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CNC
CONNECTION AND MAINTENANCE MANUAL
BNP-B2302*(ENG)
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 on or sandwich the cables, as this may lead to electric shocks.
2. Items related to smoke prevention
Incorrect wiring or connections could burn the device.
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.
NC unit
RS-232C
Device Switch AC socket
FCU6-DX561 CONNECTION AND MAITENANCE MANUAL
CONTENTS
I. CONNECTION MANUAL
1. OUTLINE ..................................................................................................................... I-1
2. CONFIGURATION ....................................................................................................... I-2
3. INSTALLATION ........................................................................................................... I-3
3.2.1 Connection of FG (Frame Ground) .............................................................. I-4
3.2.2 Shield Clamping of Cables........................................................................... I-5
3.3 Installation ........................................................................................................... I-7
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
II. MAINTENANCE MANUAL
1. EXPLANATION OF MODULE FUNCTIONS ................................................................ 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
3.2.1 Cable............................................................................................................ II-11
3.2.2 Unit............................................................................................................... II-13
I. CONNECTION MANUAL
1. OUTLINE
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)
I-1
2. CONFIGURATION
2.1 System Configuration
2. CONFIGURATION
2.1 System Configuration
Ethernet communication device
Communication terminal
MC link B
Remote I/O unit
FCU6-DX561
Remote I/O unit
DX1
Operation panel, etc.
Remote I/O unit
DX1
M64:BASE-T or BASE-5
M65/66:BASE-T
MC link A
M60/M600 Series control unit
CBUS 1 CBUS 2
MC link B
OPEN
0
CF31 CF32
CF33 CF34
Base I/O unit
SKIP
ENC1
CF10
CR31
CF11
SV2 SV1
RI02 RI01
DCIN
MC link A
MC link
B
Servo drive unit
MDS-B-SVJ2-
Servo drive unit
MDS-B/C1-V1/V2-
MR-J2-CT (auxiliary axis)
Spindle drive unit
MDS-B/C1-SP
MDS-B-SPJ2
Power supply unit
MDS-B/C1-CV
MDS-B-CVE
M I T S U B I S H I
M D S - B - S V J 2
MC link B
Remote I/O unit
DX1
Synchronous feed encoder
Sensor
Max.
8 channels
Manual pulse generator
RS-232C device
Machine control signal
Synchronous feed encoder
Servomotor Spindle motor
Legend
: Connections described in this manual
: Connections described in separate
documents
I-2
3. INSTALLATION
3.1 General Specification
3. INSTALLATION
3.1 General Specification
Unit name
Type name
Remote I/O unit
FCU6-DX561
During
Ambient operation temperature During storage
Ambient humidity
During operation
During storage
Vibration resistance
Shock resistance
Working atmosphere
Power noise
Withstand voltage
Insulation resistance
Grounding
Power voltage
0 to 55°C * Note
–20 to 60°C
45 to 75% RH (with no dew condensation)
45 to 80% RH (with no dew condensation)
4.9m/s
2
or less (during operation)
29.4m/s
98m/s
2
2
or less (during operation)
or less (during transportation)
No corrosive gases, or high levels of dust or oil mist
1kVA (P-P)
500VAC for one minute
Across entire output terminal batch and grounding terminal
5M
Ω or more with 500VDC megger tester
Across entire output terminal batch and grounding terminal
Class D grounding
Use without grounding is possible if grounding is not possible.
24VDC +10%/
−15%
(Must be insulated from 100VAC and 200VAC power supply)
Instantaneous stop tolerance time
Power fuse
Operation continues when power instantaneously stops for 4ms or less.
Chip type fuse incorporated
(SSTC 0.8A Maker: SOC UL198G approved, CSA C22.2 No. 59.2)
Approx. 10W (Only control section; excludes input/output section) Power consumption
Rush current
Sensor power
Approx. 20A/1ms, approx. 5A/10ms
None
Weight 1.8kg
Unit size Refer to Appendix.
* Note If the ambient temperature is 55°C or more, lower to 55°C or less with forced cooling.
I-3
3.2 Noise Countermeasures
3. INSTALLATION
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.
Control unit
FCU6-MU
-MA
AC input
Short bar
R220 cable
(24VDC)
R220 cable
(24VDC)
POWER
CPU-E
STOP
RUN
4
0
Remote I/O unit
FCU6-DX561
FG cable
Stabilized power supply
Short bar
AC input
Stabilized power supply
O
ERR1
ERR2
Base I/O unit
FCU6-DX3 /DX4/HR377/378
R220 cable
(24VDC)
0 0
CF31CF32
CF33 CF34
SKIP
CR31
ENC
CF10 SV2 SV1
ＲＩＯ２ ＲＩＯ１ DCIN
HR3□□
FG cable
FG cable
Main gaounding plate for electric cabinet
FG cable
I-4
3.2.2 Shield Clamping of Cables
3. INSTALLATION
3.2 Noise Countermeasures
(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.
Remote I/O unit
FCU6-DX561
Base I/O unit
FCU6-DX3 /DX4/HR377/378
0 0
Remote I/O unit
FCUA-DX1
ENC
SKIP
4
CF10 SV2 SV1
CR31
CF31 CF32
CF33 CF34
STOP
RUN
ＲＩＯ２ ＲＩＯ１ DCIN
HR3□□
Grounding plate
FG wire
X X
Grounding plate
FG wire
X X
FG wire FG wire
R211 cable R211 cable
Grounding plate
(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.
I-5
3. INSTALLATION
3.2 Noise Countermeasures
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 120
Ω.
Contact
SK
Coil
E
I-6
3. INSTALLATION
3.3 Installation
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)
100mm or more
(heat dissipation allowance)
Control unit
Remote I/O unit
(FCU6-DX561)
50mm or more
(heat dissipation allowance)
Remote I/O unit
(FCUA-DX1 ) Servo drive unit Spindle drive unit
M I T S U B I S H I
M D S - B - S V J 2
M I T S U B I S H I
M D S - B - S V J 2
CBUS 1 CBUS 2
50mm or more
OPEN
30mm or more
ST No.
POWER
CPU-E
S T O P
R U N
4
0
150mm or more
(heat dissipation, wiringallowance)
RIO
ER R 1
ER R 2
10mm or more 10mm or more 10mm
100mm or more or more
(heat dissipation, wiring allowance)
15mm or more
(wiring allowance)
15mm or more
(wiring allowance)
(Bottom)
CAUTION
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.
I-7
3. INSTALLATION
3.4 Mounting Conditions
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
Cable
Packing
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.
CAUTION
Do not allow conductive foreign matter such as screws or metal chips or combustible foreign matter such as oil enter the unit.
I-8
4. SYSTEM CONNECTION
4.1 General System Diagram
4. SYSTEM CONNECTION
4.1 General System Diagram
R S T 3-phase 200VAC to 230VAC Ethernet communication device
BASE-T
Communication terminal
CT100/CT120/LD100/DUT32/DUN33
/EL10/CR10
No fuse breaker (NFB) Remote I/O unit
DX1
ON
OF F
MC
DCIN RIO1 RIO2
MC link B terminator
R-TM
MC
CR02 CR01 CR05
Operation panel
In sert when required
MC
R211 or
FG
24VDC( +)
FG
24VDC( +)
Stabilized power supply
R211
To next remote
I/O unit
24VDC( +) R000
F G
IC card
Power supply
HR083
Op tion slot
RT2 RT1
Control unit
M60/M600 Series
CPU:HR114/146
OT rel ease swit ch
EMG
EMG
IC card: HR831
Ethernet: HR832
F120
RA
F G
AUX1 AUX2
Communication card
HR171
PLC unit
FCU6-DX561
24VDC
24VDC( +)
R220
CF11 CF10
DCIN
I/O link
24VDC (+)
Stabilized power supply
R220
To next control unit
ENC1/
ENC2
F050 F010
FG FG
Machine control contact
CF11 CF10
24VDC( +) DC24IN MJ2
Base I/O unit
HR377/HR378
FCU6-DX3
FCU6-DX4
MJ3
DI-L/
DI-R
R000
SV1
Machine control relay
R
R R
R
DO-L
RIO1RIO2
MC link B
Terminator
R-TM RIO1
MC1 MC1 or
MC1
X axis and Y axis
MDS-B-SVJ2∗∗
CN1A CN1B
L1
L2
L3
SH21
Spindle encoder
SE1024-3-15-68
Spindle
MDS-B-SP∗∗∗ Terminator
MDS-A-TM
CN1A CN1B
L1
L2
L3
R211
R211
To next remote
I/O unit Converter
MDS-B-CV-
∗
MDS-B-CVE∗
AC reactor B-AL
L1
L2
L3
AC servomotor with detector
HC153TA33
SM
1.5kW
Regenerative resist or
MR-RB
O30
L11
L21
C
P
N
D
U
V
W
Spindle motor
SJ-V15-02
7.5kW rating 30 min.
CN6
U
V
W
CN8
L1
L2
L+
L-
L11
L21
L11
L21
L+
De te ctor
CNV2/CNV12 cable
IM
L-
CN2
MC1 MC1
OSA253S
F G
F
De tector
CN4 CN4
CN5
R056 cable
(Note) This drawing is an example of the general connection for the M60/M600 Series. The actual connection will differ according to the specifications.
I-9
5. CONNECTION OF UNIT
5.1 Names of Each Part
5. CONNECTION OF UNIT
The methods for connecting to each unit and device are briefly explained in this chapter.
Front view
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.
DCIN (1)
ENC1 (2)
ENC2 (3)
ST No. (4)
RUN/STOP (5)
PROG.PORT (6)
DI-L (7)
DI-R (8)
DO-L (9)
ST No.
POWER
RUN
CPU-E
ST OP
RUN
RIO
ERR1
ERR2
4
1
2 3
Bottom view
RIO1 (10)
RIO2 (11)
I-10
5. CONNECTION OF UNIT
5.2 Unit Connection System Diagram
5.2 Unit Connection System Diagram
M60/M600 Series control unit Base I/O unit
F010 cable R211 cable
CF10 RIO1 CF10
CF11
F050 cable
Additional
I/O card
HR211
CF11
24VDC stabilized power
R220 cable
DCIN
CS1 CS2
↑
↑
0 1
Remote I/O unit
(FCU6-DX561)
RIO1
RIO2
ENC1
ENC2
DI-L
DI-R
DO-L
R211 cable
Remote I/O unit or terminator (R-TM)
R000 cable
Encoder (speed signal) 2 channels
R000 cable
Encoder (speed signal) 2 channels
R301 cable
DI
R301 cable
DI
R301 cable
DO
DCIN
ST No.
↑
2
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
ENC2
Connected with encoder via spindle amplifier.
Connected with encoder via spindle amplifier.
DI-L
DI-R
DO-L
ST No.
DI: 28 (Sink/Source)
DI: 16 (Sink/Source)
DO: 32 (Source)
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.
I-11
5. CONNECTION OF UNIT
5.3 Connection of Base I/O Unit
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)
Remote I/O unit
(FCU6-DX561)
CBUS 1 CBUS 2
OPEN
POWER
RUN
CPU-E
STOP
RUN
4
DC IN
DC OUT
PS EMG
BAT ALM
0
CF11 CF10
ENC2
F050 cable
Base I/O unit
FCU6-DX3 /DX4
/HR377/378
SKIP
ENC1
CF10
0
0
F010 cable
X
CF31 CF32
CF33 CF34
ｶｰﾄﾞｱﾄﾞｵﾝ用取付け穴(LG)
SV2 SV1
RS232C
CH1､CH2
HANDL
CH1～CH3
CR31
CF11
RIO2 RIO1 DCIN
FG
RIO2 RIO1 DCIN
R211 cable
X
RIO
ERR1
ERR2
Bottom view
(Front)
R211 cable
R211 cable
Terminator (R-TM)
(Back)
(Note) When not expanding the remote I/O units, connect the terminator (R-TM) to
RIO2.
I-12
5. CONNECTION OF UNIT
5.4 Connection of RIO Unit
5.4 Connection of RIO Unit
The RIO2 connector is used to connect several remote I/O units. Connect the R211 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)
Remote I/O unit
(FCUA-DX1 )
（Front）
Remote I/O unit
(FCU6-DX561)
Bottom view
RIO2
RIO2 RIO2
RIO1 RIO1
R211 cable
（Back）
（Front）
Remote I/O unit
(FCU6-DX561)
Bottom view
R211 cable X Terminator (R-TM)
RIO1
X
X
Remote I/O unit
(FCUA-DX1 )
(Front)
Bottom view
X
RIO1
X
Remote I/O unit
(FCUA－DX1 )
（Front）
Bottom view
RIO1
RIO2
RIO2 RIO2
Terminator (R-TM)
（Back）
Connect the terminator (R-TM) to RIO2 when not expanding the remote I/O unit.
DCIN
Terminator (R-TM)
（Back）
Connect the R211 cable from
RIO2 to RIO1 on the next remote I/O unit.
DCIN
（Back）
Connect the terminator (R-TM) to RIO2 on the final unit.
CAUTION
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.
I-13
5. CONNECTION OF UNIT
5.5 Connection of Power Supply
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)
Remote I/O unit
(FCU6-DX561)
24VDC (+)
0V
FG
FG
Stabilized power supply
(2) DI-L/-R power connection (for DI circuit)
(For source input)
DI-L DI-R
24VDC (+)
0V
FG
0V
B4
B3
A4
A3
0V
B4
B3
A4
A3
ST No.
4
1
2 3
567
POWER
RU N
CPU-E
STOP
RU N
(For sink input)
+24V
DI-L
B4
B3
A4
A3
+24V
DI-R
B4
B3
A4
A3
24VDC (+)
0V
FG
(3) DO-L power connection (for DO circuit)
(Fixed to source output)
DO-L
+24V
B4
B3
A4
A3
RI O
ERR1
ERR2
24VDC (+)
0V
FG
(Note) Connect the power or GND to all of the common pins on the DI-L/-R and DO-L connector.
CAUTION
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.
I-14
5. CONNECTION OF UNIT
5.6 Connection of Encoder Speed Signal
5.6 Connection of Encoder Speed Signal
Encoder
10 1 ENC１
ENC1/2
(Note) Refer to following
20 11 drawing.
<PCB side connector type>
Receptacle : 52822-4011
<Cable side connector type>
Shell : 10320-52F0-008
Recommended maker:
ENC２
5
6
7
8
9
10
1
2
3
4
4
5
6
7
1
2
3
8
9
10
I
I
GND
PC1
GND
PC3
15
16
17
18
19
20
11
12
13
14
14
15
16
17
11
12
13
18
19
20
I
I
GND
PC1*
GND
PC3*
Connect the connector shell (frame) to the FG via the pattern on the PCB.
I
I
GND
PC2
GND
PC4 I
I
GND
PC2*
GND
PC4*
Connect the connector shell (frame) to the FG via the pattern on the PCB.
DCIN
ENC1/2
PC3
PC3
∗
Channel 3 ENC1ENC2
PC4
PC4
∗
Channel 4
PC1
PC1
∗
Channel 1
PC2
PC2
∗
Channel 2
Station No.
setting
STOP
RUN
4
20
10
11 1
Connector
ENC pin No.
Encoder
OSE1024-3-15-68
DI-R
DI-L
DO-L
R000 cable
CN8
Spindle amplifier
CN6
F040／F041 cable
(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.
A dedicated cable is required to use channels 3/4 of the connectors ENC1/ENC2.
I-15
[Outline of connection]
ENC1/2
PC
5. CONNECTION OF UNIT
5.6 Connection of Encoder Speed Signal
1kΩ
PC ∗
1kΩ
GND
Spindle amplifier
[Signal assignment table]
1st channel X00
2nd channel
3rd channel
X01
X02
4th channel
[Input specifications]
X03
Item Specifications
Input voltage
Input sensitivity
Input response time
Line receiver input (X00 to X03) (5VDC)
OFF
→ ON 4.5mA or more, ON → OFF 1.5mA or less
X00 to X03 require 50µs or more for the second trigger to be validated.
The input pulse is detected at
Not insulated
.
Circuit insulation
CAUTION
Separate the signal wire from the drive line/power line when wiring.
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.
I-16
5. CONNECTION OF UNIT
5.7 Connection of Machine Input/Output Signal
5.7 Connection of Machine Input/Output Signal
Machine input/output signal types and number of points
Number of occupied serial
Input Output link stations
44 points 32 points 2
R300 cable/
R301 cable
DI-L DI-R
Machine signal
R300 cable/
R301 cable
DO-L
Machine signal
[Outline of connection]
X00 to X07 and Y00 to Y37 below are indicated as octal values.
DI_24V
DI_0V
A4
DI-L/R
DI_COM
B4
A3
B3
Input circuit sink type
3.3kΩ:4 points (X04 to X07)
4.3kΩ:40 points (X10 to X57)
DI_0V
DI_24V
A4
DI-L/R
DI_COM
B4
A3
B3
Input circuit source type
3.3kΩ:4 points (X04 to X07)
4.3kΩ:40 points (X10 to X57)
DO_24V
RA
PL
DO_0V
A4
B4
A3
B3
DO-L
DO_COM
Output circuit sink type
Control circuit
DO_24V
RA
PL
DO_0V
A4
B4
A3
B3
DO-L
DO_COM
Output circuit source type
Control circuit
Machine control panel RIO1 RIO2 DCIN
Machine control panel
RIO1 RIO2 DCIN
Stabilized power supply
24VDC (+)
0V
FG
Stabilized power supply
The input circuit can be switched to a sink type or source type with the connections.
24VDC (+)
The output circuit is fixed to the source type.
CAUTION
1 2 3 1 2
0V
3
FG
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.
I-17
5. CONNECTION OF UNIT
5.7 Connection of Machine Input/Output Signal
[Signal assignment table]
DI-L
(Note)
X00 to X03 are used for the encoder input, and cannot be assigned to the DI-L connector.
DI-L
Machine side control panel, etc.
DI-R
Ｂ
Ｘ０４
Ｘ０５
Ｘ０６
Ｘ０７
Ｘ１０
Ｘ１１
Ｘ１２
Ｘ１３
Ｘ１４
Ｘ１５
Ｘ１６
Ｘ１７
DI_COM1
DI_COM1
Ａ
Ｘ２０
Ｘ２１
Ｘ２２
Ｘ２３
Ｘ２４
Ｘ２５
Ｘ２６
Ｘ２７
Ｘ３０
Ｘ３１
Ｘ３２
Ｘ３３
Ｘ３４
Ｘ３５
Ｘ３６
Ｘ３７
DI_COM1
DI_COM1
2 0
1 9
1 8
1 7
1 6
1 5
1 4
1 3
1 2
1 1
1 0
9
2
1
4
3
6
5
8
7
Ｂ Ａ
Ｂ
Ｘ４０
Ｘ４１
Ｘ４２
Ｘ４３
Ｘ４４
Ｘ４５
Ｘ４６
Ｘ４７
Ｘ５０
Ｘ５１
Ｘ５２
Ｘ５３
Ｘ５４
Ｘ５５
Ｘ５６
Ｘ５７
DI_COM2
DI_COM2
Ｂ
DI-R
Ａ
7
6
5
9
8
1 3
1 2
1 1
1 0
2
1
4
3
2 0
1 9
1 8
1 7
1 6
1 5
1 4
Ａ
RA
PL
DO-L
DO-L
Base I/O unit
Remote I/O unit
Ｂ
Ｙ００
Ｙ０１
Ｙ０２
Ｙ０３
Ｙ０４
Ｙ０５
Ｙ０６
Ｙ０７
Ｙ１０
Ｙ１１
Ｙ１２
Ｙ１３
Ｙ１４
Ｙ１５
Ｙ１６
Ｙ１７
DO_COM
DO_COM
Ｂ
Ａ
Ｙ２０
Ｙ２１
Ｙ２２
Ｙ２３
Ｙ２４
Ｙ２５
Ｙ２６
Ｙ２７
Ｙ３０
Ｙ３１
Ｙ３２
Ｙ３３
Ｙ３４
Ｙ３５
Ｙ３６
Ｙ３７
DO_COM
DO_COM
2 0
1 9
1 8
1 7
1 6
1 5
1 4
1 3
1 2
1 1
1 0
9
2
1
4
3
6
5
8
7
Ａ
1
T
X
R
X
RI01
2
T
X
R
X
＊
3
LG
1
T
X
R
X
RI02
2
T
X
R
X
＊
3
LG
1
24VDC(+)
DCIN
2
0V
3
FG
24VDC (+)
X
D-3
AMP
X
D-3
AMP
Y
D-3
AMP
0V R-TM
Remote I/O unit
<Adaptive connector>
DCIN RIO1/RIO2
Connector : 2-178288-3
AMP
RI-L/DO-L
DI-R
R-TM
(Terminator)
Connector : 2-178288-3 Crimp type connector:
7940-6500SC
D-3
Maker: Sumitomo 3M
AMP
AMP
I-18
5. CONNECTION OF UNIT
5.7 Connection of Machine Input/Output Signal
[Outline of input circuit]
The digital signal input circuit includes the sink type and source type. These can be selected with each connector unit.
DI_24V
DI_COM
Connection method
Sink input
(X04 to X57)
<Octal notation>
X
X04 to X07:3.3kΩ 1/2W
X10 to X57:4.3kΩ 1/2W
DI_0V
DI_COM
DI_0V
Connection method
Source input
(X04 to X57)
<Octal notation>
DI_24V
X
X04 to X07:3.3kΩ 1/2W
X10 to X57:4.3kΩ 1/2W
[Input specifications]
Item Specifications
Input voltage, current
7mA/24VDC +10%, –15% (X04 to X07 sink/source changeover)
(External power supply)
5mA/24VDC +10%, –15% (X10 to X57 sink/source changeover)
(External power supply)
Input sensitivity OFF
→ ON 4.5mA or more, ON → OFF 1.5mA or less
Input response OFF
→ ON Approx. 4ms, ON → OFF Approx. 4ms (General input X20 to X57) time
X00 to X17 are incorporated in the digital filter. (Can be changed to 0 to 60ms; note that the minimum is 50µs) (Note)
X00 to X03 require 50µs or more for the second trigger to be validated.
The input pulse is detected at .
Circuit insulation Photo coupler insulation (* Excluding line receiver input)
(Note) The input filter value can be changed by rewriting the contents of the special data register
D8020 between 0 and 60 using the MOV command, etc. (The contents of D8020 are automatically set to 10 (10ms) when the power is turned OFF and ON.)
D8020 value
0
10 to
60
Digital filter value
0ms
10ms to
60ms
Note that in actual use, the minimum C-R filter is provided even on this input, and the value will not be lower than 50µs (20µs for X00 to X01). Refer to the FX2N Hardware Manual for details.
I-19
5. CONNECTION OF UNIT
5.7 Connection of Machine Input/Output Signal
[Outline of output circuit]
The digital signal output circuit is a source type.
Connection method
Source output
(Y00 to Y37)
<Octal notation>
DO_24V
DO_COM
DO_0V
Y
[Output specifications]
Item
Rated voltage, current
Response time
Maximum load
Specifications (per point)
5VDC to 30VDC, 0.1A
0.2ms (at 24VDC, 0.1A energizing)
Resistance load 60mA (200mA for Y0 to Y3)
Inductive load 2.4W/24VDC (7.2W/24VDC for Y0 to Y3)
Lamp load 0.3W/24VDC (0.9W/24VDC for Y0 to Y3)
Output saturation voltage
Circuit insulation
1.2V/0.1A
Photo coupler insulation
<Caution>
CAUTION
∗ When using an inductive load such as a relay, always connect a diode (voltage resistance 100V or more, 100mA or more in reverse direction) in parallel to the load. Note that the device will be damaged if the diode orientation is incorrect.
∗ When using a capacity load such as a lamp, always connect a protective resistor (R = 150
Ω) serially to the load to suppress rush currents. (Make sure that the current is less than the above tolerable current including the momentary current.)
When using an inductive load such as a relay, always connect a diode in parallel to the load as a noise countermeasure.
When using a capacity load such as a lamp, always connect a protective resistor serially to the load to suppress rush currents.
I-20
APPENDIX 1 UNIT OUTLINE DRAWINGS AND INSTALLATION DIMENSIONS
APPENDIX 1 UNIT OUTLINE DRAWINGS AND INSTALLATION
DIMENSIONS
2-M5x0.8 screw
To p
ST No.
4
5 6
7
POWER
RUN
CPU-E
ST OP
RUN
RIO
ERR1
ERR2
30
6 0
Bottom
80
Wiring allowance
I-21
180
APPENDIX 2 LIST OF CONNECTOR SETS
APPENDIX 2 LIST OF CONNECTOR SETS
□
□
□
□
I-22
APPENDIX 3 CABLE MANUFACTURING DRAWINGS
APPENDIX 3 CABLE MANUFACTURING DRAWING
As a rule, most F /R cables used with this product are not sold by Mitsubishi. Thus, manufacture the required cables using the cable manufacturing drawings on the following pages as a reference. Note that the cable-compatible connectors can be purchased from Mitsubishi.
If crimp tools are not available when manufacturing the power supply cable (R200, R220) and communication cable (R211), the cables can be manufactured by soldering a wire and connector as shown in the following procedure.
1. Carry out preparatory soldering onto the wire.
(Peel 3.5mm of the sheath.) 2. Insert the wire into the contact. Hold the sheath retainer.
Soldering iron
Contact
Wire
Solder
3. Lightly press down one side of the wire barrel using radio pliers.
Wire barrel
This is a barrier to prevent incorrect insertion. Do not bend.
4. Firmly press down the other side of the wire barrel.
(Press firmly enough that the wire will not come out when pulled lightly.)
Radio pliers
5. Firmly press down the sheath retainer in the same manner as the wire barrel.
Sheath retainer
7. Lastly, insert the soldered contact with wire into the housing.
6. Apply the soldering iron, and melt the preparatory solder inside.
Better results will be achieved if an additional, small amount of solder is applied.
Soldering iron
Contact section
Be careful that the solder does not flow into the contact section.
Pay attention to the insertion direction.
I-23
APPENDIX 3 CABLE MANUFACTURING DRAWINGS
<Cable type name table>
Appendix No.
Appendix 3.1
Appendix 3.2
Cable type
R000 cable
R211 cable
Application
Encoder : 2ch
Remote I/O
Max. length
30m
∗50m
Standard cable length
Appendix 3.3
Appendix 3.4
Appendix 3.5
Appendix 3.6
R220 cable
R300 cable
R301 cable
R-TM terminator
+24V input
DI/DO
DI/DO
RIO unit communication terminator
30m
20m
20m
(Note 1) For the cable with an asterisk (
∗) in the maximum cable length column, the total length (L1+ L2 + L3) of the cable length
(L1) from the control unit to the base I/O unit, the cable length (L2) from the base I/O unit to this unit, and the cable length (L3) from this unit to each unit must be less than this value.
Maximum cable length
L1 L2 L3
F010
Control unit
F050
Base I/O unit
Expansion
I/O unit
RIO1
R211
Remote I/O unit
(FCU6-DX561)
DI-L/-R
DO-L
RIO1
RIO2
ENC1
ENC2
R300/
F301
R211
R000
Machine operation panel
Remote I/O unit
Servo amplifier
Encoder
(Note 2) Symbols for writing cable drawings
The following symbols are used in the cable drawings.
1. indicates twist.
2. indicates the shield sheath.
3. indicates shield clamping to the ground plate.
4. In the cable drawings, the partner of the twisted pair cable is given a priority, so the pin Nos. of the connectors at both ends are not necessary in number of order.
5. Equivalent parts can be used for the connector, contact and wire material.
I-24
APPENDIX 3 CABLE MANUFACTURING DRAWINGS
Appendix 3.1 FCUA-R000 Cable Manufacturing Drawing
Appendix 3.1 FCUA-R000 Cable Manufacturing Drawing
Application: Remote I/O unit (FCU6-DX561) to spindle connection
Option (compatible connector set)
FCUA-CS000
Assembly drawing
1 2
3
1 2
No.
Part name/model
1
List of parts used
Connector
10120-6000EL
Maker
Sumitomo 3M
2
Connector case
10320-3210-000
Sumitomo 3M
R000 3
Wire material
UL20276
AWG28 × 10P
Note (1)
Qty.
2
2
(1)
(Note) This cable is the same as the SH21 cable.
R000
Connection diagram
Remote I/O unit side
ENC1/ENC2
7
1 7
8
1 8
5
1 5
6
1 6
9
1 9
1 0
2 0
3
1 3
4
1 4
1
1 1
2
1 2
Note (3)
Max. cable length: 30m
Spindle amplifier side
CN8
7
1 7
8
1 8
5
1 5
6
1 6
9
1 9
1 0
2 0
3
1 3
4
1 4
1
1 1
2
1 2
Case GND plate Case GND plate
Manufacturing precautions
(1) The wire material shall be a shielded, 10-pair stranded cable equivalent to UL20276 Standard
AWG28 (0.08mm
2
).
(2) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications.
(3) Attach the nameplate (with protective cover stamped with the cable name) in the position designated in the assembly drawing.
(4) Fold the wire material shield over the sheath, and wrap copper foil tape over it. Then clamp with the connector case frame.
(5) Part No. 1 (connector) and part No. 2 (connector case) are solderless types. If soldering types are required, use parts 10120-3000VE for the connector and 10320-52F0-008 for the connector case (both parts manufactured by Sumitomo 3M).
I-25
APPENDIX 3 CABLE MANUFACTURING DRAWINGS
Appendix 3.2 FCUA-R211 Cable Manufacturing Drawing
Appendix 3.2 FCUA-R211 Cable Manufacturing Drawing
Application: Connection between base I/O unit and remote I/O unit (FCU6-DX561)
Connection between remote I/O unit (FCU6-DX561) and remote I/O unit (FCUA-DX1 □□ )
Connection between remote I/O unit (FCUA-DX1 □□ ) and remote I/O unit (FCUA-DX1 □□ )
Option (corresponding connector set)
FCUA-CN211
(Note that when a single-end connector and contact are used, there is no crimp terminal)
List of parts used
Assembly drawing
1 2 1 2
No.
1
Part name/type
Connector
1-178288-3
Maker
Tyco
Electronics
AMP
Qty.
2
3
2
Contact
1-175218-2
Tyco
Electronics
AMP
6
R211
R211
3
4
5
Wire material
MIX3CHRV-SV-SB
Twisted pair cable with compound
3-pair shield
(TOA Electric
Industry)
Crimp terminal
V1.25-3
Crimp terminal
V1.25-5
Note (1) (1)
J.S.T. 1
J.S.T. 1
5 Note (3)
4
Connection diagram
Max. cable length: 50m
TXRX
TXRX＊
LG
1
2
3
1
2
3
TXRX
TXRX＊
LG
FG
Note (5)
FG
Manufacturing precautions
(1) The wire material shall be a shielded 3-pair stranded pair cable equivalent to AWG20 (0.5mm
2
).
(2) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications.
(3) Attach the nameplate (with protective cover stamped with the cable name) in the position designated in the assembly drawing.
(4) Install each crimp terminal side after stamping the name of each signal on the mark tube.
(5) Protect both ends of the wire material with insulation bushing.
(6) Use AWG18 (0.75mm
2
) or equivalent for the shield treatment wire material.
(7) Ground the crimp terminal connected to the shield to the control unit or communication terminal frame ground.
Note that to improve the noise resistance, there may be cases when only one end is connected, both ends are connected, or neither end is connected.
I-26
APPENDIX 3 CABLE MANUFACTURING DRAWING
Appendix 3.3 FCUA-R220 Cable Manufacturing Drawing
Appendix 3.3 FCUA-R220 Cable Manufacturing Drawing
Application: Supply of 24V to remote I/O unit (FCU6-DX561)
Option (compatible connector set)
FCUA-CN220
(Note that this corresponds only to the connector on the remote I/O unit side.)
List of parts used
No.
Part name/model Maker
Assembly drawing 1
Connector
2-178288-3
Tyco
Electronics
AMP
2
Contact
1-175218-5
Tyco
Electronics
AMP
1 2
3 4
3
Wire material
JPVV-SB
1P × 0.5mm
2
BANDO
Electric Wire
Note (1)
4
Qty.
1
3
(1)
Solderless terminal
V1.25-3
J.S.T. 3
R220
R220
Note (3)
F G
GND
+24V
Connection diagram
Remote I/O unit (FCU6-DX561) side
DCIN
FG
GND
+24V
3
2
1
WHITE
Max. cable length: 30m
Power supply side
FG
GND
+24V
BROWN
Manufacturing precautions
(1) The wire material shall be a shielded 1-pair stranded cable equivalent to AWG20 (0.5mm
2
).
(If the cable length exceeds 10m, use AWG16 (1.25mm
2
).)
(2) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications.
(3) Attach the nameplate (with protective cover stamped with the cable name) in the position designated in the assembly drawing.
(4) Install each crimp terminal side after stamping the name of each signal on the mark tube.
(5) Protect both ends of the wire material with insulation bushing.
(6) Use AWG18 (0.75mm
2
) or equivalent for the shield treatment wire material.
I-27
APPENDIX 3 CABLE MANUFACTURING DRAWING
Appendix 3.4 R300 Cable Manufacturing Drawing
Appendix 3.4 R300 Cable Manufacturing Drawing
Application: DIO – Machine electric cabinet
Assembly drawing
No.
Part name/model
1
2
List of parts used
Connector
7940-6500SC
Wire material
B40-S
Maker
Sumitomo 3M
Note (1)
First wire is colored Max. cable length: 20m
Qty.
1
(1)
Remote I/O unit
(FCU6-DX561) side
DI-L/-R
DO-L
1
3
Machine electric cabinet side
R300
Note (2)
Manufacturing precautions
(1) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications.
(2) Attach the nameplate (with protective cover stamped with the cable name) in the position designated in the assembly drawing.
(3) The cable is the same for DI and DO. However, stamp DI or DO on the connector to prevent incorrect insertion.
I-28
APPENDIX 3 CABLE MANUFACTURING DRAWING
Appendix 3.5 R301 Cable Manufacturing Drawing
Appendix 3.5 R301 Cable Manufacturing Drawing
Application: DIO – Machine electric cabinet
Assembly drawing
No.
Part name/model
1
2
3
List of parts used
Connector
7940-6500SC
Strain relief
3448-7940
Wire material
B40-S
Maker
Sumitomo 3M
Sumitomo 3M
Note (1)
First wire is colored
Qty.
2
1
(1)
Max. cable length: 20m
Remote I/O unit
(FCU6-DX561) side
DI-L/-R
DO-L
1
3
2
1
Machine electric cabinet side
R301
Note (2)
Manufacturing precautions
(1) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications.
(2) Attach the nameplate (with protective cover stamped with the cable name) in the position designated in the assembly drawing.
(3) The cable is the same for DI and DO. However, stamp DI or DO on the connector to prevent incorrect insertion.
I-29
APPENDIX 3 CABLE MANUFACTURING DRAWING
Appendix 3.6 R-TM Manufacturing Drawing
Appendix 3.6 R-TM Manufacturing Drawing
Application: Terminator for MC link B remote I/O unit (FCU6-DX561) termination
Assembly drawing
List of parts used
101 102
103
No.
Part name/model
1
Connector
1-178288-3
(X type)
2
Contact
1-175216-2
Maker
Tyco
Electronics
AMP
Tyco
Electronics
AMP
3
Resistor
100
Ω
1/4W
Qty.
1
2
KOA 1
Rear of the connector
Connection diagram
LG
R TM
3
TXRX ＊ 2
TXRX
1
100 Ω
Manufacturing precautions
(1) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications.
(2) Cover the 100
Ω terminator with a black insulation tube.
(3) Stamp the connector name "R-TM" in white on the rear of the connector.
I-30
APPENDIX 4 PRECAUTIONS FOR COMPLYING WITH UL/c-UL STANDARDS
APPENDIX 4 PRECAUTIONS FOR COMPLYING WITH UL/c-UL
STANDARDS
Observe the following matters to comply with the UL/c-UL Standards.
(1) Selecting the external 24VDC power supply unit
The remote I/O unit (FCU6-DX561) complies with UL Standards on the condition that the external power supply unit for supplying 24VDC is a UL-approved part. Use a UL-approved part for the power supply unit supplying 24VDC to this unit.
(2) Unit ambient temperature
The remote I/O unit (FCU6-DX561) complies with UL Standards on the condition that it is used within the maximum ambient temperature given in "3.1 General Specifications" in Chapter 3 of this manual.
Design so that the maximum ambient temperature of this unit does not exceed the temperature given in "3.1 General Specifications" in Chapter 3 of this manual.
I-31
II. MAINTENANCE MANUAL
1. EXPLANATION OF MODULE FUNCTIONS
1.1 FX2N-80BMT-NC Card
1. EXPLANATION OF MODULE FUNCTIONS
1.1 FX2N-80BMT-NC Card
[Block diagram]
CPU
SW1
Run
Stop
EEPROM
BPU-G/A SRAM
Encoder
I/F
IO-G/A
DO I/F
DI I/F
IO-G/A
DC-DC
24V→5V
RIO-G/A
[Explanation of functions]
The FX2N-80BMT-NC card is based on the MELSEC PLC FX2N Series, and has two remote I/O controllers mounted. This functions as the remote I/O's slave station.
IO-G/A
Memory
External I/O interface
EEPROM
SRAM
RIO-G/A Remote I/O controller
I/O interface ENC1/2 connector
DI-L/-R connector
DO-L connector
RIO1/2 connector
Power supply DCIN connector
For ladder storage
Memory for execution
Occupies two stations
Encoder speed signal connection: 4ch
Input: 44 points
Output: 32 points
Remote IO slave station
Input: 24VDC +15%/
−10% : 0.6A
II-1
1. EXPLANATION OF MODULE FUNCTIONS
1.1 FX2N-80BMT-NC Card
[Connector layout diagram]
RIO2
RIO1
U:DI-R
L:DI-L
DCIN
U:ENC2
L:ENC1
DO-L
SW2
PROG.
PORT
SW1
[Explanation of settings]
SW1
SW2
RUN-STOP slide switch Starts running when the switch is set to RUN, and stops when set to OFF.
Remote I/O station No. setting rotary switch
0 to 7: Corresponds to the RIO station No. 0 to 7
(Set an even number)
8 and following: Loop back test mode (for testing)
(If the base I/O occupies 0 and 1, set the switch to 2.)
[Explanation of LEDs]
POWER (Green) 5V power output This turns ON when the state is normal.
display
RUN
CPU-E
(Green) Operation display When the unit power is turned ON, the self-diagnosis function activates. If there is no error, the operation state is entered ("RUN" LED turns ON).
(Red) CPU error display
RIOERR1
RIOERR2
(Red) Communication alarm in onboard RIO 0th station
(Red) Communication alarm in onboard RIO 1st station
II-2
2. FAULT DIAGNOSIS
2.1 List of Unit LEDs
2. FAULT DIAGNOSIS
2.1 List of Unit LEDs
ST No.
4
1
2 3
567
POWER
RU N
CPU-E
STOP
RU N
RI O
ERR1
ERR2
[Explanation of LED functions]
POWER 5VDC output display
RUN Operation display
CPU-E CPU error display
RIOERR1
Onboard I/O 1st station communication alarm
RIOERR 2
Onboard I/O 2nd station communication alarm
Green
Green
Red
Status
When normal During error
Lit
Lit
Not lit
Not lit
Not lit
Lit
Correspondence for error
24VDC +10%/
−15%
Check the input
Check the RUN-STOP slide switch setting
Refer to section 2.2.2.
Red Not lit Lit
Check the station No. setting rotary switch setting
Red Not lit Lit
II-3
2. FAULT DIAGNOSIS
2.2 Troubleshooting
2.2 Troubleshooting
2.2.1 Confirmation of trouble state
Confirm "when", "when doing what", and "what kind of" trouble occurred.
(1) When?
What time did the trouble occur?
What was the NC operation mode?
(3) What kind of trouble?
• What was displayed on the setting display unit's Alarm Diagnosis screen?
Display the Alarm Diagnosis screen, and check the alarm details.
• What was displayed for the machine sequence alarm?
• Is the CRT and LCD screen normal?
• When did the trouble occur? What was the frequency? (Does it occur when other machines are operating?) If the trouble occurs infrequently or if it occurs during the operation of another machine, there may be an error in the power voltage or the trouble may be caused by noise, etc.
Check whether the power voltage is normal (does it drop momentarily when other machines are operating?), and whether noise measures have been taken.
• Does the trouble occur during a specific mode?
• Does the trouble occur when the overhead crane is operating?
• What is the frequency in the same workpiece?
• Check whether the same trouble can be repeated during the same operation.
• Check whether the same trouble occurs when the conditions are changed.
(Try changing the override, program details, and operation procedures, etc.)
• What is the ambient temperature?
(Was there a sudden change in the temperature?
• Is there any contact defect or insulation defect in the cables?
(Has any oil or cutting water splattered onto the cables?)
II-4
2. FAULT DIAGNOSIS
2.2 Troubleshooting
2.2.2 When in trouble
If the system does not operate as planned or if there is any trouble in the operation, confirm the following points and then contact the Mitsubishi Service Center.
− Examples of trouble −
• The power does not turn ON.
• The external power turns ON, but the control power does not turn ON.
• The power turns OFF.
• The communication alarm display "RIOERR1"/"RIOERR2" LED turns ON.
• The 5VDC output display "POWER" LED turns OFF.
• The CPU error display "CPU-E" turns ON (flickers).
• The operation display "RUN" LED does not turn ON.
• The load does not turn ON/OFF even though the corresponding output is turned ON or OFF in the ladder monitor.
II-5
2. FAULT DIAGNOSIS
2.2 Troubleshooting
(1) Problems related to the power supply
The power does not turn ON.
Cause
The door interlock is applied.
Remedy
If the control panel door is not completely closed, close it. If the door interlock is applied even when the door is closed, the door interlock circuit is damaged.
The external power supply's input voltage is not as specified.
Check that the input voltage is within 200 to 230AC
+10%/–15%.
The external power supply is faulty.
(Note) The power supply for this unit is 24VDC.
Check that the power can be turned ON with just the external power supply.
(Note) Depending on the external power supply, the power may not turn ON in the no-load state, so install a slight load and check.
The external power turns ON but the NC control power does not turn ON.
Cause Remedy
The external power supply output is not correct.
Disconnect the cable between the unit and the external power supply, and check that the external power supply output voltage is normal.
The power cable is disconnected or broken.
Check the cable between the unit and external power supply, and securely insert it.
Check that the cable is not broken, and replace if broken.
Check that no inductive foreign matter has entered the unit.
There is a short circuit in the configuration card.
The power turns OFF.
Cause Remedy
There is a problem in the supplied power.
Check whether the voltage fluctuates at certain time zones.
Check whether an instantaneous power failure has occurred.
A problem occurs when the peripheral device starts operating.
Check whether the voltage drops instantaneously when the peripheral device operation starts.
II-6
2. FAULT DIAGNOSIS
2.2 Troubleshooting
(2) Problems related to remote I/O unit (FCU6-DX561)
If any of the following problems occur, all points of the machine input/output data for the remote I/O unit (FCU6-DX561) will turn OFF or may become unreliable. Thus, detect "Mismatch of input" with the PLC for another unit (NC).
The communication alarm display "RIOERR1"/"RIOERR2" LED turns ON.
Cause Remedy
The remote I/O cable (R211) is not connected, is broken, or the connector has a contact fault.
Check the connection of the cable (R211) between the base
I/O unit and remote I/O unit (FCU6-DX561).
The remote I/O cable (R211) is being affected by noise.
Separate the remote I/O cable (R211) from the drive line and power line.
Always connect the FG wire to the grounding plate.
The station No. setting rotary switch (SW2) setting is duplicated with another unit.
Change the base I/O unit, remote I/O unit (FCU6-DX561) and other remote I/O unit (FCUA-DX1 ) station No. rotary switch settings so that the station numbers are not duplicated.
A fault has occurred in the internal circuit of the FX2N-80BMT-NC card.
Contact the Service Center and have the unit replaced.
The 5VDC output display "POWER" LED turns OFF. (Or, the CPU-E LED lights for an instant.)
Cause
The input power is not within the tolerable range, or there is a fault in the internal 5V output generation circuit.
Remedy
Check that the input voltage is +20V or less, and that the voltage has not dropped for an instant. If the power is supplied correctly, contact the Service Center.
The CPU error display "CPU-E" turns ON (flickers).
Cause
If the CPU does not run properly because inductive foreign matter has entered or because of abnormal noise from an external source, or if the operation cycle exceeds 200ms, the watch dog timer error will occur and cause this LED to turn ON.
Remedy
If the watch dog timer error has occurred, error code 6105 will be stored when D8061 is monitored with a peripheral device. Review the program to see whether the operation cycle is too long. (Monitor D8012 to find the maximum operation cycle.)
Note that if the problem is caused by any other factor, a communication error will occur and online operations will not be possible when a peripheral device is connected.
Check for the presence of an abnormal noise generation source and for the entry of inductive foreign matter.
If this LED changes from a stable light to a flicker as a result of the inspection, check the program. (Check for circuit errors and syntax errors with the peripheral device's program check function.)
If the "CPU-E" LED is still ON after completing all inspections, contact the Service Center.
CAUTION
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.
Do not connect or disconnect the connection cables between each unit while the power is
ON.
Do not connect or disconnect the PCBs while the power is ON.
II-7
2. FAULT DIAGNOSIS
2.2 Troubleshooting
The operation display "RUN" LED does not turn ON.
Cause
The RUN/STOP switch is set to
STOP.
Remedy
Set the RUN/STOP switch to RUN.
An error was detected by the unit's self-diagnosis function.
Check for circuit errors and syntax errors with the peripheral device's program check function.
If the operation is stopped with a watch dog timer error, refer to the section "The CPU error display "CPU-E" turns ON
(flickers)." on the previous page.
The load does not turn ON/OFF even though the corresponding output is turned ON or OFF in the ladder monitor.
Cause
The relay output contact has fused due to an overload, load short-circuit or the rush current of a capacity load, etc., or a contact fault has occurred due to a rough contact surface.
Remedy
If the error occurs even after the relay is replaced or the cause of the relay output contact fusion is removed, contact the Service Center.
A fault has occurred in the
FX2N-80BMT-NC card output circuit.
Check whether there are any causes of overcurrent, such as a load short-circuit.
Measure the output voltage with a tester. If the specified voltage is not output, contact the Service Center and have the unit replaced.
CAUTION
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.
Do not connect or disconnect the connection cables between each unit while the power is
ON.
Do not connect or disconnect the PCBs while the power is ON.
II-8
2.2.3 Behavior of independent faults
2. FAULT DIAGNOSIS
2.2 Troubleshooting
The EN954-1 Category 3 machine system must be designed so that the safety functions are not disabled when one of the safety-related parts fails independently. Precautions for the designs and examples of the behavior when an independent fault occurs are listed below.
<Precautions for design>
Set a safety circuit outside the FCU6-DX561 so that the entire system works safely even if an external power supply error or FCU6-DX561 fault, etc., occurs.
Detect a mismatch between PLCs or stop the machine system according to the behavior.
(1) Always configure circuits outside of the FCU6-DX561, such as an emergency stop circuit, protection circuit, interlock circuit for reciprocating operations such as forward/reverse run, and machine damage preventing interlock circuits such as positioning upper/lower limits.
(2) If the FCU6-DX561 CPU detects and error with a self-diagnosis function, such as a watch dog timer error, all DO outputs will turn OFF. Output control may be disabled when errors occur at sections, such as the input/output control section, which cannot be detected by the
FCU6-DX561 CPU.
Design an external circuit or mechanism so that the machine will operate safely in this case.
(3) The output may stay ON or may stay OFF depending on faults that occur in the output circuit's photo coupler or transistor.
Design an external circuit or mechanism for the output signals that could lead to accidents so that the machine will operate safely.
Example of behavior during independent fault occurrence
Cause of fault Behavior
The 24VDC power for control turned OFF (failed).
The power cable was disconnected (broken).
The PLC will stop.
The DO output will turn OFF.
The 24VDC power for DO turned OFF (failed) The DO output will turn OFF.
The remote I/O cable was disconnected (broken).
The remote I/O cable is affected by noise.
The RIO communication will stop.
(The communication alarm display "RIOERR1" or
"RIOERR2" LED will turn ON.)
The contact of the relay connected to DI fused, or a contact fault has occurred due to a rough contact surface.
Regardless of the machine signal's ON or OFF state, the DI input will turn OFF or ON.
The DI cable was disconnected (broken). The DI input will turn OFF.
The contact of the relay connected to DI fused, or Regardless of the DO output's ON or OFF state, a contact fault has occurred due to a rough contact surface. the relay will turn OFF or ON.
The DO cable was disconnected (broken).
The encoder failed.
The spindle amplifier's encoder I/F circuit failed.
The DO output will turn OFF.
The encoder input data will become an abnormal value or will not be input.
The encoder cable between the encoder and spindle amplifier was disconnected (broken).
The encoder cable between the spindle amplifier and FCU6-DX561 was disconnected (broken).
A watch dog timer error occurred in the
FCU6-DX561.
A fault occurred in the internal 5V output generation circuit.
The encoder input data will not be input.
(The encoder detection speed will become 0.)
The encoder input data will not be input.
(The encoder detection speed will become 0.)
The PLC will stop, and the RIO communication will stop.
The DO output will turn OFF.
(The CPU error display "CPU-E" will turn ON.)
The PLC will stop, and the RIO communication will stop.
The DO output will turn OFF.
(The 5VDC output display "POWER" will turn
OFF.)
II-9
3. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE
3.1 Maintenance Tools
3. DAILY MAINTENANCE AND PERIODIC INSPECTION AND
MAINTENANCE
3.1 Maintenance Tools
The following measuring instruments are used to confirm that the voltage is being supplied correctly to the unit, to confirm that the wiring to the unit is correct, and to carry out simple troubleshooting.
Table 3.1 Maintenance tools
Tool Condition Application
Tester To check that the wiring to the PLC unit is correct before turning the power ON.
AC voltmeter Measure the AC power voltage.
The tolerable error is
±2% or less.
To measures the AC power voltage being supplied to the external 24VDC power supply unit.
DC voltmeter Max. scale 30V.
The tolerable error is
±2% or less.
To measure the DC power voltage.
External power supply 24V (control section, machine input/output interface)
Phase rotation meter
To check the connection order of the AC 3-phase input power supply.
Synchroscope General measurement and simple troubleshooting
Note) Currently, a high-accuracy digital multi-meter is commonly used as a tester. This digital multi-meter can be used as both an AC voltmeter and a DC voltmeter.
(2) Tools
Screwdriver (large, medium, small)
Radio pliers
II-10
3. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE
3.2 Replacement Methods
3.2 Replacement Methods
3.2.1 Cable
If the cable is replaced without turning the power OFF, the normal unit or peripheral devices could be damaged, and risks could be imposed.
Disconnect each cable with the following procedures. a) For the following type of connector, press the tabs with a thumb and forefinger in the direction of the arrow, and pull the connector off.
(1) Press
(1) Press
(2) Pull
(2) Pull
(1) Press
(2) Pull
CAUTION
Do not connect or disconnect the connection cables between each unit while the power is
ON.
Do not connect the cable by pulling on the cable wire.
II-11
3. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE
3.2 Replacement Methods b) For a flat cable type connector with claws, open the claws in the directions of the arrows, and pull the connector off.
(1) Open
(2) Pull c) For a flat cable type connector without claws, hold the connector with a thumb and forefinger, and pull the connector off.
(1) Hold with thumb and forefinger.
(2) Pull
CAUTION
Do not connect or disconnect the connection cables between each unit while the power is
ON.
Do not connect the cable by pulling on the cable wire.
II-12
3.2.2 Unit
3. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE
3.2 Replacement Methods
Usually, the unit is installed on the electric cabinet side.
Always replace the unit with the machine power turned OFF.
1) Disconnect all cables connected to the unit.
2) Loosen screw A. (The screw does not need to be removed.)
3) While supporting the unit with a hand, remove screw B.
4) Lift the unit upward and remove it.
5) Replace with the new unit, and fix the unit with the fixing screw at the original position.
6) Reconnect the connected cables at the original positions.
(Connect the cables to the predetermined connectors.)
7) Check that all cables have been connected correctly, and then close the electric cabinet door.
Electric cabinet
Screw B
PLC unit
Fixing screw (two screws)
Screw A
Lift up
CAUTION
Incorrect connections may damage the devices, so connect the cables to the specified connectors.
Do not replace the control unit while the power is ON.
Do not connect or disconnect the connection cables between each unit while the power is ON.
II-13
∗ 00/12/01 First edition issued
(0110) MEE
MITSUBISHI ELECTRIC CORPORATION
HEAD OFFICE : MITSUBISHI DENKI BLDG., 2-2-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN
MODEL
MODEL
CODE
Manual No.
REMOTE I/O UNIT・FCU6-DX561
008-165
BNP-B2302* (ENG)
Specifications subject to change without notice.
Printed in Japan on recycled paper.
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