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MELSERVO-J4 Series Servo Amplifier

MELSERVO-J4 Series Servo Amplifier

Industry-leading Basic Performance

Industry-leading Level of Servo Amplifier Basic Performance

Speed frequency response of 2.5 kHz is achieved by applying our original high-speed servo control architecture evolved from the conventional two-degrees-of-freedom model adaptive control to the dedicated execution engine. Together with a high-resolution absolute position encoder of 4,194,304 pulses/rev, fast and accurate operation is enabled. The performance of the high-end machines is utilized to the fullest.

Industry-leading Level of Servo Amplifier Basic Performance

Improving Machine Performance with High-performance Servo Motors

With improved processing speed, the rotary servo motors equipped with a high-resolution encoder enables high-accuracy positioning and smooth rotation.

Improving Machine Performance with High-performance Servo Motors

Advanced Servo Gain Adjustment Function

One-touch Tuning

Just turn on the one-touch tuning function to complete servo gain adjustment automatically, including machine resonance suppression filter, advanced vibration suppression control II*1, and robust filter for maximizing your machine performance. This function also sets responsivity automatically, while the real-time auto tuning requires manual setting. Moreover, a new method*2 allows to create an optimum tuning command inside the servo amplifier.

  • *1.The advanced vibration suppression control II automatically adjusts one frequency.
  • *2.This new method is supported by MR-J4-B/MR-J4W_-B/MR-J4-A.

One-touch Tuning

Advanced Vibration Suppression Control II

The advanced vibration suppression control II suppresses two types of lowfrequency vibrations, owing to vibration suppression algorithm which supports three-inertia system. This function is effective in suppressing residual vibration with relatively low frequency of approximately 100 Hz or less generated at the end of an arm and in a machine, enabling a shorter settling time.

Advanced Vibration Suppression Control II

Robust Filter

Achieving both high responsivity and stability was difficult with the conventional control in high-inertia systems with belts and gears such as printing and packaging machines. Now, this function enables the high responsivity and the stability at the same time without adjustment. The robust filter gradually reduces the fluctuation of torque in a wide frequency range and achieves more stability as compared to the prior model.

Robust Filter

Expanded Machine Resonance Suppression Filter

With advanced filter structure, applicable frequency range is expanded from between 100 Hz and 4500 Hz to between 10 Hz and 4500 Hz. Additionally, the number of simultaneously applicable filters is increased from two to five, improving vibration suppression performance of a machine.

Expanded Machine Resonance Suppression Filter

Lost Motion Compensation Function

This function suppresses quadrant protrusion caused by friction and torsion generated when the servo motor rotates in a reverse direction. Therefore, the accuracy of circular path will be improved in trajectory control used in XY table, etc.

  • * This function is not supported by MR-J4W2-B and MR-J4W3-B.

Lost Motion Compensation Function

Super Trace Control

This function reduces a position deviation to nearly zero not only during constant-velocity operation, but also during constant acceleration/deceleration. The trajectory accuracy will be improved in high-rigidity machines.

  • * This function is not supported by MR-J4W2-B and MR-J4W3-B.

Super Trace Control

A Variety of Functions for Various Applications

* Use a compatible controller.

Tightening & Press-fit Control

This function switches position/speed control mode to torque control mode smoothly without a stop or a sudden change in speed and torque, and thus reduces load to a machine. This function is best suit for an application where control is switched from position to torque such as Tightening & Press-fit control or insertion of a work, and cap or screw tightening.

  • * This function is supported by MR-J4-B/MR-J4W2-B/MR-J4W3-B.

Tightening & Press-fit Control

Master-slave Operation Function

The master-slave operation function enables the torque of the master axis to be transmitted to the slave axes via SSCNET III/H and to control the slave axes with the same torque as the master axis. No special wiring is necessary.

Master-slave Operation Function

Scale Measurement Function

Scale Measurement Function

The scale measurement function of MR-J4-GF/MR-J4-B/MR-J4W2-B*1 servo amplifiers*2 enables to transmit position information of a scale measurement encoder to the controller when the scale measurement encoder is connected in semi closed loop control. The data of linear or synchronous encoders are transmitted to the servo system controller via the servo amplifier, resulting in less wiring.

  • *1. This function is not supported by MR-J4W2-0303B6.
  • *2. Use corresponding servo amplifier (MR-J4-GF/MR-J4-GF-RJ/MR-J4-B/MR-J4-B-RJ) for load-side encoder.

Applicable for Various Control and Driving Systems

Compatible Servo Motors

Compatible Servo Motors

MR-J4 series servo amplifier operates rotary servo motors, linear servo motors, and direct drive motors as standard*.

  • * Not all of the servo amplifiers are compatible with all three of these servo motors. For the combination, refer to "Product lines" in the catalog.

1-axis/2-axis/3-axis Servo Amplifiers

1-axis/2-axis/3-axis Servo Amplifiers

For SSCNET III/H compatible servo amplifiers, 2-axis and 3-axis types are available in addition to 1-axis type, enabling flexible systems based on the number of control axes.

Supporting Fully Closed Loop Control

Supporting Fully Closed Loop Control

Supporting a fully closed loop control system*1 as standard, MR-J4-GF/MR-J4-B/MR-J4-A servo amplifiers enable further precise positioning*2.

  • *1. MR-J4-GF/MR-J4-B/MR-J4-A servo amplifier is compatible with two-wire type serial linear encoders. For four-wire type serial and pulse train interface (A/B/Z-phase differential output type) linear encoders, use MR-J4-GF-RJ/MR-J4-B-RJ/MR-J4-A-RJ.
  • *2. Some models do not support a fully closed loop control system. Refer to "Product lines" in the catalog.

Wide Range of Power Supplies and Capacities

Wide Range of Power Supplies and Capacities

Each servo amplifier supports following main circuit power supply:
MR-J4-B/MR-J4-A: 3-phase 200 V AC/400 V AC,
1-phase 100 V AC, and 48 V DC/24 V DC
MR-J4-GF: 3-phase 200 V AC/400 V AC
MR-J4-GF-RJ/MR-J4-B-RJ/MR-J4-A-RJ also supports DC power input.

  • * Servo amplifier of 30 W supports a power supply of 48 V DC/24 V DC.

Maximum Command Pulse Frequency

Maximum Command Pulse Frequency

General-purpose interface compatible MR-J4-A servo amplifier supports maximum command pulse frequency of 4 Mpulses/s (when differential receiver is used).
When open collector is used, both sink and source inputs are enabled.

Built-in Positioning Function for Simple System

MR-J4-GF(-RJ) and MR-J4-A-RJ with Built-in Positioning Function

MR-J4-GF(-RJ) and MR-J4-A-RJ have a built-in positioning function, enabling positioning operation with point table, program-based*, and indexer (turret) methods. With these servo amplifiers, a positioning system is configured without a Positioning module (command pulse). Positioning command is executed by CC-Link IE Field network, input/output signals, or RS-422/RS-485 communication (up to 32 axes). MR Configurator2 allows easy setting of the positioning data.

MR-J4-GF(-RJ) and MR-J4-A-RJ with Built-in Positioning Function

  • * The program-based method is supported only by MR-J4-A-RJ.

Point table method

Setting position data (target position), servo motor speed, and acceleration/deceleration time constants in point table is as easy as setting a parameter. Up to 255 points are settable for the point table. The positioning operation is performed with a start signal after selecting the point table No.

Point table method

  • * For MR-J4-A-RJ, point table can be set with push buttons on the servo amplifier or with MR-PRU03 parameter unit.

Program method*

Create positioning programs with dedicated commands. The positioning operation is performed with a start signal after selecting the program No. The program-based method enables more complex positioning operation than the point table method. Maximum of 256 programs are settable. (The total number of steps of all programs: 640)

Program method*

  • * MR Configurator2 is required to create programs.

Indexer (turret) method*

Indexer (turret) method*

Perform positioning operation by specifying equally divided stations (up to 255 stations) and the number of gear teeth on machine and motor sides. The travel distance will be calculated automatically based on the number of equally divided stations set in the parameter. The positioning operation is performed with a start signal after the station position No. is selected. Rotation direction specifying indexer or shortest rotating indexer can be set.

  • * Fully closed loop control mode and linear servo motor control mode are not supported by the indexer (turret) method.

New Useful Functions with Positioning Function

* Not supported by MR-J4-03A6-RJ.

New useful functions are added to the positioning function: simple cam function, encoder following function, pulse input through function, simple cam position compensation function, and communication functions (MODBUS® RTU, Point to Point positioning, and current position latch function). Apply these useful functions to a wide variety of applications to configure positioning system easily.

Simple cam function

MR Configurator2 enables to create various patterns of cam data. Command pulse or point table/program start signal is used as input to the simple cam. The input command will be outputted to the servo motor according to the cam data.

Simple cam function

  • * The program-based method is supported only by MR-J4-A-RJ.

Encoder following function/Pulse input through function*

With the encoder following function, the servo amplifier receives A/B-phase output signal from the synchronous encoder as command pulse, and the input command will be outputted to the servo motor according to the cam data. Setting cam data that matches with the sheet length, a circumference of the rotary knife axis, and the synchronous section of the sheet enables a system in which the conveyor axis and the rotary knife axis are synchronized. Up to 4 Mpulses/s of input from a synchronous encoder is compatible with the servo amplifier. The pulse input through function allows the first axis to output A/B-phase pulses which are received from the synchronous encoder to the next axis, enabling a system in which the subsequent axes are synchronized with the synchronous encoder.

  • * The pulse input through function is available as A/B-phase pulse input through function for MR-J4-GF-RJ and as command pulse input through function for MR-J4-A-RJ.

Encoder following function/Pulse input through function*

Simple cam position compensation function*

The actual position of the servo motor is obtained based on the inputs from the sensor that detects the registration marks printed on the high-speed moving film. The servo amplifier calculates compensation amounts and corrects position errors of the rotary knife axis based on those inputs from the sensor so that the film can be cut at the set position.

  • * "Cam position compensation request" is turned on with touch probe input for MR-J4-GF-RJ and mark sensor input for MR-J4-A-RJ.

Simple cam position compensation function*

Communication function (MODBUS® RTU)

In addition to RS-422/RS-485 communication (Mitsubishi Electric general-purpose AC servo protocol), RS-485 communication (MODBUS® RTU protocol) is supported. MODBUS® RTU protocol is compatible with function code 03h (Read holding registers), etc.
Controlling and monitoring of the servo amplifier is possible by external devices.

Communication function (MODBUS<sup>®</sup> RTU)

  • * RJ-45 junction connector terminal block and RJ-45 compatible cable designed for MR-J4-A-RJ are required.

Communication function (Point to Point positioning)

Up to 255 points of Point to Point positioning are enabled when the target position is set in the point table in advance. Rewriting the next target position during an operation is also possible by the communication function.

Communication function (Point to Point positioning)

Communication function (current position latch)

Based on the data latched by the mark detection function (current position latch*), a target position is compensated by being written in the point table.

  • * When the mark detection signal turns on, a current position will be latched, and the latched data will be read with the communication function.
  • Example: Executing positioning compensation when a product is mispositioned by 50 on a handling pallet.
    Start an operation by specifying point table No. 1 (target position: 1000).
    Communication function (current position latch) measures a position gap with the mark detection function and writes the position gap of 50 to the target position in point table No. 2 for compensation during the operation.
    After the operation of point table No. 1 is completed with a position gap of 50, start the operation by specifying point table No. 2. The product will be set to the right position.

Communication function (current position latch)

All-rounder Network with CC-Link IE Field

All-in-One Network

The network is designed to simultaneously handle distributed control, I/O control, and motion control. CC-Link IE Field Network lets you connect field devices such as programmable controllers, I/O modules, high-speed counter modules, servo amplifiers, inverters, and displays, providing optimal network which best fits the needs of the application.
Choose from star, line, or ring* topology suitable for layout of lines and machines.

All-in-One Network

  • * The Simple Motion modules do not support a ring topology.

All-in-One Engineering Software

MELSOFT GX Works3

This all-in-one MELSOFT GX Works3 covers all aspects of the product development cycle from system design to maintenance - including programming, setting of CC-Link IE Field Network and Simple Motion modules, and adjustment of servo amplifiers.

All-in-One Engineering Software

All-rounder Driving System with CC-Link IE Field

Compatible with CC-Link IE Field Network

MR-J4-GF

MR-J4-GF(-RJ) is compatible with CC-Link IE Field Network as standard.
The servo amplifier is connectable with Ethernet-based CC-Link IE Field Network, enabling high-speed, seamless communication.

Easy Positioning with CC-Link IE Field Network

A combination of a master module and MR-J4-GF(-RJ) allows positioning operation with point table method or indexer (turret) method, not requiring a Positioning module. With the point table method, just set the point table No. and turn on the start signal, and then the positioning operation will be started. A continuous operation of the next point table is also possible without stopping. In the indexer (turret) method, the travel amount is automatically calculated based on the number of stations set in the parameter. For more details of the positioning function, refer to the catalog.

Easy Positioning with CC-Link IE Field Network

CC-Link IE Field Network Motion Control

A combination of a Simple Motion module and MR-J4-GF(-RJ) enables high-performance synchronous control and interpolation control with simple parameter setting and a start from a sequence program. Speed control and torque control are also possible, suitable for converting machines. In addition, using remote inputs/outputs which are compatible with the synchronized communication function enables a system synchronized with the command cycle of the servo amplifier.

An example of inputs/outputs synchronized with the command cycle of the servo amplifier

A synchronous encoder, unwinder, printing machine can be synchronized with the servo command communication cycle.

An example of inputs/outputs synchronized with the command cycle of the servo amplifier

High-response Servo System Achieved with SSCNET III/H

Three Times Faster Communication Speed

Communication speed is increased to 150 Mbps full duplex (equivalent to 300 Mbps half duplex), three times faster than the conventional speed. System response is dramatically improved.

Three Times Faster Communication Speed

Deterministic and Synchronized Communication

Complete deterministic and synchronized communication is achieved with SSCNET III/H, offering technical advantages in machines such as printing and food processing machines that require synchronous accuracy.

Deterministic and Synchronized Communication

Cycle Time as Fast as 0.222 ms

Smooth control of a machine is possible using high-speed serial communication with cycle times of 0.222 ms.

Cycle Time as Fast as 0.222 ms

No Transmission Collision

The fiber-optic cables thoroughly shut out noise that enters from the power cable or external devices. Noise tolerance is dramatically improved as compared to metal cables.

No Transmission Collision

Long Distance Wiring up to 3200 m

Long distance wiring is possible up to 3200 m per system (maximum of 100 m between stations × 32 axes), suitable for large-scale systems.

  • * This is when all axes are connected via SSCNET III/H.

Long Distance Wiring up to 3200 m

Central Control with Network

Large amounts of servo data are exchanged in real-time between the controller and the servo amplifier.
Using MELSOFT MR Configurator2 on a personal computer that is connected to the Motion controller or the Simple Motion module helps consolidate information such as parameter settings and monitoring for the multiple servo amplifiers.

Central Control with Network

Network Topology

Star and line topologies are available with MR-MV200 optical hub unit* through SSCNET III/H for a network configuration. Maintenance can be executed without stopping the whole system, and thus the operation rate will be increased.

Network Topology

I/O Signals Synchronized with Motion Control

Together with MR-MT2000 sensing module*, the I/O module, analog I/O module, pulse I/O module, and encoder I/F module will be connected via SSCNET III/H. A fast and accurate machine is enabled by synchronization of the I/Os of a general-purpose pulse train driver, sensor, and SSI encoder with the Motion control cycle time.

I/O Signals Synchronized with Motion Control

* For MR-MV200 optical hub unit and MR-MT2000 sensing module, refer to