and reset the alarm before restarting the operation. When combining one converter unit and one drive unit When the magnetic contactor drive output is enabled ■Converter unit When an alarm occurs on the converter unit, the magnetic contactor turns off and the main circuit power supply is shut off.
  • Page 54 ■Drive unit When an alarm occurs on the drive unit, the base circuit is shut off, and the servo motor begins to coast. Once the servo motor begins to coast, the dynamic brake is activated and the servo motor stops. The alarm can be canceled by cycling the control circuit power supply, turning on the error reset command from the controller, or using the CPU reset command, but it cannot be canceled unless the cause of the alarm is eliminated.
  • Page 55 When the magnetic contactor drive output is disabled ■Converter unit When an alarm occurs on the converter unit, the status becomes servo-off, but the main circuit power supply is not shut off, so shut off the main circuit power supply using an external sequence. After canceling the alarm on the converter unit (if the alarm is also on the drive unit, then after canceling the alarm on the drive unit), the operation is enabled again by turning on the error reset command from the controller.
  • Page 56 ■Drive unit When an alarm occurs on the drive unit, the status becomes servo-off, but the main circuit power supply is not shut off, so shut off the main circuit power supply using an external sequence. After canceling the alarm on the drive unit, the operation is enabled again by turning on the error reset command from the controller.

  • Page 57: When Connecting Multiple Drive Units And Servo Amplifiers To The Converter Unit

    When connecting multiple drive units and servo amplifiers to the converter unit When the magnetic contactor drive output is enabled ■Converter unit When an alarm occurs on the converter unit, the magnetic contactor turns off and the main circuit power supply is shut off. Input the emergency stop signal of the controller to the operating drive units or servo amplifiers to change all axes to servo-off.
  • Page 58 ■Drive unit If an alarm occurs on the drive unit of the axis connected by the protection coordination cable, the base circuit is shut off, and the servo motor begins to coast. If an alarm occurs on a drive unit or servo amplifier other than the axis connected by the protection coordination cable, turn off the magnetic contactor using an external sequence and shut off the main circuit power supply.
  • Page 59 When the magnetic contactor drive output is disabled ■Converter unit When an alarm occurs on the converter unit, the status becomes servo-off, but the main circuit power supply is not shut off, so shut off the main circuit power supply using an external sequence. Input the emergency stop signal of the controller to the operating drive units or servo amplifiers to change all axes to servo-off.
  • Page 60 ■Drive unit or servo amplifier When an alarm occurs on the drive unit or servo amplifier, the status becomes servo-off, but the main circuit power supply is not shut off, so shut off the main circuit power supply using an external sequence. Input the emergency stop signal of the controller to the operating drive units or servo amplifiers to change all axes to servo-off.

  • Page 61: Forced Stop Of The Converter Unit

    Forced stop of the converter unit When combining one converter unit and one drive unit When the magnetic contactor drive output is enabled When EM1 (Forced stop) of the converter unit is turned off, the magnetic contactor is turned off, and the main circuit power supply is shut off.

  • Page 62: When Connecting Multiple Drive Units And Servo Amplifiers To The Converter Unit

    When connecting multiple drive units and servo amplifiers to the converter unit To stop the converter unit and drive units at the same time, wire the converter unit and drive units so that EM1 (Forced stop) of both are turned off at the same time. When the magnetic contactor drive output is enabled When EM1 (Forced stop) of the converter unit and drive units are turned off, the magnetic contactor is turned off and the main circuit power supply is shut off.

  • Page 63: Interface

    Interface Sink I/O interface Digital input interface DI This is an input circuit in which the photocoupler cathode side is the input terminal. Transmit signals from a sink (open- collector) type transistor output, relay switch, etc. The following connection diagram is for sink input. Refer to the following for source input.

  • Page 64: Source I/O Interface

    Source I/O interface For the MR-CV_ power regeneration converter unit, source type I/O interfaces can be used. Digital input interface DI This is an input circuit in which the anode of the photocoupler is the input terminal. Transmit signals from a source (open- collector) type transistor output, relay switch, etc.

  • Page 65: Grounding

    Grounding The drive unit/servo amplifier supplies power to the servo motor by switching on and off a power transistor. Depending on the wiring and ground wire routing, the servo amplifier may be affected by the switching noise (due to di/dt and dv/dt) of the transistor.

  • Page 66: Chapter 6 Characteristics

    CHARACTERISTICS Overload protection characteristics An electronic thermal is built into the converter unit to protect the converter unit from overloads. [7E Overload 1] occurs when overload operation exceeds the electronic thermal protection curve shown in this section. [7F Overload 2] occurs when operation continues above the rated speed and rated torque. Use the equipment within the area on the left side of the graph.
  • Page 67 ■Characteristic B 10000 1000 Load ratio [%] *1 A resistive force of 100 % indicates the continuous rating of the converter unit. ■Characteristic C 10000 1000 Load ratio [%] *1 A resistive force of 100 % indicates the continuous rating of the converter unit. 6 CHARACTERISTICS 6.1 Overload protection characteristics...
  • Page 68 ■Characteristic D 10000 1000 Load ratio [%] *1 A resistive force of 100 % indicates the continuous rating of the converter unit. 6 CHARACTERISTICS 6.1 Overload protection characteristics...

  • Page 69: Power Supply Capacity And Generated Loss

    Power supply capacity and generated loss Amount of heat generated by converter unit The following table indicates the generated loss and the power supply capacity of the converter unit under rated load. Converter unit Power supply Converter unit generated heat [W] Area required for capacity [kVA] heat dissipation...

  • Page 70: Heat Dissipation Area For Enclosed Type Cabinet

    Heat dissipation area for enclosed type cabinet For the heat dissipation area of the drive unit/servo amplifier, refer to the drive unit/servo amplifier user's manual and instruction manual. The enclosed type cabinet (hereafter called the cabinet) that stores the converter unit should be designed to ensure that its internal temperature rise is within +10 °C at an ambient temperature of 40 °C.

  • Page 71: Inrush Currents At Power-On Of Main Circuit And Control Circuit

    Inrush currents at power-on of main circuit and control circuit A molded-case circuit breaker and magnetic contactor may fail or malfunction due to an inrush current flowing through the converter units power lines (input lines) at power-on. Therefore, use products with the specifications described on the following page.

  • Page 72: Chapter 7 Protection Coordination Mode Disabled

    PROTECTION COORDINATION MODE DISABLED (STANDALONE DRIVE) Precautions • Do not apply power to the main circuit power supply terminals (L1/L2/L3) of the servo amplifier. Doing so will cause the servo amplifier and converter unit to malfunction. • Connect the polarities of the DC power supply between the converter unit and the servo amplifier correctly. Connecting them incorrectly will cause the converter unit and servo amplifier to malfunction.

  • Page 73: Class

    200 V class Servo amplifier Servo amplifier Converter unit Emergency stop Operation ready malfunction malfunction malfunction switch OFF/ON Terminal MR-CV_ block reactor MCCB 3-phase 200 to 240 V AC, 50/60 Hz Servo amplifier Servo amplifier DOCOM 24 V DC DICOM Short-circuit Short-circuit connector...
  • Page 74 *1 Configure a sequence that shuts off the main circuit power supply in the following situations: When an alarm has occurred on the converter unit or servo amplifier. When EM1 (Forced stop 1) of the servo amplifier is enabled. When the main circuit of the converter unit is shut off after the converter unit became ready-on, causing an alarm that monitors the power supply of the converter unit ([62 Frequency error], [67 Open phase], or [71 Undervoltage]) to occur.

  • Page 75: Class

    400 V class Servo amplifier Servo amplifier Converter unit Emergency stop Operation ready malfunction malfunction malfunction switch OFF/ON Step-down Terminal MR-CV_ transformer block reactor MCCB 3-phase 380 to 480 V AC, 50/60 Hz Servo amplifier Servo amplifier DOCOM 24 V DC DICOM Short-circuit Short-circuit...
  • Page 76 *1 Configure a sequence that shuts off the main circuit power supply in the following situations: When an alarm has occurred on the converter unit or servo amplifier. When EM1 (Forced stop 1) of the servo amplifier is enabled. When the main circuit of the converter unit is shut off after the converter unit became ready-on, causing an alarm that monitors the power supply of the converter unit ([62 Frequency error], [67 Open phase], or [71 Undervoltage]) to occur.

  • Page 77: Chapter 8 Converter Unit Troubleshooting

    CONVERTER UNIT TROUBLESHOOTING Outline If an error occurs in the servo system, the corresponding alarm or warning is displayed on the converter unit. When an alarm occurs, ALM (Malfunction) turns off. If an alarm or warning is displayed, take appropriate measures according to the following: Page 77 Handling methods for alarms/warnings List of alarm No./warning No.

  • Page 78: List

    List Alarm/Warning Alarm deactivation Alarm reset CPU reset Power cycling    Alarm    Alarm    Alarm Alarm    Alarm       Alarm    Alarm   ...

  • Page 79: Handling Methods For Alarms/Warnings

    Handling methods for alarms/warnings Remove the cause of the alarm and warning in accordance with this section. [61_Overcurrent] • A current higher than the permissible current flowed in the converter unit. Cause Check/action method The combination of AC reactor and converter unit Check that the connected AC reactor is the correct combination.

  • Page 80: [67_Open Phase]

    [67_Open phase] • An open phase occurred in the main circuit power supply of the converter unit. Cause Check/action method An open phase occurred in the main circuit power Check that the main circuit power line is connected with the converter unit. Check if the main circuit power line of the converter unit is closed.

  • Page 81: [6A_Mc Drive Circuit Error]

    [6A_MC drive circuit error] • With an error in the magnetic contactor drive circuit, the main circuit power supply is turned on even though the magnetic contactor output is turned off. Cause Check/action method The setting value of the magnetic contactor drive Check the SW1 setting and wiring configuration.

  • Page 82: [70_Converter Forced Stop Error]

    [70_Converter forced stop error] • EM1 (Forced stop) of the converter unit was turned off. Cause Check/action method EM1 of the converter unit was turned off. Check the status of EM1 of the converter unit. After ensuring safety, turn EM1 on. An external 24 V DC power supply has not been Input the external 24 V DC power supply.

  • Page 83: [75_Overvoltage]

    [75_Overvoltage] • The value of the bus voltage exceeded the specified value. 200 V class: 420 V DC 400 V class: 840 V DC Cause Check/action method The regeneration capacity is insufficient. Set a longer deceleration time constant, then check the repeatability. If the error does not repeat, take corrective actions as follows: •...

  • Page 84: [77_Main Circuit Device Overheat]

    [77_Main circuit device overheat] • The inside of the converter unit overheated. Cause Check/action method The ambient temperature exceeded the specified Check the ambient temperature, and if the temperature exceeds the specified value, lower the ambient temperature. value (55 °C). The power was turned on and off repeatedly Check if the overload status occurred frequently.

  • Page 85: [E9_Instantaneous Power Failure Warning]

    [E9_Instantaneous power failure warning] • [71 Undervoltage] may occur. Cause Check/action method An instantaneous power failure lasted for 30 ms or Check if the power supply has a problem. After checking, cycle the power of the converter unit. more. [EA_External forced stop warning] •...

  • Page 86: Chapter 9 Dimensions

    DIMENSIONS • Refer to the following for the mounting hole location diagram. Page 12 Mounting direction and clearances MR-CV11K(4)/MR-CV18K(4) [Unit: mm] Approx. Cooling φ6 mounting hole exhaust Intake 175.5 16.2 25.6 32.4 178.5 72.8 73.5 Mass: 6.1 [kg] Mounting screw Screw size: M5 Tightening torque: 3.24 [N•m] Terminal...

  • Page 87: Mr-Cv30K(4)/Mr-Cv37K(4)/Mr-Cv45K(4)

    MR-CV30K(4)/MR-CV37K(4)/MR-CV45K(4) [Unit: mm] Approx. Cooling 2-φ6 mounting hole exhaust 175.5 Intake 178.5 113.5 Mass: 12.1 [kg] Mounting screw Screw size: M5 Tightening torque: 3.24 [N•m] Terminal TE1 Screw size: M8 Tightening torque: 6.0 [N•m] TE2 Screw size: M6 Tightening torque: 3.0 [N•m] TE3 Screw size: M4 Tightening torque: 1.2 [N•m] PE Screw size: M8...

  • Page 88: Mr-Cv55K

    MR-CV55K [Unit: mm] For eyebolts Approx. 2-φ6 mounting hole Cooling exhaust TE2-1 TE2-2 175.5 Intake 178.5 223.5 Mass: 12.1 [kg] Mounting screw Screw size: M5 Terminal Tightening torque: 3.24 [N•m] TE2-1 TE2-2 Screw size: M10 Tightening torque: 12.0 [N•m] TE2-1 Screw size: M6 Tightening torque: 3.0 [N•m] TE2-2 Screw size: M6 Tightening torque: 3.0 [N•m]...

  • Page 89: Mr-Cv55K4/Mr-Cv75K4

    MR-CV55K4/MR-CV75K4 [Unit: mm] For eyebolts Approx. 2-φ6 mounting hole Cooling exhaust TE2-1 TE2-2 175.5 Intake 178.5 223.5 Mass: 12.1 [kg] Mounting screw Screw size: M5 Terminal Tightening torque: 3.24 [N•m] TE2-1 TE2-2 Screw size: M8 Tightening torque: 6.0 [N•m] TE2-1 Screw size: M6 Tightening torque: 3.0 [N•m] TE2-2 Screw size: M6 Tightening torque: 3.0 [N•m]...

  • Page 90: Chapter 10 Options And Peripheral Equipment

    OPTIONS AND PERIPHERAL EQUIPMENT Precautions • HIV wires are recommended to wire the converter unit, options, and peripheral equipment. Therefore, the recommended wire sizes may differ from those used for the previous generation converter units. • To prevent an electric shock or a fire, correctly wire options and peripheral equipment, etc. in the correct combination. 10.1 Cables/connector sets The indicated IP rating is the cable and connector's protection against ingress of dust and water when the...

  • Page 91: Selection Example Of Wires

    10.2 Selection example of wires • To comply with the IEC/EN/UL/CSA standard for wiring, use the wires described in "MR-CV_ Instructions and Cautions for Safe Use of AC Servos (IB(NA)-0300228)". To comply with other standards, use wires that comply with each standard. •...
  • Page 92 Wire size selection examples The following table lists selection examples for 600 V Grade heat-resistant polyvinyl chloride insulated wire (HIV wire). *1*3 Converter unit Wire [mm L1/L2/L3 L11/L21 MR-CV11K 8 (AWG 8): c 1.25 to 2 (AWG 16 to 14): b MR-CV18K 22 (AWG 4): i MR-CV30K...

  • Page 93: Connection Of Converter Unit And Servo Amplifier (Mr-J4 Series)

    Connection of converter unit and servo amplifier (MR-J4 series) When introducing a fuse to the DC power supply wiring between the converter unit and the servo amplifier, use a wire size that takes the protection coordination between the wires and the fuse into consideration. The following shows the wires used for wiring.
  • Page 94 ■Wire size selection examples When connecting multiple servo amplifiers to the FR-XC, use junction terminal blocks for the wiring to terminals P4 and N- on the servo amplifiers. Also, connect the servo amplifiers in order with the largest capacity first. Wire as short as possible.

  • Page 95: Molded-Case Circuit Breakers, Fuses, Magnetic Contactors

    10.3 Molded-case circuit breakers, fuses, magnetic contactors When using a fuse instead of the molded-case circuit breaker, use the one having the specifications given in this section. Precautions • Select the molded-case circuit breakers specified in this section. • Wire the molded-case circuit breaker and magnetic contactor as recommended. For main circuit power supply Converter unit Molded-case circuit breaker...

  • Page 96: For Control Circuit Power Supply

    For control circuit power supply When the wiring for the control circuit power supply (L11/L21) is thinner than that for the main circuit power supply (L1/L2/L3), install an overcurrent protection device (molded-case circuit breaker, fuse, etc.) to protect the branch circuit. The following table lists the selection of overcurrent protection devices (molded-case circuit breaker, fuse, etc.) that are connected only to the converter unit.

  • Page 97: Ac Reactor

    10.4 AC reactor Converter unit AC reactor Variable dimensions [mm] Terminal Mass screw [kg] MR-CV11K MR-AL-11K MR-CV18K MR-AL-18K MR-CV30K MR-AL-30K MR-CV37K MR-AL-37K MR-CV45K MR-AL-45K MR-CV55K MR-AL-55K 11.5 MR-CV11K4 MR-AL-11K4 MR-CV18K4 MR-AL-18K4 MR-CV30K4 MR-AL-30K4 MR-CV37K4 MR-AL-37K4 MR-CV45K4 MR-AL-45K4 MR-CV55K4 MR-AL-55K4 10.5 MR-CV75K4 MR-AL-75K4 13.0...

  • Page 98: Noise Reduction Techniques

    10.5 Noise reduction techniques Noises are classified into external noises, which enter the converter unit/drive unit to cause it to malfunction, and those radiated by the converter unit/drive unit to cause peripheral equipment to malfunction. Because the converter unit/drive unit is an electronic device that handles small signals, the following general noise reduction techniques are required.
  • Page 99 ■Techniques for noises radiated by the converter unit/drive unit that cause peripheral equipment to malfunction Noises produced by the converter unit/drive unit are classified into those radiated from the cables connected to the converter unit/drive unit and its main circuits (input/output), those induced electromagnetically or statically by the signal cables of the peripheral equipment located near the main circuit cables, and those transmitted through the power supply cables.
  • Page 100 Noise transmission Suppression techniques route (1), (2), (3) A malfunction due to noise transmitted through the air may occur in devices which handle weak signals and are susceptible to noise, such as measuring instruments, receivers and sensors. In addition, a malfunction may also occur when their signal cables are stored in a cabinet together with a converter unit/drive unit or when the signal cables run near it.
  • Page 101 ■Radio noise filter (FR-BIF(-H)) This filter is effective in suppressing noise radiated from the power supply side of the converter unit, especially in 10 MHz and lower radio frequency bands. The FR-BIF(-H) is designed for the input only. 200 V class: FR-BIF 400 V class: FR-BIF-H Connection diagram Dimensions [Unit: mm]...

  • Page 102: Earth-Leakage Current Breaker

    Rated sensitivity current ≥ 10 • {Ig1 + Ign + Iga + K • (Ig2 + Igm)} [mA] . . . (10.1) Wire Noise filter Wire Converter Drive unit unit Earth-leakage current breaker Type Mitsubishi Electric products Models provided with harmonic and surge NV-SV reduction techniques NV-SVF NV-SW NV-CV NV-CVF NV-CW...
  • Page 103 Example of leakage current (Ig1, Ig2) per km of CV cable run in metal conduit • 200 V class 5.5 14 38 100 60 150 Wire size [mm²] • 400 V class 30 80 Wire size [mm 10 OPTIONS AND PERIPHERAL EQUIPMENT 10.6 Earth-leakage current breaker...

  • Page 104: Selection Example

    Selection example This section shows examples of selecting an earth-leakage current breaker under the following conditions. 22 mm × 5 m 30 mm × 5 m Converter Drive unit Servo motor unit Use an earth-leakage current breaker designed for suppressing harmonics/surges. Find each term of formula (10.1) from the diagram.

  • Page 105: Emc Filter (Recommended)

    10.7 EMC filter (recommended) It is recommended that one of the following filters be used to comply with EN EMC directive. Some EMC filters have a large leakage current. When connecting one or more converter units to one EMC filter, satisfy the following conditions: •...
  • Page 106 Connection example ■For 3-phase 200 V AC to 240 V AC power supply EMC filter MR-CV_ AC reactor MCCB 3-phase 200 V AC to 240 V AC Surge protector Drive unit *1 When a surge protector is used. ■For 3-phase 380 V AC to 480 V AC power supply EMC filter MR-CV_ AC reactor...
  • Page 107 Dimensions ■EMC filter For dimensions including dimensional tolerances, contact the manufacturer of the EMC filter being used. • FSB-20-355/FSB-30-355 [Unit: mm] Terminal block cover 87.5 2-φ5.5 Protective earth (PE) Mounting hole 3-M4 Output 3-M4 Input Protective earth (PE) Mounting plate t = 1.2 •...
  • Page 108 • FSB-80-355/FSB-100-355 [Unit: mm] 3-M8 3-M8 Input Output Protective earth (PE) Protective earth (PE) Terminal block cover Terminal block cover Mounting hole 2-φ6.5 Mounting plate t = 2.0 Mounting hole 10 OPTIONS AND PERIPHERAL EQUIPMENT 10.7 EMC filter (recommended)
  • Page 109 • FSB-150-355 [Unit: mm] 3-M8 3-M8 Input Output Terminal block cover Terminal block cover Protective earth (PE) Protective earth (PE) Mounting hole 2-φ6.5 Mounting plate t = 2.0 Mounting hole 10 OPTIONS AND PERIPHERAL EQUIPMENT 10.7 EMC filter (recommended)
  • Page 110 • HF3030C-SZL/HF3060C-SZL [Unit: mm] R2.2 Mounting plate t = 1.0 5 × 6 φ4.5 *1 This applies to HF3030C-SZL. The mounting plate thickness of HF3060C-SZL is 1.2 mm. • HF3100C-SZL [Unit: mm] (245) φ6.5 (196) 10 OPTIONS AND PERIPHERAL EQUIPMENT 10.7 EMC filter (recommended)
  • Page 111 • HF3150C-SZL [Unit: mm] (208) φ6.5 10 OPTIONS AND PERIPHERAL EQUIPMENT 10.7 EMC filter (recommended)
  • Page 112 ■Surge protector (recommended) • To use an EMC filter with the converter unit, a surge protector is required. To prevent damage due to surges (such as lightning and sparks) applied to the AC power supply lines, connect the following surge protectors to the main circuit power supply (L1/L2/L3). Surge protector Maximum DC operating...

  • Page 113: Chapter 11 Compliance With Global Standards

    Some products are required to comply with China Compulsory Certification (hereinafter referred to as CCC) if exported, distributed, or sold to China. An outline of CCC is explained in this section. Mitsubishi Electric servo products are not subject to CCC.

  • Page 114: Compliance With The China Rohs Directive

    11.3 Compliance with the China RoHS directive Outline 电子信息产品污染控制管理办法 TThe China RoHS directive: (Management Methods for Controlling Pollution by Electronic Information Products) came into effect on March 1, 2007. The China RoHS directive was replaced by the following 电器电子产品有害物质限制使用管理办法 China RoHS directive: (Management Methods for the Restriction of the Use of Hazardous Substances in Electrical and Electronic Products).
  • Page 115 Difference between the China RoHS directive and the EU RoHS directive The China RoHS directive allows no restriction exemption unlike the EU RoHS directive. Although a product complies with the EU RoHS directive, a hazardous substance in the product may be considered to be above the limit requirement (marked "") in the China RoHS directive.

  • Page 116: Revisions

    First edition This manual confers no industrial property rights or any rights of any other kind, nor does it confer any patent licenses. Mitsubishi Electric Corporation cannot be held responsible for any problems involving industrial property rights which may occur as a result of using the contents noted in this manual.

  • Page 117: Warranty

    WARRANTY Warranty 1. Warranty period and coverage We will repair any failure or defect hereinafter referred to as "failure" in our FA equipment hereinafter referred to as the "Product" arisen during warranty period at no charge due to causes for which we are responsible through the distributor from which you purchased the Product or our service provider.

  • Page 118: Trademarks

    TRADEMARKS MELSERVO is a trademark or registered trademark of Mitsubishi Electric Corporation in Japan and/or other countries. All other product names and company names are trademarks or registered trademarks of their respective companies. IB(NA)-0300553ENG-A...
  • Page 120 IB(NA)-0300553ENG-A(2106)MEE MODEL: MODEL CODE: HEAD OFFICE : TOKYO BUILDING, 2-7-3 MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN NAGOYA WORKS : 1-14 , YADA-MINAMI 5-CHOME , HIGASHI-KU, NAGOYA , JAPAN When exported from Japan, this manual does not require application to the Ministry of Economy, Trade and Industry for service transaction permission. Specifications are subject to change without notice.

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