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Mitsubishi FCU6-DX561 Remote Maintenance Manual PDF
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
II-7
(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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