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Mitsubishi FCU6-DX561 Remote Maintenance Manual PDF

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Summary of Content for Mitsubishi FCU6-DX561 Remote Maintenance Manual PDF

CNC

FCU6-DX561

CONNECTION AND MAINTENANCE MANUAL

BNP-B2302*(ENG)

REMOTE I/O UNIT

Precautions for Safety Always read the specifications issued by the machine maker, this manual, related manuals and enclosed documents before starting installation, operation, programming, maintenance or inspection to ensure correct usage. Thoroughly understand the basics, safety information and precautions of this numerical controller before using the unit. This manual ranks the safety precautions into DANGER , WARNING and CAUTION .

DANGER When there is a great risk that the user could be subject to fatalities or serious injuries if handling is mistaken.

WARNING When the user could be subject to fatalities or serious injuries if handling is mistaken.

CAUTION When the user could be subject to injuries or when physical damage could occur if handling is mistaken.

Note that even if the item is ranked as CAUTION , serious results could occur depending on the state. Always observe the described matters.

DANGER

Not applicable in this manual.

WARNING

1. Items related to prevention of electric shocks

Do not operate the switches with wet hands, as this may lead to electric shocks.

Do not damage, apply excessive stress, place heavy things on or sandwich the cables, as this may lead to electric shocks.

2. Items related to smoke prevention Incorrect wiring or connections could burn the device.

CAUTION

1. Items related to noise

Always treat the shield cables indicated in this manual with grounding measures such as cable clamps.

Separate the signal wire from the drive line/power line when wiring.

2. Items related to installation

Install the unit on noncombustible material. Installation directly on or near combustible material may lead to fires.

Always observe the installation direction.

Do not install or operate a unit that is damaged or that have missing parts.

Do not allow conductive foreign matter such as screws or metal chips or combustible foreign matter such as oil enter the unit.

The unit is a precision device so does not drop or apply strong impacts on them.

Do not install the unit where it may be subject to cutting oil.

3. Items related to connection

Do not apply voltages other than those indicated in this manual on the connector. Doing so may lead to destruction or damage.

Incorrect connections may damage the devices, so connect the cables to the specified connectors.

When using an inductive load such as relays, always connect a diode in parallel to the load as a noise measure.

When using a capacitive load such as a lamp, always connect a protective resistor serially to the load to suppress rush currents.

Do not connect or disconnect the connection cables between each unit while the power is ON.

When using an RS-232C device as a peripheral device, caution will be required when connecting and disconnecting the connector.

Always use a double-OFF type AC power supply switch on the device side, and connect/ disconnect the connector with the AC power supply on the device side OFF.

RS-232C NC unit Device Switch AC socket

FCU6-DX561 CONNECTION AND MAITENANCE MANUAL

CONTENTS I. CONNECTION MANUAL 1. OUTLINE ..................................................................................................................... I-1 2. CONFIGURATION ....................................................................................................... I-2 2.1 System Configuration .......................................................................................... I-2 3. INSTALLATION ........................................................................................................... I-3 3.1 General Specification .......................................................................................... I-3 3.2 Noise Countermeasures...................................................................................... I-4 3.2.1 Connection of FG (Frame Ground) .............................................................. I-4 3.2.2 Shield Clamping of Cables........................................................................... I-5 3.2.3 Connecting Spark Killers.............................................................................. I-6 3.3 Installation ........................................................................................................... I-7 3.4 Mounting Conditions............................................................................................ I-8 4. SYSTEM CONNECTION.............................................................................................. I-9 4.1 General System Diagram .................................................................................... I-9 5. CONNECTION OF UNIT.............................................................................................. I-10 5.1 Names of Each Part ............................................................................................ I-10 5.2 Unit Connection System Diagram ....................................................................... I-11 5.3 Connection of Base I/O Unit ................................................................................ I-12 5.4 Connection of RIO Unit ....................................................................................... I-13 5.5 Connection of Power Supply ............................................................................... I-14 5.6 Connection of Encoder Speed Signal ................................................................. I-15 5.7 Connection of Machine Input/Output Signal ........................................................ I-17 APPENDIX 1 UNIT OUTLINE DRAWINGS AND INSTALLATION DIMENSIONS......... I-21 APPENDIX 2 LIST OF CONNECTOR SETS................................................................... I-22 APPENDIX 3 CABLE MANUFACTURING DRAWING ................................................... I-23 Appendix 3.1 FCUA-R000 Cable Manufacturing Drawing........................................ I-25 Appendix 3.2 FCUA-R211 Cable Manufacturing Drawing........................................ I-26 Appendix 3.3 FCUA-R220 Cable Manufacturing Drawing........................................ I-27 Appendix 3.4 R300 Cable Manufacturing Drawing................................................... I-28 Appendix 3.5 R301 Cable Manufacturing Drawing................................................... I-29 Appendix 3.6 R-TM Manufacturing Drawing............................................................. I-30 APPENDIX 4 PRECAUTIONS FOR COMPLYING WITH UL/c-UL STANDARDS......... I-31

II. MAINTENANCE MANUAL 1. EXPLANATION OF MODULE FUNCTIONS ................................................................ II-1 1.1 FX2N-80BMT-NC Card ....................................................................................... II-1 2. FAULT DIAGNOSIS..................................................................................................... II-3 2.1 List of Unit LEDs.................................................................................................. II-3 2.2 Troubleshooting................................................................................................... II-4 2.2.1 Confirmation of trouble state........................................................................ II-4 2.2.2 When in trouble............................................................................................ II-5 2.2.3 Behavior of independent faults .................................................................... II-9 3. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE......... II-10 3.1 Maintenance Tools .............................................................................................. II-10 3.2 Replacement Methods ........................................................................................ II-11 3.2.1 Cable............................................................................................................ II-11 3.2.2 Unit............................................................................................................... II-13

I. CONNECTION MANUAL

1. OUTLINE

I-1

1. OUTLINE

This manual explains the items required for installing and connecting the remote I/O unit (FCU6-DX561). The FCU6-DX561 is a remote I/O unit with PLC functions. This unit is used as to monitor both the machine signals and the spindle speed. Read this manual thoroughly and understand the product's functions and performance before starting use. Refer to the following documents for explanations on the functions. FX2N Hardware Manual (JY992D66301G) FX Programming Manual (JY992D88101A) MELDAS AC Servo/Spindle MDS-C1 Series Specifications Manual (BNP-C3000) Refer to the following material for details on EMC Directives for the European CE Marking. EMC Installation Guideline (BNP-B2230)

2. CONFIGURATION 2.1 System Configuration

I-2

2. CONFIGURATION 2.1 System Configuration

0

OPEN

CBUS 2CBUS 1

M I T S U B I S H I M D S - B - S V J 2

Remote I/O unit FCU6-DX561

Remote I/O unit DX1

Servo drive unit MDS-B/C1-V1/V2-

Spindle drive unit MDS-B/C1-SP- MDS-B-SPJ2-

Power supply unit MDS-B/C1-CV- MDS-B-CVE-

Ethernet communication device

Servo drive unit MDS-B-SVJ2- MR-J2-CT (auxiliary axis)

Communication terminal Operation

panel, etc.

MC link A

M60/M600 Series control unit

Base I/O unit

MC link A

MC link B

Sensor

Max. 8 channels

Synchronous feed encoder

Manual pulse generator RS-232C device

Servomotor Spindle motor

Machine control signal Legend : Connections described in this manual

: Connections described in separate documents

MC link B

Remote I/O unit DX1

M64:BASE-T or BASE-5 M65/66:BASE-T

MC link B

Remote I/O unit DX1

MC link B

Synchronous feed encoder

ENC1

SV2 SV1

RI02 RI01 DCIN

0 0

CF31 CF32

CF34CF33

CF10

CR31

SKIP

HANDL CH1CH3

CF11

RS232C CH1CH2

3. INSTALLATION 3.1 General Specification

I-3

3. INSTALLATION 3.1 General Specification

Unit name Remote I/O unit Type name FCU6-DX561

During operation 0 to 55C * Note

Ambient temperature During

storage 20 to 60C

During operation 45 to 75% RH (with no dew condensation)

Ambient humidity During

storage 45 to 80% RH (with no dew condensation)

Vibration resistance 4.9m/s2 or less (during operation) Shock resistance 29.4m/s2 or less (during operation)

98m/s2 or less (during transportation) Working atmosphere No corrosive gases, or high levels of dust or oil mist Power noise 1kVA (P-P) Withstand voltage 500VAC for one minute

Across entire output terminal batch and grounding terminal Insulation resistance 5M or more with 500VDC megger tester

Across entire output terminal batch and grounding terminal

G en

er al

s pe

ci fic

at io

ns

Grounding Class D grounding Use without grounding is possible if grounding is not possible.

Power voltage 24VDC +10%/15% (Must be insulated from 100VAC and 200VAC power supply)

Instantaneous stop tolerance time

Operation continues when power instantaneously stops for 4ms or less.

Power fuse Chip type fuse incorporated (SSTC 0.8A Maker: SOC UL198G approved, CSA C22.2 No. 59.2)

Power consumption Approx. 10W (Only control section; excludes input/output section) Rush current Approx. 20A/1ms, approx. 5A/10ms Sensor power None Weight 1.8kg

P ow

er s

pe ci

fic at

io ns

Unit size Refer to Appendix.

* Note If the ambient temperature is 55C or more, lower to 55C or less with forced cooling.

3. INSTALLATION 3.2 Noise Countermeasures

I-4

3.2 Noise Countermeasures 3.2.1 Connection of FG (Frame Ground)

The frame should basically be grounded at one ground point. Connect the control unit and base I/O unit's and remote I/O unit's 0V (RG) to the FG on the 24VDC stabilized power supply side.

D C

24V (+) FG0V

0

0 0

CF31CF32 CF34CF33

SV2 SV1

HR3

DCIN

CF10

ENC

CR31

SKIP

Control unit FCU6-MU -MA

Main gaounding plate for electric cabinet

FG cable

FG cable

R220 cable

R220 cable

R220 cable (24VDC)

(24VDC)

(24VDC)

FG cable

FCU6-DX3 /DX4 /HR377/378 Base I/O unit

4

ST No.

POWERRUNCPU-E

STOP

RUN

RIO ERR1 ERR2

Remote I/O unit FCU6-DX561

Stabilized power supply

D C

24V (+) FG0V Short bar

AC input

FG cable

FG0V

24VD C

(+)

Stabilized power supply

Short bar

AC input

FG0V

24VD C

(+)

3. INSTALLATION 3.2 Noise Countermeasures

I-5

3.2.2 Shield Clamping of Cables

(1) Cables requiring ground connection with lead wire The FG wire of the RIO cable (R211) connected between the base I/O and each remote I/O unit must be connected to the grounding plate near the unit.

4 ST No.

POWERRUNCPU-E

STOP

RUN

RIO ERR1 ERR2

0 0

CF31CF32 CF34CF33

SV2 SV1

HR3

DCIN

CF10

ENC

CR31

SKIP

Grounding plate

Grounding plate

Grounding plate

X

X

R211 cable R211 cable

FG wire

FG wire FG wire

FG wire

X

X

FCU6-DX3 /DX4 /HR377/378

Base I/O unit

Remote I/O unit FCU6-DX561

Remote I/O unit FCUA-DX1

(2) Cables which require shield clamp with connector cases The shield of encoder cable (R000) for the speed signal input must be clamped with the connector case.

Fold the cable shield on the sheath, and wrap copper foil tape over it. Connect with the connector GND plate.

3. INSTALLATION 3.2 Noise Countermeasures

I-6

3.2.3 Connecting Spark Killers

Connect a spark killer on the coil or contact in parallel for noise countermeasures. Use spark killers which are 0.033 to 0.1F, 10 to 120.

Coil

Contact

E

SK S

K

3. INSTALLATION 3.3 Installation

I-7

3.3 Installation

Each unit is installed in the sealed structure cabinet as a principle. When installing into the cabinet, refer to the following drawings to consider the unit's heat dissipation and wiring, and secure enough space for ventilation.

(1) Install the unit vertically so that the front is visible. (2) Refer to the following drawings to consider the unit's heat dissipation and wiring, and secure enough

space for ventilation.

(Top)

Control unit Servo drive unit Spindle drive unit

30mm or more

0

OPEN

CBUS 2CBUS 1

M I T S U B I S H I M D S - B - S V J 2

M I T S U B I S HI M D S - B - S V J2

4

ST No.

POWER RUNCPU-E

S T O P

R U N

RIO ER R 1 ER R 2

Remote I/O unit (FCU6-DX561)

Remote I/O unit (FCUA-DX1 )

100mm or more (heat dissipation allowance)

50mm or more (heat dissipation allowance)

50mm or more

10mm or more 10mm or more 10mm or more

15mm or more (wiring allowance)

15mm or more (wiring allowance)

150mm or more (heat dissipation, wiringallowance)

100mm or more (heat dissipation, wiring allowance)

(Bottom)

Install the unit on noncombustible material. Installation directly on or near combustible material may lead to fires.

Always observe the installation direction.

Do not install or operate a unit that is damaged or that has missing parts.

The unit is a precision device so do not drop or apply strong impacts on it.

CAUTION

3. INSTALLATION 3.4 Mounting Conditions

I-8

3.4 Mounting Conditions

(1) Parts, highly susceptible to dust, are mounted with a high density inside the unit. Always use a sealed structure for the cabinet, and provide the following treatments. Always plug the cable inlet with packing, etc., to prevent dust and oil from entering. Take care so that outdoor air does not enter the heat dissipation holes, etc. Plug all clearances. Always install door packing. If there is a back lid, always install packing. Oil will easily accumulate at the ceiling, and can enter the cabinet from the screw holes. Always

take special measures such as using oil-preventing packing.

Fitting

Packing

Cable

Cable inlet (Example) (2) Avoid machining in the area after installing each unit. Cutting chips, etc., could get on the electronic

parts and cause damage.

(3) Design so that the cabinet's internal temperature rise is 10C or less in respect to the outdoor

temperature, and so that it is within the unit's temperature conditions.

Do not allow conductive foreign matter such as screws or metal chips or combustible foreign matter such as oil enter the unit.

CAUTION

4. SYSTEM CONNECTION 4.1 General System Diagram

I-9

4. SYSTEM CONNECTION

4.1 General System Diagram

FG

SV1

CF10CF11

R000

MC1 MC1

MC1

CF11 CF10

AUX2

EMG

BASE-T

F010F050

R000

ON OFF

MC

MC

R S T

MC

FG

FG

RA

MDS-B-SVJ2- MDS-B-SP-

IM

CN1A CN1B L1 L2 L3

L+ L- MC1

L11 L21

SH21

CN5 CN4OSA253S

MR-RB O30

CN2

CN1A CN1B L1 L2 L3

C P N D

U V W

F G

L11 L21

FG

FG

U V W

L+ L-

L1 L2

CN4

L1 L2 L3

L11 L21

SM 1.5kW

MC1

CN6

DC24IN

AUX1

CPU:HR114/146

FG

CR02 CR01 CR05

FG

CT100/CT120/LD100/DUT32/DUN33 /EL10/CR10

RIO1

MJ2

MJ3

CN8

R

R

R

R

4

4

RIO1RIO2

DCIN RIO1 RIO2

F120

EMG

R211

R211

R211 R211

R220

R220

24VDC(+)

MDS-B-CV-

Stabilized power supply

Base I/O unit HR377/HR378 FCU6-DX3 FCU6-DX4

MC link B Terminator

R-TM

Machine control contact

To next remote I/O unit

Operation panel

Remote I/O unit DX1

Communication terminal

MC link B terminator R-TM

MDS-B-CVE-

To next remote I/O unit

Ethernet communication device

3-phase 200VAC to 230VAC

No fuse breaker (NFB)

OT release switch

Insert when required

X axis and Y axis Spindle

AC servomotor

with detector HC153TA33

Spindle motor SJ-V15-02

R056 cable

7.5kW rating 30 min.

Regenerative resistor

CNV2/CNV12 cable

Terminator MDS-A-TM

AC reactor B-AL Spindle encoder SE1024-3-15-68

Detec- tor

Detec- tor

Converter

24VDC(+)

24VDC(+)

or

Power supply HR083

Option slot RT2 RT1

IC card

Control unit M60/M600 Series

24VDC

IC card: HR831 Ethernet: HR832

Communication card HR171

PLC unit FCU6-DX561

24VDC(+)

or

Machine control relay

FG

24VDC(+)

24VDC (+) Stabilized power supply

I/O link

To next control unit

DCIN

ENC1/ ENC2

DI-L/ DI-R

DO-L

(Note) This drawing is an example of the general connection for the M60/M600 Series. The actual

connection will differ according to the specifications.

5. CONNECTION OF UNIT 5.1 Names of Each Part

I-10

5. CONNECTION OF UNIT

The methods for connecting to each unit and device are briefly explained in this chapter.

5.1 Names of Each Part

(1) 24VDC input connector (2) Connector 1 for encoder (speed signal)

connection (Note) (3) Connector 2 for encoder (speed signal)

connection (Note) (4) Station No. setting rotary switch (5) RUN-STOP slide switch (6) Programming unit connection connector (7) Digital signal input connector (8) Digital signal input connector (9) Digital signal output connector (10) Remote I/O connection connector (11) Remote I/O connection connector (Note) The encoder speed signal is connected

via the spindle amplifier. As there is no power supply, the encoder cannot be directly connected to the connectors ENC1/ENC2.

Front view

ENC1 (2)

ST No. (4)

DO-L (9)

DI-L (7)

0 1

2 3 4

567 89

ABCDE

FST No.

POWER

RUN

CPU-E STOP

RUN

P R

O G

. P

O R

T D

I- R

D I-

L D

O -

L

RIO

ERR1

ERR2

E N

C 1

E N

C 2

D C

INDCIN (1)

ENC2 (3)

PROG.PORT (6)

DI-R (8)

RUN/STOP (5)

Bottom view

RIO1 (10)

RIO2 (11)

R IO

1 R

IO 2

5. CONNECTION OF UNIT 5.2 Unit Connection System Diagram

I-11

5.2 Unit Connection System Diagram

F010 cable CF10 RIO1

0 1

CS1 CS2

CF10

Remote I/O unit or terminator (R-TM)

Encoder (speed signal) 2 channels

Encoder (speed signal) 2 channels

DI

DI

DO

2

ST No.

RIO1

RIO2

ENC1

ENC2

DI-L

DI-R

DO-L DCIN

F050 cableCF11

CF11

DCINR220 cable

R211 cable

R211 cable

R000 cable

R000 cable

R301 cable

R301 cable

R301 cable

M60/M600 Series control unit Base I/O unit

Additional I/O card HR211

24VDC stabilized power

Remote I/O unit (FCU6-DX561)

Name Explanation RIO1 This is connected to the base I/O unit.

RIO2 This is used to connect the terminator or to expand the remote I/O unit. The remote I/O unit can be expanded by up to four stations.

ENC1 Connected with encoder via spindle amplifier. ENC2 Connected with encoder via spindle amplifier. DI-L DI: 28 (Sink/Source) DI-R DI: 16 (Sink/Source) DO-L DO: 32 (Source)

ST No.

Set the station No. In the above example, "0, 1" is set for the base I/O, so set to "2". As this unit occupies two stations, set this switch to an even number (0, 2, 4, 6). (Note) If an odd number (1, 3, 5, 9) is set, the station number for when an even number

(0, 2, 4, 6) is set will be selected.

5. CONNECTION OF UNIT 5.3 Connection of Base I/O Unit

I-12

5.3 Connection of Base I/O Unit The RIO1 connector is used for connection to the base I/O unit. Connect the R211 cable from the RIO1 connector on this unit to the RIO1 connector on the base I/O unit.

Control unit (FCU6-MU /MA )

Base I/O unit FCU6-DX3 /DX4 /HR377/378

0

OPEN

CBUS 2

DC IN

DC OUT PS EMG

BAT ALM

NC RST

NC SYS

NC LED

WD ER

ENC2

CBUS 1

ENC1

SV2 SV1

0

0

SKIP

HANDL CH1CH3

RS232C CH1CH2

FG

(LG)

CF31 CF32 CF33 CF34

RIO1RIO2 DCIN

CF10

CF11

4

ST No.

POWER RUN CPU-E

STOP

RUN

RIO ERR1 ERR2

(Front)

(Back)

Bottom view

Remote I/O unit (FCU6-DX561)

CF11 CF10

R211 cable

F010 cableF050 cable

RIO1RIO2 DCIN

R IO

1 R

IO 2

X

R211 cableR211 cable

X

Terminator (R-TM)

CR31

(Note) When not expanding the remote I/O units, connect the terminator (R-TM) to RIO2.

5. CONNECTION OF UNIT 5.4 Connection of RIO Unit

I-13

5.4 Connection of RIO Unit The RIO2 connector is used to connect several remote I/O units. Connect the R211 cable from the RIO2 connector on this unit to RIO1 on the remote I/O unit. When connecting several remote I/O units, connect the R211 cable from the RIO2 connector on the remote I/O unit to the RIO1 connector on the next remote I/O unit. Connect the terminator (R-TM) to the RIO2 connector on the final remote I/O unit. When manufacturing the R211 cable, use the enclosed connector and contacts. If there are not enough accessories, use the single-ended connector CN211 (option, single-ended). (Refer to the cable manufacturing drawings for details.) (Example for expanding remote I/O units)

Terminator (R-TM)

XR211 cable R211 cable

RIO2 RIO2 RIO2

RIO1 RIO1

X

X

Front

Back

Bottom view

RIO1

RIO2

DCIN

RIO2

RIO1

DCIN

RIO2

RIO1

R IO

1 R

IO 2

R IO

1 R

IO 2

X

X

Front

Back

Bottom view

(Front)

Back

Bottom view Front

Back

Bottom view

Remote I/O unit (FCU6-DX561)

Remote I/O unit (FCU6-DX561)

Remote I/O unit (FCUA-DX1 )

Remote I/O unit (FCUA-DX1 )

Remote I/O unit (FCUADX1 )

Terminator (R-TM)

Terminator (R-TM)

Connect the terminator (R-TM) to RIO2 when not expanding the remote I/O unit.

Connect the R211 cable from RIO2 to RIO1 on the next remote I/O unit.

Connect the terminator (R-TM) to RIO2 on the final unit.

Incorrect connections could damage the device, so always connect the cable to the designated connector.

Do not connect or disconnect the connection cables between each unit while the power is ON.

CAUTION

5. CONNECTION OF UNIT 5.5 Connection of Power Supply

I-14

5.5 Connection of Power Supply Supply the 24VDC power supply for the control circuit to the DCIN connector (DCIN). The 24VDC power for the input/output circuit is supplied from an external source. Supply to each connector (DI-L/-R, DO-L).

(1) DCIN power connection (for control circuit)

Y

FG

24VDC (+)

FG

0V

Stabilized power supply

(2) DI-L/-R power connection (for DI circuit)

DI-R

24VDC (+)

FG

0V

0V

B4 B3 A4 A3

0V

B4 B3 A4 A3

DI-L

DI-R

24VDC (+)

FG

0V

DI-L

+24V

B4 B3 A4 A3

+24V

B4 B3 A4 A3

(For sink input)

(For source input)

(3) DO-L power connection (for DO circuit) (Fixed to source output)

24VDC (+)

FG

0V

DO-L

+24V

B4 B3 A4 A3

(Note) Connect the power or GND to all of the common pins on the DI-L/-R and DO-L connector.

Incorrect connections could damage the device, so always connect the cable to the designated connector.

Do not connect or disconnect the connection cables between each unit while the power is ON.

CAUTION

Remote I/O unit (FCU6-DX561)

D C

IN E N

C 1

E N

C 2

ST No.

POWER RUN CPU-E STOP

RUN

RIO ERR1 ERR2

D I-

R D

I- L

P R

O G

. P

O R

T D

O - L

0 1

2 3 4

567 8 9

ABCDE

F

5. CONNECTION OF UNIT 5.6 Connection of Encoder Speed Signal

I-15

5.6 Connection of Encoder Speed Signal

Encoder

ENC1/2 (Note) Refer to

following drawing.

4

STOP

RUN

PC1 PC1

PC3 PC3

PC4 PC4

PC2 PC2

ENC1ENC2

Encoder OSE1024-3-15-681

10

11

20

ENC1/2

DI-L

DO-L

DCIN

CN8 CN6 R000 cable

F040F041 cable

Station No. setting

Channel 1

Connector ENC pin No.

Spindle amplifier

Channel 3 Channel 4

Channel 2

DI-R

110

1120

GND

PC1

GND

PC3

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

I

I

I

I

GND

PC1*

GND

PC3*

GND

PC2

GND

PC4

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

I

I

I

I

GND

PC2*

GND

PC4*

ENC

ENC

Connect the connector shell (frame) to the FG via the pattern on the PCB.

Connect the connector shell (frame) to the FG via the pattern on the PCB.

Receptacle : 52822-4011 Maker : Molex Plug : 10120-3000VE Shell : 10320-52F0-008 Recommended maker: Sumitomo 3M

(Note) The encoder speed signal is connected via the spindle amplifier.

As there is no power supply, the encoder cannot be directly connected to the connectors ENC1/ENC2.

A dedicated cable is required to use channels 3/4 of the connectors ENC1/ENC2.

5. CONNECTION OF UNIT 5.6 Connection of Encoder Speed Signal

I-16

[Outline of connection]

GND

PC

PC

1k

1k

10 0

ENC1/2

Spindle amplifier

[Signal assignment table]

1st channel X00 2nd channel X01 3rd channel X02 4th channel X03

[Input specifications]

Item Specifications Input voltage Line receiver input (X00 to X03) (5VDC) Input sensitivity OFF ON 4.5mA or more, ON OFF 1.5mA or less Input response time X00 to X03 require 50s or more for the second trigger to be validated.

The input pulse is detected at . Circuit insulation Not insulated

Separate the signal wire from the drive line/power line when wiring.

Incorrect connections could damage the device, so always connect the cable to the designated connector.

Do not connect or disconnect the connection cables between each unit while the power is ON.

CAUTION

5. CONNECTION OF UNIT 5.7 Connection of Machine Input/Output Signal

I-17

5.7 Connection of Machine Input/Output Signal

Input Output Number of occupied serial link stations Machine input/output signal

types and number of points 44 points 32 points 2

Machine signal

Machine signal

R300 cable/ R301 cable

R300 cable/ R301 cable

DI-L

DO-L

DI-R

[Outline of connection] X00 to X07 and Y00 to Y37 below are indicated as octal values.

B3 Input circuit sink type

A3

DI_COM

3.3k:4 points (X04 to X07) 4.3k:40 points (X10 to X57)

DI_0V

DI_24V

RIO1 RIO2

1 2 Stabilized power supply

DCIN

3

0V24VDC (+) FG

B4 A4

Control circuit

RA

PL

B3

DO_COM

A3

DO_24V

DO_0V

B4 A4

Output circuit sink type

DI-L/R

DO-L

Machine control panel

B3 Input circuit

A3

Control circuit

Output circuit

RA

PL

source type

source type

RIO1 RIO2 1 2

Stabilized power supply

DCIN 3

0V24VDC (+) FG

B3

DO_COM

A3

DO_24V

DO_0V

DI_0V

DI_24V

DI_COM

B4 A4

B4 A4

3.3k:4 points (X04 to X07) 4.3k:40 points (X10 to X57)

DI-L/R

DO-L

Machine control panel

The input circuit can be switched to a sink type or source type with the connections. The output circuit is fixed to the source type.

Incorrect connections could damage the device, so always connect the cable to the designated connector.

Do not connect or disconnect the connection cables between each unit while the power is ON.

CAUTION

5. CONNECTION OF UNIT 5.7 Connection of Machine Input/Output Signal

I-18

[Signal assignment table]

DO-L

DI-L

DI-R

DO-L

DI-L

Remote I/O unit

R-TM

RI02 DCINRI01

AMPD-3

X AMP

D-3

Y AMPD-3

DI-R

2 0

1 9

1 8

1 7

1 6

1 5

1 4

1 3

1 2

1 1

1 0

9

8

7

6

5

4

3

2

1

DI_COM1

DI_COM1

DI_COM1

DI_COM1

2 0

1 9

1 8

1 7

1 6

1 5

1 4

1 3

1 2

1 1

1 0

9

8

7

6

5

4

3

2

1

2 0

1 9

1 8

1 7

1 6

1 5

1 4

1 3

1 2

1 1

1 0

9

8

7

6

5

4

3

2

1

Machine side control panel, etc.

0V

24VDC (+)

PL

RA

X

DO_COM

DO_COM

DO_COM

DO_COM

21 3

LG 24VDC(+)

1 2 3

FG0V

1 2 3

LGTXRX TXRX TXRX TXRX

DI_COM2

DI_COM2

Remote I/O unit

Base I/O unit

DCIN RIO1/RIO2 RI-L/DO-L R-TM DI-R (Terminator)

AMP D-3

X

(Note) X00 to X03 are used for the encoder input, and cannot be assigned to the DI-L connector.

Connector : 2-178288-3 Contact : 1-175218-5 Maker : Tyco Electronics AMP

Connector : 2-178288-3 Contact : 1-175218-5 Maker : Tyco Electronics AMP

Crimp type connector: 7940-6500SC Maker: Sumitomo 3M

5. CONNECTION OF UNIT 5.7 Connection of Machine Input/Output Signal

I-19

[Outline of input circuit] The digital signal input circuit includes the sink type and source type. These can be selected with each connector unit.

Connection method Sink input (X04 to X57)

DI_COM

X

X04 to X07:3.3k 1/2W X10 to X57:4.3k 1/2WDI_0V

DI_24V

68 0k

Connection method Source input (X04 to X57)

DI_0V

DI_24V

DI_COM

X

X04 to X07:3.3k 1/2W X10 to X57:4.3k 1/2W

68 0k

[Input specifications] Item Specifications

7mA/24VDC +10%, 15% (X04 to X07 sink/source changeover) (External power supply)

Input voltage, current

5mA/24VDC +10%, 15% (X10 to X57 sink/source changeover) (External power supply)

Input sensitivity OFF ON 4.5mA or more, ON OFF 1.5mA or less OFF ON Approx. 4ms, ON OFF Approx. 4ms (General input X20 to X57) X00 to X17 are incorporated in the digital filter. (Can be changed to 0 to 60ms; note that the minimum is 50s) (Note)

Input response time

X00 to X03 require 50s or more for the second trigger to be validated. The input pulse is detected at .

Circuit insulation Photo coupler insulation (* Excluding line receiver input) (Note) The input filter value can be changed by rewriting the contents of the special data register

D8020 between 0 and 60 using the MOV command, etc. (The contents of D8020 are automatically set to 10 (10ms) when the power is turned OFF and ON.)

D8020 value Digital filter value 0 10 to 60

0ms 10ms

to 60ms

Note that in actual use, the minimum C-R filter is provided even on this input, and the value will not be lower than 50s (20s for X00 to X01). Refer to the FX2N Hardware Manual for details.

5. CONNECTION OF UNIT 5.7 Connection of Machine Input/Output Signal

I-20

[Outline of output circuit] The digital signal output circuit is a source type.

Connection method Source output (Y00 to Y37)

DO_0V

DO_24V

DO_COM

Y

[Output specifications] Item Specifications (per point)

Rated voltage, current 5VDC to 30VDC, 0.1A Response time 0.2ms (at 24VDC, 0.1A energizing)

Resistance load 60mA (200mA for Y0 to Y3) Inductive load 2.4W/24VDC (7.2W/24VDC for Y0 to Y3) Maximum

load Lamp load 0.3W/24VDC (0.9W/24VDC for Y0 to Y3)

Output saturation voltage 1.2V/0.1A Circuit insulation Photo coupler insulation

When using an inductive load such as a relay, always connect a diode (voltage resistance 100V or more, 100mA or more in reverse direction) in parallel to the load. Note that the device will be damaged if the diode orientation is incorrect.

When using a capacity load such as a lamp, always connect a protective resistor (R = 150) serially to the load to suppress rush currents. (Make sure that the current is less than the above tolerable current including the momentary current.)

When using an inductive load such as a relay, always connect a diode in parallel to the load as a noise countermeasure.

When using a capacity load such as a lamp, always connect a protective resistor serially to the load to suppress rush currents.

CAUTION

APPENDIX 1 UNIT OUTLINE DRAWINGS AND INSTALLATION DIMENSIONS

I-21

APPENDIX 1 UNIT OUTLINE DRAWINGS AND INSTALLATION DIMENSIONS

0 1

2 3 4

5 67 8 9

ABCDE

FST No.

POWER

RUN

CPU-E ST OP

RUN

P R

O G

. P

O R

T D

I- R

D I-

L D

O -

L

RIO

ERR1

ERR2

E N

C 1

E N

C 2

D C

IN

Wiring allowance

2-M5x0.8 screw

80 180

60

30

H ea

t d is

si pa

tio n,

w iri

ng a

llo w

an ce

H ea

t di

ss ip

at io

n al

lo w

an ce

Top 10 50

36 0

10

10 0

38 0

Bottom

APPENDIX 2 LIST OF CONNECTOR SETS

I-22

APPENDIX 2 LIST OF CONNECTOR SETS

C on

ne ct

or c

as e

(3 M

) 10

23 0-

52 F0

-0 08

2

p cs

. S

tra in

re lie

f ( 3M

) 34

48 -7

94 0

2

pc s.

M

et al

c on

ta ct

(T

yc o

E le

ct ro

ni cs

A M

P )

1- 17

52 18

-2

3 p

cs .

Ti n

co nt

ac t

(T yc

o E

le ct

ro ni

cs A

M P

) 1-

17 52

18 -5

3

p cs

.

Pa ck

ag e

co nt

en ts

C on

ne ct

or (3

M )

10 12

0- 30

00 V

E

2 p

cs .

C on

ne ct

or (3

M )

79 40

-6 50

0S C

4

p cs

. C

on ne

ct or

(T

yc o

E le

ct ro

ni cs

A M

P )

1- 17

82 88

-3

1 p

c.

C on

ne ct

or

(T yc

o E

le ct

ro ni

cs A

M P

) 2-

17 82

88 -3

1

p c.

C

on ne

ct or

(3 M

) 79

40 -6

50 0S

C

2 p

cs .

A pp

lic at

io n

R em

ot e

I/O u

ni t (

FC U

6- D

X 56

1)

- S pi

nd le

a m

pl ifi

er

(M D

S -B

/C 1-

S P

M

D S

-B -S

P J2

-

)

D IO

c on

ne ct

or -

te rm

in al

b lo

ck

I/O c

om m

un ic

at io

n co

nn ec

to r

24 V

D C

p ow

er c

on ne

ct or

D IO

c on

ne ct

or

Ty pe

FC U

A -

C S

00 0

FC U

A -

C S

30 1

FC U

A -

C N

21 1

FC U

A -

C N

22 0

FC U

A -

C N

30 0

3 M

3 M

APPENDIX 3 CABLE MANUFACTURING DRAWINGS

I-23

APPENDIX 3 CABLE MANUFACTURING DRAWING As a rule, most F /R cables used with this product are not sold by Mitsubishi. Thus, manufacture the required cables using the cable manufacturing drawings on the following pages as a reference. Note that the cable-compatible connectors can be purchased from Mitsubishi. If crimp tools are not available when manufacturing the power supply cable (R200, R220) and communication cable (R211), the cables can be manufactured by soldering a wire and connector as shown in the following procedure. 1. Carry out preparatory soldering onto the wire. (Peel 3.5mm of the sheath.)

Soldering iron

Wire

Solder 3. Lightly press down one side of the wire barrel

using radio pliers.

Wire barrel This is a barrier to prevent incorrect insertion. Do not bend.

Radio pliers

5. Firmly press down the sheath retainer in the

same manner as the wire barrel.

Sheath retainer

7. Lastly, insert the soldered contact with wire

into the housing.

Pay attention to the insertion direction.

2. Insert the wire into the contact. Hold the sheath retainer.

Contact

4. Firmly press down the other side of the

wire barrel. (Press firmly enough that the wire will

not come out when pulled lightly.)

6. Apply the soldering iron, and melt the

preparatory solder inside. Better results will be achieved if an

additional, small amount of solder is applied.

Soldering iron

Contact section

Be careful that the solder does not flow into the contact section.

APPENDIX 3 CABLE MANUFACTURING DRAWINGS

I-24

Appendix No. Cable type Application Max. length Standard cable length

Appendix 3.1 R000 cable Encoder : 2ch 30m Appendix 3.2 R211 cable Remote I/O 50m Appendix 3.3 R220 cable +24V input 30m Appendix 3.4 R300 cable DI/DO 20m Appendix 3.5 R301 cable DI/DO 20m Appendix 3.6 R-TM terminator RIO unit communication terminator

(Note 1) For the cable with an asterisk () in the maximum cable length column, the total length (L1+ L2 + L3) of the cable length (L1) from the control unit to the base I/O unit, the cable length (L2) from the base I/O unit to this unit, and the cable length (L3) from this unit to each unit must be less than this value.

R211

Control unit

Base I/O unit

Maximum cable length

RIO1

ENC1 ENC2

F010

Servo amplifier

Remote I/O unit

Encoder

L2L1

R300/ F301

F050 Expansion I/O unit RIO1

RIO2

L3

R211

R000

Remote I/O unit (FCU6-DX561)

DI-L/-R DO-L

Machine operation panel

(Note 2) Symbols for writing cable drawings The following symbols are used in the cable drawings.

1. indicates twist.

2.

indicates the shield sheath.

3.

indicates shield clamping to the ground plate.

4. In the cable drawings, the partner of the twisted pair cable is given a priority, so the pin Nos. of the connectors at both

ends are not necessary in number of order. 5. Equivalent parts can be used for the connector, contact and wire material.

APPENDIX 3 CABLE MANUFACTURING DRAWINGS Appendix 3.1 FCUA-R000 Cable Manufacturing Drawing

I-25

Appendix 3.1 FCUA-R000 Cable Manufacturing Drawing

Application: Remote I/O unit (FCU6-DX561) to spindle connection Option (compatible connector set) FCUA-CS000 Assembly drawing

1 2

3

1 2

R000

Note (3)

R000

Connection diagram

Max. cable length: 30m

1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20

Case GND plate

1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20

Case GND plate

Remote I/O unit side ENC1/ENC2

Spindle amplifier side CN8

Manufacturing precautions

(1) The wire material shall be a shielded, 10-pair stranded cable equivalent to UL20276 Standard AWG28 (0.08mm2).

(2) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications.

(3) Attach the nameplate (with protective cover stamped with the cable name) in the position designated in the assembly drawing.

(4) Fold the wire material shield over the sheath, and wrap copper foil tape over it. Then clamp with the connector case frame.

(5) Part No. 1 (connector) and part No. 2 (connector case) are solderless types. If soldering types are required, use parts 10120-3000VE for the connector and 10320-52F0-008 for the connector case (both parts manufactured by Sumitomo 3M).

List of parts used No. Part name/model Maker Qty.

1 Connector 10120-6000EL Sumitomo 3M 2

2 Connector case 10320-3210-000 Sumitomo 3M 2

3 Wire material UL20276 AWG28 10P

Note (1) (1)

(Note) This cable is the same as the SH21 cable.

APPENDIX 3 CABLE MANUFACTURING DRAWINGS Appendix 3.2 FCUA-R211 Cable Manufacturing Drawing

I-26

Appendix 3.2 FCUA-R211 Cable Manufacturing Drawing

Application: Connection between base I/O unit and remote I/O unit (FCU6-DX561) Connection between remote I/O unit (FCU6-DX561) and remote I/O unit (FCUA-DX1) Connection between remote I/O unit (FCUA-DX1) and remote I/O unit (FCUA-DX1) Option (corresponding connector set) FCUA-CN211

(Note that when a single-end connector and contact are used, there is no crimp terminal)

Assembly drawing

1 2

3

R211

Note (3)

1 2

5 4

R211

Connection diagram

1 2 3

1 2 3

TXRX TXRX LG

TXRX TXRX LG

FGFG

Note (5)

Manufacturing precautions

(1) The wire material shall be a shielded 3-pair stranded pair cable equivalent to AWG20 (0.5mm2). (2) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing

they are compatible with the specifications. (3) Attach the nameplate (with protective cover stamped with the cable name) in the position designated

in the assembly drawing. (4) Install each crimp terminal side after stamping the name of each signal on the mark tube. (5) Protect both ends of the wire material with insulation bushing. (6) Use AWG18 (0.75mm2) or equivalent for the shield treatment wire material. (7) Ground the crimp terminal connected to the shield to the control unit or communication terminal

frame ground. Note that to improve the noise resistance, there may be cases when only one end is connected, both ends are connected, or neither end is connected.

List of parts used No. Part name/type Maker Qty.

1 Connector 1-178288-3

Tyco Electronics AMP

2

2 Contact 1-175218-2

Tyco Electronics AMP

6

3

Wire material MIX3CHRV-SV-SB Twisted pair cable with compound 3-pair shield (TOA Electric Industry)

Note (1) (1)

4 Crimp terminal V1.25-3 J.S.T. 1

5 Crimp terminal V1.25-5 J.S.T. 1

Max. cable length: 50m

APPENDIX 3 CABLE MANUFACTURING DRAWING Appendix 3.3 FCUA-R220 Cable Manufacturing Drawing

I-27

Appendix 3.3 FCUA-R220 Cable Manufacturing Drawing

Application: Supply of 24V to remote I/O unit (FCU6-DX561) Option (compatible connector set) FCUA-CN220 (Note that this corresponds only to the connector on the remote I/O unit side.)

Assembly drawing

R220

Note (3)

FG

+24V

GND

1 2 3 4

R220

Connection diagram

BROWN

WHITE 3 2 1

FG GND +24V

FG GND +24V

Power supply sideRemote I/O unit (FCU6-DX561) side DCIN

Manufacturing precautions

(1) The wire material shall be a shielded 1-pair stranded cable equivalent to AWG20 (0.5mm2). (If the cable length exceeds 10m, use AWG16 (1.25mm2).)

(2) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications.

(3) Attach the nameplate (with protective cover stamped with the cable name) in the position designated in the assembly drawing.

(4) Install each crimp terminal side after stamping the name of each signal on the mark tube. (5) Protect both ends of the wire material with insulation bushing. (6) Use AWG18 (0.75mm2) or equivalent for the shield treatment wire material.

List of parts used No. Part name/model Maker Qty.

1 Connector 2-178288-3

Tyco Electronics AMP

1

2 Contact 1-175218-5

Tyco Electronics AMP

3

3 Wire material JPVV-SB 1P 0.5mm2

BANDO Electric Wire Note (1)

(1)

4 Solderless terminal V1.25-3 J.S.T. 3

Max. cable length: 30m

APPENDIX 3 CABLE MANUFACTURING DRAWING Appendix 3.4 R300 Cable Manufacturing Drawing

I-28

Appendix 3.4 R300 Cable Manufacturing Drawing

Application: DIO Machine electric cabinet Assembly drawing

1

Note (2)

Remote I/O unit (FCU6-DX561) side DI-L/-R DO-L

3

R300

First wire is colored

Machine electric cabinet side

Manufacturing precautions

(1) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications.

(2) Attach the nameplate (with protective cover stamped with the cable name) in the position designated in the assembly drawing.

(3) The cable is the same for DI and DO. However, stamp DI or DO on the connector to prevent incorrect insertion.

List of parts used No. Part name/model Maker Qty.

1 Connector 7940-6500SC Sumitomo 3M 1

2 Wire material B40-S Note (1) (1)

Max. cable length: 20m

APPENDIX 3 CABLE MANUFACTURING DRAWING Appendix 3.5 R301 Cable Manufacturing Drawing

I-29

Appendix 3.5 R301 Cable Manufacturing Drawing

Application: DIO Machine electric cabinet Assembly drawing

1 2

Note (2)

Remote I/O unit (FCU6-DX561) side DI-L/-R DO-L

3

1

R301

First wire is colored

Machine electric cabinet side

Manufacturing precautions

(1) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications.

(2) Attach the nameplate (with protective cover stamped with the cable name) in the position designated in the assembly drawing.

(3) The cable is the same for DI and DO. However, stamp DI or DO on the connector to prevent incorrect insertion.

List of parts used No. Part name/model Maker Qty.

1 Connector 7940-6500SC Sumitomo 3M 2

2 Strain relief 3448-7940 Sumitomo 3M 1

3 Wire material B40-S Note (1) (1)

Max. cable length: 20m

APPENDIX 3 CABLE MANUFACTURING DRAWING Appendix 3.6 R-TM Manufacturing Drawing

I-30

Appendix 3.6 R-TM Manufacturing Drawing

Application: Terminator for MC link B remote I/O unit (FCU6-DX561) termination

Assembly drawing

101

103

Rear of the connector

102

Connection diagram

3

2

1

R-TM

LG

TXRX

TXRX

100

Manufacturing precautions

(1) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications.

(2) Cover the 100 terminator with a black insulation tube. (3) Stamp the connector name "R-TM" in white on the rear of the connector.

List of parts used No. Part name/model Maker Qty.

1 Connector 1-178288-3 (X type)

Tyco Electronics AMP

1

2 Contact 1-175216-2

Tyco Electronics AMP

2

3 Resistor 100 1/4W KOA 1

APPENDIX 4 PRECAUTIONS FOR COMPLYING WITH UL/c-UL STANDARDS

I-31

APPENDIX 4 PRECAUTIONS FOR COMPLYING WITH UL/c-UL STANDARDS

Observe the following matters to comply with the UL/c-UL Standards. (1) Selecting the external 24VDC power supply unit

The remote I/O unit (FCU6-DX561) complies with UL Standards on the condition that the external power supply unit for supplying 24VDC is a UL-approved part. Use a UL-approved part for the power supply unit supplying 24VDC to this unit.

(2) Unit ambient temperature The remote I/O unit (FCU6-DX561) complies with UL Standards on the condition that it is used within the maximum ambient temperature given in "3.1 General Specifications" in Chapter 3 of this manual. Design so that the maximum ambient temperature of this unit does not exceed the temperature given in "3.1 General Specifications" in Chapter 3 of this manual.

II. MAINTENANCE MANUAL

1. EXPLANATION OF MODULE FUNCTIONS 1.1 FX2N-80BMT-NC Card

II-1

1. EXPLANATION OF MODULE FUNCTIONS

1.1 FX2N-80BMT-NC Card

[Block diagram]

R IO

1 R

IO 2

D O

-LDO I/F

E N

C 1

D I-

R D I-

L

Encoder I/F

DI I/F

E N

C 2

C N

1

D C

IN

CPU

BPU-G/A

EEPROM

SRAM

IO-G/A

DC-DC 24V5V

RIO-G/A

IO-G/A

Run

Stop

SW1

[Explanation of functions]

The FX2N-80BMT-NC card is based on the MELSEC PLC FX2N Series, and has two remote I/O controllers mounted. This functions as the remote I/O's slave station.

CPU System control BPU-G/A PLC operation IO-G/A External I/O interface Memory EEPROM For ladder storage SRAM Memory for execution RIO-G/A Remote I/O controller Occupies two stations I/O interface ENC1/2 connector Encoder speed signal connection: 4ch DI-L/-R connector Input: 44 points DO-L connector Output: 32 points RIO1/2 connector Remote IO slave station Power supply DCIN connector Input: 24VDC +15%/10% : 0.6A

1. EXPLANATION OF MODULE FUNCTIONS 1.1 FX2N-80BMT-NC Card

II-2

[Connector layout diagram]

RIO2

U:DI-R L:DI-L

U:ENC2 L:ENC1

SW2

DCIN DO-L

SW1

PROG. PORT

RIO1

C P

U -E

P O

W E R

R U

N

R IO

E R

R 1

R IO

E R

R 2

[Explanation of settings]

SW1 RUN-STOP slide switch Starts running when the switch is set to RUN, and stops when set to OFF.

SW2 Remote I/O station No. 0 to 7: Corresponds to the RIO station No. 0 to 7 setting rotary switch (Set an even number)

8 and following: Loop back test mode (for testing) (If the base I/O occupies 0 and 1, set the switch to 2.)

[Explanation of LEDs]

POWER (Green) 5V power output This turns ON when the state is normal. display

RUN (Green) Operation display When the unit power is turned ON, the self-diagnosis function activates. If there is no error, the operation state is entered ("RUN" LED turns ON).

CPU-E (Red) CPU error display

RIOERR1 (Red) Communication alarm in onboard RIO 0th station

RIOERR2 (Red) Communication alarm in onboard RIO 1st station

2. FAULT DIAGNOSIS 2.1 List of Unit LEDs

II-3

2. FAULT DIAGNOSIS 2.1 List of Unit LEDs

D C

IN E N

C 1

E N

C 2

ST No.

POWER RUN CPU-E STOP

RUN

RIO ERR1 ERR2

D I-

R D

I- L

P R

O G

. P

O R

T D

O - L

0 1

2 3 4

567 8 9

ABCDE

F

[Explanation of LED functions]

Status Name Function Color When normal During error

Correspondence for error

POWER 5VDC output display Green Lit Not lit 24VDC +10%/15% Check the input

RUN Operation display Green Lit Not lit Check the RUN-STOP slide switch setting

CPU-E CPU error display Red Not lit Lit Refer to section 2.2.2.

RIOERR1 Onboard I/O 1st station communication alarm Red Not lit Lit

RIOERR 2 Onboard I/O 2nd station communication alarm Red Not lit Lit

Check the station No. setting rotary switch setting

2. FAULT DIAGNOSIS 2.2 Troubleshooting

II-4

2.2 Troubleshooting 2.2.1 Confirmation of trouble state

Confirm "when", "when doing what", and "what kind of" trouble occurred.

(1) When?

What time did the trouble occur?

(2) When doing what?

What was the NC operation mode?

(3) What kind of trouble?

What was displayed on the setting display unit's Alarm Diagnosis screen? Display the Alarm Diagnosis screen, and check the alarm details. What was displayed for the machine sequence alarm? Is the CRT and LCD screen normal?

(4) How frequently?

When did the trouble occur? What was the frequency? (Does it occur when other machines are operating?) If the trouble occurs infrequently or if it occurs during the operation of another machine, there may be an error in the power voltage or the trouble may be caused by noise, etc. Check whether the power voltage is normal (does it drop momentarily when other machines are operating?), and whether noise measures have been taken.

Does the trouble occur during a specific mode? Does the trouble occur when the overhead crane is operating? What is the frequency in the same workpiece? Check whether the same trouble can be repeated during the same operation. Check whether the same trouble occurs when the conditions are changed. (Try changing the override, program details, and operation procedures, etc.) What is the ambient temperature? (Was there a sudden change in the temperature? Is there any contact defect or insulation defect in the cables? (Has any oil or cutting water splattered onto the cables?)

2. FAULT DIAGNOSIS 2.2 Troubleshooting

II-5

2.2.2 When in trouble If the system does not operate as planned or if there is any trouble in the operation, confirm the following points and then contact the Mitsubishi Service Center.

Examples of trouble

The power does not turn ON. The external power turns ON, but the control power does not turn ON. The power turns OFF. The communication alarm display "RIOERR1"/"RIOERR2" LED turns ON. The 5VDC output display "POWER" LED turns OFF. The CPU error display "CPU-E" turns ON (flickers). The operation display "RUN" LED does not turn ON. The load does not turn ON/OFF even though the corresponding output is turned ON or OFF in the

ladder monitor.

2. FAULT DIAGNOSIS 2.2 Troubleshooting

II-6

(1) Problems related to the power supply

The power does not turn ON.

Cause Remedy The door interlock is applied. If the control panel door is not completely closed, close it. If

the door interlock is applied even when the door is closed, the door interlock circuit is damaged.

The external power supply's input voltage is not as specified.

Check that the input voltage is within 200 to 230AC +10%/15%. (Note) The power supply for this unit is 24VDC.

The external power supply is faulty.

Check that the power can be turned ON with just the external power supply. (Note) Depending on the external power supply, the power

may not turn ON in the no-load state, so install a slight load and check.

The external power turns ON but the NC control power does not turn ON.

Cause Remedy The external power supply output

is not correct. Disconnect the cable between the unit and the external power supply, and check that the external power supply output voltage is normal.

The power cable is disconnected or broken.

Check the cable between the unit and external power supply, and securely insert it. Check that the cable is not broken, and replace if broken.

There is a short circuit in the configuration card.

Check that no inductive foreign matter has entered the unit.

The power turns OFF. Cause Remedy

There is a problem in the supplied power.

Check whether the voltage fluctuates at certain time zones. Check whether an instantaneous power failure has occurred.

A problem occurs when the peripheral device starts operating.

Check whether the voltage drops instantaneously when the peripheral device operation starts.

2. FAULT DIAGNOSIS 2.2 Troubleshooting

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(2) Problems related to remote I/O unit (FCU6-DX561) If any of the following problems occur, all points of the machine input/output data for the remote I/O unit (FCU6-DX561) will turn OFF or may become unreliable. Thus, detect "Mismatch of input" with the PLC for another unit (NC).

The communication alarm display "RIOERR1"/"RIOERR2" LED turns ON.

Cause Remedy The remote I/O cable (R211) is not

connected, is broken, or the connector has a contact fault.

Check the connection of the cable (R211) between the base I/O unit and remote I/O unit (FCU6-DX561).

The remote I/O cable (R211) is being affected by noise.

Separate the remote I/O cable (R211) from the drive line and power line. Always connect the FG wire to the grounding plate.

The station No. setting rotary switch (SW2) setting is duplicated with another unit.

Change the base I/O unit, remote I/O unit (FCU6-DX561) and other remote I/O unit (FCUA-DX1 ) station No. rotary switch settings so that the station numbers are not duplicated.

A fault has occurred in the internal circuit of the FX2N-80BMT-NC card.

Contact the Service Center and have the unit replaced.

The 5VDC output display "POWER" LED turns OFF. (Or, the CPU-E LED lights for an instant.)

Cause Remedy The input power is not within the

tolerable range, or there is a fault in the internal 5V output generation circuit.

Check that the input voltage is +20V or less, and that the voltage has not dropped for an instant. If the power is supplied correctly, contact the Service Center.

The CPU error display "CPU-E" turns ON (flickers).

Cause Remedy If the CPU does not run properly

because inductive foreign matter has entered or because of abnormal noise from an external source, or if the operation cycle exceeds 200ms, the watch dog timer error will occur and cause this LED to turn ON.

If the watch dog timer error has occurred, error code 6105 will be stored when D8061 is monitored with a peripheral device. Review the program to see whether the operation cycle is too long. (Monitor D8012 to find the maximum operation cycle.) Note that if the problem is caused by any other factor, a communication error will occur and online operations will not be possible when a peripheral device is connected. Check for the presence of an abnormal noise generation source and for the entry of inductive foreign matter. If this LED changes from a stable light to a flicker as a result of the inspection, check the program. (Check for circuit errors and syntax errors with the peripheral device's program check function.) If the "CPU-E" LED is still ON after completing all inspections, contact the Service Center.

Do not apply voltages other than those indicated in this manual on the connector. Doing so may lead to destruction or damage.

Incorrect connections may damage the devices, so connect the cables to the specified connectors.

Do not connect or disconnect the connection cables between each unit while the power is ON.

Do not connect or disconnect the PCBs while the power is ON.

CAUTION

2. FAULT DIAGNOSIS 2.2 Troubleshooting

II-8

The operation display "RUN" LED does not turn ON.

Cause Remedy The RUN/STOP switch is set to

STOP. Set the RUN/STOP switch to RUN.

An error was detected by the unit's self-diagnosis function.

Check for circuit errors and syntax errors with the peripheral device's program check function. If the operation is stopped with a watch dog timer error, refer to the section "The CPU error display "CPU-E" turns ON (flickers)." on the previous page.

The load does not turn ON/OFF even though the corresponding output is turned ON or OFF in the ladder monitor.

Cause Remedy The relay output contact has

fused due to an overload, load short-circuit or the rush current of a capacity load, etc., or a contact fault has occurred due to a rough contact surface.

If the error occurs even after the relay is replaced or the cause of the relay output contact fusion is removed, contact the Service Center.

A fault has occurred in the FX2N-80BMT-NC card output circuit.

Check whether there are any causes of overcurrent, such as a load short-circuit. Measure the output voltage with a tester. If the specified voltage is not output, contact the Service Center and have the unit replaced.

Do not apply voltages other than those indicated in this manual on the connector. Doing so may lead to destruction or damage.

Incorrect connections may damage the devices, so connect the cables to the specified connectors.

Do not connect or disconnect the connection cables between each unit while the power is ON.

Do not connect or disconnect the PCBs while the power is ON.

CAUTION

2. FAULT DIAGNOSIS 2.2 Troubleshooting

II-9

2.2.3 Behavior of independent faults The EN954-1 Category 3 machine system must be designed so that the safety functions are not disabled when one of the safety-related parts fails independently. Precautions for the designs and examples of the behavior when an independent fault occurs are listed below.

Set a safety circuit outside the FCU6-DX561 so that the entire system works safely even if an external power supply error or FCU6-DX561 fault, etc., occurs. Detect a mismatch between PLCs or stop the machine system according to the behavior. (1) Always configure circuits outside of the FCU6-DX561, such as an emergency stop circuit,

protection circuit, interlock circuit for reciprocating operations such as forward/reverse run, and machine damage preventing interlock circuits such as positioning upper/lower limits.

(2) If the FCU6-DX561 CPU detects and error with a self-diagnosis function, such as a watch dog timer error, all DO outputs will turn OFF. Output control may be disabled when errors occur at sections, such as the input/output control section, which cannot be detected by the FCU6-DX561 CPU. Design an external circuit or mechanism so that the machine will operate safely in this case.

(3) The output may stay ON or may stay OFF depending on faults that occur in the output circuit's photo coupler or transistor. Design an external circuit or mechanism for the output signals that could lead to accidents so that the machine will operate safely.

Example of behavior during independent fault occurrence

Cause of fault Behavior The 24VDC power for control turned OFF (failed). The power cable was disconnected (broken).

The PLC will stop. The DO output will turn OFF.

The 24VDC power for DO turned OFF (failed) The DO output will turn OFF. The remote I/O cable was disconnected (broken). The remote I/O cable is affected by noise.

The RIO communication will stop. (The communication alarm display "RIOERR1" or "RIOERR2" LED will turn ON.)

The contact of the relay connected to DI fused, or a contact fault has occurred due to a rough contact surface.

Regardless of the machine signal's ON or OFF state, the DI input will turn OFF or ON.

The DI cable was disconnected (broken). The DI input will turn OFF. The contact of the relay connected to DI fused, or a contact fault has occurred due to a rough contact surface.

Regardless of the DO output's ON or OFF state, the relay will turn OFF or ON.

The DO cable was disconnected (broken). The DO output will turn OFF. The encoder failed. The spindle amplifier's encoder I/F circuit failed.

The encoder input data will become an abnormal value or will not be input.

The encoder cable between the encoder and spindle amplifier was disconnected (broken).

The encoder input data will not be input. (The encoder detection speed will become 0.)

The encoder cable between the spindle amplifier and FCU6-DX561 was disconnected (broken).

The encoder input data will not be input. (The encoder detection speed will become 0.)

A watch dog timer error occurred in the FCU6-DX561.

The PLC will stop, and the RIO communication will stop. The DO output will turn OFF. (The CPU error display "CPU-E" will turn ON.)

A fault occurred in the internal 5V output generation circuit.

The PLC will stop, and the RIO communication will stop. The DO output will turn OFF. (The 5VDC output display "POWER" will turn OFF.)

3. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 3.1 Maintenance Tools

II-10

3. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 3.1 Maintenance Tools

(1) Measuring instruments The following measuring instruments are used to confirm that the voltage is being supplied correctly to the unit, to confirm that the wiring to the unit is correct, and to carry out simple troubleshooting.

Table 3.1 Maintenance tools

Tool Condition Application Tester To check that the wiring to the PLC unit is correct

before turning the power ON. AC voltmeter Measure the AC power voltage.

The tolerable error is 2% or less. To measures the AC power voltage being supplied to the external 24VDC power supply unit.

DC voltmeter Max. scale 30V. The tolerable error is 2% or less.

To measure the DC power voltage. External power supply 24V (control section, machine input/output interface)

Phase rotation meter

To check the connection order of the AC 3-phase input power supply.

Synchroscope General measurement and simple troubleshooting

Note) Currently, a high-accuracy digital multi-meter is commonly used as a tester. This digital multi-meter can be used as both an AC voltmeter and a DC voltmeter.

(2) Tools

Screwdriver (large, medium, small) Radio pliers

3. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 3.2 Replacement Methods

II-11

3.2 Replacement Methods 3.2.1 Cable

If the cable is replaced without turning the power OFF, the normal unit or peripheral devices could be damaged, and risks could be imposed. Disconnect each cable with the following procedures.

a) For the following type of connector, press the tabs with a thumb and forefinger in the direction of the arrow, and pull the connector off.

(1) Press

(2) Pull

Y

(1) Press

(2) Pull

(1) Press

(2) Pull

Do not connect or disconnect the connection cables between each unit while the power is ON.

Do not connect the cable by pulling on the cable wire.

CAUTION

3. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 3.2 Replacement Methods

II-12

b) For a flat cable type connector with claws, open the claws in the directions of the arrows, and pull the connector off.

(1) Open

(2) Pull

c) For a flat cable type connector without claws, hold the connector with a thumb and forefinger, and pull the connector off.

(2) Pull

(1) Hold with thumb and forefinger.

Do not connect or disconnect the connection cables between each unit while the power is ON.

Do not connect the cable by pulling on the cable wire.

CAUTION

3. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 3.2 Replacement Methods

II-13

3.2.2 Unit Usually, the unit is installed on the electric cabinet side. Always replace the unit with the machine power turned OFF. 1) Disconnect all cables connected to the unit. 2) Loosen screw A. (The screw does not need to be removed.) 3) While supporting the unit with a hand, remove screw B. 4) Lift the unit upward and remove it. 5) Replace with the new unit, and fix the unit with the fixing screw at the original position. 6) Reconnect the connected cables at the original positions. (Connect the cables to the predetermined connectors.) 7) Check that all cables have been connected correctly, and then close the electric cabinet door.

Electric cabinet

PLC unit

Fixing screw (two screws)

Lift up

Screw B

Screw A

CAUTION

Incorrect connections may damage the devices, so connect the cables to the specified connectors. Do not replace the control unit while the power is ON. Do not connect or disconnect the connection cables between each unit while the power is ON.

Revision history

Revision Date of revision Revision details

00/12/01 First edition issued

BNP-B2302* (ENG)

REMOTE I/O UNIT

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