What is the Mitsubishi MR-J5 Series AC Servo System?
The Mitsubishi MR-J5 series represents the latest generation of MELSERVO-J5 AC servo systems, designed to deliver superior performance, enhanced safety features, and seamless integration capabilities for modern industrial automation applications. As the successor to the popular MR-J4 series, the MR-J5 brings significant improvements in encoder resolution, communication protocols, and diagnostic functionality that make it an ideal choice for high-precision motion control applications.
This comprehensive guide covers the complete technical specifications, compatibility information, application scenarios, and practical recommendations to help engineers and system integrators make informed decisions when selecting servo components for their projects.
Technical Specifications Matrix
MR-J5-G Series (CC-Link IE TSN Interface)
| Model | Power Capacity (kW) | Rated Current (A) | Power Supply | Weight (kg) |
|---|---|---|---|---|
| MR-J5-10G | 0.1 | 1.3 | 200V AC / 283V DC | 0.8 |
| MR-J5-20G | 0.2 | 1.8 | 200V AC / 283V DC | 1.0 |
| MR-J5-40G | 0.4 | 2.8 | 200V AC / 283V DC | 1.4 |
| MR-J5-60G | 0.6 | 3.2 | 200V AC / 283V DC | 1.4 |
| MR-J5-100G | 1.0 | 6.0 | 200V AC / 283V DC | 2.0 |
| MR-J5-200G | 2.0 | 11.0 | 200V AC / 283V DC | 3.2 |
| MR-J5-350G | 3.5 | 17.0 | 200V AC / 283V DC | 4.4 |
| MR-J5-700G | 7.0 | 37.0 | 200V AC / 283V DC | 6.2 |
| MR-J5-12KG | 12.0 | 68.0 | 200V AC | — |
| MR-J5-17KG | 17.0 | 87.0 | 200V AC | — |
| MR-J5-25KG | 25.0 | 126.0 | 200V AC | — |
Key Technical Parameters
| Parameter | Specification |
|---|---|
| Encoder Resolution | 26-bit batteryless absolute position encoder |
| Control Method | Sine-wave PWM control / current control method |
| Communication Protocols | CC-Link IE TSN, CC-Link IE Field Network Basic, EtherCAT, EtherNet/IP |
| Communication Cycle (CC-Link IE TSN) | 31.25 μs to 8 ms (Class B), 500 μs to 500 ms (Class A) |
| Interface Power Supply | 24V DC ±10% (0.3A including CN8 signals) |
| Dynamic Brake | Built-in (7kW or less) |
| Operating Temperature | 0°C to 60°C (operation) |
| Protection Rating | IP20 (Open style) |
| Safety Standards | ISO 13849-1 PLe, IEC 61508 SIL 3, EN 61800-5-2 SIL 3 |
| MTTFd | ≥ 100 years |
| Ambient Humidity | 5% to 95% RH (non-condensing) |
Communication Protocol Compatibility Analysis
CC-Link IE TSN (Time Sensitive Networking)
The MR-J5-G series supports CC-Link IE TSN as its primary communication interface, offering the following advantages:
- High-speed synchronization: Communication cycles as fast as 31.25 μs enable precise multi-axis coordination
- Time-sensitive data transmission: Ensures deterministic control for critical motion applications
- Mixed network capability: TCP/IP devices can coexist on the same network with real-time control communications
- CiA 402 drive profile support: Enables profile position, velocity, and torque control modes
EtherCAT Integration
The MR-J5-G-N1 variants provide native EtherCAT support with the following specifications:
| EtherCAT Feature | Specification |
|---|---|
| Communication Stack | CANopen over EtherCAT (CoE), Ethernet over EtherCAT (EoE), Safety over EtherCAT (FSoE) |
| Drive Profile | CiA 402 |
| Communication Cycle | 125 μs, 250 μs, 500 μs, 1 ms, 2 ms, 4 ms, 8 ms |
| Control Modes | Cyclic synchronous position/velocity/torque (csp/csv/cst), Profile position/velocity/torque (pp/pv/tq), Homing (hm) |
| Touch Probe Accuracy | 1 μs |
EtherNet/IP Support
For systems requiring EtherNet/IP connectivity, the MR-J5-G-HSN1 and MR-J5-G-RJN1 variants offer:
- Communication cycles selectable from 1 ms to 100 ms
- Profile position, velocity, and torque control modes
- CIP Safety support for functional safety applications
MR-J4 vs MR-J5: Performance Comparison
| Feature | MR-J4 Series | MR-J5 Series |
|---|---|---|
| Encoder Resolution | 22-bit | 26-bit (4x improvement) |
| Machine Diagnosis | Ball screw only | Ball screw, gear, belt |
| Disconnection Detection | Not provided | Main circuit input open phase / Motor output open phase |
| Tuning Method | One-touch tuning | Auto tuning (automatic) |
| Cooling Fan Replacement | Not supported | Supported |
| Safety Sub-functions | STO only | STO, SS1, SS2, SOS, SBC, SLS, SSM, SDI, SLI, SLT |
| Network Safety | Not supported | Supported via network (MR-J5-G-HS) |
| Safety I/O Points | 1 input / 1 output | 3 inputs / 3 outputs (MR-J5-G-HS) |
| Operating Temperature | 55°C | 60°C |
| Maximum Capacity | 7 kW | 25 kW |
Application Scenarios and Use Cases
1. High-Precision CNC Machinery
The 26-bit encoder resolution of the MR-J5 series provides exceptional positioning accuracy, making it ideal for:
- CNC machining centers requiring micron-level precision
- Laser cutting and waterjet cutting systems
- PCB drilling and routing equipment
- High-speed pick-and-place machines
2. Robotics and Motion Control
With support for CC-Link IE TSN and EtherCAT, the MR-J5 enables synchronized multi-axis control for:
- Articulated robots and SCARA systems
- Collaborative robots (cobots) with enhanced safety functions
- Automated assembly lines
- Packaging and palletizing systems
3. Large-Capacity Applications
The new 12 kW to 25 kW models expand the application range to include:
- Large presses and stamping machines
- Industrial mixers and agitators
- Heavy-duty conveyor systems
- Metal forming equipment
4. Energy-Efficient Systems
The common bus connection feature allows regenerative energy from one axis to power other axes, reducing energy consumption by up to 30% in multi-axis applications. This makes the MR-J5 particularly suitable for:
- Energy-conscious manufacturing facilities
- Systems with high duty cycles
- Applications with frequent acceleration/deceleration
Compatible Servo Motors
| Motor Series | Type | Power Range | Key Features |
|---|---|---|---|
| HK-KT | Low inertia | 0.05 kW to 2.0 kW | High-speed response, compact design |
| HK-MT | Ultra-low inertia | 0.05 kW to 1.0 kW | Maximum acceleration capability |
| HK-ST | Medium inertia | 0.5 kW to 11 kW | Versatile, general-purpose applications |
| HK-RT | Ultra-low inertia | 1.0 kW to 7.0 kW | High-speed, high-precision applications |
| HK-JT | Medium/large, low inertia | 7 kW to 22 kW | One-touch lock connectors, large-capacity |
Safety Functions and Certification
The MR-J5-G-HS variant offers comprehensive safety sub-functions compliant with international standards:
- STO (Safe Torque Off): Prevents the motor from generating torque
- SS1 (Safe Stop 1): Controlled stop followed by STO activation
- SS2 (Safe Stop 2): Controlled stop maintaining position
- SOS (Safe Operating Stop): Maintains position without torque
- SBC (Safe Brake Control): Controls external brake for vertical loads
- SLS (Safely Limited Speed): Limits speed to safe levels during operation
- SSM (Safe Speed Monitor): Monitors speed against configurable limits
- SDI (Safe Direction): Prevents motion in unsafe direction
- SLI (Safe Limited Position): Prevents exceeding position limits
- SLT (Safe Limited Torque): Limits torque to safe values
Safety certifications include:
- EN ISO 13849-1:2015: Category 3, Performance Level e (PLe)
- IEC 61508: SIL 3
- EN IEC 62061: Maximum SIL 3
- EN 61800-5-2: SIL 3
- CE, UL/cUL, UKCA, EAC: Global market compliance
Replacement and Upgrade Guide
From MR-J4 to MR-J5
For users planning to upgrade from the MR-J4 series:
- Parameter conversion: Use Mitsubishi’s engineering software for automatic parameter migration
- Communication compatibility: MR-J5-B is compatible with existing SSCNET III/H systems
- Motor compatibility: Most HK series motors are backward compatible
- Safety function migration: MR-J5-G-HS provides enhanced safety functions beyond MR-J4-B’s STO
Recommended Spare Parts
| Accessory | Model Number | Application |
|---|---|---|
| USB Communication Cable | MR-J3USBCBL3M | PC connection for MR Configurator2 |
| Brake Resistor | MR-RB3N | 9 Ohm / 400W regenerative resistor |
| Signal Connector | MR-J3CN1 | Signal connection for MR-J5-A |
| Power Connector Kit | MR-J5-200/350 CON.-CNP1 | Power connections |
Purchase Recommendations
For New Installations
- General purpose automation: Choose MR-J5-G with CC-Link IE TSN for best integration with Mitsubishi PLCs
- EtherCAT systems: Select MR-J5-G-N1 for seamless EtherCAT network integration
- EtherNet/IP environments: Use MR-J5-G-HSN1 for Rockwell Allen-Bradley system compatibility
- High safety requirements: Opt for MR-J5-G-HS with comprehensive safety sub-functions
For Upgrades
- SSCNET III/H systems: Replace with MR-J5-B for direct compatibility
- Legacy pulse-train systems: Use MR-J5-A for analog/pulse command compatibility
- Fully closed loop applications: Select MR-J5-G-RJ or MR-J5-G-RJN1 with expanded encoder support
Configuration Tips
- Ensure adequate cooling with proper cabinet ventilation
- Use shielded cables for encoder and motor connections
- Leverage MR Configurator2 software for quick commissioning
- Enable machine diagnosis functions for predictive maintenance
- Configure disconnection detection for enhanced system reliability
Conclusion
The Mitsubishi MR-J5 series represents a significant leap forward in servo technology, offering 4x higher encoder resolution compared to the MR-J4, expanded power capacity up to 25 kW, and comprehensive support for modern industrial Ethernet protocols including CC-Link IE TSN, EtherCAT, and EtherNet/IP. The enhanced safety functions and improved diagnostic capabilities make it an excellent choice for both new machine designs and system upgrades.
Whether you’re building high-precision CNC machinery, implementing multi-axis robotic systems, or upgrading existing automation infrastructure, the MR-J5 series provides the performance, flexibility, and reliability required for demanding industrial applications.