Mitsubishi Electric MELDAS FCU6-DX561 User manual

CNC
FCU6-DX561
CONNECTION AND MAINTENANCE MANUAL
BNP-B2302*(ENG)
REMOTE I/O UNIT
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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 onorsandwich the cables, as this may
lead to electric shocks.
2. Items related to smoke prevention
Incorrect wiring or connections could burn the device.
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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
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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
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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
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I. CONNECTION MANUAL
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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)
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2. CONFIGURATION
2.1 System Configuration
I-2
2. CONFIGURATION
2.1 System Configuration
0
OPEN
CBUS 2CBUS 1
MITSU BISHI
MDS-B -SVJ2
Remote I/O unit
FCU6-DX561
Remote I/O unit
DX1
Servo drive unit
MDS-B/C1-V1/V2- Spindle driveunit
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
SV2SV1
RI02 RI01 DCI N
0 0
CF31 CF3 2
CF34CF33
CF10
CR31
SKIP
HANDL
CH1～CH3
CF11
RS232C
CH1､CH2
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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 55°C * Note
Ambient
temperature During
storage –20 to 60°C
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/s2or less (during operation)
Shock resistance 29.4m/s2or less (during operation)
98m/s2or 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 5MΩor more with 500VDC megger tester
Across entire output terminal batch and grounding terminal
General specifications
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
Power specifications
Unit size Refer to Appendix.
* Note If the ambient temperature is 55°C or more, lower to 55°C or less with forced cooling.
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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.
DC24V (+)
FG 0V
0
0 0
CF31CF32
CF34
CF33
SV2 SV1
HR3□□
ＲＩＯ１
ＲＩＯ２ 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.
POWER
RUN
CPU-E
STOP
RUN
RIO
ERR1
ERR2
Remote I/O unit
FCU6-DX561
Stabilized power supply
DC24V (+)
FG 0V
Short bar
AC input
FG cable
FG 0V
24VDC (+)
Stabilized power supply
Short bar
AC input
FG 0V
24VDC (+)
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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 .
POWER
RUN
CPU-E
STOP
RUN
RIO
ERR1
ERR2
0 0
CF31 CF32
CF34CF33
SV2 SV1
HR3□□
ＲＩＯ１ＲＩＯ２ 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
BaseI/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.
<Shield clamp method>
Fold the cable shield on the sheath, and wrap copper foil tape over it.
Connect with the connector GND plate.
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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 0.1µF, 10 to 120Ω.
Coil
Contact
E
SK
SK
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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 2
CBUS 1
MITSUBISHI
MDS-B-SVJ2
MITSUBISHI
MDS-B-SVJ2
4
ST N o .
POWER
RUN
CPU-E
STOP
RU 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
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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 10°C 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
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4. SYSTEM CONNECTION
4.1 General System Diagram
I-9
4. SYSTEM CONNECTION
4.1 General System Diagram
FG
SV1
CF10
CF11
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 CN4
OSA253S
MR-RB
O30
CN2
CN1A CN1B
L1
L2
L3
C
P
N
D
U
V
W
F
G
L11
L21
FG
FG
U
V
WL+
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
Tonext 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
Tonext
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.
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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
5
6
7
8
9
A
B
C D
E
F
ST No.
POWER
RUN
CPU-E
ST OP
RUN
PROG. PORT DI-R
DI-L DO-L
RI O
ERR1
ERR2
ENC1 ENC2
DCIN
DCIN (1)
ENC2 (3)
PROG.PORT (6)
DI-R (8)
RUN/STOP (5)
Bottom view
RIO1 (10)
RIO2 (11)
RIO1 RIO2
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5. CONNECTION OF UNIT
5.2 Unit Connection System Diagram
I-11
5.2 Unit Connection System Diagram
F010 cable CF10 RIO1
↑
01
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 cable
CF11
CF11
DCIN
R220 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.
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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)
BaseI/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
HAND L
CH1～CH3
RS23 2 C
CH1､CH2
未使用
未使用
未使用
FG
ｶｰﾄﾞｱﾄﾞｵﾝ用取付け穴 (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 cable
F050 cable
RIO1RIO2 DCIN
RIO1 RIO2
X
R211 cable
R211 cable
X
Terminator (R-TM)
CR31
(Note) When not expanding the remote I/O
units, connect the terminator (R-TM) to
RIO2.
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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 theR211 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)
X
R211 cable R211 cable
RIO2 RIO2 RIO2
RIO1 RIO1
X
X
（Front）
（Back）
Bottom view
RIO1
RIO2
DCIN
RIO2
RIO1
DCIN
RIO2
RIO1
RIO1 RIO2
RIO1 RIO2
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
(FCUA－DX1)
Terminator (R-TM)
Terminator (R-TM)
Connect the terminator (R-TM)
to RIO2 when not expanding
the remoteI/O unit.
Connect the R211 cablefrom
RIO2 toRIO1 on thenext
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
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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)
DCIN ENC1
ENC2
ST No.
POWER
RUN
CPU-E
STOP
RUN
RIO
ERR1
ERR2
DI-R DI-L
PROG. PORT DO-L
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
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