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Mitsubishi Electric MELSERVO MR-D30 Installation Manual
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Copyright©2014 Mitsubishi Electric Corporation All Rights Reserved.Installation Guide JIB(NA)-0300227-J(2309)MEEHEAD OFFICE: TOKYO BLDG., 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPANSpecifications are subject to change without notice.Compliance with the indicated global standards and regulationsis current as of the release date of this installation guide.The original instructions for Europe are in English.MR-D30Functional safety unitModelGeneral-Purpose AC ServoCountry/RegionUSAGermanyChinaKoreaJapanSales officeMitsubishi Electric Automation, Inc.500 Corporate Woods Parkway, Vernon Hills, IL 60061, U.S.A.Mitsubishi Electric Europe B.V. German BranchMitsubishi-Electric-Platz 1, 40882 Ratingen, GermanyMitsubishi Electric Automation (China) Ltd.Mitsubishi Electric Automation Center, No.1386 Hongqiao Road, Shanghai, ChinaMitsubishi Electric Automation Korea Co., Ltd.7F to 9F, Gangseo Hangang Xi-tower A, 401, Yangcheon-ro, Gangseo-Gu, Seoul, KoreaMitsubishi Electric CorporationTokyo Building, 2-7-3, Marunouchi, Chiyoda-ku, Tokyo 100-8310, JapanTelTelTelTelTelTel: +1-847-478-2100: +49-2102-486-0: +86-21-2322-3030: +82-2-6103-9474: +81-3-3218-2111Contents of the packageContents QuantityMR-D30 functional safety unit 1MR-D30 Installation Guide (this guide) 1Rating plateThe following shows an example of rating plate forexplanation of each item.Warning plateAn example of warning plate is shown below.Serial numberModelIP rating, Manual numberCapacityApplicable power supplyRated outputStandardAmbient temperatureKC numberDate of manufactureCountry of originRegulation/legislation markingAn example of regulation/legislation marking is shownbelow.1. About the manualsTo use the MR-D30 safely, read "MR-D30 Instruction Manual" carefully.1.1 MELSERVO-J4 relevant manualsThis installation guide explains how to mount MR-J4 servo amplifiers. You can also check it with our website for free.http://www.mitsubishielectric.com/fa/If you have any questions about the operation or programming of the equipment described in this guide, contact yourlocal sales office.In addition, when you mount a protective device, specific technical skills which are not detailed in the guide will berequired.Servo amplifiers and drive units are written as servo amplifiers in this guide under certain circumstances, unlessotherwise stated.1.2 Purpose of this guideThis installation guide explains the safe operation of MR-J4 servo amplifiers for engineers of machinery manufacturersand machine operators. For detailed information of the products, refer to "MR-D30 Instruction Manual". This installationguide does not explain how to operate equipment in which MR-D30 and MR-J4 servo amplifier are integrated.1.3 Terms related to safety(1) STO (Safe torque off)Shuts off servo motor drive energy electronically based on an input signal from an external device (secondary-sideoutput shut-off). This corresponds to stop category 0 of IEC/EN 60204-1.(2) SS1 (Safe stop 1)Starts deceleration based on an input signal from an external device (EM2). After a specified time for the check ofstop, STO function will be activated (SS1). This corresponds to stop category 1 of IEC/EN 60204-1.(3) SS2 (Safe stop 2)Starts deceleration based on an input signal from an external device (EM2). After a specified time for the check ofstop, the SOS function will be activated (SS2). This corresponds to stop category 2 of IEC/EN 60204-1.(4) SOS (Safe operating stop)This is a function to monitor whether the servo motor stops within the prescribed range for the stop position. Thepower is supplied to the servo motor.(5) SLS (Safely-limited speed)This is a function to observe whether the speed is within a regulated speed limit value. When the speed is over aspecified speed, energy will be shut off by STO.(6) SSM (Safe speed monitor)Outputs a safety output signal when the servo motor speed is within a regulated speed.(7) SBC (Safe brake control)Outputs a safety output signal for an external brake control.(8) Status monitor (SM)Outputs a signal for the safety observation function status. This function is not the one defined in IEC/EN 61800-5-2. The function is an original function of the functional safety unit.2. About safetyThis chapter explains safety of users and machine operators. Please read the chapter carefully before mounting theequipment. In this installation guide, the specific warnings and cautions levels are classified as follows.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 injuryto personnel or may cause physical damage.2.1 Professional engineerOnly professional engineers should mount this to MR-J4 servo amplifiers.Here, professional engineers should meet all the conditions below.(1) Persons who took a proper training of related work of electrical equipment or persons who can avoid risk based onpast experience.(2) Persons who have read and familiarized himself/herself with this installation guide and operating manuals for theprotective devices (e.g. light curtain) connected to the safety control system.2.2 Applications of the devicesMR-D30 has a control system whose configuration is possible to be for safety.This product complies with the following standards.EN ISO 13849-1:2015 Category 3 PL d and Category 4 PL eIEC 61508 SIL 2 and SIL 3EN IEC 62061:2021 maximum SIL 2 and maximum SIL 3EN 61800-5-2IEC/EN 61800-3/GB 12668.3/KN 61800-3 (KS C 9800-3)An achieved safety level depends on external circuit, wiring conditions, parameter settings, sensor selections, andmounting position on the machine.A photoelectric and contact sensor such as light curtain, laser scanner, safety switch, sensor, and push button foremergency stop can be used with programs. The power of an actuator mounted on the machine or system can be shutoff safely using switching output of the safety control system.2.3 Correct useWARNING If you need to get close to the moving parts of the machine for inspection or others, ensuresafety by confirming the power off, etc. Otherwise, it may cause an accident.CAUTION MR-D30 complies with basic specifications concerning radiation electromagnetic immunityand fulfills requirements of industrial uses. Therefore, MR-D30 is only for use in industrialenvironment, not for general use.Use the MR-D30 within specifications. Refer to "MR-D30 Instruction Manual" for specifications such as voltage,temperature, etc. Mitsubishi Electric Co. accepts no claims for liability if the equipment is used in any other way or ifmodifications are made to the device, even in the context of mounting and installation.2.3.1 Peripheral deviceThe following are selected based on IEC/EN 61800-5-1, UL 61800-5-1, UL 508C, and CSA C22.2 No. 274.(1) Motor overload and Over temperature protectionThe overload protection of the servo motor does not include a thermal memory function, and is not speedsensitive. The servo amplifier cannot detect overheating of the servo motor. The servo motors are protected by theservo motor overheat protection function of the servo amplifiers (a protection characteristic based on 120 % of therated current). To provide the servo motor with overheat protection, use a magnetic contactor (electromagneticswitch) with a thermal relay. Alternatively, install a thermal sensor or equivalent equipment near the rating plate ofthe servo motor to check that the servo motor temperature is under 105 °C with sensing device. (Refer to Chapter4)2.3.2 Europe/UK complianceThe CE/UKCA marking proves the compliance of the servo product with the essential requirements specified in therelevant EU Directives and UK Regulations, and this marking also applies to machines and equipment incorporatingservos.(1) EMC requirementThe combination of MR-J4 servo amplifier and MR-D30 complies with EN/BS EN IEC 61800-3. As for I/O wires(max. length 10 m) and encoder cables (max. length 50 m), use shielded wires and ground the shields.Install an EMC filter and surge protector on the primary side. The following shows recommended products.EMC filter: Soshin Electric HF3000A-UN seriesSurge protector: Okaya Electric Industries RSPD-250-U4 seriesMR-J4 Series are not intended to be used on a low-voltage network which supplies domestic premises;electromagnetic interference is expected if used on such a network.The installer shall provide a guide for Installation and use, including recommended mitigation devices. To avoid therisk of crosstalk to signal cables, the installation instructions shall either recommend that the power interface cablebe segregated from signal cables.(2) For Declaration of Conformity (DoC)We declare that the servo amplifier with MR-D30 is in compliance with EC directives (Machinery directive(2006/42/EC), EMC directive (2014/30/EU), Low-voltage directive (2014/35/EU), and RoHS directive (2011/65/EU,(EU) 2015/863)) and applicable regulations of the UK. For the copy of Declaration of Conformity, contact your localsales office.2.3.3 USA/Canada complianceThe servo amplifiers on which MR-D30 is mounted are designed in compliance with UL 508C or UL 61800-5-1 for theuse in the United States. For the use in Canada, the servo amplifiers on which MR-D30 is mounted are designed incompliance with CSA C22.2 No. 274.(1) InstallationThe minimum cabinet size is 150 % of each MR-J4 servo amplifier's volume including MR-D30. Also, design thecabinet so that the ambient temperature in the cabinet is 55 ˚C or less. The servo amplifiers on which MR-D30 ismounted must be installed in a metal cabinet. For environment, the units should be used in open type (UL 50) andovervoltage category III or lower. MR-D30 and servo amplifier needs to be installed at or below pollution degree 2.For connection, use only copper wires.(2) Short-circuit current rating (SCCR)Each servo amplifier on which MR-D30 is mounted has checked with a short-circuit test.(3) Capacitor dischargeIt takes 15 minutes for capacitor discharging of the servo amplifier on which MR-D30 is mounted. Do not touch theunit and terminals immediately after power off.(4) Branch circuit protectionFor installation in United States, branch circuit protection must be provided, in accordance with the NationalElectrical Code and any applicable local codes. For installation in Canada, branch circuit protection must beprovided, in accordance with the Canadian Electrical Code and any applicable provincial codes.2.3.4 South Korea complianceProducts that bear the KC mark comply with the Radio Wave Law. Please note the following to use the product.이 기기는 업무용 (A급) 전자파적합기기로서 판매자 또는 사용자는 이 점을 주의하시기 바라며, 가정외의지역에서사용하는 것을 목적으로 합니다.(The product is for business use (Class A) and meets the electromagnetic compatibility requirements. The seller and theuser must note the above point, and use the product in a place except for home.)2.4 Safety observation function compatible unitThe safety observation function is executed by writing a parameter to MR-D30 in a system using an MR-J4 servoamplifier, motion CPU and safety programmable controller in the following table. Set the parameters of MR-D30correctly for a proper operation of the safety observation function. Protective functions such as the safety observationfunction may not work due to an incorrect setting. Refer to "MR-D30 Instruction Manual" for the parameter settingdetails.(1) List of safety observation function compatible unitProduct name ModelServo amplifierMR-J4-_GF-RJ/MR-J4-_GF4-RJMR-J4-_B-RJ/MR-J4-_B4-RJ/MR-J4-_B1-RJ/MR-J4-DU_B-RJ/MR-J4-DU_B4-RJMR-J4-_A-RJ/MR-J4-_A4-RJ/MR-J4-_A1-RJ/MR-J4-DU_A-RJ/MR-J4-DU_A4-RJProgrammable controller (Note 1) R_SFCPUMotion CPU module (Note 2) Q173DSCPU/Q172DSCPUNote 1. For using the safety observation function through CC-Link IE Field2. For using the safety observation function through SSCNET III/H(2) List of safety observation function compatible unit version(a) Servo amplifier and functional safety unit1) MR-J4-_GF_-RJa) Safety observation function control by input deviceMR-D30software versionServo amplifiersoftware version Safety observation function Servo motor withfunctional safety Servo amplifierA1 or later A3 or later (Note) STO/SS1/SBC/SLS/SSM/SOS/SS2/SMHG-KR_W0CHG-SR_W0CHG-JR_W0CMR-J4-_GF_-RJNote. CC-Link IE Field Network Basic communication is not supported. While CC-Link IE Field Network Basic has been set, connectingwith the MR-D30 functional safety unit triggers [AL. 3E.8].b) Safety observation function control by networkMR-D30software versionServo amplifiersoftware version Safety observation function Servo motor withfunctional safety Servo amplifierA2 or later A3 or later STO/SS1/SBC/SLS/SSM/SOS/SS2/SMHG-KR_W0CHG-SR_W0CHG-JR_W0CMR-J4-_GF_-RJ2) MR-J4-(DU)B_-RJ/MR-J4-(DU)A_-RJMR-D30software versionServo amplifiersoftware version Safety observation function Servo motor withfunctional safety Servo amplifierA0 B3 or later STO/SS1/SBC/SLS/SSM/SM Not compatible MR-J4-_B_-RJA1 or laterB3/B4 STO/SS1/SBC/SLS/SSM/SM Not compatible MR-J4-_B_-RJB5 or later STO/SS1/SBC/SLS/SSM/SOS/SS2/SMHG-KR_W0CHG-SR_W0CHG-JR_W0CMR-J4-_B_-RJMR-J4-_A_-RJ (Note)MR-J4-DU_B_-RJMR-J4-DU_A_-RJ (Note)Note. The servo amplifiers manufactured in November, 2014 or later is supported.(b) Programmable controllerModel Software versionR_SFCPU 07 or later(c) Motion controllerModel OS Software versionQ173DSCPU SW8DNC-SV22QJ/SW8DNC-SV13QJ 05 or laterQ172DSCPU SW8DNC-SV22QL/SW8DNC-SV13QL2.5 General cautions for safety protection and protective measuresPOINTObserve the cautions for safety protection and protective measures.Observe the items in this section for proper use of MR-D30.(1) When mounting, installing, and using the MR-D30, always observe standards and directives applicable in thecountry.(2) When using an MR-D30 in an EU member state, comply with the following directives.Machinery directive 2006/42/ECEMC directive 2014/30/EULow voltage directive 2014/35/EURoHS directive 2011/65/EUOther laws/regulations of labor safety(3) The manufacturer and owner of machines on which an MR-D30 is used should be familiarized with all theapplicable laws and regulations and should be responsible to observe them.For Declaration of Conformity (DoC), our company declares that the servo amplifiers are in compliance with thenecessary requirements and standards (2006/42/EC, 2014/30/EU, 2014/35/EU and 2011/65/EU). You can obtainthe copy of Declaration of Conformity from our website.(4) The contents of "MR-D30 Instruction Manual" must be observed.(5) Tests should be performed by professional engineers, especially qualified and responsible personnel, and shouldbe recorded/documented for a third party to rebuild and confirm the tests.(6) Based on IEC/EN 60204-1, connect to a power supply that has tolerance against instantaneous power failure of 20ms or more.2.6 DisposalDisposal of unusable or irreparable devices should always occur in accordance with the applicable country-specificwaste disposal regulations.2.7 Risk assessmentTo ensure safety, users should decide all the risk assessments and residual risks in the entire machine equipment. Acompany and/or individual who constructed the safety related system must take full responsibility for installation andcommissioning of the system. Additionally, when complying with a European machinery directive, the system mustacquire safety standards certification as a whole.Perform all risk assessments and safe level certification to the machine or the system as a whole. It is recommendedthat a Certification Body final safety certification of the system be used.The following shows residual risks concerning the safety observation function of this product.2.7.1 Common residual risks in each function(1) At the shipment to end-users, check the settings of safety related components with programming tools andmonitored/displayed contents on display and record and save the setting data concerning the safety observationfunction and the programming tools you used. Perform them using a check sheet, etc.(2) The safety will not be ensured such as in assembling machine until installing, wiring, and adjustment arecompleted properly. Install, wire, and adjust your system referring to installation guide for each unit.(3) Only qualified personnel are authorized to install, start-up, repair or adjust the machines in which thesecomponents are installed. Only trained engineers should install and operate the equipment. (ISO 13849-1:2015Table F.1 No. 5)(4) Separate the wiring for safety observation function from other signal wirings.(ISO 13849-1:2015 Table F.1 No. 1)(5) Protect the cables with appropriate ways (routing them in a cabinet, using a cable guard, etc.).(6) We recommend using a switch, relay, sensor, etc. which comply with safety standards. When using a switch,relay, sensor, etc. which do not comply with safety standards, perform a safety confirmation.(7) Keep the required clearance/creepage distance depending on voltage you use.(8) The time to a safety observation error depends on parameter settings.2.7.2 Residual risks in each function(1) Speed monitoring (SLS)(a) Speed monitoring function guarantees the servo motor speed), but it does not guarantee the actual machinesafety speed. Set parameters so that the safe speed of the machine is the same as the safety speed of thespecified motor.(b) Check if the speed of the monitored servo axis is the same as the actual speed by using a tachometer, etc.considering the speed includes an error caused by the command and encoder resolution.(c) The defect of the mechanical section such as slid of shaft and wanting of a timing belt, etc. is not covered. Besure to eliminate the risk of mechanical section before operation.(d) Speed monitoring error detection time is set to 1 ms. Error in shorter than this time are not detected.(e) After speed is over the limit, safety observation error (shut-off signal off) does not occur during the speed errordetection time set by the parameter. Make sure that safety can be ensured during this period.(2) Safe speed monitor (SSM)When SSM is used as a restart trigger, perform it according to IEC/EN 60204-1.(3) Safe brake control (SBC)This function guarantees only that power to mechanic break is properly supplied and abrasion of the brake cannotbe detected. Check this function regularly that the mechanic brake can operate.3. Conditions of use for the product(1) MR-D30 complies with a safety standard, but this fact does not guarantee that MR-D30 will be free from anymalfunction or failure. The user of this product shall comply with any and all applicable safety standard, regulationor law and take appropriate safety measures for the system in which the product is installed or used and shall takethe second or third safety measures other than the product. Our company is not liable for damages that could havebeen prevented by compliance with any applicable safety standard, regulation or law.(2) Our company prohibits the use of Products with or in any application involving, and we shall not be liable for adefault, a liability for defect warranty, a quality assurance, negligence or other tort and a product liability in theseapplications.(a) Power plants(b) Trains, railway systems, airplanes, airline operations, and other transportation systems(c) Hospitals, medical care, dialysis and life support facilities or equipment(d) Amusement equipment(e) Incineration and fuel devices(f) Handling of nuclear or hazardous materials or chemicals(g) Mining and drilling(h) Other applications where the level of risk to human life, health or property are elevated.4. Block diagram and timing chart(1) Function block diagram (for using input signal)This is an example of a combination with MR-J4-_B_-RJ.MCCB MCPowerL1L2L3L11L21Servo amplifier Servo motor (Note 2)MUVWUVWGate circuitControl circuitpower supply 24 V DC B1B2 BEncoderRACN9CN90CN7CN70Not used(Remove the short-circuit connector.)SSCNETIII/HSSCNETIII/HController orservo amplifierServo amplifierParameter settingFunctional safety unitInput signal(Note 1) Output signal(Note 1)CN8ControlCN1ACN1BCN5USBCN2Safety observation functionprocessing part 1Safety observation functionprocessing part 2CN10ACN10BCN10ACN10BSensing deviceElectromagneticbrakeNote 1. Safety switch, safety relay, etc.2. The servo motor with functional safety is required to use the SS2/SOS functions.(2) How to use the functionsTo use the safety observation functions, combine MR-D30 with MR-J4. For how to use the functions, refer to "MR-D30 Instruction Manual".5. Maintenance and disposalMR-D30 safety logic unit is equipped with LED displays to check errors for maintenance.Please dispose this unit according to your local laws and regulations.Changing the combination of MR-D30 and MR-J4 servo amplifier will trigger [AL. 7A.4 Functional safety unit combinationerror (safety observation function)] and the safety observation function you set will not operate.6. Functions and configuration6.1 Summary(1) Safety observation functions are available with your servo amplifier.Mounting the functional safety unit to the servo amplifier enables you to use the safety observation functions suchas STO/SS1/SS2/SOS/SLS/SSM/SBC without depending on a controller.(2) Drive safety compatible integrated motion controllerSafety communication with motion controllers is available by using MR-D30 with MR-J4-_B_-RJ. With this, thewiring which was required can be reduced for the STO signal and encoder signal for safety observation.(3) Drive safety integrated programmable controllerSafety communication with safety programmable controller is available by using MR-D30 with MR-J4-_GF_-RJ.With this, the wiring which was required can be reduced for the STO signal and encoder signal for safetyobservation.6.2 Transportation and storageCAUTIONTransport the products correctly according to their mass.Stacking in excess of the limited number of product packages is not allowed.Install the equipment in a load-bearing place in accordance with "MR-D30 InstructionManual".Do not put excessive load on the machine.When you keep or use it, please fulfill the following environment.Item EnvironmentAmbient temperatureOperation [°C] 0 to 55 Class 3K3 (IEC/EN 60721-3-3)Transportation(Note) [°C] -20 to 65 Class 2K12 (IEC/EN 60721-3-2)Storage (Note) [°C] -20 to 65 Class 1K4 (IEC/EN 60721-3-1)Ambient humidity Operation, transportation,storage 5 %RH to 90 %RHVibration resistanceTest condition10 Hz to 57 Hz with amplitude of 0.075 mm57 Hz to 150 Hz with constant acceleration of 9.8 m/s 2 to IEC/EN 61800-5-1 (Test Fc of IEC60068-2-6)Operation 5.9 m/s 2 (X, Y, Z axes)Transportation(Note) Class 2M3 (IEC/EN 60721-3-2)Storage Class 1M2 (IEC/EN 60721-3-2)Pollution degree 2IP ratingMounted on a servo amplifier: IP20 (IEC/EN 60529)MR-D30 (single): IP00 (IEC/EN 60529)Open type (UL 50)Altitude Operation, storage 2000 m or lessTransportation 10000 m or lessNote. In regular transport packaging6.3 SpecificationsModel MR-D30Output Rated voltage 24 V DCRated current [A] 0.3Interface power supplyVoltage 24 V DC ± 10 %Power supplycapacity [A] 0.8 (Note 1)Safety performanceStandards certified by CBEN ISO 13849-1:2015 Category 4, PL e and Category 3, PL dIEC 61508 SIL 2 and SIL 3EN IEC 62061:2021 maximum SIL 2 and maximum SIL 3EN 61800-5-2Mean time to dangerousfailure (MTTFd) MTTFd ≥ 100 [years] (313a)Diagnostic coverage (DC) DC = High, 97.6 [%]Probability of dangerousfailures per hour (PFH) PFH = 6.57 × 10-9 [1/h]Mission time (TM ) T M = 20 [years]Response performance(Note 2)Using input device: 15 ms or lessUsing a drive Safety integrated motion controller: 60 ms or lessUsing drive safety integrated programmable controller: 65 ms or lessSpeed observation resolution Depends on a command resolution (22 bit position command: 0.1 r/min or less)Position observationresolution 1/32 revSafety position data resolution 32 pulses/rev (5 bits)Input device 6 points × 2 systems (source/sink)Output device Source: 3 points × 2 systems and 1 point × 1 systemSink: 1 point × 1 systemSafety observationfunction(IEC/EN 61800-5-2)Safe torque off (STO) Category 4, PL e, SIL 3 (Note 3)/Category 3, PL d, SIL 2Safe stop 1 (SS1) Category 4, PL e, SIL 3 (Note 3)/Category 3, PL d, SIL 2Safely-limited speed (SLS)(Note 7) Category 4, PL e, SIL 3 (Note 3, 4)/Category 3, PL d, SIL 2Safe speed monitor (SSM)(Note 7) Category 4, PL e, SIL 3 (Note 3, 4)/Category 3, PL d, SIL 2Safe brake control (SBC) Category 4, PL e, SIL 3 (Note 3)/Category 3, PL d, SIL 2Safe operating stop (SOS)(Note 5, 7) Category 4, PL e, SIL 3 (Note 3)/Category 3, PL d, SIL 2Safe stop 2 (SS2) (Note 5, 7) Category 4, PL e, SIL 3 (Note 3)/Category 3, PL d, SIL 2Safety observationfunction Status monitor (STO/SOS) Category 4, PL e, SIL 3/Category 3, PL d, SIL 2 (Note 6)Compliance to globalstandards CE marking EMC: EN 61800-3MD: EN ISO 13849-1:2015, EN 61800-5-2, EN IEC 62061:2021Structure (IP rating) Natural cooling, open (mounted on a servo amplifier: IP20, MR-D30 (single): IP00)Mass [g] 150Note 1. This is the value applicable when all I/O signals are used. The current capacity can be decreased by reducing the number of I/O points.2. Time from STO input off to energy shut off3. To meet Category 4, PL e, SIL 3 for input signals, a diagnosis using test pulses is required.4. To meet Category 4, PL e, SIL 3, using with a servo motor with functional safety is required.5. To enable SS2 and SOS, using with a servo motor with functional safety is required.6. For the achievable safety level, refer to the section of "Safety observation function (IEC/EN 61800-5-2)".7. The scale measurement function of the semi closed loop system, linear servo system, direct drive servo system, and fully closed loopsystem are not compatible with SLS, SSM, SS2, and SOS. The MR-J4-_GF_-RJ with software version B0 or later used in a direct driveservo system is compatible with SLS and SSM. |
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