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.”