Mitsubishi Limiservo X G Series Technical document

Mitsubishi Limiservo X G series
TECHNICAL INFORMATION MANUAL Motor XL-G554-10(Y), XL-G554-20(Y),
XL-G754-20(Y)
Control box XC-GMFY
Induction type AC servo motor
and control box with automatic
needle positioner
Thank you for purchasing this product.
Please read this manual thoroughly before use to ensure safe and proper use.
Please read the instruction manual for the machine head together with this manual.
Save this manual for future reference.
E723D700-C(201407)

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1 Contents······································································································································ 1
2 Safety Instructions························································································································· 2
3 Points of Caution··························································································································· 3
4 Names of Each Part······················································································································· 4
5 Installation ··································································································································· 5
1. Installation of the motor··························································································································5
2. Installation of the control box···················································································································5
3. Installation of the pulley··························································································································5
4. Mounting of the belt·······························································································································5
5. Installation of the protective cover ············································································································6
6. Installation of the position detector ···········································································································7
7. Connection of the Mitsubishi sewing machine and control box ·······································································7
6 Wire and Grounding······················································································································· 8
1. Insertion of the power connector··············································································································8
2. Connection of 3-phase power··················································································································8
3. Current capacity ···································································································································8
4. When using the 3-phase 200 - 240V class Limiservo X with single phase 200 - 240V class·································8
7 Confirmation································································································································· 9
1. Before turning switches on.......... ·············································································································9
2. Turn on the power..........·························································································································9
8 Adjustments································································································································ 10
1. Adjustment of stopping position ··············································································································10
2. Adjustment of pedal toe down pressure, and heeling pressure······································································10
3. Adjustment of operation speed ···············································································································11
9 Changing the solenoid voltage and output voltage··············································································· 12
1. To change solenoid voltage DC24V/DC30V ······························································································12
2. Changing the output voltage between 0VDC and 5VDC ··············································································12
10 Operation of the Control switch Panel Keys······················································································ 13
1. Displays during normal mode and functions of each key··············································································13
2. Selection of each mode·························································································································13
(1) Types of program mode···············································································································13
(2) Selection of each program mode from the normal mode.····································································14
(3) Direct number call function···········································································································15
3. Using the normal mode·························································································································16
4. Changing to the tacking, preset, pattern NO. selection mode········································································17
(1) Tacking setting mode ··················································································································17
(2) No. of tacking stitches setting mode·······························································································17
(3) Preset stitching setting mode········································································································18
(4) Pattern No. selection mode ··········································································································18
5. Using the program mode [1] simple setting ·······························································································19
6. Using the program mode [2] simple setting ·······························································································21
7. Using the program mode [3] simple setting ·······························································································23
11 Function List······························································································································ 25
12 How to Use the Option Connector·································································································· 29
1. Connector Layout ································································································································29
2. To use as a standing work type sewing machine························································································30
13 Error Display······························································································································ 31
14 Specifications ···························································································································· 32
<Reference> Table of digital display ································································································ 32
Dimensions (MOTOR and CONTROL BOX)···········································································
1 Contents

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1. To ensure safe use
*Always observe the following items to ensure safe use of the industrial sewing machine drive unit (motor and control box).
1.1 Before starting
Read all instruction manuals thoroughly before starting use of this drive unit, and follow the technical manuals. Also read the instruction
manuals for the installed sewing machine.
1.2 Application and purpose
This drive unit is designedto drive a sewing machine and must not be used for other applications or purposes. Do not use this drive unit until
it can be confirmed that safety measures for the installed sewing machine have been taken.
1.3 Work environment
Use this drive unit in dry and well-kept clean locations, e.g. in the clothing industry, and which process dry sewing material.
Avoid using this control unit in the following types of environments.
(1) Power voltage
- Place where voltage fluctuation exceeds ±10% of the rated voltage.
- Place where the specified power capacity cannot be secured. (Refer to page 8)
(2) Electromagnetic
noise
- Place where strong electric or magnetic fields are generated such as near a large-output high frequency
oscillator or high frequency welding machine.
(3) Temperature
and humidity
- Place where atmospheric temperature is 35 degree or higher and 5 degree or lower.
- Place subject to direct sunlight or outdoors.
- Near a heat source such as a heater.
- Place where relative humidity is 45% or less and 85% or more, or where dew condensation occurs.
(4) Atmosphere
- Atmosphere with dust or corrosive gases.
- Atmosphere with combustible gases or explosive atmosphere.
(5) Altitude
- Place where altitudes exceeds 1,000m above mean sea level.
(6) Storage
- Place where storage temperature is 55 ℃or higher and -25℃or lower.
(7) Vibration
- If excessive vibration occurs when the control box is installed on the sewing machine, install it separately.
2. Installation
2.1 Motor and control box
- Correctly install according to the attached technical manuals.
2.2 Accessories
- Always disconnect this control unit from the main power supply when installing any accessories listed in the technical manual. (Turn the
main switch OFF, and remove the plug from the outlet (power supply line).)
2.3 Cable
(1)Arrange the connection cable so that excessive force is not applied during use, and do not excessively bend the cable.
(2) Cables near moving parts (e.g., pulley) must be wired at a minimum distance of 25mm.
(3) Confirm that the power voltage of the power cable for supplying to the control box meets the specifications on the motor and control box
rating nameplates before connecting it to the power line. Connect it to the designated places to supply the power. Perform this step with the
power switch turned OFF.
2.4 Grounding
- Correctly connect the power cable grounding to the power supply grounding.
2.5 Accompanying appliances and accessories
- Electric accompanying appliances and accessories must be connected to the place listed in this manual.
2.6 Removal
(1) Turn the power switch OFF and remove the plug from the outlet (power supply line) before removing the motor or control box.
(2) Do not pull on the cord when removing the plug. Always hold the plug itself.
(3) There is a high voltage applied inside the control box, so always wait at least 10 minutes after running the power switch OFF and
remove the plug from the outlet (power supply line) before opening the control box panel.
3. Maintenance, inspection and repairs
- Follow the technical manuals for maintenance and inspection of this control unit.
- Repairs and maintenance must be done and approved by specially trained personnel.
- Do not run this control with the ventilation openings of the motor's dust-proof filter blocked or clogged with dust, loose cloth, etc.
- Always turn the power switch OFF and remove the plug from the outlet (power supply line) before replacing the sewing machine needle or
bobbin, etc.
- Always use original replacement parts for repairs or maintenance.
4. Other safety measures
- Keep fingers away from all moving machine parts (especially near sewing machine needle, etc.).
- Do not drop this control unit.
- Do not operate this product without parts such as the protective cover or protective devices such as the safety breaker.
- The servomotor surface may reach high temperatures depending on the operation conditions and loads. Do not touch directly.
- If any damage is observed on this control unit, if the drive does not run properly or if operator is uncertain about operation, do not operate the
drive unit. Operate the drive only after adjustments, repairs and approvals have been made by qualified personnel.
- The user must avoid making modifications or changes based on user's judgment.
- When system have to be stop in case of emergency, remove the power supply plug from the power supply line.
5. Hazard display, warning display
(1) This symbol indicates risk that may cause personal injury or risk to the machine
when mishandling of products.
(2) This symbol indicates electrical risks and warnings.
(3) This symbol indicates thermal risks and warnings.
- Always deliver this instruction manual to the end user.
- Save these technical manuals for future reference.
2 Safety Instructions

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Caution
1. Please remove your foot from the pedal when turning the power ON.
2. Always turn the power OFF when leaving the machine.
3. Do not inspect the control circuit with a tester.
4. Always turn the power switch OFF before tilting the sewing machine, replace the needle or threading the needle.
5. Always ground the grounding wire.
6. Do not use branched wiring.
7. The brakes may not function when the power is turned OFF or when there is a power failure during sewing machine operation.
8. Match the connector shape and direction, and insert securely.
9. Keep the signal wire as short as possible when connecting the external switch to the connector of control box. If it is long, malfunctions may
occur. Use a shield wire when possible.
10. Install the sewing machine away from sources of strong noise such as high-frequency welders.
11. An optical method is used for the detector's detection element so take care not to let dust or oils get on the detection plate when removing
the cover for adjustment, etc. If these do get on the plate, wipe off with a soft cloth and do not scratch the plate. Take care not to let oils
enter between the detector discs.
12. When the position detector connector or the belt has come off or when the sewing machine is completely locked, the motor will be
automatically turned OFF after a set time to prevent damage to the motor. (The motor may not turn OFF if the locking is not complete.)After
the problem has been resolved, turn the power OFF and ON and normal operation will be possible. The same operation should be taken
when the position detector or wires are broken.
13. Be sure to ground the lever unit when using it to separate from the control box.
14. Always turn off the power switch before connecting or disconnecting each connector
15. Do not alter this motor and control box including accessories to avoid any accident
The altered examples: To connect the power supply to the other device through the push button switch, to take out signals of the encoder
and the detector to use the external devices.
Our company does not assume the responsibility on any accident caused by altering.
16. A high voltage is applied inside the machine, so wait at
least 10 minutes after turning the power OFF before
opening the control box. There is a cable connecting the PCB
on the cover side with the PCB on the box side. When
disconnecting the cable, gently disconnect at the connector
section. Do not pull with force.
18. If the fuse blows, remove the cause, and replace the blown fuse with one having the same capacity.
(Front view of cover side PCB with control box cover removed.)
(Front view of box side PCB with control box cover removed.)
17. Remove the dust that has adhered on the motor's
dust-proof filter once every two to three weeks.
Dust-proof filter
If the motor is run while the
filter is clogged, the motor
may overheat and affect the
motor life.
3 Points of Caution
Always wait at least 10 minutes after
turning the power switch OFF before
opening the control box cover.
2.5A Fuse
Two 20A Fuses
* The above 2.5A fuse is for
protection of the 12V power
supply section.
* The above fuses are for
protection of the control box
power supply section.
High voltage warning
Control box cover side
Control box side

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1. Front side of control box
2. Back side of control box
3. Left side of control box
4 Names of Each Part
Control switch panel
connector
Encoder connector
Lever connector
Presser foot
connector
Sewing machine connector
Motor connector
Lever
Lever Unit
Power connector
Status indication LED
Connector indication
nameplate
High-voltage warning plate
XC-G10-S control switch panel installation screw hole
Front cover fixing screw
Detector connector
Option A connector
Option B connector
Protective cap (Remove the cap when using.)
Be sure to ground the lever unit
when using it to separate from the
control box.

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1. Installation of the motor
Open three 9mm holes on the table as seen from
the above. Install the motor securely using the
installation bolts, washers, spring washers and
nuts.
The installation bolts, etc., are included with the
motor as accessories.
3. Installation of the pulley
*To properly install, the protective cover A (motor side of the protective cover) must be
installed onto the motor before the pulley is installed. (Refer to "5. Installing the protective
cover”.)
Securely tighten the pulley.
Select the correct pulley diameter to ensure complete use of the motor performance.
Selection of the motor pulley:
Motor pulley
outer diameter (mm)
(*) The motor speed should be set at 3,600rpm. When the motor pulley diameter is selected with the above method
and the pulley diameter is too small, select the minimum pulley in the range that the belt will not slip.
(**) Refer to page 20 for the pulley diameter to be used when using the Mitsubishi thread trimming sewing machine.
4. Mounting of the belt To adjust the belt tension, press down on the center of
the belt with your hand, and turn the upper and lower nuts
of the adjustment nut to increase or decrease the center
height of the motor so that the belt dips approximately
15mm.
5 Installation
2. Installation of the control box
(1) Tighten the control box onto the motor.
(2) Insert the power cord from the motor into the connector on the
back of the control box. Insert the encoder cord from the motor
into the encoder connector on the front of the control box.
If the belt tension is too low, the medium
and low speeds will be inconsistent, and
the stopping precision will be poor.
When too tight, the motor bearings will
deteriorate.
Caution
For safety always turn the power
switch off, before adjusting the belt.
Caution
Use the JIS K6323 sewing
machine belt M-type.
15mm (approx. 9.8N(1kg))
Adjustment nut
Table
Belt hole
Bobbin
winder
66
3-9 holes
159
57
Encoder
cord
Power cord from motor
100V : White connector
200V : Brown connector
The protective cover A is not shown.
Normal sewing machine speed
（*）Motor speed
Sewing machine pulley diameter
(effective diameter)
= x + 5 mm
Incomplete tightening may
cause malfunctions.
Caution
The direction
of the plate

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5. Installation of the protective cover (with belt slip off prevention part)
The protective cover is enclosed with the motor as an accessory.
1. Install the protective coverA onto the motor.
2. Install the pulley and attach the belt. (Refer to "3. Installing the
pulley" and "4. Mounting of the belt".)
3. Install the "belt slip off prevention part mounting plate" onto protective cover B with the following procedures.
* Change the direction of the long and short side of the attachment plate according to the motor pulley outer diameter.
(a) For motor pulley outer diameter φ55 to φ80 (b) For motor pulley outer diameter φ80 to φ125
* Set the center of the washer to the pulley diameter indication scale and tighten the bolt.
* Confirm that the belt does not contact the attachment plate.
4. Install the "protective rod" onto the protective cover B with the following steps.
* Set the protective rod to the motor pulley rotation direction and install between the belt and motor pulley.
(a) For counterclockwise rotation (b) For clockwise rotation
* Set the center of the protective rod to the position at the center of the belt and motor pulley and tighten the bolt
5. Set protective cover B onto protective coverA,
and tighten with the four set screws.
* Confirm that the belt and motor pulley do not
contact the protective rod.
6. If necessary, adjust the position of the
"protective rod" and "belt slip off prevention part
mounting plate". Securely tighten after
adjusting.
(View from back of protective cover)
Attachment plate
rectangle side
Pulley outer
diameter φ55 to 80
indication scale
(front)
Cross-section A-A
Cross-section B-B
(View from front of protective cover)
Belt
Motor pulley
Protective
cover
Protective rod
Protective cover A
Belt
Pulley
Set screw
Set screw
Set screw
Set screw
Tightening bolt
Nut
*The nut can be installed
according to either direction.
Attachment plate
rectangle side
Pulley outer
diameter φ80 to 125
indication scale
(front)
(View from back of protective cover)
Protective rod
(View from front of protective cover)

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6. Installation of the position detector (1) The installation of the position detector will differ according
to the sewing machine model, so please consult with your
sewing machine dealer for details.
The diagram on the left shows an example of the position
detector installation.
(2) Insert the connector from the position detector into the
control box position connector.
(3) To prevent malfunctions caused by static electricity, connect
the grounding wires (green/yellow) from the position
detector onto the sewing machine head.
7. Connection of the Mitsubishi sewing machine and control box.
Wire the units as shown below.
Align the connector shape and direction, and securely insert it.
[View of control box from cover side] [View of control box from box side]
This can not be used with except
XC-G, XC-F and XC-E Series.
Caution
Position detector
Stopper
This can be installed onto
the sewing machine table
as shown here.
Grounding wire
(green/yellow)
Control box
Lever
connector
Encoder
connector
Sewing machine
connector
Motor
connector
Control switch panel
connector (Option)
Status indication LED
Caution
For safety purposes, always turn the power switch OFF and wait for
the status indication LED or the [PWR. OF] (displayed for approx. 10
seconds) LED display on the control switch panel to turn OFF before
connecting or disconnecting each connector.
This [PWR.OF] display is not an error.

- 8 -
1. Insertion of the power connector
Confirm the connector form and insertion direction when inserting the power connector into the control box and insert
completely.
Right side of control box Back side of control box
2. Connection of 3-phase power
3. Current capacity
Use a fuse or complete breaker for the power.
4. When using the 3-phase 200 - 240V class Limiservo X with single phase 200 - 240V class
Connect the "red" and "white" lead wires from the push-button switch to the power.
The black wire is not used.
Tape it with insulation tape, etc., to insulate securely.
Always ground the green/yellow (green) grounding wire.
6 Wire and Grounding
Power connector
(6-Pole)
Power connector
Power
Recommended
current capacity
Single phase
100 to 120V 550W
200 to 240V 550W / 750W
15A
3- phase
200 to 240V 550W / 750W
10A
3-phase power
R- S- T-
phase phase phase
Connect to ground
(Green/yellow)
Black
Green
Red
White
Cord for push-button switch
Ground the green (green/yellow)
wire to the grounding terminal.
Consult with an electrician for
the grounding wires.
Connection connector
to control box
Push-button switch
(Green/yellow)
Black
Green
Red
White
Connect to
grounding terminal
Connect these
lead wires to
the power.
Do not connect.
(Securely insulate by taping.)

- 9 -
1. Before turning switches on..........
Places to confirm
Reference
(1) Is the power and capacity suitable ?
Current capacity on page 8.
(2) Is the power voltage the same as the factory preset voltage of the
rated nameplate on the side of the control box?
Voltage value given on rated nameplate on side of control box.
XC-GMFY-20-05 : 200 to 240V
XC-GMFY-10-05 : 100 to 120V
(3) Are the connectors inserted correctly?
-Power connector from push-button switch
-Motor connector
-Motor encoder connector
-Position detection connector
Insertion of the power connector on page 8.
Connection of the Mitsubishi sewing machine
and control box on page 7.
Insertion of the position detector on page 7.
(4) Is the lead wire contacting the V belt ?
-
(5) Is the belt tension okay ?
Mounting of the belt on page 5.
(6)Are the pulley nuts securely tightened ?
Installation of the pulley on page 5.
(7) Can the sewing machine be rotated lightly by hand ?
-
2. Turn on the power..........
(1) Does the status indication LED on the control box light up in
green?
There is a problem if the LED is flickering or is lit up in red.
(2) Is the control switch panel LED turning ON?
(When control switch panel is connected)
(3) Does the position detector lamp light ?
(4) Is the sewing machine rotation direction correct? (When control switch panel is connected)
- For left rotation
- For right rotation
The rotation direction can be changed by pressing the [] key and [M] key simultaneously.
(5) Is there any heat, odors or abnormal sounds coming from the motor or control box?
7 Confirmation
Turn the power OFF and disconnect the power
plug from the socket if any heating, abnormal
odors or abnormal noise is found. Contact your
dealer immediately.
Control switch panel
Status indication LED
The sewing machine rotates to
the left looking from the pulley
side. The factory setting is left
rotation.
Control switch panel
Position detection
The sewing machine rotates to
the right looking from the pulley
side.