Mitsubishi Electric PLK-J-CU-20S, Technical Manual

Page 1: ...INDUSTRIAL SEWING MACHINE MODEL PLK J CU 20S TECHNICAL MANUAL Control Unit A180E816P01 ...

Page 2: ...ng chart _______________________________________________ 7 1 8 Customized input output _____________________________________ 8 1 9 Input Output signal ________________________________________ 9 1 10 What happened Could it be an error ________________________ 10 1 11 How to reinstalling the system _______________________________ 11 1 12 Several power supply ______________________________________ 12...

Page 3: ...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 2019 MITSUBISHI ELECTRIC CORPORATION ...

Page 4: ...e applied so that operation can not be performed Where the unit will be subject to direct sunlight or outdoors Near sources of heat such as heating appliances Where the relative humidity is 45 or less or 85 or more and where dew may condense 4 Atmosphere In an atmosphere containing dust or corrosive gases etc In a flammable gas or explosive environment 5 Vibration If excessive vibration could occu...

Page 5: ...ers away from all moving machine parts especially around the sewing machine needle etc 2 Never drop the control unit or place objects in the clearances 3 Do not operate the sewing machine without the protective parts such as the cover or protection devices such as the safety breaker 4 If any damage is observed in the control unit if the unit does not operate correctly or if the operation is suspic...

Page 6: ... 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 7: ...e A long wire could cause malfunctions Use a shielded wire for the signal wire when possible 14 If the fuse blows remove the cause and replace the blown fuse with one having the same capacity View from the front with cover removed View from the front with the cover and CPU removed I F board located on back of machine head 15 Attention when power supply is turned on again Please make sure not to tu...

Page 8: ...ea Front view of control box installation area Insert the four bolts into the holes on the top plate and install the control box 80 427 Top plate Damper cushion Control box Leg Nuts Spring washer Washer Installation bolt M8 x 60 Leg Control box Installation bolt Fix at four positions 4 Ø9 ...

Page 9: ...Power LED green Warning LED red Front panel Cover installation screw M4 screw Cover CON A I F board power Connect to I F board MIF CON B Main servo motor Connect to spindle servo motor CON H general purpose port Connect to PC CON K universal serial communication port CON D XY axis stepping motor Connect to sewing machine head stepping motor CON E PF axis stepping motor Connect to sewing machine he...

Page 10: ...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 11: ...tor Other connectors I F board MIF etc 3 Does the hand pulley turn easily 2 After turning the switch ON 1 Is the front panel power LED green on 2 Is the front panel warning LED red on or flickering 3 Is there any heating odors or abnormal noise from the motor or control box When you turn ON the power a click noise comes from inside the control box This noises are not abnormal Turn the sewing machi...

Page 12: ... PAL installing MDL_DATA Folder Model data for model data reading JPAL PLK File Key file for PAL system installing 1 KEY_FILE JPAL PLK File Key file for PAL system installing MAMUAL PLK J Version information PDF install information Device and installation place Device Version up USB flash drive connection Operation Control box System data MAIN SYSTEM DRIVE SYSTEM FPGA MAIN FPGA MIF CON W PAL Insta...

Page 13: ...ED is blinking the installation has failed Check the PLKJ_SYSTEM folder inside the USB flash drive and try again 4 After the installation is completed the model set initialize function screen will be displayed If SELECT select model data from USB flash drive Please select the model name by key And it is decided by push the key Please correctly select the model to be used Message is displayed Pleas...

Page 14: ...er and use it 2 Please insert USB flash drive to CON W connector on PAL 3 Turn the power on The buzzer sounds eight times If the buzzer does not sound it will not install Please check the key file Startup screen will appear after a while 4 Installing complete Display is switched to standard screen after installing complete Note When setting up for the first time the setting screen is always displa...

Page 15: ... install bar will turn blue Note If the red LED is blinking the installation has failed Check the PLKJ_SYSTEM folder inside the USB flash drive and try again 3 Installing complete The buzzer beeps once and the installation is completed Display is switched to standard screen after installing complete When the motor axis and machine position has already been set Note When setting up for the first ti...

Page 16: ... setting up for the first time the setting screen is always displayed Refer to 2 the motor axis and machine position setting described later 2 The motor axis and machine position setting 1 Motor axis and machine alignment Here align the upper position of the needle bar 2 press Please set the upper position according to the contents of the screen When the position is decided please press to save th...

Page 17: ... switch Operation details 1 Selection of Easy setting Press on the standard screen and open the menu mode Press 2 Select Language setting Press 3 Select language Select the language to set Press 4 Language switching complete Message will be displayed please press ...

Page 18: ... When USB flash drive is unconnected and pushes the button it is made all reversing display 3 Check with the PLK J Version information PDF in the USB flash drive against the version display screen PLK J Version information PDF contains the software version at the time of shipment PAL 画面 PLK J Version information 4 If there is a part that does not match the software version please re install the pa...

Page 19: ...iming 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 up position UP Thread trimming output signal T LTM T1 T2 T3 T4 T5 Thread release output signal L LLM L1 L2 L3 L4 L5 Wiper Output signal W 0 TRS deg TRE ms TRS deg TRE deg TRS deg TRS ms T Thread trimming output signal ON T UP1 UP2 ON L T...

Page 20: ... 4 OF4 Note WHY OFF The clamp input signal IF1 IF2 IF3 IF4 is validated 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 signa...

Page 21: ...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 22: ...nd can be set WHY OF OFB 4 F2BN 2 When not using the clamp step input Clamp input 1 IF1 Clamp input 2 IF2 Clamp input 3 IF3 Clamp input 4 IF4 Start input signal SRT Clamp output 1 OF1 Clamp output 2 OF2 Clamp output 3 OF3 Clamp output 4 OF4 Movement of sewing machine １ ２ ON ON ON ON ON 4A 3A 2A 1A ON ON ON ON ２ ２ Block number of clamp Number of clamps 2B 2A ON 2B 2A ON ON ON 1A ON 1B ON ...

Page 23: ...tep forward direction general input signal FSP The clamp step backward direction general input signal FSM Start input signal SRT Clamp output 1 OF1 Clamp output 2 OF2 Clamp output 3 OF3 Clamp output 4 OF4 Movement of sewing machine 8 Oil lubrication output setting OILV ON Oil lubricate timing set by OL1C 2C and OL1T 2T OL1C 2C is not clear by after next sewing this number is accumlate DSW FEED SEW...

Page 24: ...ock Connector I1 I2 I3 I4 I5 Alternate Input reversal Input control section Physical input Sewing machine operation prohibit Home position return prohibit NO SRT IF1 NO STP Virtual input 0 Virtual input 1 Virtual output 0 Virtual output 1 Sewing machine control DSW T W L OF1 OIL1 Virtual input Virtual output O1 O2 O3 O4 O5 Physical output Output control section WL Alternate output reversal ON OFF ...

Page 25: ...the output control section no operation delay circuit alternate etc and is then output to the output port Refer to page 8 4 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 port T ...

Page 26: ...l 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 The C point sig...

Page 27: ...he signal is connected to the output port E 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 OFF delay 100 ON 100 ON other then Full wave time Duty ON delay OF ON Alte...

Page 28: ...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 output of E point is on while se...

Page 29: ...on by the home positioning key or HP signal is prohibited THS Upper thread sensor input signal When setting of Program mode Needle thread breaking sensor ON OFF is on the signal can be used for thread breakage detection input ARS Less pressure detection signal When ARS input is on all operation is interrupted and error E 3108 is displayed Returns by power supply re turning on IO0 to IOF General pu...

Page 30: ...ignal that invalidates speed key When SNK is on speed key becomes invalid HNK Signal that invalidates PF height setting icon When HNK is on PF height setting key becomes invalid DHK Signal that invalidates digital tension gauge icon When DKK is on digital tension gauge key becomes invalid ENK Signal that invalidates easy setting icon When ENK is on easy setting key becomes invalid P3NK Signal that...

Page 31: ...CK2 Cassette jig sensor 2 signal BCDR Barcode reading input signal When input BCDR is turned ON the pattern can be read with a barcode This signal is effective when Program mode Communication UBCT is OFF DFCR Input signal of material Thickness detection clear Material thickness detection OK Output signal DFOK material thickness detection NG output signal DPNG DNNG are turned OFF SKCR Input signal ...

Page 32: ...off TSE Trimming start output When trimming sequence down position is started TSE output is turned on When trimming sequence is finished when all the outputs of T 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 ...

Page 33: ...pect of abnormality stitch This signal is effective when Program mode the stitch abnormality detection SKCF is on SKOK Abnormal stitch detection OK output SKOK output turns ON When sewing is completed with no suspected abnormal stitch detected This signal is effective when Program mode the stitch abnormality detection SKCF is on DPNG Thickness detection NG side output DPNG output turns ON when mat...

Page 34: ...s 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 section 13 Is there a blown fuse in the control box Replace the blown fuse with a fuse of identical c...

Page 35: ...WAS DETECTED appears Or the message START PROHIBIT SIGNAL BEING 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 bobbin door open Close the bobbin door Check if the sensor switch of bobbin door is damaged or disconnected Is the signal HES among ...

Page 36: ...board is broken consult with your local representative Is the front panel red warning LED showing Blink pattern 2 Fig1 PAL communication error Please make sure that PAL is connected If you take a corrective action but no improvement is made consult with your local representative Is the front panel red warning LED showing Blink pattern 3 Fig1 It is a 12V error on the CPU board Is fuse 2 5A on the C...

Page 37: ...e setting of the sewing machine you are using to Initialize to the initial value Initial setting value in internal memory It decide by key A message will be displayed so please operate according to the message Note When returning to the standard screen without changing the initial value When you press the key a message like the one on the right appears If you touch key it is possible to move stand...

Page 38: ... 12 Several power supply 1 3Ø AC200V 240V 50 60Hz 2 1Ø AC200V 240V 50 60Hz Except Europe 12 1 ...

Page 39: ...3 3Ø AC380V 415V 50 60Hz Except Europe 4 1Ø AC200V 240V 50 60Hz Europe 12 2 ...

Page 40: ... CON4 ZH CON27 O2 CON29 O4 24V CON R CON X To control unit CON A O5 CON26 I F unit Y axis HP sensor Oil injection 1 Invert SW bobbin open close sensor Trimming Halt SW LED Digital tension motor P2 axis P2 axis encoder Thread release X axis HP sensor PF axis HP sensor Wiper Work holder To control unit CON J I F board MIF 13 1 CON30 CON3 CON22 ...

Page 41: ...g motor CON R CON U CON T CON S PLK J CU 20S CON V PAL Foot switch CON X Power switch box Main servo motor X encoder Y encoder Y stepping motor X stepping motor Main servo encoder 13 2 I F unit in Back side of machine head ...

Page 42: ...4 1 14 Connectors layout front panel of the control box About CON H Please only connect PC I F unit in Back side of machine head PAL CON T CON S CON V CON U CON R CON W USB connector INSTALL Button CON X ...

Page 43: ...CON14 PENC O1 CON26 O2 CON27 O3 CON28 O4 CON29 O5 CON30 TE2 CON1 CON R CON15 PM PULT1 CON V CON12 CON U CON24 I4 O6 CON9 DA CON16 24V TE1 A1 A16 B1 B16 A1 B1 1 B16 3 1 4 1 3 1 4 1 5 3 1 4 1 1 4 1 3 1 5 1 3 4 1 1 7 1 5 1 1 12 6 1 4 1 8 1 5 1 10 A16 1 1 1 1 1 CON2 XH CON6 CH ...

Page 44: ...ZB2 5 FG 6 CON F POWER SUPPLY Signal Pin No R 1 S 2 T 3 NC 4 FG 5 FG 6 CON G LCD PANEL Signal Pin No 12V 1 GND 2 TXD0 3 RXD0 4 INSTALL 5 VBUS 6 DP 7 DM 8 CON H OPTION PORT PC connection Signal Pin No VBUS 1 DM 2 DP 3 NC 4 GND 5 Please only connect PC CON J I F BOARD signal same for CON R Signal Pin No 12V 1 RXD0 2 TXD0 3 GND 4 12V 5 RXD1 6 TXD1 7 GND 8 XHOME 9 YHOME 10 ZHOME 11 STP 12 UP 13 DN 14 ...

Page 45: ...V 7 IA NO Do not 8 GND GND 9 12V 12V 10 IB NO Do not 11 GND GND 12 CON T OPTION OUTPUT output for solenoid valve Signal Initial setting Pin No 24V 24V 1 O7 DSW Sewing in progress output 2 GND GND 3 24V 24V 4 O8 NO Do not 5 GND GND 6 24V 24V 7 O9 NO Do not 8 GND GND 9 24V 24V 10 OA NO Do not 11 GND GND 12 24V 24V 13 OB NO Do not 14 GND GND 15 Refer to page 14 6 for the ratings of solenoid valve CON...

Page 46: ...put 0 2 AN1 Analog input 1 3 GND Ground 4 CON14 Printed character Signal Pin No PENC 5V DC5V power supply 1 5V DC5V power supply 2 3 4 5 6 P2_AP P2 axis encoder A 7 P2_AN P2 axis encoder A 8 P2_BP P2 axis encoder B 9 P2_BN P2 axis encoder B 10 GND Ground 11 GND Ground 12 CON16 Printed character Signal Pin No 24V 24V DC24V power supply 1 PGND Ground 2 A24V Analog 24V Power supply 3 AGND Analog grou...

Page 47: ...not A8 IK NO Do not A9 IL NO Do not A10 IM NO Do not A11 IN NO Do not A12 IO NO Do not A13 IP NO Do not A14 IQ NO Do not A15 IR NO Do not A16 TE1 12V DC12V B1 GND Ground B2 12V DC12V B3 GND Ground B4 12V DC12V B5 GND Ground B6 12V DC12V B7 GND Ground B8 12V DC12V B9 GND Ground B10 12V DC12V B11 GND Ground B12 12V DC12V B13 GND Ground B14 12V DC12V B15 GND Ground B16 ...

Page 48: ...er output 1 1 24V DC24V Power supply 2 CON30 Printed character Signal Pin No O5 O5 OIL1 Oil lubrication output 1 1 NC 2 24V DC24V Power supply 3 TE2 Printed character Signal Pin No TE2 OC NO Do not A1 OD NO Do not A2 OE NO Do not A3 OF NO Do not A4 OG NO Do not A5 OH NO Do not A6 OI NO Do not A7 OJ NO Do not A8 OK NO Do not A9 OL NO Do not A10 OM NO Do not A11 ON NO Do not A12 OO NO Do not A13 OP ...

Page 49: ...ad normally Inapplicable devices USB device requiring an external power supply including Computer devices USB hard disk drive keyboard mouse USB flash drive with fingerprint authentication function or with security function USB flash drive with hub function Media reader USB device without data storage function USB connecting device PAL CON W MIF board CON U Control box CON H USB flash drive Standa...

Page 50: ...s 3 0A 3 Output for display light or buzzer Output Printed character Power Maximum ratings current O6 I4 O6 DC12V 0 1A or less 4 Analog output Output Printed character Power Output voltage Maximum ratings current DA0 DA DC12V DC 0 to 10V 0 01A or less DA1 DA DC12V DC 0 to 10V 0 01A or less Use the input resistance of the connection destination at 1kΩ or more Example of use Input device 4 Analog in...

Page 51: ...N P XY ENCODER CON Q PF ENCODER CON D XY STEPPING MOTOR CON E PF STEPPING MOTOR 6P 12P 4P 9P 15P 5P 8P 8P 9P 9P 6P REGENERATIVE RESISTOR CON 19 CON 3 CON1 CON 5 CON 3 CON 1 CON 4 CON 5 CON 4 CON 1 CON 3 CON4 CON2 CON 7 CON 5 CON 5 CON 4 CON 6 CON 6 CON 3 CON 2 CON 7 CON 1 CON 1 CON 8 CON 12 CON 7 CON 3 CON 11 CON 4 CON 21 CON 20 CON 2 ＣＰＵ ＰＭＤ ＳＲＶ ＰＷＲ ＰＷＲ PWR LED ERR LED PLK J2 CU 20 CON A I F BOAR...

Page 52: ...hase Europe 380 to 415V 50 60Hz 3 phase Power unit PLK B PUC B40 Noise filter unit PLK J CE PLK J ACR Main servo motor Rated output 750W Rated speed 3 000rpm Control box Model name PLK J CU 20S Rated output DC 24V Condition Power source 1KVA Range of rating voltage 10 Ambient temperature 5 C to 35 C Ambient humidity 45 to 85 ...

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Page 56: ...Printed in Japan ...