Mitsubishi Electric PLK - G Series User manual

Industrial Sewing Machine
TECHNICAL MANUAL
Electronic Pattern Sewing Machine
PLK - G Series
Control Unit
A180E604P02

Contents
[1] For safe use_________________________________________________ [1]-1
[2] Precautions for use __________________________________________ [2]-1
[3] Installation__________________________________________________ [3]-1
[4] Names of each part, wiring and grounding _______________________ [4]-1
[5] Confirmation ________________________________________________ [5]-1
[6] Initial Settings of System Software (Model/Language Settings) ______ [6]-1
[7] Timing chart ________________________________________________ [7]-1
[8] Customized input/output ______________________________________ [8]-1
[9] Input/Output signal___________________________________________ [9]-1
[10] What happened? Could it be an error? _________________________ [10]-1
[11] Several power supply________________________________________ [11]-1
[12] Unit wiring diagram _________________________________________ [12]-1
[13] Connectors layout __________________________________________ [13]-1
[14] Pin number of connectors____________________________________ [14]-1
[15] Wiring diagram inside control box _____________________________ [15]-1
[16] Specifications ______________________________________________ [16]-1
- 1 -

- 2 -
Thank you for purchasing the Mitsubishi industrial sewing machine PLK-G Series.
Please read this technical manual before starting to ensure correct and long-term
use.
* The contents of this manual may not be reproduced in part or whole.
* The contents of this manual are subject to change without notice.
* An utmost effort has been made to cover all points of operation in this manual.
Contact Mitsubishi if you have any questions regarding the contents.
COPYRIGHT(C)2008 MITSUBISHI ELECTRIC CORPORATION

[1] - 1
[1] For safe use
■For safe use
Always observe the following matters to safely use the Mitsubishi industrial electronic sewing machine PLK-G
Series.
Before starting
Before using this control unit, read all of the technical manuals carefully, and correctly use the unit
following the manual. Also read the "Mitsubishi Industrial Sewing Machine Technical Manual <Sewing
Machine Head>" for details on the general configuration and sewing machine head.
Application and purpose
This control unit is designed to drive and control the Mitsubishi industrial electronic sewing machine
PLK-G Series. Do not use this control unit for other applications or purposes. Do not use this control unit
until it has been confirmed that safety measures have been accurately taken for the installed electronic
sewing machine head section.
Working environment
Do not use this control unit in the following type of environment.
(1) Power voltage
* Where the voltage fluctuation exceeds ±10% of the rated voltage.
* Where the specified power capacity (refer to page [4]-2 “5. Power capacity”) cannot be ensured.
(2) Magnetic noise
* Where strong fields or magnetic fields are generated, such as near a high-output high frequency
oscillating machine or high frequency welder.
(3) Temperature and humidity
* Where the ambient temperature is 35°C or more and 5°C or less.
* Where the unit will be subject to direct sunlight, or outdoors.
* Near sources of heat, such as heating appliances.
* Where the relative humidity is 45% or less, or 85% or more, and where dew may condense.
(4) Atmosphere
* In an atmosphere containing dust or corrosive gases, etc.
* In a flammable gas or explosive environment.
(5) Vibration
* If excessive vibration could occur when installed on the sewing machine, separately install the
control box.
■Installation
Control box
Correctly install the control box according to this manual.
Accessories
Always disconnect the control unit from the main power supply before installing the accessories listed in
this manual. (Turn the power switch OFF, and disconnect the plug from the socket (power supply line).)
Cable
(1) Lay the connection cables so that excessive force will not be applied during operation. Do not
excessively bend the cables.
(2) Cables laid near operating machine sections must be separated by at least 25mm.
(3) Before connecting the power cable to the control box, confirm that the power voltage matches the
specifications given on the control box's rating nameplate and factory shipment voltage nameplate.
Connect the cable to the indicated positions, and then supply the power. When using a power unit,
connect the cable to the power unit and supply the power. In addition, when using a power unit,
confirm that the power voltage matches the specifications given on the power unit's rating nameplate.
Turn the power switch OFF before making any connections.
Grounding
Always ground the power cord's grounding wire.

[1] - 2
Enclosed units and accessories
Connect the electrical enclosed units and accessories only to the positions indicated in the manual.
Removal
(1) Always turn the power switch OFF and disconnect the plug from the socket (power supply line) before
removing the control box.
(2) Do not pull out the cord when disconnecting the plug. Always hold the plug receptacle when
disconnecting the plug.
(3) Note that a high voltage is applied inside the control panel, so always turn the power OFF and wait
at least ten minutes before opening the control box cover.
■Maintenance, inspection and repairs
(1) Follow this manual when carrying out maintenance or inspections related to this control unit.
(2) This unit must be repaired, serviced and inspected only by a worker that has received special training.
(3) Always turn the power OFF before replacing the needle or bobbin, etc., on the head.
(4) Use genuine replacement parts for repairs and maintenance.
■Other safety measures
(1) Keep fingers away from all moving machine parts (especially around the sewing machine needle,
etc.).
(2) Never drop the control unit, or place objects in the clearances.
(3) Do not operate the sewing machine without the protective parts such as the cover, or protection
devices such as the safety breaker.
(4) If any damage is observed in the control unit, if the unit does not operate correctly, or if the operation
is suspicious, always suspend operation. Only operate the machine after the supervisor has adjusted,
repaired or inspected the machine.
(5) The user must not make improvements or changes without instruction from Mitsubishi.
■Caution displays and danger displays
(1)In this manual, the dangers and danger levels that arise with incorrect handling are classified using the
following displays.
Warning The warning display shows that incorrect handling can lead to
death or serious injuries.
Caution The caution display shows that incorrect handling can lead to
injuries or damages to your house, household goods, and
others.
(2)The meanings of these symbols are as follows.
This symbol indicates that the
instructions must be followed.
This symbol indicates an
electrical hazard or caution
(electric shock caution).
This symbol indicates hot
temperature requiring caution.
This symbol indicates that
ground wire connection is
required.
This symbol indicates a
prohibited action.
* Always deliver this manual to the end user.
* Store this manual nearby where it can be referred to when necessary.

[2] - 1
[2] Precautions for use
Warning
1. Do not place foot on the foot switch when turning the power ON.
2. Always turn the power OFF when leaving the sewing machine.
3. Do not inspect the control circuit with a tester.
The tester voltage could be applied on the semiconductor
parts, and cause damage.
4. Always turn the power switch OFF before tilting the sewing
machine head, replacing the needle, or passing thread through the
needle.
5. Always ground the grounding wire.
Always ground the provided grounding wire
(green(green/yellow)).
6. Do not use excessive wiring.
7. A high voltage is applied inside creating a hazardous state, so
always turn the power OFF and wait ten minutes before opening
the cover.
High voltage risk
8. Radiation fins and other parts may be hot. Do not touch the parts.
Control circuit
Green
(Green/yellow)
Power supply

[2] - 2
9. The sewing machine will coast to a stop when the power is turned OFF or a power failure occurs during sewing machine operation.
10. Always align the connector shape and direction, and securely insert the connector.
11. If the position detector's connector dislocates, or the sewing machine is completely locked, the motor will be turned OFF automatically for a
set time to prevent burning. (Note that the motor may not turn OFF if there is incomplete locking or an overload.) When the fault has been
recovered, turn the power OFF and ON once to resume normal operation. The same type of operation will take place if a detector fault or
disconnection occurs.
12．Use the machine away from strong noise sources such as high
frequency welders.
13. When connecting the external switch to an optional connector,
etc., keep the signal wire as short as possible. A long wire could
cause malfunctions.
Use a shielded wire for the signal wire when possible.
14. If the fuse blows, remove the cause, and replace the blown fuse with one having the same capacity.
(View from the front with cover removed) (View from the front
with the cover and CPU removed)
Solenoid board located
on back of machine head
15．Attention when power supply is turned on again
Please make sure that turning on the power supply switch,
after the LED of the front panel on the controlbox is completely turned off.
(Please do not turn on the power supply again while displaying
the screen of the oepration panel.)
Noise
PLK-G2-PMD
XC-G2-2B-PLK
PLK-G2-CPU
PLK-G2-PMD
PLK-G2-PMM
8
A
fuse
(
one fuse
)
2.5
A
fuse
(
two fuses
)
20
A
fuse
(
two fuses
)
20
A
fuse
(
two fuses
)
15
A
fuse
(
one fuse
)
XC-G2-2B-PLK

[3] - 1
[3] Installation
1. Installing the control box
●Insert the four bolts into the holes
on the top plate and install the
control box.
Top view of control box
installation area
Front view of control box
installation area
80
427
Top plate
Damper
cushion
control box
4-Ø9
Leg
Nuts
Spring
washe
r
Washer
Installation bolt
(M8×60)
Leg
control box
Installation bolt
(Fix at four positions)

[4] - 1
[4] Names of each part, wiring and grounding
1.Front side
2.Back side
Heat sink
Power
LED(green)
Warning
LED(red) CONR
USB（TYPE A）
with Protective cap
CONS
RS-232C（MINI DIN）
with Protective cap
Front
p
anel
CONA
Operation panel
(Connect to Operation panel)
CONE
Various solenoids
(Connect to sewing machine
head section)
CONF
Spindle encoder
(Connect to spindle servo
motor)
CONG
XY axis encoder
(Connect to XY axis stepping motor)
CONH
Foot switch
(Connect to foot switch)
CONJ
XY axis stepping motor
(Connect to sewing machine
head stepping motor)
Cover installation screw
(M4 screw)
Cove
r
Function button
CONB
Power supply
(Connect to power switch box)
CONC
DC power for solenoid
(Connect to sewing machine head
section)
COND
Spindle servo motor
(Connect to spindle servo motor)
CONK
PF axis stepping motor
(Connect to sewing machine head
PF axis stepping motor)
Rating plate
Caution: Be sure to connect all connectors
before turning ON the power.
Connect each connector fully to
ensure sufficient contact. Refer to
“[12] Unit Wiring Diagram.”

[4] - 2
3. Connecting the power connector
Caution1: Always confirm the connector shape and insertion
orientation and completely insert the power connector
into the control box. Always turn the power OFF before
connecting the connector.
Caution2: Please do not bundle the power cable and other
cables together. It may cause of malfunction by the
influence of the power supply noise etc.
4. Connecting the 3-phase power supply
3-phase power supply R-phase S-phase T-phase
Push-button switch cord
Warning
Always connect the green wire to the grounding terminal.
Consult with your electrician for details on the grounding wire.
5. Power capacity
Use a fuse or safety breaker on the power supply.
Power supply Recommended current capacity value
3-phase 200V 10A
6. Using the 3-phase 200V control box with single-phase 200 to 220V
Connect power supply to the "red" and "white" lead wires for the push-button switch.
The black wire is not used, so insulate it by wrapping insulation tape, etc., around it.
Always ground the green grounding wire. Connect to ground
Connection connector to control box Push-button switch
To
p
p
late
Control box
p
owe
r
Power connector
(
6-
p
ole
)
Control box
Red(black)
White(brown)
Black(blue)
Green(green/yellow)
Green
Red
White
Black
Do not connect
(Accurately insulate
with tape.)
Connect these lead
wires to the power
supply.
OFF ON

[5] - 1
[5] Confirmation
1. Before turning the switch ON
(1)Are the power and capacity correct?
(2)Are the connectors correctly inserted? (Refer to “[12] Unit Wiring Diagram.”)
* Power connector from push-button switch
* Connector for connection with sewing machine
* Motor connector
* Motor encoder connector
* Foot switch connector
* Other connectors (solenoid, etc.)
(3)Does the hand pulley turn easily?
2. After turning the switch ON
(1)Is the front panel power LED (green) on?
(2)Is the front panel warning LED (red) on or flickering?
(3)Is there any heating, odors or abnormal noise from the motor or control box?
●When you turn ON the power, a click noise comes from inside the control box. This noises are not
abnormal.
Turn the sewing machine OFF and contact your
dealer if there is any heating, odors or abnormal
noise.
For actions to be taken
when the warning LED (red)
is on or flickering, refer to
“[10] What Happened?
Could it Be an Error?”

[6] - 1
[6] Initial Settings of System Software (Model/Language Settings)
1.Model/Language Settings
The model to be used and the language to be displayed need to be set. When you turn on the machine
power with the system in an initial state, the “Model/Language Setting” screen appears. Perform the
procedures below.
(1)When the power supply is turned on first time, [Model/Language setting] screen is displayed.
►For language setting, press .
►For model setting, press .
(2)Language setting
►press .
►Choose Language button, then press .
(3)Model setting
►press .
►Choose Model button, then press .

[6] - 2
(4)Setting table / Step file setting
►For Setting table/ step file setting, press .
If setting is not necessary, goto (5).
►Choose one of following buttons.
Reads Setting table and Step file
Reads Setting table only
Reads Step file only
Reads System file ,Setting table and Step file
►Connect USB memory [*1], which above data is contained,
to the connector on the front panel of the control box, then,
press .
►After file name selection screen is displayed, choose target
filename by using up and down arrow button, then press
. Goto (6)
[*1] Setting table and Step file must be saved in the
[] folder in the USB memory.
(5) Model / Language setting screen is displayed again.
►press .
Note Do not press at this time.

[6] - 3
(6)Re-turning on the power supply
►Turn the power off.
►After check the LED lamp on the front panel of the control box
Is completely off, turn the power on.
Check the LED lamp is OFF
(7)Initial condition
►At initial condition, the message like a right picture is
displayed.
Press to switch to the Standard screen, then create
or read sewing pattern data. ( Refer to technical manual
[ Operation panel ].)

[7] - 1
[7] Timing chart
1.Thread trimming timing chart
·Timing for thread trimming output [T] :
Program mode [Thread trimming/release timing] -- [LTM] T1~T5
Program mode [Thread trimming/release timing] -- [TRS] msec / deg
Program mode [Thread trimming/release timing] -- [TRE] msec / deg
·Timing for thread release output [L] :
Program mode [Thread trimming/release timing] -- [LLM] L1~L5
Program mode [Thread trimming/release timing] -- [LRS] msec / deg
Program mode [Thread trimming/release timing] -- [LRE] msec / deg
·Timing for wiper output [W] :
Program mode [Wiper] -- [W1] msec
Program mode [Wiper] -- [W2] msec
Needle down
position DN
Needle up
position UP
LTM
setting
T1 TRS(deg) TRE(ms)
T2 TRS(deg) TRE(deg)
T3 TRS(deg) TRE(ms)
T4 TRS(ms) TRE(ms)
Thread trimming output [T]
T5 TRS(ms) TRE(ms)
LLM
setting
L1 LRS(deg) LRE(ms)
L2 LRS(deg) LRE(deg)
L3 LRS(deg) LRE(ms)
L4 LRS(ms) LRE(ms)
Thread release output [L]
L5 LRS(ms) LRE(ms)
Wiper [W] W1(ms) W2(ms)
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON

[7] - 2
2.Timing chart for [Clamp of output ON/OFF delay setting]
Clamp input 1~8
IF1~IF8
Clamp output 1~8
OF1~OF8
3.Timing chart for [Priority of clamp]
Clamp input 1
IF1
Clamp input 2
IF2
Clamp input 3
IF3
Clamp input 4
IF4
[WHY]=[OFF]
Clamp output 1
OF1
Clamp output 2
OF2
Clamp output 3
OF3
Clamp output 4
OF4
[WHY]=[ON]
Clamp output 1
OF1
Clamp output 2
OF2
Clamp output 3
OF3
Clamp output 4
OF4
Note: [WHY]=[ON]
* The clamp input signal [IF2],[IF3],[IF4] is invalidated when clamp output 1 is not ON.
* The clamp input signal [IF2] is validated when clamp output 1 is ON.
* The clamp input signal [IF3] is validated when clamp output 2 is ON.
* The clamp input signal [IF4] is validated when clamp output 3 is ON.
1A~8A 1B~8B
ON ON
ON
ON ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON

[7] - 3
4.Timing chart for
[Clamp link setting (CF)]=ON, [Valid Number of clamp setting (FN)]=4
Clamp input 1
IF1
Clamp output 1
OF1
Clamp output 2
OF2
Clamp output 3
OF3
Clamp output 4
OF4
Note: Halt switch is validated.
5.Timing chart for
[Selection of pneumatic pressure two-step (AF2)]=ON
Can not use other function in “Work holder” mode.
Pneumatic pressure
two-step clamp
input signal A2F
Start
input signal SRT
Pneumatic pressure
two-step clamp
low pressure output AFL
Pneumatic pressure
two-step clamp
high pressure output AFH
Pneumatic pressure
two-step clamp
eject pressure output AFE
Movement of
sewing machine
ON
ON
ON
ON
ON
ON
1A
2A
3A
4A 4B
3B
2B
1B
ON
1T
ON ON ON ON ON
ON ON
ON ON ON
ON ON ON
ON
ON ON

[7] - 4
6.The divisions of clamp setting [OFB]=2
Setting of [FN],[CF],[F4BN],[F4SN] is invalidated when above setting.
[WHY]=OF,[OFB]=2,[CF1]=ON,[CF2]=OF,[F21N]=4,[F22N]=3
When not using the clamp step input.
Clamp input 1
IF1
Clamp input 2
IF2
Clamp input 3
IF3
Clamp input 4
IF4
Clamp input 5
IF5
Clamp input 6
IF6
Clamp input 7
IF7
Clamp input 8
IF8
Start input signal
SRT
Clamp output 1
OF1
Clamp output 2
OF2
Clamp output 3
OF3
Clamp output 4
OF4
Clamp output 5
OF5
Clamp output 6
OF6
Clamp output 7
OF7
Clamp output 8
OF8
Movement of
sewing machine
Note 1.When the setting ([CF1]=ON), clamp input 1 is link input.
2.When the setting ([CF2]=ON), clamp input 5 is link input.
7A
The divisions of clamp 1, [F21N]=4 The divisions of clamp 2,
[F22N]=3
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
6A
5A
4A
3A
2A
1A
2A
3A
4A
2B
3B
4B
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON

[7] - 5
7.The divisions of clamp setting [OFB]=2(When using the clamp step input.)
Setting of [FN],[CF],[F4BN],[F4SN] is invalidated when above setting.
[WHY]=OF,[OFB]=2,[CF1]=ON,[CF2]=OF,[F21N]=4,[F22N]=4
When using the clamp step input.
The clamp step
(forward direction)
division 1 FP1
The clamp step
(backward direction)
division 1 FM1
The clamp step
(forward direction)
division 2 FP2
The clamp step
(backward direction)
division 2 FM2
Start input signal
SRT
Clamp output 1
OF1
Clamp output 2
OF2
Clamp output 3
OF3
Clamp output 4
OF4
Clamp output 5
OF5
Clamp output 6
OF6
Clamp output 7
OF7
Clamp output 8
OF8
Movement of
sewing machine
7A
ON
ON
ON
ON
ON
6A
5A
4A
3A
2A
1A
3A
3B
ON
ON
ON
ON
ON
ON
ON
ON
ON ON
ON
ON
ON ON ON ON
8A ON 8A ON
ON
8B
The divisions of clamp 1, [F21N]=4 The divisions of clamp 2,
[F22N]=4