Mitsubishi Electric PLK - G Series, Technical Manual

Page 1: ...Industrial Sewing Machine TECHNICAL MANUAL Electronic Pattern Sewing Machine PLK G Series Control Unit A180E604P02 ...

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Page 3: ..._____________________________ 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...

Page 4: ...ct 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 ...

Page 5: ...it 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...

Page 6: ...s 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 im...

Page 7: ... 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 Ra...

Page 8: ...s 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 a...

Page 9: ...n 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 washer Washer Installation bolt M8 60 Leg control box Installation bolt Fix at four positions ...

Page 10: ...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 Cover 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 m...

Page 11: ...h your electrician for details on the grounding wire 5 Power capacity Use a fuse or safety breaker on the power supply Power supply Recommended current capacity value 3 phase 200V 10A 6 Using the 3 phase 200V control box with single phase 200 to 220V Connect power supply to the red and white lead wires for the push button switch The black wire is not used so insulate it by wrapping insulation tape...

Page 12: ...he hand pulley turn easily 2 After turning the switch ON 1 Is the front panel power LED green on 2 Is the front panel warning LED red on or flickering 3 Is there any heating odors or abnormal noise from the motor or control box When you turn ON the power a click noise comes from inside the control box This noises are not abnormal Turn the sewing machine OFF and contact your dealer if there is any ...

Page 13: ... the machine power with the system in an initial state the Model Language Setting screen appears Perform the procedures below 1 When the power supply is turned on first time Model Language setting screen is displayed For language setting press For model setting press 2 Language setting press Choose Language button then press 3 Model setting press Choose Model button then press ...

Page 14: ...tem file Setting table and Step file Connect USB memory 1 which above data is contained to the connector on the front panel of the control box then press After file name selection screen is displayed choose target filename by using up and down arrow button then press Goto 6 1 Setting table and Step file must be saved in the folder in the USB memory 5 Model Language setting screen is displayed agai...

Page 15: ... panel of the control box Is completely off turn the power on Check the LED lamp is OFF 7 Initial condition At initial condition the message like a right picture is displayed Press to switch to the Standard screen then create or read sewing pattern data Refer to technical manual Operation panel ...

Page 16: ...ogram mode Thread trimming release timing LRS msec deg Program mode Thread trimming release timing LRE msec deg Timing for wiper output W Program mode Wiper W1 msec Program mode Wiper W2 msec Needle down position DN Needle up position UP LTM setting T1 TRS deg TRE ms T2 TRS deg TRE deg T3 TRS deg TRE ms T4 TRS ms TRE ms Thread trimming output T T5 TRS ms TRE ms LLM setting L1 LRS deg LRE ms L2 LRS...

Page 17: ...amp output 3 OF3 Clamp output 4 OF4 WHY ON Clamp output 1 OF1 Clamp output 2 OF2 Clamp output 3 OF3 Clamp output 4 OF4 Note WHY ON The clamp input signal IF2 IF3 IF4 is invalidated when clamp output 1 is not ON The clamp input signal IF2 is validated when clamp output 1 is ON The clamp input signal IF3 is validated when clamp output 2 is ON The clamp input signal IF4 is validated when clamp output...

Page 18: ...ic pressure two step AF2 ON Can not use other function in Work holder mode Pneumatic pressure two step clamp input signal A2F Start input signal SRT Pneumatic pressure two step clamp low pressure output AFL Pneumatic pressure two step clamp high pressure output AFH Pneumatic pressure two step clamp eject pressure output AFE Movement of sewing machine ON ON ON ON ON ON 1A 2A 3A 4A 4B 3B 2B 1B ON 1T...

Page 19: ... 7 IF7 Clamp input 8 IF8 Start input signal SRT Clamp output 1 OF1 Clamp output 2 OF2 Clamp output 3 OF3 Clamp output 4 OF4 Clamp output 5 OF5 Clamp output 6 OF6 Clamp output 7 OF7 Clamp output 8 OF8 Movement of sewing machine Note 1 When the setting CF1 ON clamp input 1 is link input 2 When the setting CF2 ON clamp input 5 is link input 7A The divisions of clamp 1 F21N 4 The divisions of clamp 2 ...

Page 20: ...ion division 1 FM1 The clamp step forward direction division 2 FP2 The clamp step backward direction division 2 FM2 Start input signal SRT Clamp output 1 OF1 Clamp output 2 OF2 Clamp output 3 OF3 Clamp output 4 OF4 Clamp output 5 OF5 Clamp output 6 OF6 Clamp output 7 OF7 Clamp output 8 OF8 Movement of sewing machine 7A ON ON ON ON ON 6A 5A 4A 3A 2A 1A 3A 3B ON ON ON ON ON ON ON ON ON ON ON ON ON O...

Page 21: ... input Clamp input 1 IF1 Clamp input 2 IF2 Clamp input 3 IF3 Clamp input 4 IF4 Clamp input 5 IF5 Clamp input 6 IF6 Clamp input 7 IF7 Clamp input 8 IF8 Start input signal SRT Clamp output 1 OF1 Clamp output 2 OF2 Clamp output 3 OF3 Clamp output 4 OF4 Clamp output 5 OF5 Clamp output 6 OF6 Clamp output 7 OF7 Clamp output 8 OF8 Movement of sewing machine 1 2 2 2 3 2 4 2 Block number of clamp Number of...

Page 22: ...Y OF OFB 4 F4BN 4 F4SN 4 When not using the clamp step input The clamp step forward direction general input signal SFP The clamp step backward direction general input signal SFM Start input signal SRT Clamp output 1 OF1 Clamp output 2 OF2 Clamp output 3 OF3 Clamp output 4 OF4 Clamp output 5 OF5 Clamp output 6 OF6 Clamp output 7 OF7 Clamp output 8 OF8 Movement of sewing machine 7A ON ON 6A 5A 4A 3A...

Page 23: ...or I1 I2 I3 I4 I5 Alternate Input reversal Input control section Physical input Sewing machine operation prohibit Home position return prohibit Two stage clamp input S1 F Virtual input 0 Virtual input 1 Virtual output 0 Virtual output 1 Sewing machine control Two stage clamp output T L W OF1 PF Virtual input Virtual output O1 O2 O3 O4 O5 Physical output Output control section WL Alternate output r...

Page 24: ...ough the output control section no operation delay circuit alternate etc and is then output to the output port Refer to page 8 3 3 Customizing the virtual input output Selection and connection of physical input output port and virtual input output port For example to connect the physical input port I1 and virtual input port SRT start and to connect the physical output port O1 and virtual output po...

Page 25: ... the input signal A point C point 1 When the operation selection is set to normal NO the operation will be the same as the input signal B point 2 When the operation selection is set to alternate AL the signal will turn ON at the first rising edge turn OFF at the second rising edge and will turn ON at the third rising edge The signal waveform will repeatedly turn ON and OFF at the input rising edge...

Page 26: ...and then the signal is connected to the output port F point A point Logic operation selection 1 When normal NO is selected the input waveform is connected 2 When alternate AL is selected the signal will alternately turn ON and OFF turning ON at the first rising edge and OFF at the next rising edge Input signal O1 Normal A Alternate A OF ON Alternate NO AL A C B OF ON NO D ON delay OFF delay D OF O...

Page 27: ...ing 1 When normal is selected the C point signal will be output to the D point without any changes 2 When reverse is selected D point signal will be reversing signal of the C point signal Input signal C Normal D Reverse D E point Chopping setting 1 When 100 ON is set there is no change and input signal of D point is output to E point 2 When other than 100 ON is set outpu of E point is on while set...

Page 28: ... same from IF2 toIF8 F1C F8C Clamp output prohibition signal 1 8 When F1C input is on OF1 output is prohibited same from F2C to F8C OFC All clamp output cancel signal When OFC input is on OF1 to OF8 outputs are prohibited WC Wiper output cancel signal When WC input is on W output is prohibited TC Trimmer output cancel signal When TC input is on Thread trimmer sequence output T L and W is prohibite...

Page 29: ...that invalidates teaching input key When INK is on teaching input key becomes invalid MNK Signal that invalidates teaching modification key When MNK is on teaching modification key becomes invalid CNK Signal that invalidates teaching conversion key When CNK is on teaching conversion key becomes invalid PNK Signal that invalidates program mode key When PNK is on program mode key becomes invalid NNK...

Page 30: ... L and W are turned off TSE output is turned off END Sewing completion output When a sewing pattern operation is finished END output is turned on When the next sewing is started END output is turned off DCS Halt code output When the halt code data USTP DSTP is read while sewing DCS output is turned on When the machine restarts DCS output is turned off DST Halt in progress output When the machine i...

Page 31: ...tems and Corrective Actions Is the power switch definitely turned ON Check the power supply connection and turn ON the power switch again Is the power supply connector fully connected Check the power supply connector connection contact state and others and then turn ON the power switch again Refer to 12 Unit Wiring Diagram Is there a blown fuse in the control box Replace the blown fuse with a fuse...

Page 32: ...1 Refer to the above table A communication error occurred Please turn on the power again after check connection of the operation panel cable If you take a corrective action but no improvement is made consult with your local representative Is the front panel red warning LED showing flickering pattern 2 Refer to the above table Open the control panel lid Is fuse 2 5A on the PLK G2 CPU board blown Re...

Page 33: ...al but the machine does not run The message MACHINE HEAD TILT WAS DETECTED appears Checking Items and Corrective Actions Is the machine tilted Return the machine back to its proper state and try again Check if the tilting sensor switch is damaged or disconnected Is the signal HES among the input signals changed Check input customization Case5 No screen appears on the operation panel when you turn ...

Page 34: ...he system data in a USB memory Refer to page 10 8 System data save to USB memory Copy the folder where the installed system datas are included into the root directory of USB memory 2 Turn the machine power OFF and insert the USB memory 3 While holding down the F key on the front panel of the control box turn the machine power ON Keep pushing F key until red LED on the front panel is turned on 4 In...

Page 35: ...llation complete Machine type Language setting screen on the operationpanel is appeared 6 Pull out USBmemory 7 Language setting press Choose Language button then press 8 Model setting press Choose Model button then press ...

Page 36: ...e only Reads System file Setting table and Step file Connect USB memory 1 which above data is contained to the connector on the front panel of the control box then press After file name selection screen is displayed choose target filename by using up and down arrow button then press Goto 12 1 Setting table and Step file must be saved in the folder in the USB memory 10 Model Language setting screen...

Page 37: ...ill be returned to the factory setting To exit without setting press 12 Re turning on the power supply Turn the power off After check the LED lamp on the front panel of the control box Is completely off turn the power on Check the LED lamp is OFF Reinstallation is complete ...

Page 38: ...ck the CD ROM drive and USB memory drive ex CD ROM drive D USB memory drive E 2 Open the CD ROM root directory by using exploler etc Double click PLKG System Setup exe 3 After open the PLKG System Setup window select CD ROM drive and USB memory drive respectively 4 Click the SystemCopy button Data copy will be executed 5 When copying is complete the message will be appeared then click OK button Pr...

Page 39: ...rive of the computer Insert the USB memory that system data will be preserved 2 folder exists under System Folder Copy the folder onto the root directory of USB memory 3 Left click the with the mouse 4 Click the File Properties on the menu bar 5 Click Reading exclusive use and then clear the check box make the check box blank Then click OK button 6 Choose The change is applied to this folder the s...

Page 40: ...ow Green 1 2 3 4 5 6 1 2 3 4 5 1 2 3 4 1 2 3 4 1 2 3 4 5 Push button switch assay K14M47932203 60 9090 306 108 002 60 9090 306 208 002 Power unit PLK B PUC B40 60 9090 304 118 006 60 9090 304 218 006 60 9090 304 118 006 60 9090 305 108 005 60 9090 306 108 005 1 2 3 4 5 6 Black Brown Blue Green Yellow Black Brown Blue Black Red Blue Green Yellow Black Brown Blue Green Yellow Black Brown Blue Green ...

Page 41: ...ack Brown Black Brown Green Yellow Black Red Black Green Yellow Brown Blue Black Green Yellow Brown Blue Black Green Yellow Brown Blue Green Yellow To control box CONB Ferrite core PLK B1 FIL P W B Ground Blue Brown Green Yellow 1 2 3 4 5 6 Blue Brown Green Yellow Green 1 2 3 4 5 6 1 2 3 4 1 2 3 4 1 2 3 4 5 1 2 3 4 5 60 9090 305 108 005 60 9090 305 208 005 60 9090 306 208 005 60 9090 304 118 006 6...

Page 42: ... 12 1 12 Unit wiring diagram For connector pin details refer to 13 Connectors Layout and 14 Pin Number of Connectors ...

Page 43: ... 12 2 ...

Page 44: ... 13 1 13 Connectors layout Back side of control box front panel of the control box Back side of machine head ...

Page 45: ...A IN 7 GND 8 X HOME 9 Y HOME 10 Z HOME 11 STP 12 SCL OFF 13 SCL_TE 14 SDA_TE 15 CONF Main axis encoder Signal Pin No GND 1 UP 2 DN 3 5V 4 FG 5 EA 6 ERA 7 EB 8 ERB 9 10 EZ 11 ERZ 12 EU 13 EV 14 EW 15 CONG XY axis encoder Signal Pin No GND 1 5V 2 GND 3 FG 4 ENXAN 5 ENXBN 6 ENYAN 7 ENYBN 8 ENXAP 9 ENXBP 10 ENYAP 11 ENYBP 12 CONH Foot switch Signal Initial setting Pin No 12V 12V 1 I1 SRT Start input 2...

Page 46: ...RS 232C Signal Pin No RXD1 1 RXD0 2 TXD1 3 GND 4 12V 5 TXD0 6 2 PLK G2 SOL 1 Input CON3 Printed character Signal Pin No GND Ground 1 XHOME X axis home position detection 2 XH 12V DC12V power supply 3 CON4 Printed character Signal Pin No GND Ground 1 GND Ground 2 YHOME Y axis home position detection 3 YH 12V DC12V power supply 4 CON5 Printed character Signal Pin No GND Ground 1 GND Ground 2 GND Gro...

Page 47: ...the solenoid valve output Output Name Power Resistance Ratings O1 T DC24V 6Ω or more Moment O2 W DC24V 6Ω or more Moment O3 L DC24V 10Ω or more Moment O4 FU DC24V 6Ω or more Continuity Note1 O5 OP1 DC24V 12Ω or more Note2 Continuity Note1 O7 OP2 DC24V 12Ω or more Note2 Continuity Note1 Note 1 Continuity ratings is available when chopping duty is set to 33 or lower Note 2 When neither OP1 nor OP2 a...

Page 48: ... 15 Wiring diagram inside control box 15 1 ...

Page 49: ...hase Europe 50 60Hz 380 415V 3 phase 50 60Hz Power unit PLK B PUC A10 PLK B PUC B40 Noise filter unit PLK E NU 20 Model name XL K756 20 Rated output 750W Main motor Rated speed 3 000rpm Model name PLK G CU 20 Control box Rated output DC 24V Power source 1KVA Range of rating voltage 10 Ambient temperature 5 C 35 C Condition Ambient humidity 45 85 ...

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Page 52: ...FACTORY AUTOMATION SYSTEM TOKYO BLDG 2 7 3 Marunouchi Chiyoda ku Tokyo 100 8310 Japan FAX 81 3 3218 6821 New publication effective OCT 2008 Specifications subject to change without notice ...