Mitsubishi Electric MELSEC System Q User manual

MELSEC System Q
Motion Controller
Installation Manual
SW3RNC-GSVE/GSVHELPE
INDUSTRIAL AUTOMATION
MIT
SU
BI
S
HI ELE
C
TRI
C
MIT
SU
BI
S
HI ELE
C
TRI
C
Art. no.: 147253
01 12 2001
IB(NA)-0300018-F

−I −
INTRODUCTION
Thank you for purchasing the Mitsubishi Motion Controller/Personal Machine Controller. This instruction
manual describes the handling and precautions of this unit. Incorrect handing will lead to unforeseen events,
so we ask that you please read this manual thoroughly and use the unit correctly.
Please make sure that this manual is delivered to the final user of the unit and that it is stored for future
reference.
Precautions for Safety
Please read this instruction manual and enclosed documents before starting installation,
operation, maintenance or inspections to ensure correct usage. Thoroughly understand the
machine, safety information and precautions before starting operation.
The safety precautions are ranked as "Warning" and "Caution" in this instruction manual.
WARNING When a dangerous situation may occur if handling is mistaken
leading to fatal or major injuries.
CAUTION When a dangerous situation may occur if handling is mistaken
leading to medium or minor injuries, or physical damage.
Note that some items described as cautions may lead to major results depending on the
situation. In any case, important information that must be observed is described.

−II −
For Sate Operations
1. Prevention of electric shocks
WARNING
Never open the front case or terminal covers while the power is ON or the unit is running, as
this may lead to electric shocks.
Never run the unit with the front case or terminal cover removed. The high voltage terminal
and charged sections will be exposed and may lead to electric shocks.
Never open the front case or terminal cover at times other than wiring work or periodic
inspections even if the power is OFF. The insides of the control unit and servo amplifier are
charged and may lead to electric shocks.
When performing wiring work or inspections, turn the power OFF, wait at least ten minutes,
and then check the voltage with a tester, etc. Failing to do so may lead to electric shocks.
Always ground the control unit, servo amplifier and servomotor with Class 3 grounding. Do
not ground commonly with other devices.
The wiring work and inspections must be done by a qualified technician.
Wire the units after installing the control unit, servo amplifier and servomotor. Failing to do
so may lead to electric shocks or damage.
Never 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.
Do not touch the control unit, servo amplifier or servomotor terminal blocks while the power
is ON, as this may lead to electric shocks.
Do not touch the internal power supply, internal grounding or signal wires of the control unit
and servo amplifier, as this may lead to electric shocks.
2. For fire prevention
CAUTION
Install the control unit, servo amplifier, servomotor and regenerative resistor on inflammable
material. Direct installation on flammable material or near flammable material may lead to
fires.
If a fault occurs in the control unit or servo amplifier, shut the power OFF at the servo
amplifier's power source. If a large current continues to flow, fires may occur.
When using a regenerative resistor, shut the power OFF with an error signal. The
regenerative resistor may abnormally overheat due to a fault in the regenerative transistor,
etc., and may lead to fires.
Always take heat measures such as flame proofing for the inside of the control panel where
the servo amplifier or regenerative resistor is installed and for the wires used. Failing to do
so may lead to fires.

−III −
3. For injury prevention
CAUTION
Do not apply a voltage other than that specified in the instruction manual on any terminal.
Doing so may lead to destruction or damage.
Do not mistake the terminal connections, as this may lead to destruction or damage.
Do not mistake the polarity (+/−), as this may lead to destruction or damage.
The servo amplifier's heat radiating fins, regenerative resistor and servo amplifier, etc., will
be hot while the power is ON and for a short time after the power is turned OFF. Do not
touch these parts as doing so may lead to burns.
Always turn the power OFF before touching the servomotor shaft or coupled machines, as
these parts may lead to injuries.
Do not go near the machine during test operations or during operations such as teaching.
Doing so may lead to injuries.
4. Various precautions
Strictly observe the following precautions.
Mistaken handling of the unit may lead to faults, injuries or electric shocks.
(1) System structure
CAUTION
Always install a leakage breaker on the control unit and servo amplifier power source.
If installation of a magnetic contactor for power shut off during an error, etc., is specified in
the instruction manual for the servo amplifier, etc., always install the magnetic contactor.
Install an external emergency stop circuit so that the operation can be stopped immediately
and the power shut off.
Use the control unit, servo amplifier, servomotor and regenerative resistor with the
combinations listed in the instruction manual. Other combinations may lead to fires or faults.
If safety standards (ex., robot safety rules, etc.,) apply to the system using the control unit,
servo amplifier and servomotor, make sure that the safety standards are satisfied.
If the operation during a control unit or servo amplifier error and the safety direction
operation of the control unit differ, construct a countermeasure circuit externally of the
control unit and servo amplifier.
In systems where coasting of the servomotor will be a problem during emergency stop,
servo OFF or when the power is shut OFF, use dynamic brakes.
Make sure that the system considers the coasting amount even when using dynamic
brakes.
In systems where perpendicular shaft dropping may be a problem during emergency stop,
servo OFF or when the power is shut OFF, use both dynamic brakes and magnetic brakes.
The dynamic brakes must be used only during emergency stop and errors where servo OFF
occurs. These brakes must not be used for normal braking.
The brakes (magnetic brakes) assembled into the servomotor are for holding applications,
and must not be used for normal braking.
Construct the system so that there is a mechanical allowance allowing stopping even if the
stroke end limit switch is passed through at the max. speed.
Use wires and cables that have a wire diameter, heat resistance and bending resistance
compatible with the system.

−IV −
CAUTION
Use wires and cables within the length of the range described in the instruction manual.
The ratings and characteristics of the system parts (other than control unit, servo amplifier,
servomotor) must be compatible with the control unit, servo amplifier and servomotor.
Install a cover on the shaft so that the rotary parts of the servomotor are not touched during
operation.
There may be some cases where holding by the magnetic brakes is not possible due to the
life or mechanical structure (when the ball screw and servomotor are connected with a
timing belt, etc.). Install a stopping device to ensure safety on the machine side.
(2) Parameter settings and programming
CAUTION
Set the parameter values to those that are compatible with the control unit, servo amplifier,
servomotor and regenerative resistor model and the system application. The protective
functions may not function if the settings are incorrect.
The regenerative resistor model and capacity parameters must be set to values that
conform to the operation mode, servo amplifier and servo power unit. The protective
functions may not function if the settings are incorrect.
Set the mechanical brake output and dynamic brake output validity parameters to values
that are compatible with the system application. The protective functions may not function if
the settings are incorrect.
Set the stroke limit input validity parameter to a value that is compatible with the system
application. The protective functions may not function if the setting is incorrect.
Set the servomotor encoder type (increment, absolute position type, etc.) parameter to a
value that is compatible with the system application. The protective functions may not
function if the setting is incorrect.
Set the servomotor capacity and type (standard, low-inertia, flat, etc.) parameter to values
that are compatible with the system application. The protective functions may not function if
the settings are incorrect.
Set the servo amplifier capacity and type parameters to values that are compatible with the
system application. The protective functions may not function if the settings are incorrect.
Use the program commands for the program with the conditions specified in the instruction
manual.
Set the sequence function program capacity setting, device capacity, latch validity range,
I/O assignment setting, and validity of continuous operation during error detection to values
that are compatible with the system application. The protective functions may not function if
the settings are incorrect.
Some devices used in the program have fixed applications, so use these with the conditions
specified in the instruction manual.
The input devices and data registers assigned to the link will hold the data previous to when
communication is terminated by an error, etc. Thus, an error correspondence interlock
program specified in the instruction manual must be used.
Use the interlock program specified in the special function unit's instruction manual for the
program corresponding to the special function unit.

−V −
(3) Transportation and installation
CAUTION
Transport the product with the correct method according to the weight.
Use the servomotor suspension bolts only for the transportation of the servomotor. Do not
transport the servomotor with machine installed on it.
Do not stack products past the limit.
When transporting the control unit or servo amplifier, never hold the connected wires or
cables.
When transporting the servomotor, never hold the cables, shaft or detector.
When transporting the control unit or servo amplifier, never hold the front case as it may fall
off.
When transporting, installing or removing the control unit or servo amplifier, never hold the
edges.
Install the unit according to the instruction manual in a place where the weight can be withstood.
Do not get on or place heavy objects on the product.
Always observe the installation direction.
Keep the designated clearance between the control unit or servo amplifier and control panel
inner surface or the control unit and servo amplifier, control unit or servo amplifier and other
devices.
Do not install or operate control units, servo amplifiers or servomotors that are damaged or
that have missing parts.
Do not block the intake/outtake ports of the servomotor with cooling fan.
Do not allow conductive matter such as screw or cutting chips or combustible matter such
as oil enter the control unit, servo amplifier or servomotor.
The control unit, servo amplifier and servomotor are precision machines, so do not drop or
apply strong impacts on them.
Securely fix the control unit and servo amplifier to the machine according to the instruction
manual. If the fixing is insufficient, these may come off during operation.
Always install the servomotor with reduction gears in the designated direction. Failing to do
so may lead to oil leaks.
Store and use the unit in the following environmental conditions.
Condition
Environment Control unit/servo amplifier Servomotor
Ambient
temperature 0°C to +55°C (With no freezing) 0°C to +40°C (With no freezing)
Ambient humidity According to each instruction
manual. 80%RH or less (With no dew condensation)
Storage
temperature According to each instruction manual. −20°C to +65°C
Atmosphere Indoors (where not subject to direct sunlight).
No corrosive gases, flammable gases, oil mist or dust must exist.
Altitude 1000m (305 Feet) or less above sea level.
Vibration According to each instruction manual.

−VI −
CAUTION
When coupling with the synchronization encoder or servomotor shaft end, do not apply
impact such as by hitting with a hammer. Doing so may lead to detector damage.
Do not apply a load larger than the tolerable load onto the servomotor shaft. Doing so may
lead to shaft breakage.
When not using the unit for a long time, disconnect the power line from the control unit or
servo amplifier.
Place the control unit and servo amplifier in static electricity preventing vinyl bags and store.
(4) Wiring
CAUTION
Correctly and securely wire the wires. Reconfirm the connections for mistakes and the
terminal screws for tightness after wiring. Failing to do so may lead to run away of the
servomotor.
After wiring, install the protective covers such as the terminal covers to the original
positions.
Do not install a phase advancing capacitor, surge absorber or radio noise filter (option FR-
BIF) on the output side of the servo amplifier.
Correctly connect the output side (terminals U, V, W). Incorrect connections will lead the
servomotor to operate abnormally.
Do not connect a commercial power supply to the servomotor, as this may lead to trouble.
Do not mistake the direction of the surge absorbing diode
installed on the DC relay for the control signal output of
brake signals, etc. Incorrect installation may lead to signals
not being output when trouble occurs or the protective
functions not functioning.
Do not connect or disconnect the connection cables
between each unit, the encoder cable or sequence
expansion cable while the power is ON.
Servo amplifier
VIN
(24VDC)
Control output
signal RA
Securely tighten the cable connector fixing screws and fixing mechanisms. Insufficient fixing
may lead to the cables combing off during operation.
Do not bundle the power line or cables.
(5) Trial operation and adjustment
CAUTION
Confirm and adjust the program and each parameter before operation. Unpredictable
movements may occur depending on the machine.
Extreme adjustments and changes may lead to unstable operation, so never make them.
When using the absolute position system function, on starting up, and when the controller or
absolute value motor has been replaced, always perform a home position return.

−VII −
(6) Usage methods
CAUTION
Immediately turn OFF the power if smoke, abnormal sounds or odors are emitted from the
control unit, servo amplifier or servomotor.
Always execute a test operation before starting actual operations after the program or
parameters have been changed or after maintenance and inspection.
The units must be disassembled and repaired by a qualified technician.
Do not make any modifications to the unit.
Keep the effect or magnetic obstacles to a minimum by installing a noise filter or by using
wire shields, etc. Magnetic obstacles may affect the electronic devices used near the control
unit or servo amplifier.
Use the units with the following conditions.
Item Conditions
Input power According to the separate instruction manual.
Input frequency According to the separate instruction manual.
Tolerable momentary
power failure According to the separate instruction manual.
(7) Remedies for errors
CAUTION
If an error occurs in the self diagnosis of the control unit or servo amplifier, confirm the
check details according to the instruction manual, and restore the operation.
If a dangerous state is predicted in case of a power failure or product failure, use a
servomotor with magnetic brakes or install a brake mechanism externally.
Use a double circuit construction so that the
magnetic brake operation circuit can be
operated by emergency stop signals set
externally.
If an error occurs, remove the cause, secure
the safety and then resume operation.
The unit may suddenly resume operation
after a power failure is restored, so do not go
near the machine. (Design the machine so
that personal safety can be ensured even if
the machine restarts suddenly.)
Servo motor
Magnetic
brakes
Shut off servo ON signal OFF,
alarm, magnetic brake signal.
Shut off with the
emergency stop
signal (EMG).
24VDC
RA1 EMG
(8) Maintenance, inspection and part replacement
CAUTION
Perform the daily and periodic inspections according to the instruction manual.
Perform maintenance and inspection after backing up the program and parameters for the
control unit and servo amplifier.
Do not place fingers or hands in the clearance when opening or closing any opening.
Periodically replace consumable parts such as batteries according to the instruction
manual.

−VIII −
CAUTION
Do not touch the lead sections such as ICs or the connector contacts.
Do not place the control unit or servo amplifier on metal that may cause a power leakage or
wood, plastic or vinyl that may cause static electricity buildup.
Do not perform a megger test (insulation resistance measurement) during inspection.
When replacing the control unit or servo amplifier, always set the new unit settings correctly.
When the controller or absolute value motor has been replaced, carry out a home position
return operation using one of the following methods, otherwise position displacement could
occur.
1) After writing the servo data to the PC using peripheral device software, switch on the
power again, then perform a home position return operation.
2) Using the backup function of the peripheral device software, load the data backed up
before replacement.
After maintenance and inspections are completed, confirm that the position detection of the
absolute position detector function is correct.
Do not short circuit, charge, overheat, incinerate or disassemble the batteries.
The electrolytic capacitor will generate gas during a fault, so do not place your face near the
control unit or servo amplifier.
The electrolytic capacitor and fan will deteriorate. Periodically change these to prevent
secondary damage from faults. Replacements can be made by the Service Center or
Service Station.
(9) Disposal
CAUTION
Dispose of this unit as general industrial waste.
Do not disassemble the control unit, servo amplifier or servomotor parts.
Dispose of the battery according to local laws and regulations.
(10) General cautions
CAUTION
All drawings provided in the instruction manual show the state with the covers and safety
partitions removed to explain detailed sections. When operating the product, always return
the covers and partitions to the designated positions, and operate according to the
instruction manual.

Revisions
*The manual number is given on the bottom left of the back cover.
Print Date *Manual Number Revision
Jul., 2000 IB(NA)-0300018-A First edition
Jan., 2001 IB(NA)-0300018-B Addition
Addition of SW3RN-GSV43P description
Mar., 2001 IB(NA)-0300018-C Addition
Addition of RS232C communication description, Section 4.5
Apr., 2001 IB(NA)-0300018-D Addition
Addition of SW3RN-GSV51P description, Section 3.6, Section 4.6,
Section 4.6.1
Correction
CONTENTS, Section 2.2 (1), Section 2.2 (2), Section 2.3, Section 2.5,
Section 3.1,
Aug., 2001 IB(NA)-0300018-E Addition
Addition of SW20RN-DOCPRNP and SW20RN-LADDERP description,
Section 3.4.2, Section 3.4.3, Section 3.4.4, Section 3.4.5, Section 3.4.6,
Chapter5
Correction
CONTENTS, Section 2.2 (1), Section 2.2 (2), Section 2.3, Section 3.1,
Section 3.2, Section 4.1, Section 4.1.1, Section 4.1.2, Section 4.2,
Dec., 2001 IB(NA)-0300018-F Addition
Addition of Windows 2000 and A10BD-PCF interface board description,
Section 4.1.3, Section 4.3.1, Section 4.3.2, Section 3.7, Section 5.5
Correction
Section 2.2, Section 2.5, Section 3.1, Section 3.3, Section 3.4.1, Section 3.4.2,
Section 3.4.3, Section 3.4.4, Section 3.4.5, Section 3.4.6, Section 4.6.1,
Section 5.1, Section 5.2, Section 5.3, Section 5.4
This manual confers no industrial property rights or any rights of any other kind, nor does it confer any patent
licenses. Mitsubishi Electric Corporation cannot be held responsible for any problems involving industrial
property rights which may occur as a result of using the contents noted in this manual.
© 2001 Mitsubishi Electric Corporation