Mitsubishi M850W, M830W, M850S, M830S, M80W Maintenance Manual

Introduction

This manual covers the items required for maintaining the MITSUBISHI CNC M800/M80/E80 Series.

Supported models are as follows:

Supported models Abbreviations in this manual

M800W Series M850W, M830W M800S Series M850S, M830S M80W Series M80W M80 Series M80 TypeA, M80 TypeB E80 Series E80 TypeA, E80 TypeB

Abbreviations in this manual are as follows:

Abbreviations Supported models

M800, M800 Series M800W Series/M800S Series M80, M80 Series M80W Series/M80 Series M800/M80, M800/M80 Series M800W Series/M800S Series/M80W Series/M80 Series M8, M8 Series M800W Series/M800S Series/M80W Series/M80 Series/E80 Series

Read this manual thoroughly and understand the product's functions and performance before starting to use. The unit names, cable names and various specifications are subject to change without notice. Please confirm these before placing an order. Be sure to keep this manual always at hand. The following screens described in this manual are the screens for Mitsubishi Electric's display unit. If the display unit you are using is not manufactured by Mitsubishi, please contact the machine tool builder.

CAUTION

For items described as "Restrictions" or "Usable State" in this manual, the instruction manual issued by the machine tool builder (MTB) takes precedence over this manual.

Items not described in this manual must be interpreted as "not possible".

This manual is written on the assumption that all the applicable functions are included. Some of them, however, may not be available for your NC system. Refer to the specifications issued by the machine tool builder before use.

Refer to the manuals issued by the machine manufacturer for each machine tool explanation.

Some screens and functions may differ depending on the NC system (or its version), and some functions may not be possible. Please confirm the specifications before use.

Do not connect NC system to the Internet-connected network.

To maintain the safety of the NC system against unauthorized access from external devices via the network, take appropriate measures.

In this manual, the following abbreviations might be used. MTB: Machine tool builder

Also refer to the manuals on "Manual List" as necessary.

Manual List

Manuals related to M800/M80/E80/C80 Series are listed as follows. These manuals are written on the assumption that all optional functions are added to the targeted model. Some functions or screens may not be available depending on the machine or specifications set by MTB. (Confirm the specifications before use.) The manuals issued by MTB take precedence over these manuals.

Manual IB No. Purpose and Contents

M800/M80/E80 Series Instruction Manual

C80 Series Instruction Manual

M800/M80/E80/C80 Series Programming Manual (Lathe System) (1/2)

M800/M80/E80/C80 Series Programming Manual (Lathe System) (2/2)

M800/M80/E80/C80 Series Programming Manual (Machining Center System) (1/2)

M800/M80/E80/C80 Series Programming Manual (Machining Center System) (2/2)

M800/M80/E80 Series Alarm/Parameter Manual

C80 Series Alarm/Parameter Manual

IB-1501274

IB-1501453

IB-1501275

IB-1501276

IB-1501277

IB-1501278

IB-1501279

IB-1501560

 Operation guide for NC  Explanation for screen operation, etc.

 G code programming for lathe system  Basic functions, etc.

 G code programming for lathe system  Functions for multi-part system, high-accuracy function, etc.

 G code programming for machining center system  Basic functions, etc.

 G code programming for machining center system  Functions for multi-part system, high-accuracy function, etc.

 Alarms  Parameters

Manuals for MTBs (NC)

Manual IB No. Purpose and Contents

M800/M80/E80/C80 Series Specifications Manual (Function)

M800/M80/E80/C80 Series Specifications Manual (Hardware)

M800W/M80W Series Connection and Setup Manual

M800S/M80/E80 Series Connection and Setup Manual

C80 Series Connection and Setup Manual

M800/M80/E80 Series PLC Development Manual

M800/M80/E80 Series PLC Programming Manual

M800/M80/E80/C80 Series PLC Interface Manual

M800/M80/E80 Series Maintenance Manual

C80 Series Maintenance Manual

IB-1501505

IB-1501506

IB-1501268

IB-1501269

IB-1501452

IB-1501270

IB-1501271

IB-1501272

IB-1501273

IB-1501454

 Model selection  Outline of various functions

 Model selection  Specifications of hardware unit

 Detailed specifications of hardware unit  Installation, connection, wiring, setup (startup/adjustment)

 Electrical design  I/O relation (assignment, setting, connection), field network  Development environment (PLC on-board, peripheral

development environment), etc.

 Electrical design  Sequence programming  PLC support functions, etc.

 Electrical design  Interface signals between NC and PLC

 Cleaning and replacement for each unit  Other items related to maintenance

Manuals for MTBs (drive section)

Manual IB No. Contents

MDS-E/EH Series Specifications Manual

MDS-E/EH Series Instruction Manual

MDS-EJ/EJH Series

ecifications Manual

MDS-EJ/EJH Series Instruction Manual

MDS-EM/EMH Series Specifications Manual

MDS-EM/EMH Series Instruction Manual

DATA BOOK IB-1501252  Specifications of servo drive unit, spindle drive unit, motor, etc.

IB-1501226  Specifications for power supply regeneration type

IB-1501229  Instruction for power supply regeneration type

IB-1501232  Specifications for regenerative resistor type

IB-1501235  Instruction for regenerative resistor type

IB-1501238

IB-1501241  Instruction for multi-hybrid, power supply regeneration type

 Specifications for multi-hybrid, power supply regeneration

type

Manuals for MTBs (Others)

Manual No. Purpose and Contents

GOT2000 Series User’s Manual (Hardware)

GOT2000 Series User’s Manual (Utility)

GOT2000 Series User’s Manual (Monitor)

GOT2000 Series Connection Manual (Mitsubishi Electric Products)

GT Designer3 (GOT2000) Screen Design Manual

■ For M800/M80/E80 Series

Manual No. Purpose and Contents

GOT2000/GOT1000 Series CC-Link Communication Unit User's Manual

GX Developer Version 8 Operating Manual (Startup)

GX Developer Version 8 Operating Manual

GX Converter Version 1 Operating Manual

GX Works2 Installation Instructions BCN-P5999-0944

GX Works2 Version 1 Operating Manual (Common)

GX Works2 Version 1 Operating Manual (Simple Project)

GX Works2 Version 1 Operating Manual (Simple Project, Function Block)

GX Works3 Installation Instructions BCN-P5999-0391

MELSEC-Q CC-Link System Master/ Local Module User’s Manual

GOT2000 Series Connection Manual (Non-Mitsubishi Electric Products 1)

GOT2000 Series Connection Manual (Non-Mitsubishi Electric Products 2)

GOT2000 Series Connection Manual (Microcomputers, MODBUS/ Fieldbus Products, Peripherals)

GT SoftGOT2000 Version1 Operating Manual

SH-081194

SH-081195

SH-081196  Outline of each monitor function of GOTs

SH-081197

SH-081220

IB-0800351

SH-080372E

SH-080373E

IB-0800004E

SH-080779ENG

SH-080780ENG

SH-080984ENG

SH-080394E

SH-081198ENG

SH-081199ENG

SH-081200ENG

SH-081201ENG

 Outline of hardware such as part names, external dimensions,

installation, wiring, maintenance, etc. of GOTs

 Outline of utilities such as screen display setting, operation

method, etc. of GOTs

 Outline of connection types and connection method between

GOT and Mitsubishi Electric connection devices

 Outline of screen design method using screen creation

software GT Designer3

 Explanation for handling CC-Link communication unit (for

GOT2000 series/GOT1000 series)

 Explanation for system configuration, installation, etc. of PLC

development tool GX Developer

 Explanation for operations using PLC development tool GX

Developer

 Explanation for operations using data conversion tool GX

Converter

 Explanation for the operating environment and installation

method of GX Works2

 Explanation for the system configuration of GX Works2 and

the functions common to Simple project and Structured project such as parameter setting, operation method for the online function

 Explanation for methods for such as creating and monitoring

programs in Simple project of GX Works2

 Explan

 Explanation for the operating environment and installation

 Explanation for system configuration, installation, wiring, etc.

 Explanation for connection types and connection method

 Explanation for system configuration, screen configuration

ation for methods for such as creating function blocks, pasting function blocks to sequence programs, and operating FB library in Simple project of GX Works2

method of GX Works3

of master/local modules for CC-Link system

between GOT and other company's devices

between GOT and microcomputers, MODBUS/fieldbus products, peripherals

and operation method of monitoring software GT SoftGOT2000

■ For C80 Series

Manual No. Purpose and Contents

MELSEC iQ-R Module Configuration Manual

MELSEC iQ-R CPU Module User’s Manual (Startup)

MELSEC iQ-R CPU Module User’s Manual (Application)

QCPU User’s Manual (Hardware Design, Maintenance and Inspection)

GX Works3 Operating Manual SH-081215  Outline of functions, programming, etc.

Reference Manual for MTBs

Manual No. Purpose and Contents

M800/M80 Series Smart safety observation Specification manual

C80 Series Smart safety observation Specification manual

M800/M80 Series CC-Link (Master/ Local) Specification manual

M800/M80 Series PROFIBUS-DP Specification manual

M800/M80 Series Interactive cycle insertion (Customization) Specification manual

M800/M80 Series EtherNet/IP Specifications manual

SH-081262

SH-081263

SH-081264

SH-080483

BNP-C3072-022

BNP-C3077-022

BNP-C3072-089  Explanation for CC-Link

BNP-C3072-118  Explanation for PROFIBUS-DP communication function

BNP-C3072-121-

0003

BNP-C3072-263  Explanation for EtherNet/IP

 Outline of system configuration, specifications, installation,

wiring, maintenance, etc.

 Outline of specifications, procedures before operation,

troubleshooting, etc. for CPU module

 Outline of memory, functions, devices, parameters, etc. for

CPU module

 Outline of specifications, necessary knowledge to configure

the system and maintenance-related descriptions for Q series CPU module, etc.

 Explanation for smart safety observation function

 Explanation for interactive cycle insertion

Precautions for Safety

Always read the specifications issued by the MTB, this manual, related manuals and attached documents before installation, operation, programming, maintenance or inspection to ensure correct use. Understand this numerical controller, safety items and cautions before using the unit. This manual ranks the safety precautions into "DANGER", "WARNING" and "CAUTION".

DANGER

When the user may be subject to imminent fatalities or major injuries if handling is mistaken.

WARNING

When the user may be subject to fatalities or major injuries if handling is mistaken.

CAUTION

When the user may be subject to bodily injury or when physical damage may occur if handling is mistaken.

Note that even items ranked as " CAUTION", may lead to major results depending on the situation. In any case, important information that must always be observed is described.

The following signs indicate prohibition and compulsory.

This sign indicates prohibited behavior (must not do).

For example, "Keep fire away" is indicated by .

This sign indicates a thing that is critical (must do).

For example, "it must be grounded" is indicated by .

The meaning of each pictorial sign is as follows.

CAUTION

Prohibited

CAUTION rotate ob-

ject

Disassembly is pro-

hibited

CAUTION HOT

KEEP FIRE AWAY

Danger Electric

shock risk

General instruction

Danger explosive

Earth ground

For Safe Use

MITSUBISHI CNC is designed and manufactured solely for applications to machine tools to be used for industrial purposes. Do not use this product in any applications other than those specified above, especially those which are substantially influential on the public interest or which are expected to have significant influence on human lives or properties.

1. Items related to prevention of electric shocks

WARNING

Do not open or remove the front cover while the power is ON or during operation. The high voltage terminals and charged sections are exposed, and this could result in electric shocks.

Do not remove the front cover even when the power is OFF, except for the wiring works or periodic inspections. The inside of the controller and drive unit are charged, and this could result in electric shocks.

Always wait at least 15 minutes after turning the power OFF. Then, check the voltage with a tester, etc., before wiring works, inspections or connecting with peripheral devices. Failure to observe this could result in electric shocks.

Earth ground the controller, drive unit and motor according to the local laws. (In Japan, ground the 200V Series input products with Class C or higher protective grounding and the 400V Series input with Class D or higher protective grounding.)

All wiring works, maintenance and inspections must be carried out by a qualified technician. Failure to observe this could result in electric shocks. Contact your nearby Service Center for replacing parts and servicing.

Wire the controller, drive unit and motor after installation. Failure to observe this could result in electric shocks.

Do not operate the switches with wet hands. Failure to observe this could result in electric shocks.

Do not damage, apply excessive stress, place heavy things on or sandwich the cables. Failure to observe this could result in electric shocks.

Insulate the power lead using a fixed terminal block. Failure to observe this could result in electric shocks.

Before starting maintenance or inspections, turn the main circuit power and control power both OFF. Wait at least fifteen minutes until the CHARGE lamp turns OFF, and then confirm that the input and output voltage are zero using a tester, etc. Failure to observe this could lead to electric shocks.

2. Items related to prevention of fire

Install the controller, drive unit, motor and regenerative resistor on non-combustible material. Installation directly on or near combustible materials could result in fires.

If any malfunction in the unit is observed, shut off the power at the unit’s power supply side. Continuous flow of large current could result in fires.

Install an appropriate no fuse breaker (NFB) and contactor (MC) on the power input section of the drive unit and configure the sequence that shuts the power off upon drive unit’s emergency stop or alarm.

When a breaker is shared for multiple power supply units, the breaker may not function upon short-circuit failure in a small capacity unit. Do not share a breaker for multiple units as this is dangerous.

CAUTION

Incorrect wiring and connections could cause the devices to damage or burn.

3. Items related to prevention of bodily injury or property damage

DANGER

When transporting or installing a built-in IPM spindle or linear servomotor, be careful so that your hand or property is not trapped in the motors or other metal objects. Also keep the devices with low magnetic tolerance away from the product.

CAUTION

Do not apply voltages to the connectors or terminals other than voltages indicated in the connection and setup manual for the controller or specifications manual for the drive unit. Failure to observe this could cause bursting, damage, etc.

Incorrect connections could cause the devices to rupture or damage, etc. Always connect the cables to the indicated connectors or terminals.

Incorrect polarity (+ -) could cause the devices to rupture or damage, etc.

Persons wearing medical devices, such as pacemakers, must stay away fro m th is un it. The e lect roma gne tic waves could adversely affect the medical devices.

Fins on the rear of the unit, regenerative resistor and motor, etc., may be hot during operation and for a while after the power has been turned OFF. Do not touch or place the parts and cables, etc. close to these sections. Failure to observe this could result in burns.

Do not enter the machine’s movable range during automatic operation. Keep your hands, feet or face away from the spindle during rotation.

4. Other items

Always follow the precautions below as well. Incorrect handling could result in faults, injuries or electric shocks, etc.

(1) Product and manual

CAUTION

For items described as "Restrictions" or "Usable State" in this manual, the instruction manual issued by the machine tool builder (MTB) takes precedence over this manual.

Items not described in this manual must be interpreted as "not possible"

Refer to the manuals issued by the machine manufacturer for each machine tool explanation.

Some screens and functions may differ depending on the NC system (or its version), and some functions may not be possible. Please confirm the specifications before use.

Do not connect NC system to the Internet-connected network.

To maintain the safety of the NC system against unauthorized access from external devices via the network, take appropriate measures.

(2) Transportation and installation

CAUTION

Correctly transport the products according to the mass.

Use motor’s suspension bolts to transport the motor itself. Do not use it to transport the motor after installation onto the machine.

Do not stack the products exceeding the indicated limit.

Do not hold the cables, shaft or encoder when transporting the motor.

CAUTION

Do not transport the controller or drive unit by suspending or holding the connected wires or cables.

Do not hold the front cover when transporting the unit, or the front cover could come off, causing the unit to drop.

Install on a non-combustible place where the unit's or motor's mass can be withstood according to the instruction manual.

The motor does not have a complete water-proof (oil-proof) structure. Do not allow oil or water to contact or enter the motor. Prevent the cutting chips from being accumulated on the motor as they easily soak up oil.

When installing the motor facing upwards, take measures on the machine side so that gear oil, etc., will not enter the motor shaft.

Do not remove the encoder from the motor. (The encoder installation screw is treated with sealing.)

Do not allow foreign matters, especially, conductive foreign matters such as screws or metal chips, or combu stibl e forei g n matt ers suc h as oil , to en ter the co ntroll er, drive unit or motor. Failure to observe this could result in rupture or damage.

Do not get on the product or place heavy objects on it.

Provide prescribed distance between the controller/drive unit and inner surface of the control panel/other devices.

Do not install or operate the controller, drive unit or motor that is damaged or has missing parts.

Take care not to cut hands, etc. with the heat radiating fins or metal edges.

Do not block the intake/outtake ports of the motor with the cooling fan.

Install the controller’s display section and operation board section on the spot where cutting oil will not reach.

The controller, drive unit and motor are precision devices, so do not drop or apply thumping vibration and strong impacts on them.

Store and use the units according to the environment conditions indicated in each specifications manual.

When disinfectants or insecticides must be used to treat wood packaging materials, always use methods other than fumigation (for example, apply heat treatment at the minimum wood core temperature of 56 °C for a minimum duration of 30 minutes (ISPM No. 15 (2009))).

If products such as units are directly fumigated or packed with fumigated wooden materials, halogen substances (including fluorine, chlorine , bromi ne and i o dine) c ontained in fumes may contribute to the erosion of the capacitors. When exporting the products, make sure to comply with the laws and regulations of each country.

Do not use the products in conjunction with any components that contain halogenated flame retardants (bromine, etc). Failure to observe this may cause the erosion of the capacitors.

Securely fix the motor to the machine. The motor could come off during operation if insecurely fixed.

Always install the motor with reduction gear in the designated direction. Failure to observe this could result in oil leaks.

Always install a cover, etc., over the shaft so that the rotary section of the motor cannot be touched during motor rotation.

When installing a coupling to the servomotor shaft end, do not apply impacts by hammering, etc. The encoder could be damaged.

Use a flexible coupling when connecting with a ball screw, etc., and keep the shaft core deviation smaller than the tolerable radial load of the shaft.

Do not use a rigid coupling as an excessive bending load may be applied on the shaft and could cause the shaft to break.

Do not apply a load exceeding the tolerable level onto the motor shaft. The shaft or bearing could be damaged.

Before using this product after a long period of storage, please contact the Service Center.

Following the UN recommendations, battery units and batteries should be transported based on the inter-

COM COM

Control output signal

Drive unit

Control output signal

Drive unit

(24VDC) (24VDC)

national regulations such as those determined by International Civil Aviation Organization (ICAO), International Air Transport Association (IATA), International Maritime Organization (IMO) and U.S. Department of Transportation (DOT).

Install the unit in a place which can withstand its weight.

(3) Items related to wiring

Correctly wire this product. Failure to observe this could result in motor runaway, etc.

Do not install a phase advancing capacitor, surge absorber or radio noise filter on the output side of the drive unit.

Correctly connect the output side (terminal U, V, W). The motor will not run properly if incorrectly connected.

Always install an AC reactor per each power supply unit.

Always install an appropriate breaker per each power supply unit. A breaker cannot be shared for multiple power supply units.

Do not directly connect a commercial power supply to the motor. Failure to observe this could result in faults.

When using an inductive load such as relays, always connect a diode in parallel to the load as a noise countermeasure.

When using a capacitive load such as a lamp, always connect a protective resistor serially to the load to suppress rush currents.

Do not mistake the direction of the surge absorption diode to be installed on the DC relay for the control output signal. If mistaken, the signal will not be output due to fault in the drive unit, and consequently the protective circuit, such as emergency stop, could be disabled.

CAUTION

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.

Do not pull the cables when connecting/disconnecting them.

Securely tighten the cable connector fixing screw or fixing mechanism. The motor could come off during operation if insecurely fixed.

Always treat the shield cables indicated in the Connection Manual with grounding measures such as cable clamps.

Separate the signal wire from the drive line or power line when wiring.

Use wires and cables whose wire diameter, heat resistance level and bending capacity are compatible with the system.

Ground the device according to the requirements of the country where the device is to be used.

Wire the heat radiating fins and wires so that they do not contact.

CAUTION

When using the RS-232C device as a peripheral device, caution must be paid for connector connection/disconnection. 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.

(4) Set up

NC unit

RS-232C

Using a stabilized power supply without overcurrent protection may cause the unit's failure due to miswiring of 24V.

12V, 5V, and 3.3V output from connectors are to supply the power for dedicated peripheral devices. Do not use for other equipment to supply the power since we do not guarantee the NC operation by voltage down or noise sneaking.

When using an inductive load such as a relay, always connect a diode in parallel to the load to prevent a counter-electromotive force.

When the rush current exceeds the maximum output current, always connect a protective resistor serially to the load to suppress rush currents.

The wires from the surge absorber should be connected without extensions.

Device

Switch

AC socket

WARNING

Do not cancel the emergency stop before confirming the basic operation.

Always set the stored stroke limit. Failure to set this could result in collision with the machine end.

If the battery low warning is issued, save the machining programs, tool data and parameters in an input/ output device, and then replace the battery. When the battery alarm is issued, the machining programs, tool data and parameters may be destroyed. Reload the data after replacing the battery.

Do not adjust the spindle when possible risks associated with adjustment procedures are not thoroughly taken into consideration.

Be careful when touching spindle's rotating section, or your hand may be caught in or cut.

(5) Adjustments

Check and adjust programs and each parameter before starting operation. Failure to observe this could result in unpredictable operations depending on the machine.

Do not make drastic adjustments or changes as the operation could become unstable.

CAUTION

(6) Usage

CAUTION

Install an external emergency stop circuit so that the operation can be stopped and the power turns OFF immediately when unforeseen situation occurs. A contactor, etc., is required in addition to the shutoff function mounted in the controller.

Turn OFF the power immediately if any smoke, abnormal noise or odor is generated from the controller, drive unit or motor.

Only a qualified technician may disassemble or repair this product.

Do not alter.

Use a noise filter, etc. to reduce the effect of electromagnetic disturbances in the case where electromagnetic disturbances could adversely affect the electronic devices used near the drive unit.

Use the drive unit, motor and each regenerative resistor with the designated combination. Failure to observe this could result in fires or faults.

The combination of the motor and drive unit that can be used is determined. Be sure to check the models of motor and drive unit before test operation.

The brakes (electromagnetic brakes) mounted in the servomotor are used for the purpose of holding, and must not be used for normal braking. Also, do not run the motor with the motor brake applied. Motor brake is used for the purpose of holding.

For the system running via a timing belt, install a brake on the machine side so that safety can be ensured.

Be sure to confirm SERVO OFF (or READY OFF) when applying the electromagnetic brake. Also, be sure to confirm SERVO ON prior to releasing the brake.

When using the DC OFF type electromagnetic brake, be sure to install a surge absorber on the brake terminal.

Do not connect or disconnect the cannon plug while the electromagnetic brake’s power is ON. The cannon plug pins could be damaged by sparks.

After changing programs/parameters, or after maintenance/inspecti o n, alw ays ca r ry out a test o perat i on before starting actual operation.

Use the power that are complied with the power specification conditions (input voltage, input frequency, tolerable time for instantaneous power interruption) indicated in each specifications manual.

When making encoder cables, do not mistake connection. Failure to observe this could result in malfunction, runaway or fire.

Surge absorber to be selected varies depending on input power voltage.

Always keep the touchscreen surface clean. When it gets dirty, remove the dirt immediately. Do not perform any operation on the dirty touchscreen.

Pay close attention to the sequence operation when carrying out forced data setting (forced output) in the I/F diagnosis screen during machine operation.

(7) Troubleshooting

MBR EMG

Motor

Electromagnetic brake

Shut off with motor brake control output

Shut off with CNC brake control PLC output

24VDC

Use a motor with electromagnetic brakes or establish an external brake mechanism for the purpose of holding; this serves as countermeasures for possible hazardous situation caused by power failure or product fault.

Use a double circuit structure for the electromagnetic brake's operation circuit so that the brakes will activate even when the external emergency stop signal is issued.

The machine could suddenly restart when the power is restored after an instantaneous power failure, so stay away from the machine. (Design the machine so that the operator safety can be ensured even if the machine restarts.)

To secure the absolute position, do not shut off the servo drive uni t’s control p ower supp ly when i ts ba tter y voltage drops (warning 9F) in the servo drive unit side.

If the battery voltage drop warning alarm occurs in the controller side, make sure to back up the machining programs, tool data and parameters, etc. with the input/output device before replacing the battery. Depending on the level of voltage drop, memory loss could have happened. In that case, reload all the data backed up before the alarm occurrence.

CAUTION

(8) Maintenance, inspection and part replacement

Periodically back up the programs, tool data and parameters to avoid potential data loss. Also, back up those data before maintenance and inspections.

When replacing the battery on the controller side, the machining programs, tool data and parameters should be backed up with the input/output device beforehand. In case the memory is damaged in replacing the batteries, reload all the data backed up before replacing the battery.

The electrolytic capacitor’s capacity will drop due to deterioration. To prevent secondary damage due to capacitor's faults, Mitsubishi recommends the electrolytic capacitor to be replaced approx. every five years even when used in a normal environment. Contact the Service Center for replacements.

Never perform a megger test (measure the insulation resistance) of the drive unit. Failure to observe this could lead to faults.

Do not replace parts or devices while the power is ON.

Do not short-circuit, charge, overheat, incinerate or disassemble the battery.

There may be a unit filled with substitute Freon in the heat radiating fins of the 37kW or smaller unit. Be careful not to break the heat radiating fins during maintenance or replacement.

Connect the encoder (CN2/CN3) immediately after the installation of the servo drive unit. In addition, when a battery box is used, immediately connect to the BTA/BTB connector. (prevention of absolute position data lost)

Replace the batteries with new ones immediately after the battery voltage drop alarm (9F) has been output.

CAUTION

Replace the batteries while applying the drive unit’s control power.

Replace the batteries with new ones that are in their recommended use period.

Wrong connection may cause liquid leakage, heat generation and/or explosion.

Do not mix new batteries with used ones or mix different types of batteries.

(9) Disposal

CAUTION

Take the batteries and backlights for LCD, etc., off from the controller, drive unit and motor, and dispose of them as general industrial wastes.

Do not alter or disassemble controller, drive unit, or motor.

Collect and dispose of the spent batteries and the backlights for LCD according to the local laws.

Dispose the spent cooling fan according to local laws.

(10) General precautions

To explain the details, drawings given in the instruction manual, etc., may show the unit with the cover or safety partition removed. When operating the product, always place the cover or partitions back to their original position, and operate as indicated in the instruction manual, etc.

Treatment of waste

The following two laws will apply when disposing of this product. Considerations must be made to each law. The following laws are in effect in Japan. Thus, when using this product overseas, the local laws will have a priority. If necessary, indicate or notify these laws to the final user of the product.

(1) Requirements for "Law for Promotion of Effective Utilization of Resources"

(a) Recycle as much of this product as possible when finished with use. (b) When recycling, often parts are sorted into steel scraps and electric parts, etc., and sold to scrap

contractors. Mitsubishi recommends sorting the product and selling the members to appropriate contractors.

(2) Requirements for "Law for Treatment of Waste and Cleaning"

(a) Mitsubishi recommends recycling and selling the pr oduct when n o longer needed a ccording to item

(1) above. The user should make an effort to reduce waste in this manner. (b) When disposing a product that cannot be resold, it shall be treated as a waste product. (c) The treatment of industrial waste must be commissioned to a licensed industrial waste treatment

contractor, and appropriate measures, including a manifest co ntrol, must be taken. (d) Batteries correspond to "primary batteries", and must be disposed of according to local disposal

laws.

Disposal

(Note) This symbol mark is for EU countries only.

This symbol mark is according to the directive 2006/66/EC Article 20 Information for endusers and Annex II.

Your MITSUBISHI ELECTRIC product is designed and manufactured with high quality materials and components which can be recycled and/or reused. This symbol means that batteries and accumulators, at their end-of-life, should be disposed of separately from your household waste. If a chemical symbol is printed beneath the symbol shown above, this chemical symbol means that the battery or accumulator contains a heavy metal at a certain concentration. This will be indicated as follows: Hg: mercury (0,0005%), Cd: cadmium (0,002%), Pb: lead (0,004%) In the European Union there are separate collection systems for used batteries and accumulators. Please, dispose of batteries and accumulators correctly at your local community waste collection/ recycling centre.

Please, help us to conserve the environment we live in!

Trademarks

MELDAS, MELSEC, EZSocket, EZMotion, iQ Platform, MELSEC iQ-R, MELSOFT, GOT, CC-Link, CC-Link/LT, CC-Link IE, CC-Link IE/field, EcoMonitorLight and SLMP are either trademarks or registered trademarks of Mitsubishi Electric Corporation in Japan and/or other countries.

Ethernet is a registered trademark of Xerox Corporation in the United States and/or other countries. Microsoft®, Windows®, SQL Server® and Access® are either trademarks or registered trademarks of Microsoft Corporation in the United States and/or other countries. SD logo and SDHC logo are either registered trademarks or trademarks of LLC. UNIX is a registered trademark of The Open Group in the United States and/or other countries. Intel® and Pentium® are either trademarks or registered trademarks of Intel Corporation in the United States and/or other countries. MODBUS® is either a trademark or a registered trademark of Schneider Electric USA, Inc. or the affiliated companies in Japan and/or other countries. EtherNet/IP is a trademark of Open DeviceNet Vendor Association,Inc. PROFIBUS-DP and PROFINET are either trademarks of Profibus International. Oracle® is a registered trademark of Oracle Corporation, the subsidiaries, or the affiliated companies in the United States and /or other countries. VNC is a registered trademark of RealVNC Ltd. in the United States and other countries.

Other company and product names that appear in this manual are trademarks or registered trademarks of the respective companies.

本製品の取扱いについて

( 日本語 /Japanese) 本製品は工業用 ( クラス A) 電磁環境適合機器です。販売者あるいは使用者はこの点に注意し、住商業環境以外での使用をお願いいたします。

Handling of our product

(English) This is a class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures.

본 제품의 취급에 대해서

( 한국어 /Korean) 이 기기는 업무용 (A 급 ) 전자파적합기기로서 판매자 또는 사용자는 이 점을 주의하시기 바라며 가정외의 지역에 서 사용하는 것을 목적으로 합니다 .

1 System Basic Configuration ....................................................................................................................... 1

1.1 System Basic Configuration Drawing ....................................................................................................................... 2

1.2 General Connection Diagram ................................................................................................................................... 4

1.2.1 General Connection Diagram [M800W] ........................................................................................................... 4

1.2.2 General Connection Diagram [M80W] ............................................................................................................. 7

1.2.3 General Connection Diagram [M800S] .......................................................................................................... 10

1.2.4 General Connection Diagram [M80]............................................................................................................... 11

1.2.5 General Connection Diagram [E80] ............................................................................................................... 13

1.3 How to Check the System Configuration ................................................................................................................ 14

1.3.1 System Configuration Screen ........................................................................................................................ 14

1.3.2 Option Display Screen ................................................................................................................................... 17

1.4 Each Unit Status Display ........................................................................................................................................ 18

1.4.1 Control Unit .................................................................................................................................................... 18

1.4.2 Personal Computer Unit................................................................................................................................. 21

1.4.3 Operation Panel I/O Unit................................................................................................................................ 22

1.4.4 Remote I/O Unit ............................................................................................................................................. 25

1.4.5 Communication Expansion Unit ..................................................................................................................... 27

1.4.5.1 CC-Link Expansion Unit ....................................................................................................................... 27

1.4.5.2 PROFIBUS-DP Expansion Unit............................................................................................................ 28

1.4.5.3 CC-Link IE Field ................................................................................................................................... 29

1.4.5.4 EtherNet/IP........................................................................................................................................... 30

1.4.6 7-segment LEDs on the Control Unit ............................................................................................................. 31

1.4.6.1 Normal State Display............................................................................................................................ 31

1.4.6.2 Error Display at NC Startup.................................................................................................................. 31

1.4.6.3 Display when an Alarm Occurs ............................................................................................................ 32

2 Daily Maintenance and Periodic Maintenance ........................................................................................ 41

2.1 Daily Maintenance .................................................................................................................................................. 43

2.1.1 Touchscreen .................................................................................................................................................. 43

2.1.2 Escutcheon .................................................................................................................................................... 43

2.2 Periodic Maintenance ............................................................................................................................................. 44

2.2.1 List of Durable Parts....................................................................................................................................... 44

2.2.2 List of Replacing Parts ................................................................................................................................... 44

2.2.3 Durable Parts Replacement ........................................................................................................................... 45

2.2.3.1 Control Unit Battery .............................................................................................................................. 45

2.2.3.2 Personal Computer Unit Cooling Fan................................................................................................... 47

2.2.4 Replacing Fuse .............................................................................................................................................. 48

3 Maintenance of the Drive Unit................................................................................................................... 51

3.1 Periodic Inspections................................................................................................................................................ 52

3.2 Durable Parts.......................................................................................................................................................... 53

3.3 Adding and Replacing Units and Parts ................................................................................................................... 54

3.3.1 MDS-E/EH Series .......................................................................................................................................... 54

3.3.1.1 Replacing the Drive Unit....................................................................................................................... 54

3.3.1.2 Replacing the Unit Fan......................................................................................................................... 55

3.3.1.3 Replacing the Battery ........................................................................................................................... 57

3.3.2 MDS-EJ/EJH Series....................................................................................................................................... 60

3.3.2.1 Replacing the Drive Unit....................................................................................................................... 60

3.3.2.2 Replacing the Unit Fan......................................................................................................................... 60

3.3.2.3 Replacing the Battery ........................................................................................................................... 66

3.3.3 MDS-EM/EMH Series .................................................................................................................................... 69

3.3.3.1 Replacing the Drive Unit....................................................................................................................... 69

3.3.3.2 Replacing the Fan Unit......................................................................................................................... 70

3.3.3.3 Replacing the Battery ........................................................................................................................... 71

4 Failure Diagnosis ....................................................................................................................................... 75

4.1 Introduction ............................................................................................................................................................. 76

4.2 Failure Diagnosis Procedure .................................................................................................................................. 76

4.3 Diagnosis Based on the Alarm ............................................................................................................................... 77

4.3.1 How To Check the Alarm Information ............................................................................................................ 77

4.3.2 Alarm History.................................................................................................................................................. 79

4.3.3 Alarm Message Details .................................................................................................................................. 81

4.4 Diagnosis Based on the I/F Diagnosis Screen ....................................................................................................... 82

4.4.1 I/F Diagnosis Screen...................................................................................................................................... 82

4.4.1.1 Displaying the PLC Device Data ........................................................................................................... 84

4.4.1.2 Carrying Out Modal Output ................................................................................................................... 85

4.4.1.3 Carrying Out One-shot Output .............................................................................................................. 86

4.4.2 List of Devices for PLC Uses ......................................................................................................................... 87

4.5 Diagnosis Based on the Self Diagnosis Screen ..................................................................................................... 88

4.5.1 Self Diagnosis Screen.................................................................................................................................... 88

4.6 Diagnosis Based on the Data Sampling Screen..................................................................................................... 93

4.7 Diagnosis Based on the Drive Monitor Screen ....................................................................................................... 94

4.7.1 Drive Monitor Screen (Servo Unit) ................................................................................................................. 94

4.7.2 Drive Monitor Screen (Spindle Unit)............................................................................................................... 99

4.7.3 Drive Monitor Screen (Power Supply Unit) .................................................................................................. 104

4.7.4 Drive Monitor Screen (Synchronous Error) .................................................................................................. 106

4.7.5 Clearing the Alarm History on Drive Monitor Screen ................................................................................... 107

4.8 NC Memory Diagnosis Screen ............................................................................................................................. 108

4.9 Safety Observation Screen................................................................................................................................... 110

4.9.1 Safety Observation Screen (Configuration Diagnosis)................................................................................. 110

4.9.2 Safety Observation Screen (Signal Monitor)................................................................................................ 112

4.9.3 Safety Observation Screen (Drive Monitor) ................................................................................................. 114

4.9.4 Safety Observation Screen (Version Display).............................................................................................. 117

4.10 Servo Diagnosis Screen ..................................................................................................................................... 118

4.11 Diagnosis Data Collection Setting ...................................................................................................................... 121

4.11.1 Starting the Data Collection ....................................................................................................................... 123

4.11.2 Stopping the Data Collection.............................................................................................

4.11.3 Clearing the Collected Data ....................................................................................................................... 124

4.11.4 Referring to the Collected Data.................................................................................................................. 124

4.11.5 Display Delay Function for Communication Errors and Servo/Spindle Alarms .......................................... 127

4.12 Application Error Detection ................................................................................................................................. 128

4.13 IP Address Resetting Procedure at Disabled Network Communication [M800W/M80W Series Only]............... 129

4.13.1 Connectable Control Unit IP Address List Screen ..................................................................................... 129

4.13.2 Resetting Procedure .................................................................................................................................. 130

4.13.3 Message..................................................................................................................................................... 131

4.14 Field Network Diagnostics Function ................................................................................................................... 132

4.14.1 Diagnosis Procedure.................................................................................................................................. 133

4.14.1.1 Statistical Information in Packet Transmission and Reception..........................................................133

4.14.1.2 Protocol-Specific Information ............................................................................................................ 135

4.14.2 Diagnosis Command.................................................................................................................................. 136

4.14.2.1 Clearing Statistical Information of Packet Transmission and Reception ........................................... 136

4.14.2.2 Error Code List .................................................................................................................................. 137

......................... 123

5 Troubleshooting....................................................................................................................................... 139

5.1 Troubleshooting .................................................................................................................................................... 140

5.1.1 Possible Causes of Trouble ......................................................................................................................... 141

6 Replacing Each Unit ................................................................................................................................ 143

6.1 Data Backup and Restoration............................................................................................................................... 144

6.1.1 All Backup .................................................................................................................................................... 145

6.1.2 All Restoration.............................................................................................................................................. 147

6.2 Control Unit........................................................................................................................................................... 149

6.3 Display Unit........................................................................................................................................................... 151

6.4 Personal Computer Unit ....................................................................................................................................... 156

6.5 Keyboard Unit ....................................................................................................................................................... 157

6.6 Operation Panel I/O Unit....................................................................................................................................... 164

6.7 Remote I/O Unit .................................................................................................................................................... 166

6.8 Function Expansion Unit....................................................................................................................................... 168

6.8.1 Encoder (Manual Pulse Generator) I/F Expansion Unit [M800W/M80W] .................................................... 168

6.8.2 Functional Safety Expansion Unit [M80] ...................................................................................................... 169

6.9 Communication Expansion Unit............................................................................................................................ 170

6.10 Built-in Disk of the Display Unit........................................................................................................................... 172

6.11 SD Card .............................................................................................................................................................. 173

6.12 USB memory ...................................................................................................................................................... 174

6.13 MITSUBISHI CNC Machine Operation Panel ..................................................................................................... 175

IB-1501273-F

System Basic Configuration

M800/M80/E80 Series Maintenance Manual

1 System Basic Configuration

1System Basic Configuration

1.1 System Basic Configuration Drawing

For M800W/M80W

Display unit

Keyboard unit

Windows-based display non-Windows-based display

Personal

computer unit

Operation panel

I/O unit

Grahpic

control unit

Control unit

Remote I/O unit

Manual pulse penerator

Remote I/O unit

Synchronous

feed encoder

Manual pulse generator

M800W M80W

Motor group

Servo/Spindle

drive unit

Note

(1) For the drive unit configuration, refer to the drive unit's manual.

IB-1501273-F

M800/M80/E80 Series Maintenance Manual

1 System Basic Configuration

For M800S/M80/E80

Display unit

(Control unit is added onto back of display unit.)

Control unit

Keyboard unit

(Operation panel I/O unit is added onto back of keyboard unit.)

Operation panel I/O unit

Remote I/O unit

Manual pulse penerator

Remote I/O unit

Synchronous

feed encoder

Manual pulse generator

Note

(1) For the drive unit configuration, refer to the drive unit's manual.

Motor group

Servo/Spindle

drive unit

IB-1501273-F

M800/M80/E80 Series Maintenance Manual

1 System Basic Configuration

SIO

1ch：J030 2ch：J031

2ch

RS232C

SKIP

RIO2

RIO3

GDI

LAN

J303

Network

FCU8-EX56x

J100

FCU8-DX2xx/DX6xx

/DX4xx

RIO1

DCIN

J070/071

(EcoMonitor)

OPTH1

OPTH2

J395/J396

EMG

J120

Max. 8 points

J070/071

J210

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

J350/351

J070/071

J210

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

J350/351

(R2-TM)

5V：J023/J024/J025

12V：J020/J021/J022

L1 L2

(NFB)

DCOUT

ACIN

ON OFF

J350/351

FCU8-EX54x

EXT1

EXT3

G430

device

Skip signal input

Communication

expansion unit

Control unit

Max. 32 units for each port

Remote I/O unit

24VDC

Energy measuring units

Drive units

Stored in control unit

To the next remote I/O or terminator connector

Emergency stop switch

SD memory card

24VDC24VDC

Machine control relay/contact

24VDC

Manual pulse generator (5V/12V)

Machine operation panel made by the machine tool builder

Dotted lines indicate the sections prepared by the machine tool builder.

<> Angle brackets indicates attached cable of unit.

No-fuse breaker

24VDC stabilized

power supply

Function

expansion unit

(Note 1)

Handy terminal

FCU8-EX56x

FCU8-EX54x

FCU8-MA041/MU042

MA041：M850W MU042：M830W

RIO8

AIO

J026/J027

J220

EXT2

EXT4

RIO4

RIO6

RIO7

RIO5

Communication

expansion unit

Function

expansion unit

Analog input : 4 points

Analog output : 2 points

Manual pulse generator (5V)

J120

ON/OFF

CFAST

CFast

LVDS1

USB2-1

USB2-2

FCU8-PC231

LAN

J303

MENUKEY

RIO3EXT

OFF

G170

MPG

INV

RS232C

USB-RS232C

GDI

KEYUSB

RIO3

J303

NCKB

KEYUSB

J210

J291

J210

LVDS2

DCIN

J070/071

EMG

USB

USB3-2

USB3-1

USB2-4

USB2-3

USB2-6

USB2-5

FCU8-DX2xx/DX6xx/DX4xx

CJ71

FCU8-CF001-001

DCIN

J070/071

Network

CG31

CG32

FCU8-DX830/837

CG33

CG34

SDI

Max. 8 points

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

J350/351

(R2-TM)

J210

FCU8-KB92x

FCU8-KB941/KB931

<G460>

24VDC

MITSUBISHI CNC Machine Operation Panel

Emergency stop switch

Personal computer unit

device

conversion

24VDC

USB memory

24VDC

Remote I/O unit

24VDC

Operation panel I/O unit

Safety signal input

DX830： No safety signal input

DX837：

With safety signal input

Stored in personal computer unit

CFast unit

(Safety signal input is

DX837 only.)

To the next remote I/O or terminator connector

Added onto back of display unit

SD memory card

24VDC

Machine control relay/contact

Backlight I/F PCB

FCU8-KB04x/KB083

<G402>

<J09x>

USB

<J292>

<J190>

<J290>

<J081>

<J420>

Keyboard unit

(Note 2)

15-type LCD

with touch panel

Display unit

Menukey

FCU8-DU181-34

1.2 General Connection Diagram

1.2.1 General Connection Diagram [M800W]

Windows-based display (15-type)

(Note 1) For information on how to connect the drive unit, refer to the drive unit's manual. (Note 2) When using a keyboard unit, install the operation panel I/O unit on the back of the keyboard unit.

Note

(1) For the connection of MITSUBISHI CNC machine operation panel, refer to "M800W/M80W Series Connection and Set-

up Manual".

IB-1501273-F

M800/M80/E80 Series Maintenance Manual

1 System Basic Configuration

SIO

1ch：J030 2ch：J031

2ch

RS232C

SKIP

RIO2

RIO3

GDI

LAN

J303

Network

FCU8-EX56x

J100

FCU8-DX2xx/DX6xx

/DX4xx

RIO1

DCIN

J070/071

(EcoMonitor)

OPTH1

OPTH2

J395/J396

EMG

J120

Max. 8 points

J070/071

J210

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

J350/351

J070/071

J210

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

J350/351

(R2-TM)

5V：J023/J024/J025

12V：J020/J021/J022

L1 L2

(NFB)

DCOUT

ACIN

ON OFF

J350/351

FCU8-EX54x

EXT1

EXT3

G430

device

Skip signal input

Communication

expansion unit

Control unit

Max. 32 units for each port

Remote I/O unit

24VDC

Energy measuring units

Drive units

Stored in control unit

To the next remote I/O or terminator connector

Emergency stop switch

SD memory card

24VDC24VDC

Machine control relay/contact

24VDC

Manual pulse generator (5V/12V)

Machine operation panel made by the machine tool builder

Dotted lines indicate the sections prepared by the machine tool builder.

<> Angle brackets indicates attached cable of unit.

No-fuse breaker

24VDC stabilized

power supply

Function

expansion unit

(Note 1)

Handy terminal

FCU8-EX56x

FCU8-EX54x

FCU8-MA041/MU042

MA041：M850W MU042：M830W

RIO8

AIO

J026/J027

J220

EXT2

EXT4

RIO4

RIO6

RIO7

RIO5

Communication

expansion unit

Function

expansion unit

Analog input : 4 points

Analog output : 2 points

Manual pulse generator (5V)

J120

ON/OFF

CFAST

CFast

LVDS1

USB2-1

USB2-2

FCU8-PC231

LAN

J303

MENUKEY

RIO3EXT

OFF

G170

MPG

INV

RS232C

USB-RS232C

GDI

KEYUSB

RIO3

J303

NCKB

KEYUSB

J210

J291

J210

LVDS2

DCIN

J070/071

EMG

USB

USB3-2

USB3-1

USB2-4

USB2-3

USB2-6

USB2-5

FCU8-DX2xx/DX6xx/DX4xx

CJ71

FCU8-CF001-001

DCIN

J070/071

Network

CG31

CG32

FCU8-DX830/837

CG33

CG34

SDI

Max. 8 points

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

J350/351

(R2-TM)

J210

FCU8-KB92x

FCU8-KB941/KB931

<G460>

24VDC

MITSUBISHI CNC Machine Operation Panel

Emergency stop switch

Personal computer unit

device

conversion

24VDC

USB memory

24VDC

Remote I/O unit

24VDC

Operation panel I/O unit

Safety signal input

DX830： No safety signal input

DX837：

With safety signal input

Stored in personal computer unit

CFast unit

(Safety signal input is

DX837 only.)

To the next remote I/O or terminator connector

Added onto back of display unit

SD memory card

24VDC

Machine control relay/contact

Backlight I/F PCB

<J09x>

<J292>

<J190>

<J290>

<G195>

<J420>

FCU8-EP201-2

USB

PCUSB

19-type LCD

Side memory I/F unit

wth touch panel

Display unit

FCU8-DU191-75 FCU8-DU192-75

Windows-based display (19-type)

(Note 1) For information on how to connect the drive unit, refer to the drive unit's manual.

(1) For the connection of MITSUBISHI CNC machine operation panel, refer to "M800W/M80W Series Connection and Set-

Note

up Manual".

IB-1501273-F

M800/M80/E80 Series Maintenance Manual

1 System Basic Configuration

SIO

1ch：J030 2ch：J031

2ch

RS232C

SKIP

RIO2

RIO3

GDI

LAN

J303

Network

FCU8-EX56x

J100

FCU8-DX2xx/DX6xx

/DX4xx

RIO1

DCIN

J070/071

(EcoMonitor)

OPTH1

OPTH2

J395/J396

EMG

J120

Max. 8 points

J070/071

J210

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

J350/351

J070/071

J210

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

J350/351

(R2-TM)

5V：J023/J024/J025

12V：J020/J021/J022

L1 L2

(NFB)

DCOUT

ACIN

ON OFF

J350/351

FCU8-EX54x

EXT1

EXT3

G430

device

Skip signal input

Communication

expansion unit

Control unit

Max. 32 units for each port

Remote I/O unit

24VDC

Energy measuring units

Drive units

Stored in control unit

To the next remote I/O or terminator connector

Emergency stop switch

SD memory card

24VDC24VDC

Machine control relay/contact

24VDC

Manual pulse generator (5V/12V)

Machine operation panel made by the machine tool builder

Dotted lines indicate the sections prepared by the machine tool builder.

<> Angle brackets indicates attached cable of unit.

No-fuse breaker

24VDC stabilized

power supply

Function

expansion unit

(Note 1)

Handy terminal

FCU8-EX56x

FCU8-EX54x

FCU8-MA041/MU042

MA041：M850W MU042：M830W

RIO8

AIO

J026/J027

J220

EXT2

EXT4

RIO4

RIO6

RIO7

RIO5

Communication

expansion unit

Function

expansion unit

Analog input : 4 points

Analog output : 2 points

Manual pulse generator (5V)

J070/071

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

<J09x>

USB_F

SDC_F

USB_B

SDC_B

<J08x>

FCU8-GC211

RIO3EXT

RS232C

CJ71

FCU8-DX730

CG31

MPG

CG32

NCKB

CG33

CG34

LAN1

J303

Network

LAN2

J303

J210

G402

J210

EMG

DCIN

J070/071

LCD

MENUKEY

FRONT

ENC

OFF

CJ71

J010

SIO

FCU8-DX2xx/DX6xx/DX4xx

max. 29 units

J170

<J421>

RIO1

J210

FCU8-KB92x

FCU8-KB941/KB931

<G460>

24VDC

MITSUBISHI CNC Machine Operation Panel

24VDC

Remote I/O unit

(Note 2)

Emergency stop switch

Graphic control unit

device

24VDC

Operation panel I/O unit

Menu key

Display unit

Memory mediums

Front memory I/F card

Keyboard unit

(Note 3)

FCU8-KB04x/083

<J421>

10.4-type:FCU8-DU141-31 15-type:FCU8-DU181-31

Non-Windows-based display (10.4-type/15-type)

I/O unit.

(Note 3) There is no need to connect a terminator R2-TM to the graphic control unit.

Note

(1) For the connection of MITSUBISHI CNC machine operation panel, refer to "M800W/M80W Series Connection and Set-

IB-1501273-F

up Manual".

M800/M80/E80 Series Maintenance Manual

1 System Basic Configuration

SIO

1ch：J030 2ch：J031

2ch

RS232C

SKIP

RIO2

RIO3

GDI

LAN

J303

Network

FCU8-EX56x

J100

FCU8-DX2xx/DX6xx

/DX4xx

RIO1

DCIN

J070/071

(EcoMonitor)

OPTH1

OPTH2

J395/J396

EMG

J120

Max. 8 points

J070/071

J210

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

J350/351

J070/071

J210

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

J350/351

(R2-TM)

5V：J023/J024/J025

12V：J020/J021/J022

L1 L2

(NFB)

DCOUT

ACIN

ON OFF

J350/351

FCU8-EX54x

EXT1

EXT3

G430

device

Skip signal input

Communication

expansion unit

Control unit

Max. 32 units for each port

Remote I/O unit

24VDC

Energy measuring units

Drive units

Stored in control unit

To the next remote I/O or terminator connector

Emergency stop switch

SD memory card

24VDC24VDC

Machine control relay/contact

24VDC

Manual pulse generator (5V/12V)

Machine operation panel made by the machine tool builder

Dotted lines indicate the sections prepared by the machine tool builder.

<> Angle brackets indicates attached cable of unit.

No-fuse breaker

24VDC stabilized

power supply

Function

expansion unit

(Note 1)

Handy terminal

FCU8-MU044

RIO4/M

BTBOX

J120

ON/OFF

CFAST

CFast

LVDS1

USB2-1

USB2-2

FCU8-PC231

LAN

J303

MENUKEY

RIO3EXT

OFF

G170

MPG

INV

RS232C

USB-RS232C

GDI

KEYUSB

RIO3

J303

NCKB

KEYUSB

J210

J291

J210

LVDS2

DCIN

J070/071

EMG

USB

USB3-2

USB3-1

USB2-4

USB2-3

USB2-6

USB2-5

FCU8-DX2xx/DX6xx/DX4xx

CJ71

FCU8-CF001-001

DCIN

J070/071

Network

CG31

CG32

FCU8-DX830/837

CG33

CG34

SDI

Max. 8 points

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

J350/351

(R2-TM)

J210

FCU8-KB92x

FCU8-KB941/KB931

<G460>

24VDC

MITSUBISHI CNC Machine Operation Panel

Emergency stop switch

Personal computer unit

device

conversion

24VDC

USB memory

24VDC

Remote I/O unit

24VDC

Operation panel I/O unit

Safety signal input

DX830： No safety signal input

DX837：

With safety signal input

Stored in personal computer unit

CFast unit

(Safety signal input is

DX837 only.)

To the next remote I/O or terminator connector

Added onto back of display unit

SD memory card

24VDC

Machine control relay/contact

Backlight I/F PCB

FCU8-KB04x/KB083

<G402>

<J09x>

USB

<J292>

<J190>

<J290>

<J081>

<J420>

Keyboard unit

(Note 2)

15-type LCD

with touch panel

Display unit

Menukey

FCU8-DU181-36

1.2.2 General Connection Diagram [M80W]

Windows-based display (15-type)

(1) For the connection of MITSUBISHI CNC machine operation panel, refer to "M800W/M80W Series Connection and Set-

(2) When the handle of handy terminal is used, connect ENC connector of G430 cable to MPG connector of the operation

Note

up Manual".

panel I/O unit. Because the pin assignment of ENC connector of G430 is different from that of MPG connector of the operation panel I/O unit, conversion is required. The conversion cable needs to be prepared by the MTB.

IB-1501273-F

M800/M80/E80 Series Maintenance Manual

1 System Basic Configuration

SIO

1ch：J030 2ch：J031

2ch

RS232C

SKIP

RIO2

RIO3

GDI

LAN

J303

Network

FCU8-EX56x

J100

FCU8-DX2xx/DX6xx

/DX4xx

RIO1

DCIN

J070/071

(EcoMonitor)

OPTH1

OPTH2

J395/J396

EMG

J120

Max. 8 points

J070/071

J210

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

J350/351

J070/071

J210

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

J350/351

(R2-TM)

5V：J023/J024/J025

12V：J020/J021/J022

L1 L2

(NFB)

DCOUT

ACIN

ON OFF

J350/351

FCU8-EX54x

EXT1

EXT3

G430

device

Skip signal input

Communication

expansion unit

Control unit

Max. 32 units for each port

Remote I/O unit

24VDC

Energy measuring units

Drive units

Stored in control unit

To the next remote I/O or terminator connector

Emergency stop switch

SD memory card

24VDC24VDC

Machine control relay/contact

24VDC

Manual pulse generator (5V/12V)

Machine operation panel made by the machine tool builder

Dotted lines indicate the sections prepared by the machine tool builder.

<> Angle brackets indicates attached cable of unit.

No-fuse breaker

24VDC stabilized

power supply

Function

expansion unit

(Note 1)

Handy terminal

FCU8-MU044

RIO4/M

BTBOX

J120

ON/OFF

CFAST

CFast

LVDS1

USB2-1

USB2-2

FCU8-PC231

LAN

J303

MENUKEY

RIO3EXT

OFF

G170

MPG

INV

RS232C

USB-RS232C

GDI

KEYUSB

RIO3

J303

NCKB

KEYUSB

J210

J291

J210

LVDS2

DCIN

J070/071

EMG

USB

USB3-2

USB3-1

USB2-4

USB2-3

USB2-6

USB2-5

FCU8-DX2xx/DX6xx/DX4xx

CJ71

FCU8-CF001-001

DCIN

J070/071

Network

CG31

CG32

FCU8-DX830/837

CG33

CG34

SDI

Max. 8 points

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

J350/351

(R2-TM)

J210

FCU8-KB92x

FCU8-KB941/KB931

<G460>

24VDC

MITSUBISHI CNC Machine Operation Panel

Emergency stop switch

Personal computer unit

device

conversion

24VDC

USB memory

24VDC

Remote I/O unit

24VDC

Operation panel I/O unit

Safety signal input

DX830： No safety signal input

DX837：

With safety signal input

Stored in personal computer unit

CFast unit

(Safety signal input is

DX837 only.)

To the next remote I/O or terminator connector

Added onto back of display unit

SD memory card

24VDC

Machine control relay/contact

Backlight I/F PCB

<J09x>

<J292>

<J190>

<J290>

<G195>

<J420>

FCU8-EP201-2

USB

PCUSB

19-type LCD

Side memory I/F unit

wth touch panel

Display unit

FCU8-DU191-77 FCU8-DU192-77

Windows-based display (19-type)

(Note 1) For information on how to connect the drive unit, refer to the drive unit's manual.

Note

(1) For the connection of MITSUBISHI CNC machine operation panel, refer to "M800W/M80W Series Connection and Set-

up Manual".

(2) When the handle of handy terminal is used, connect ENC connector of G430 cable to MPG connector of the operation

IB-1501273-F

M800/M80/E80 Series Maintenance Manual

1 System Basic Configuration

Non-Windows-based display (8.4-type/10.4-type/15-type)

Dotted lines indicate the sections prepared by the machine tool builder.

<> Angle brackets indicates attached cable of unit.

Graphic control unit

L1 L2

No-fuse breaker (NFB)

ON OFF

24VDC stabilized

power supply

DCOUT

ACIN

RS232C

device

Network

24VDC

J170

OFF

J303

Emergency stop switch

J070/071

24VDC

FCU8-DX2xx/DX6xx/DX4xx

max. 29 units

Remote I/O unit

24VDC

DCIN

J070/071

DO:CJ32/34

RIO1

(Note 2)

ENC

SIO

LAN1

LAN2

EMG

DCIN

DI:CJ31/33

RIO2

FCU8-GC211

LCD

MENUKEY

(Note 3)

CJ71

J010

J210

24VDC

FRONT

RIO1

Operation panel I/O unit

FCU8-DX730

CJ71

RIO3EXT

MITSUBISHI CNC Machine Operation Panel

FCU8-KB92x

<J09x>

<J08x>

<J421>

Front memory I/F card

USB_F

SDC_F

USB_B

SDC_B

NCKB

MPG

J350/351

CG31

J350/351

CG32

J350/351

CG33

J350/351

CG34

FCU8-KB941/KB931

<G460>

(Note 4)

Memory mediums

G402

5V：J023/J024/J025

12V：J020/J021/J022

Machine operation panel made by the machine tool builder

Display unit

8.4-type:FCU8-DU121-12

10.4-type:FCU8-DU141-32 15-type:FCU8-DU181-32

Menu key

Keyboard unit

FCU8-KB02x/04x/083

Manual pulse generator (5V/12V)

24VDC

J210

Control unit

FCU8-MU044

Drive units

Handy terminal

(Note 1)

G430

Network

Skip signal input

Max. 8 points

RS232C

device

2ch

Emergency stop switch

J395/J396

24VDC

SD memory card

J303

J100

1ch：J030 2ch：J031

J120

J070/071

RIO3

GDI

LAN

OPTH1

OPTH2

SKIP

SIO

EMG

DCIN

BTBOX

RIO1

RIO2

RIO4/M

EXT1

EXT3

Remote I/O unit

DCIN

J070/071

J210

RIO1

Remote I/O unit

DCIN

J070/071

J210

RIO1

FCU8-DX2xx/DX6xx

Function

expansion unit

FCU8-EX54x

Communication

expansion unit

FCU8-EX56x

DI:CJ31/33

J070/071

DO:CJ32/34

RIO2

DI:CJ31/33

J070/071

DO:CJ32/34

RIO2

/DX4xx

Stored in control unit

Remote I/O unit

24VDC24VDC

DI:CJ31/33

DCIN

DO:CJ32/34

RIO1

Remote I/O unit

24VDC24VDC

DI:CJ31/33

DCIN

DO:CJ32/34

RIO1

Max. 32 units for each port

Energy measuring units

J350/351 J350/351

RIO2

J350/351 J350/351

RIO2

(EcoMonitor)

Machine control relay/contact

To the next remote I/O or terminator connector

(R2-TM)

Machine control relay/contact

To the next remote I/O or terminator connector

(R2-TM)

(Note 1) For information on how to connect the drive unit, refer to the drive unit's manual. (Note 2) When connecting a remote I/O unit to the 3rd RIO channel, insert it between the control unit and operation panel I/O unit. (Note 3) There is no need to connect a terminator R2-TM to the graphic control unit. (Note 4) For the 8.4-type display unit, TP connector is not used.

Note

(1) For the connection of MITSUBISHI CNC machine operation panel, refer to "M800W/M80W Series Connection and Set-

up Manual".

(2) When the handle of handy terminal is used, connect ENC connector of G430 cable to MPG connector of the operation

IB-1501273-F

M800/M80/E80 Series Maintenance Manual

1 System Basic Configuration

1.2.3 General Connection Diagram [M800S]

Dotted lines indicate the sections prepared by the machine tool builder.

L1 L2

<> Angle brackets indicates attached cable of unit.

No-fuse breaker

ON OFF

CP/NFB

Circuit protector (CP)

CP/NFB

AC reactor D-AL

(NFB)

24VDC stabilized

power supply

DCOUT

ACIN

Skip signal inputs

Manual pulse generator (5V)

EMG

Ethernet device

RS-232C

device

Handy terminal

Skip signal input

Max. 8 points

ENC

J026(1ch) J027(2ch)

Field Network

J120

J303

J070/071

1ch: J030 2ch: J031

24VDC

G430

J100

J395/J396/G380

Drive unit

(Note 1)

J395/J396/G380

Drive unit

Synchronous feed encoder

FCU8-MU54x/FCU8-MA54x

EMG

LAN1

LAN2

DCIN

Add-on

CPU card

SIO

OPTH1 OPTH2

SKIP

1ch

FCUA-R050/054

Control unit

FCU8-EX70x

Option Relay Unit

Communication expansion unit

FCU8-EX56x

RIO2ENC CJ71

RIO1

J210

Front memory I/F card

USB_F

FRONT

LCD

MENUKEY

FCU8-DX731/DX750/DX760/DX761

J010

SDC_F

USB_B

SDC_B

Operation panel I/O unit

CJ71

DI : CJ37/39

DO : CJ38/40

RIO3EXT

5V : J023(1ch)/024(2ch)/025(3ch)

12V : J020(1ch)/021(2ch)/022(3ch)

J210

24VDC

Remote I/O unit

24VDC

J070/071

J210

24VDC

J070/071

DI:CJ31/33

DCIN

DO:CJ32/34

RIO1

Remote I/O unit

DI:CJ31/33

DCIN

DO:CJ32/34

RIO1

RIO2

FCU8-DX2xx/DX6xx/DX4xx

Memory mediums

< J09x>

< J08x>

< J421>

NCKB

MPG

24VDC

<G402>

J460/461 J350/351

3ch

Remote I/O unit

DCIN

RIO1

DO:CJ32/34

Display unit

10.4-type:FCU8-DU141-31

15-type:FCU8-DU181-31

Machine operation panel made by the machine tool builder

RIO2

J350/351 J350/351

DI:CJ31/33

Menu key

Keyboard unit

FCU8-KB04x FCU8-KB083

MITSUBISHI CNC Machine Operation Panel

FCU8-KB92x FCU8-KB941/KB931

<G460>

Remote I/O unit

RIO2

24VDC

J070/071

24VDC

J070/071

DI:CJ31/33

DCIN

DO:CJ32/34

RIO1

Remote I/O unit

DI:CJ31/33

DCIN

DO:CJ32/34

RIO1

RIO2

J350/351 J350/351

Manual pulse generator (5V/12V)

Machine control relay/contact

To the next remote I/O or terminator connector

(R2-TM)

Machine control relay/contact

To the next remote I/O or terminator connector

(R2-TM)

Machine control relay/contact

To the next remote I/O or terminator connector

(R2-TM)

(Note 1) For information on how to connect the drive unit, refer to the drive unit's manual.

Note

(1) For the connection of MITSUBISHI CNC machine operation panel, refer to "M800S/M80/E80 Series Connection and

Setup Manual".

IB-1501273-F

M800/M80/E80 Series Maintenance Manual

1 System Basic Configuration

J395/J396/G380

FCUA-R050/054

1ch

ENC

Field Network

J026(1ch) J027(2ch)

L1 L2

Skip signal inputs

D-AL

DCOUT

ACIN

CP/NFB

ON OFF

CP/NFB

Max. 8 points

EMG

J120

J303

J070/071

J303

J100

1ch: J030 2ch: J031

EMG

LAN1

SKIP

DCIN

SIO

LAN2

FCU8-EX56x

FCU8-EX70x

FRONT

RIO2ENC CJ71

< J09x>

RIO1

USB_F

SDC_F

USB_B

SDC_B

< J08x>

NCKB

3ch

J010

CJ71

<G402>

J210

RIO3EXT

MPG

J070/071

5V : J023(1ch)/024(2ch)/025(3ch)

12V : J020(1ch)/021(2ch)/022(3ch)

FCU8-DX731/DX750/DX760/DX761

DI : CJ37/39

DO : CJ38/40

J460/461 J350/351

J210

LCD

MENUKEY

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

J350/351

J070/071

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

J350/351

J070/071

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

J350/351

(R2-TM)

G430

J210

FCU8-KB92x FCU8-KB941/KB931

<G460>

24VDC

MITSUBISHI CNC Machine Operation Panel

(Note 1)

Drive unit

Control unit

Synchronous feed encoder

No-fuse breaker

(NFB)

AC reactor

Circuit protector (CP)

Ethernet device

24VDC

RS-232C

device

Communication expansion unit

Menu key

Display unit

Memory mediums

Front memory I/F card

Operation panel I/O unit

Machine control relay/contact

Remote I/O unit

24VDC

Remote I/O unit

24VDC

Remote I/O unit

24VDC

Remote I/O unit

24VDC

Remote I/O unit

24VDC

Keyboard unit

To the next remote I/O or terminator connector

Machine operation panel made by the machine tool builder

Skip signal input

24VDC stabilized

power supply

To the next remote I/O or terminator connector

Manual pulse generator (5V/12V)

Manual pulse generator (5V)

Dotted lines indicate the sections prepared by the machine tool builder.

<> Angle brackets indicates attached cable of unit.

Option Relay Unit

Machine control relay/contact

Handy terminal

< J421>

FCU8-KB04x FCU8-KB083

FCU8-KB026/KB028/KB029

OPTH1

FCU8-MU5x1/FCU8-MU5x2

FCU8-DX2xx/

DX4xx

8.4-type:FCU8-DU121-12

10.4-type:FCU8-DU141-32

15-type:FCU8-DU181-32

(Note 2)

1.2.4 General Connection Diagram [M80]

Without smart safety observation

(Note 1) For information on how to connect the drive unit, refer to the drive unit's manual. (Note 2) For the 8.4-type display unit, TP connector is not used.

(1) For the connection of MITSUBISHI CNC machine operation panel, refer to "M800S/M80/E80 Series Connection and

Note

Setup Manual".

IB-1501273-F

M800/M80/E80 Series Maintenance Manual

1 System Basic Configuration

J395/J396/G380

FCUA-R050/054

1ch

ENC

Field Network

J026(1ch) J027(2ch)

L1 L2

Skip signal inputs

D-AL

DCOUT

ACIN

CP/NFB

ON OFF

CP/NFB

Max. 8 points

EMG

J120

J303

J070/071

J303

J100

1ch: J030 2ch: J031

EMG

LAN1

SKIP

DCIN

SIO

LAN2

FCU8-EX56x

FCU8-EX70x

FRONT

RIO2ENC CJ71

< J09x>

RIO1

USB_F

SDC_F

USB_B

SDC_B

< J08x>

NCKB

3ch

J010

CJ71

<G402>

J210

RIO3EXT

MPG

J070/071

5V : J023(1ch)/024(2ch)/025(3ch)

12V : J020(1ch)/021(2ch)/022(3ch)

FCU8-DX731/DX750/DX760/DX761

DI : CJ37/39

DO : CJ38/40

J460/461 J350/351

J210

LCD

MENUKEY

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

J350/351

J070/071

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

J350/351

J070/071

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

J350/351

(R2-TM)

G430

J210

FCU8-KB92x FCU8-KB941/KB931

<G460>

24VDC

MITSUBISHI CNC Machine Operation Panel

(Note 1)

Drive unit

Control unit

Synchronous feed encoder

No-fuse breaker

(NFB)

AC reactor

Circuit protector (CP)

Ethernet device

24VDC

RS-232C

device

Communication expansion unit

Menu key

Display unit

Memory mediums

Front memory I/F card

Operation panel I/O unit

Machine control relay/contact

Remote I/O unit

24VDC

Remote I/O unit

24VDC

Remote I/O unit

24VDC

Remote I/O unit

24VDC

Remote I/O unit

24VDC

Keyboard unit

To the next remote I/O or terminator connector

Machine operation panel made by the machine tool builder

Skip signal input

24VDC stabilized

power supply

To the next remote I/O or terminator connector

Manual pulse generator (5V/12V)

Manual pulse generator (5V)

Dotted lines indicate the sections prepared by the machine tool builder.

<> Angle brackets indicates attached cable of unit.

Option Relay Unit

Machine control relay/contact

Handy terminal

FCU8-KB04x FCU8-KB083

< J421>

FCU8-DX2xx/DX6xx

/DX4xx

FCU8-KB026/KB028/KB029

OPTH1

FCU8-MU511/FCU8-MU512

FCU8-EX133

8.4-type:FCU8-DU121-12

10.4-type:FCU8-DU141-32

15-type:FCU8-DU181-32

(Note 2)

Functional

safety

expansion unit

(Note 3)

With smart safety observation

(Note 1) For information on how to connect the drive unit, refer to the drive unit's manual. (Note 2) For the 8.4-type display unit, TP connector is not used. (Note 3) The safety remote I/O unit is available only when the functional safety expansion unit is mounted.

Note

(1) For the connection of MITSUBISHI CNC machine operation panel, refer to "M800S/M80/E80 Series Connection and

Setup Manual".

IB-1501273-F

M800/M80/E80 Series Maintenance Manual

1 System Basic Configuration

J395/J396/G380

FCUA-R050/054

1ch

ENC

Field Network

J026(1ch) J027(2ch)

L1 L2

Skip signal inputs

D-AL

DCOUT

ACIN

CP/NFB

ON OFF

CP/NFB

Max. 8 points

EMG

J120

J303

J070/071

J303

J100

1ch: J030 2ch: J031

EMG

LAN1

SKIP

DCIN

SIO

LAN2

FCU8-EX56x

FCU8-EX70x

FRONT

RIO2ENC CJ71

< J09x>

RIO1

USB_F

SDC_F

USB_B

SDC_B

< J08x>

NCKB

3ch

J010

CJ71

<G402>

J210

RIO3EXT

MPG

J070/071

5V : J023(1ch)/024(2ch)/025(3ch)

12V : J020(1ch)/021(2ch)/022(3ch)

FCU8-DX731/DX750/DX760/DX761

DI : CJ37/39

DO : CJ38/40

J460/461 J350/351

J210

LCD

MENUKEY

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

J350/351

J070/071

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

J350/351

J070/071

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

DI:CJ31/33

DO:CJ32/34

RIO1

DCIN

RIO2

J350/351

(R2-TM)

G430

J210

FCU8-KB92x FCU8-KB941/KB931

<G460>

24VDC

MITSUBISHI CNC Machine Operation Panel

(Note 1)

Drive unit

Control unit

Synchronous feed encoder

No-fuse breaker

(NFB)

AC reactor

Circuit protector (CP)

Ethernet device

24VDC

RS-232C

device

Communication expansion unit

Menu key

Display unit

Memory mediums

Front memory I/F card

Operation panel I/O unit

Machine control relay/contact

Remote I/O unit

24VDC

Remote I/O unit

24VDC

Remote I/O unit

24VDC

Remote I/O unit

24VDC

Remote I/O unit

24VDC

Keyboard unit

To the next remote I/O or terminator connector

Machine operation panel made by the machine tool builder

Skip signal input

24VDC stabilized

power supply

To the next remote I/O or terminator connector

Manual pulse generator (5V/12V)

Manual pulse generator (5V)

Dotted lines indicate the sections prepared by the machine tool builder.

<> Angle brackets indicates attached cable of unit.

Option Relay Unit

Machine control relay/contact

Handy terminal

FCU8-KB024/KB025

OPTH1

FCU8-MU513/FCU8-MU514

FCU8-DX2xx/

DX4xx

8.4-type:FCU8-DU121-13

1.2.5 General Connection Diagram [E80]

(Note 1) For information on how to connect the drive unit, refer to the drive unit's manual.

Note

(1) For the connection of MITSUBISHI CNC machine operation panel, refer to "M800S/M80/E80 Series Connection and

Setup Manual".

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1.3 How to Check the System Configuration

(1) (2)

(4) 

(3) 

1.3.1 System Configuration Screen

Diagn

Select the menu [Config] on the diagnosis (Diagn) screen to display the hardware configuration (card name and sub-number), software configuration (software number and sub-number), and PLC program configuration (file name, file label, and execution type).

Software configuration

Hardware configuration

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PLC program configuration

(6) - a

(5)  (6) - b

(6) - c

(6) - d

Display items

Display items Details Remarks

(1) Software list This displays a list of the software being used.

Use / keys to change the pages and refer it.

(2) Installed lang This displays a list of installed languages.

<ENG>: English <SWE>: Swedish

<JPN>: Japanese <HUN>: Hungarian

<DEU>: German <POL>: Polish

<FRA>: French <CHI1>: Simplified Chinese

<ITA>: Italian <RUS>: Russian

<SPA>: Spanish <TUR>: Turkish

<CHI2>: Traditional Chinese <CZE>: Czech

<KOR>: Korean

<POR>: Portuguese

<DUT>: Dutch

(3) NC serial No. This displays the NC model name, serial No, system type, and unit type.

NC TYPE: NC type

MODEL NAME: System type name

SERIAL NO.: Serial No.

UNIT NAME: Unit type

(6) 

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Display items Details Remarks

(4) Hardware list The hardware names are displayed.

Use / keys to change the pages and refer it. The following display is an example.

CNC :WN111 Main card A single unit of CNC unit

:WN891 Back panel card

:WN091 7SEG-RSW card

Existing cards are displayed from

is formed with a maximum of 4 PCBs. All of these cards are connected by bus.

the top in the above order.

ATT CARD :WN521

Front-side SD IF card

EXT :WN561 CC-Link expansion unit The extension unit is a

:WN563 PROFIBUS-DP expansion unit

:WN564

:WN511

CC-Link IE Field unit or EtherNet/IP unit (WN564 and WN511 are one set.)

<Note>

hardware additional specification. The back panel and maximum of 5 cards are displayed.

For the expansion unit type, refer to the description of expansion unit.

Existing expansion units are dis-

played from the top in the above order.

DISPLAY :DU191 Display unit The unit type varies by

model.

KEYBOARD :KB046 Keyboard unit The unit type varies by

the keyboard unit being connected.

ECOMON1 to ECOMON16

:EMU4-BD1 :EMU4-HD1

EcoMonitorLight unit The unit type varies de-

pending on the connected EcoMonitor Light unit. The status for up to 16 part systems is displayed.

RIO1[n] :WN301 Remote IO unit 1 (n = 1 to 64) The unit type varies by

RIO2[n] :WN301 Remote IO unit 2 (n = 1 to 64)

RIO3[n] :WN301 Remote IO unit 3 (n = 1 to 64)

(5) Project The list of project Nos. is displayed.

If the selected project is switched with [↑] or [↓] key, the list of ladder files that belong to the project is displayed.

the remote I/O unit being connected. Maximum of 3 channels are displayed.

Maximum of 10 singlebyte alphanumeric characters for the label

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Display items Details Remarks

Ladder

config

(6) PLC ladder file

list

This displays the file name, file label, execution type for each PLC ladder program.

Use / keys to change the pages and refer it.

(a) Registration No. This displays the registration No. of

each PLC program file.

(b) File name This displays the file name of PLC pro-

gram file. (data of GX Developer/GX Woks2)

(d) Execution type This displays the execution type of

PLC program. HIGH: High-speed PLC program MIDDLE: Middle-speed PLC program INTIAL: Initial state of PLC program WAIT: Standby PLC program LOW: Low-speed PLC program (blank): Not the target of the execution.

The total number of registration size and target file to be executed for all projects is as follows: M800W/M800S: 120 M80W/M80/E80: 60

Max. 8 characters

Max. 32 characters

Menus

Menus Details

S/W

config

H/W

config

This displays the software list.

This displays the hardware list.

This displays the PLC program list (file name, file label, and execution type).

1.3.2 Option Display Screen

Diagn

Select the menu [Option] on the diagnosis (Diagn) screen to display the contents of the additional specifications registered in the NC.

The additional specification items are displayed by name. If all of the additional specifications cannot be seen in one screen, the rest of items can be displayed by pressing the page up/down keys.

Display items

Display items Details

(1) Option items The list of currently usable additional specifications is displayed.

As for the currently usable items, the background color is displayed in blue. The items set when the power supply was turned ON can be currently used.

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1.4 Each Unit Status Display

(1)

(2)

(5)

(4)

(3)

Cover opened

Each unit status can be confirmed by checking the LED mounted on each unit.

1.4.1 Control Unit

FCU8-MU042/FCU8-MA041 (M800W)

[LED]

No. Name Lamp state Details

(1) 24VDCIN Lit (Green) 24V power is being supplied from the external power supply.

Not lit

(2) DCOUT Lit (Green) The followings are all successfully output: 5V and 3.3V generated from

Not lit

(3) READY Lit (Green) Servo ON (or ready ON) state.

(4) ERR Lit (Red)

(5) SDACC Flashing (Green) Accessing to front-side SD card.

Not lit Servo OFF (or ready OFF) state.

Not lit H/W is operating properly.

Not lit Not accessing to front-side SD card.

The followings may have caused an error:

No 24V-power supply from the external power supply. Disconnection of fuse near DCIN connector. Failure of LED.

24V; 2.5V,1.8V,1.5V,1.15V, and 1.1V on the main card.

The followings may have caused an error:

No 24V-power supply from the external power supply. Failure in any of the power output circuits. Failure of LED or IC which helps turn the LED ON.

H/W is not operating properly. The followings may have caused an error:

Occurrence of NC watchdog error. Failure of main CPU card.

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FCU8-MU044 (M80W)

(1)

(2)

(5)

(4)

(3)

Cover opened

[LED]

No. Name Lamp state Details

(1) 24VDCIN Lit (Green) 24V power is being supplied from the external power supply.

Not lit

The followings may have caused an error:

No 24V-power supply from the external power supply. Disconnection of fuse near DCIN connector. Failure of LED.

(2) DCOUT Lit (Green) The followings are all successfully output: 5V and 3.3V generated from

24V; 2.5V,1.8V,1.5V,1.15V, and 1.1V on the main card.

Not lit

The followings may have caused an error:

No 24V-power supply from the external power supply. Failure in any of the power output circuits. Failure of LED or IC which helps turn the LED ON.

(3) READY Lit (Green) Servo ON (or ready ON) state.

Not lit Servo OFF (or ready OFF) state.

(4) ERR Lit (Red)

H/W is not operating properly. The followings may have caused an error:

Occurrence of NC watchdog error. Failure of main CPU card.

Not lit H/W is operating properly.

(5) SDACC Flashing (Green) Accessing to front-side SD card.

Not lit Not accessing to front-side SD card.

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FCU8-MU542 / FCU8-MA542 / FCU8-MU541 / FCU8-MA541(M800S)

(1)

(2)

(5)

(4)

(3)

FCU8-MU511 / FCU8-MU512 / FCU8-MU501 / FCU8-MU502(M80) FCU8-MU513 / FCU8-MU514(E80)

[LED]

No. Name Lamp state Details

(1) 24VIN Lit (Green) 24VDC power is being supplied from the external power supply.

Not lit

The followings may have caused an error:

No 24VDC-power supply from the external power supply. Disconnection of fuse near DCIN connector. Failure of LED.

(2) DCOUT Lit (Green) Internal voltage is normally output.

Not lit

The followings may have caused an error:

No 24V-power supply from the external power supply. Failure in any of the power output circuits. Failure of LED or IC which helps turn the LED ON.

(3) LCDON Lit (Green) 12VDC for the backlight of display unit is normally output.

Not lit

The followings may have caused an error:

Failure of 12VDC output in control unit. 24VDC input voltage is +20V or less.

(4) READY Lit (Green) Ready ON state.

Not lit

(5) ERR Lit (Red)

Ready OFF state.

H/W is not operating properly. The followings may have caused an error:

Occurrence of NC watchdog error. Failure of main CPU card.

Not lit H/W is operating properly.

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1.4.2 Personal Computer Unit

FCU8-PC231 (M800W)

[LED]

(5)(1) (2) (4)(3)

No. Name Function Color State

Normal At fault

(1) DCIN 24VDC input observation Green Lit Not lit

(2) DCOUT DC internal power supply output obser-

vation

(3) 12V 12VDC output observation Green Lit Not lit

(4) 5V 5VDC output observation Green Lit Not lit

(5) 3.3V 3.3VDC output observation Green Lit Not lit

Green Lit Not lit

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1.4.3 Operation Panel I/O Unit

(1)

(2)

(3)

(8)

(5)

(4)

(7)

(6)

(9)

(11)

(10)

FCU8-DX830/FCU8-DX837/FCU8-DX730 (M800W/M80W)

[LED]

FCU8-DX830/FCU8-DX837 FCU8-DX730

(1)

(2)

(7)

(5)

(6)

(8)

(9)

No. Name Function Color State Supplement

Normal At fault

(1) FUSE Fuse status Green Lit Not lit Not lit when a fuse has been

blown out.

(2) DOCOM Energization status of DC24V input

Green Lit Not lit Lit when a current is applied.

(DOCOM) of CG32/CG34 connector

(3) EMG Emergency stop input status Red Not lit Lit Lit when an emergency stop

has occurred.

(4) 24VDCIN Energization status of 24VDC input of

Green Lit Not lit Lit when a current is applied.

DCIN connector

(5) 5VIN 5V power supply circuit status Green Lit Not lit Lit when the circuit is normally

operated.

(6) 3VIN 3.3V power supply circuit status Green Lit Not lit Lit when the circuit is normally

operated.

(7) 12VON 12V power supply circuit status Green Lit Not lit Lit when the circuit is normally

operated.

(8) ALM1 RIO communication error Red Not lit Lit Lit when RIO communication

error has occurred.

(9) ALM2 RIO communication error Red Not lit Lit Lit when RIO communication

error has occurred.

(10) ALM3 RIO communication error Red Not lit Lit Lit when RIO communication

(11) ALM4 RIO communication error Red Not lit Lit Lit when RIO communication

error has occurred.

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FCU8-DX731/DX750/FCU8-DX760/FCU8-DX761 (M800S/M80/E80)

(1)

(2)

(4)

(3)

(5)

(6)

(1)

(2)

(4)

(3)

(5)

(7)

(6)

(8)

(1)

(2)

(4)

(3)

(5)

(7)

(6)

(8)

(9)

(11)

(10)

(1)

(2)

(4)

(3)

(5)

(7)

(6)

(8)

(9)

[LED]

FCU8-DX731 FCU8-DX750

FCU8-DX760 FCU8-DX761

No. Name Function Color State Supplement

Normal At fault

(1) FUSE Fuse status Green Lit Not lit Not lit when a fuse has been

blown out.

(2) DOCOM Energization status of DC24V input

Green Lit Not lit Lit when a current is applied. (DOCOM) of CG32/CG36/CJ38/CJ40 connector

(3) 12VON 12V power supply circuit status Green Lit Not lit Lit when the circuit is normally

operated.

(4) 5VIN 5V power supply circuit status Green Lit Not lit Lit when the circuit is normally

operated.

(5) 3VIN 3.3V power supply circuit status Green Lit Not lit Lit when the circuit is normally

(6) ALM1 RIO communication error Red Not lit Lit Lit when RIO communication

(7) ALM2 RIO communication error Red Not lit Lit Lit when RIO communication

(8) ALM3 RIO communication error Red Not lit Lit Lit when RIO communication

operated.

error has occurred.

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No. Name Function Color State Supplement

Normal At fault

(9) ALM4 RIO communication error Red Not lit Lit Lit when RIO communication

error has occurred.

(10) FUSE2 Fuse status Green Lit Not lit Not lit when a fuse has been

blown out.

(11) DOCOM2 Energization status of 24VDC input

Green Lit Not lit Lit when a current is applied.

(DOCOM) of CJ42 connector

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1.4.4 Remote I/O Unit

(3)

(4)

(2)

(1)

(4)

(2)

(1)

FCU8-DX220/FCU8-DX230/FCU8-DX231/FCU8-DX202/FCU8-DX213/FCU8-DX213-1/FCU8-DX654/FCU8-DX654-1/

FCU8-DX651/FCU8-DX408/FCU8-DX409

[LED: FCU8-DX220/FCU8-DX230/FCU8-DX231/FCU8-DX202/FCU8-DX213/FCU8-DX213-1/FCU8-DX654/ FCU8-DX654-1/FCU8-DX408/FCU8-DX409]

FCU8-DX220/FCU8-DX230/FCU8-DX231/

FCU8-DX213/FCU8-DX213-1/

FCU8-DX654/FCU8-DX654-1

FCU8-DX202 FCU8-DX408 FCU8-DX409

(1)

(2)

(4)

No. Name Function Color State Supplement

Normal At fault

(1) RIOVER RIO communication status Green Lit during RIO 2.0

communication

Not lit during RIO 1.0 communication

(2) ALM RIO communication error Red Not lit Lit Lit when RIO communication

error has occurred.

(3) FUSE Fuse status Green Lit Not lit Not lit when a fuse has been

blown out.

(4) 24VDCIN Energization status of 24VDC input of

DCIN connector

Green Lit Not lit Lit when a current is applied.

(2)

(1)

(4)

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[LED: FCU8-DX651]

(2)

(4)(3)

(1)

No. Name Function Color State Supplement

Normal At fault

(1) H1 Safety relay output SYR00 status Green Lit Not lit Not lit when a relay has been

blown out.

H2 Safety relay output SYR01 status Green Lit Not lit Not lit when a relay has been

blown out.

H3 Safety relay output SYR02 status Green Lit Not lit Not lit when a relay has been

blown out.

H4 Safety relay output SYR03 status Green Lit Not lit Not lit when a relay has been

blown out.

(2) ALM RIO communication error Red Not lit Lit Lit when RIO communication

error has occurred.

(3) DCIN Energization status of 24VDC input of

Green Lit Not lit Lit when a current is applied.

DCIN connector

(4) FUSE Fuse status Green Lit Not lit Not lit when a fuse has been

blown out.

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1.4.5 Communication Expansion Unit

(1)

(2)

(5)

(4)

(3)

(6)

1.4.5.1 CC-Link Expansion Unit

FCU8-EX561

[LED]

No. Name Color State Details

(1) RUN Green Lit CC-Link module in the normal state

Not lit Watchdog timer error

(2) LRUN Green Lit Data link in process of execution

(3) SD Green Lit During data transmission

(4) RD Green Lit During data reception

(5) ERR Red Lit Switch setting error (LERR is also lit), overlapping of mas-

ter, parameter error, communication error

Flashing Other station data link error (when it is master station.)

(6) LERR Red Lit Data link communication error

Flashing Station and mode change during operation

Note

(1) All LED (RUN, LRUN, SD, RD, ERR, LERR) are lit during resetting of the CC-Link module.

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1.4.5.2 PROFIBUS-DP Expansion Unit

(1)

(2)

(3)

(4)

FCU8-EX563

[LED]

Name Color State Details

(1) RUN (Green) Green Lit Lit when PROFIBUS-DP module is normally operated.

(2) RDY (Yellow) Green/yellow Flashing Boot standby

(Module status) Yellow Lit Boot error

- Lit No power supply, module failure

(3) STA (Green) Green Lit regularly Configuration successful, communication unestablished

(4) ERR (Red) Green Lit randomly Configuration failure, stuck error

(Communication status) Green Lit Communicating with slave(s)

Red Flashing Communication is interrupted with at least one slave.

Red Lit Communication is interrupted with all the slaves.

Note

(1) All LED (RUN, RDY, STA and ERR) are lit during the reset of PROFIBUS-DP module.

(2) The status of PROFIBUS-DP module is displayed by the combination of RUN/RDY.

(3) The status of PROFIBUS-DP communication is displayed by the combination of STA/ERR.

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1.4.5.3 CC-Link IE Field

(1) (2) (3)

(4)

(5)

(6)

(7)

(8)

FCU8-EX564

[LED]

No. Name Color State Details

(1) L ERR Red Not lit Normal data received and loopback not performed

Lit Abnormal data received or loopback being performed

(2) SD/RD Green Lit Data being sent or received

Not lit Data not sent nor received

(3) D LINK Green Lit Data link (cyclic transmission being performed)

Flashing Data link (cyclic transmission stopped)

Not lit Data link not performed (disconnected)

(4) MST Green Lit Operating as master station

Not lit Operating as local station

(5) ERR Red Not lit Normal operation

Flashing (500 ms interval)

Flashing (200 ms interval)

Lit Error in all stations detected or occurring

(6) RUN Green Lit Hardware running normally

Not lit Hardware error occurring

(7) LINK Green Lit Link-up

Not lit Link-down

(8) L ER Red Lit Normal data received and loopback not performed

Not lit Abnormal data received or loopback being performed

A data link faulty station detected

Failure occurring

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1.4.5.4 EtherNet/IP

(1)

(2)

(1) (2)

FCU8-EX565

[LED]

Name Greed LED Red LED Details

(1) MS (Green/Red) Flashing Flashing In self-test

(Module status) Flashing Not lit Waiting for initialization

Lit Not lit Normal operation

Not lit Flashing Recoverable failure

Not lit Lit Unrecoverable failure (The hardware needs to be re-

placed.)

(2) NS (Green/Red) Flashing green/red(alternately) In self-diagnosis

(Communication status) Not lit Not lit No IP address

Flashing Not lit No connection

Lit Not lit Normal operation

Not lit Flashing Connection time out

Not lit Lit IP address duplication

Note

(1) Ignore LED which is not written in the table above.

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1.4.6 7-segment LEDs on the Control Unit

The 7-segment LEDs mounted on the control unit can display NC status. When alarms occur, an alarm with the highest priority within each part system is displayed.

1.4.6.1 Normal State Display

In normal state, the 7-segment LEDs display in flashing.

1.4.6.2 Error Display at NC Startup

If an error occurs at NC start up, the 7-segment LEDs change as follows.

The state of sub CPU (NCLD2) is displayed on the left and that of the main CPU (NCLD1) is displayed on the right by two 7-segment LEDs. Take a note of the displayed contents and contact the Service Center.

NCLD2 NCLD1

Main CPU

Sub CPU

LED display Cause

E Undefined interruption occurred

F Bus error, address error or interrupt exception (ASIC)

d Memory test error in DRAM

U Unsupported H/W

A CRC check error occurred (Boot ROM, FROM entry, OS, EEPROM)

C Sequence error occurred at OS startup

G Initialization error in graphic controller

. (Period) No correct boot data in flash ROM

(cf) In case of SRAM clear, the 7-segment LEDs change as follows. (RSW2: "C")

LED display Cause

y Memory test pass in SRAM

c Memory test error in SRAM

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1.4.6.3 Display when an Alarm Occurs

WhenAlarm(Stopcode)occurs

flashes three times

- Flashes when an alarm occurs in the 1st part system

-

Flashes when an alarm occurs in the 2nd part system

When an alarm doesn't occur in the 1st part system

This means that indicated alarm belongs to the 1st part system.

Alarmcodeisshowninthree steps.

Example

)

M01

H/Wstrokeendaxisexists

0006 XYZ

When an alarm doesn't occur in the 2nd part system

This means that indicated alarm belongs to the 2nd part system.

Alarmcodeisshowninthree steps.

Example) P232No.programNo.

If an alarm occurs, these LEDs show both the occurrence and the meaning of the alarm in two stages.

At first, flashes three times. In case of stop code, is shown instead.

Then, the meaning of the alarm is indicated in three different stages.

[Transition of 7-segment LED display]

Innormalstate WhenAlarm(Stopcode)occurs

flashes three times

Alarmcodeisshowninthreediﬀerentstages.

Example)Z53CNCoverheat0003

[Example of alarm display for 2-part systems]

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Note

(1) When only any of the following alarms occur, LED shows the normal indication.

Emergency stop EXIN Emergency stop WAIT M01 Cutting block start interlock 0110 M01 In synchronous correction mode 0120

[Display of the 7-segment LEDs and their meanings]

Alarm code for the first time

Left side LED

Alarm/warning

Operation error

Stop code

Emergency stop

Program error

System alarm/waring

MCP alarm/waring

Servo alarm/waring

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Example of alarm display (Operation error)

Note

Alarm/Warning code

M01 H/W stroke end axis exists 0006 XYZ

1L 1R 2L 2R 3L 3R

Operation error Error # (lower 3 digits) Axis bit

M01 No operation mode 0101

1L 1R 2L 2R 3L 3R

Operation error Error # (lower 3 digits) No meaning

M00 Aux ax R ret invld at ini 0025 0004

1L 1R 2L 2R 3L 3R

Auxiliary axis

operation error

M01 Aux ax handle ratio too large 0060 0002

1L 1R 2L 2R 3L 3R

Auxiliary axis

operation error

M90 Parameter set mode

1L 1R 2L 2R 3L 3R

Parameter can be set No meaning

M50 Multiple key inputs invalid 5002 0001

1L 1R 2L 2R 3L 3R

Operation error Error # (lower 3 digits) Key code (e.g.)

Error # (lower 3 digits) Axis bit

Displays of 7-segment LEDs (transition)

1L 1R 2L 2R 3L 3R

(1) Axis bit of the spindle in which the operation error has occurred is not displayed.

(2) Since the following alarms are displayed in the same state by the LEDs, it is difficult to distinguish them. Check the

details for each alarm on the diagnosis screen.

"0001 to 0099" and "1000 to 1099" of [M01 Operation error] "0100 to 0199" and "1100 to 1199" of [M01 Operation error] [M01 Operation error], [M00 Auxiliary axis operation error] and [M01 Auxiliary axis operation error] "0002" of [M01 Operation error] and "5002" of [M50 Operation warning]

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Example of alarm display (Stop code)

Alarm/Warning code

T01 H/W stroke end axis exists 0105

1L 1R 2L 2R 3L 3R

Stop code Error # (lower 2 digits) No meaning

T02 S/W stroke end axis exists 0202

1L 1R 2L 2R 3L 3R

Stop code Error # (lower 2 digits) No meaning

T03 Single block stop signal ON 0301

1L 1R 2L 2R 3L 3R

Stop code Error # (lower 2 digits) No meaning

T04 Collation stop 0401

1L 1R 2L 2R 3L 3R

Stop code Error # (lower 2 digits) No meaning

T10 Fin wait 0001

1L 1R 2L 2R 3L 3R

Stop code Error # (lower 2 digits) No meaning

Note

Displays of 7-segment LEDs (transition)

1L 1R 2L 2R 3L 3R

(1) Among the causes of [T10 Fin wait], "In dwell execution" and "Unclamp signal wait" is not

indicated.

Example of alarm display (Emergency stop)

Alarm/Warning code

EMG Emergency stop STOP

1L 1R 2L 2R 3L 3R

Emergency stop R69 (upper 2 digits) R69 (lower 2 dig-

its)

Example of alarm display (Program error)

Alarm/Warning code

P273 Macro call nesting over

1L 1R 2L 2R 3L 3R

Program error Error # No meaning

Displays of 7-segment LED (transition)

1L 1R 2L 2R 3L 3R

Displays of 7-segment LED (transition)

1L 1R 2L 2R 3L 3R

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1 System Basic Configuration

Example of alarm display (System alarm)

Note

Alarm/Warning code

Z70 Abs posn base set incomplete 0001 X

1L 1R 2L 2R 3L 3R

Absolute position data er-

ror

Z71 Abs encoder failure 0002 X

1L 1R 2L 2R 3L 3R

Encoder failure Error # Axis bit

Z72 Position check error 0001 Z

1L 1R 2L 2R 3L 3R

Position check error Error # Axis bit

Z73 Absolute position data warning 0003 XYZ

1L 1R 2L 2R 3L 3R

Absolute position data

warning

Z70 Aux ax abs position error 0001 0001

1L 1R 2L 2R 3L 3R

Auxiliary axis absolute

position error

Z71 Aux ax drop voltage 0001 0001

1L 1R 2L 2R 3L 3R

Auxiliary axis voltage

drop

Z73 Aux ax system warning 0001 0001

1L 1R 2L 2R 3L 3R

Auxiliary axis system

warning

Z40 Format mismatch

1L 1R 2L 2R 3L 3R

Format mismatch No meaning

Error # Axis bit

Displays of 7-segment LED (transition)

1L 1R 2L 2R 3L 3R

(1) Since the following alarms are displayed in the same state by the LEDs, it is difficult to distinguish them. Check the

details for each alarm on the diagnosis screen.

"0001" and "0101" of [Z70 Abs data error]

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M800/M80/E80 Series Maintenance Manual

1 System Basic Configuration

Example of alarm display (System warning)

Note

Alarm/Warning code

Z51 E2PROM error 0011

1L 1R 2L 2R 3L 3R

System warning Warning code Type

Z52 Battery fault 0001

1L 1R 2L 2R 3L 3R

System warning Warning code No meaning

Z53 CNC overheat 0003

1L 1R 2L 2R 3L 3R

System warning Warning code Unit bit

Z55 RIO communication stop 0007

1L 1R 2L 2R 3L 3R

System warning Warning code Unit bit

Z57 System warning 0010

1L 1R 2L 2R 3L 3R

System warning Warning code Type

Z58 ROM write not completed

1L 1R 2L 2R 3L 3R

System warning Warning code No meaning

Displays of 7-segment LED (transition)

1L 1R 2L 2R 3L 3R

Z59 Acc/dec time cnst too large

1L 1R 2L 2R 3L 3R

System warning Warning code No meaning

(1) Remote I/O 2nd part system and Remote I/O 3rd part system is not displayed in the case of [Z55 RIO communication

stop].

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M800/M80/E80 Series Maintenance Manual

1 System Basic Configuration

Example of alarm display (MCP alarm)

Note

Alarm/Warning code

Y02 SV commu er 0051 0004

1L 1R 2L 2R 3L 3R

System alarm Error # (lower 2

digits)

Y03 Drive unit unequipped XYZS

1L 1R 2L 2R 3L 3R

Drive unit unequipped Axis bit No meaning

Y05 Initial parameter error 1039

1L 1R 2L 2R 3L 3R

Initial parameter error Parameter #

(lower 2 digits)

Y06 mcp_no setting error

1L 1R 2L 2R 3L 3R

mcp_no setting error No meaning No meaning

Y02 Aux ax system alarm 0051 0004

1L 1R 2L 2R 3L 3R

mcp_no setting error No meaning No meaning

Y03 Aux ax drive unit unequipped 0001

1L 1R 2L 2R 3L 3R

mcp_no setting error No meaning No meaning

Error code

No meaning

Displays of 7-segment LEDs (transition)

1L 1R 2L 2R 3L 3R

(1) Axis bit of the spindle in which the operation error has occurred is not displayed.

(2) The data ID error or the axis No. of the received frame No. error for [Y02 System alarm 0051] or [Y02 Aux ax system

alarm 0051] is not displayed.

Example of alarm display (MCP warning)

Alarm/Warning code

Y51 Parameter stapt1-4 illegal 0012 Z

1L 1R 2L 2R 3L 3R

Parameter error Error # (lower 2 digits) Axis bit

Y90 No spindle signal 0003

1L 1R 2L 2R 3L 3R

No spindle signal Open-phase bit No meaning

(1) Axis bit of the spindle in which the operation error has occurred is not displayed.

Displays of 7-segment LED (transition)

1L 1R 2L 2R 3L 3R

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M800/M80/E80 Series Maintenance Manual

1 System Basic Configuration

Example of alarm display (Servo alarm)

Alarm/Warning code

S01 Servo alarm: PR 0031 X

1L 1R 2L 2R 3L 3R

Servo alarm: PR Error # (lower 2

digits)

S02 Initial parameter error 3225 S

1L 1R 2L 2R 3L 3R

Initial parameter error Error # (lower 2

digits)

S03 Servo alarm: NR 0052 Y

1L 1R 2L 2R 3L 3R

Servo alarm: NR Error # (lower 2

digits)

S04 Servo alarm: AR 006F Y

1L 1R 2L 2R 3L 3R

Servo alarm: AR Error # (lower 2

digits)

S01 Aux ax servo alarm 0016 0004

1L 1R 2L 2R 3L 3R

Auxiliary axis servo alarm Error # (lower 2

digits)

S02 Aux ax servo alarm 0020 0001

1L 1R 2L 2R 3L 3R

Auxiliary axis servo alarm Error # (lower 2

digits)

S02 Aux ax servo alarm 0031 0002

1L 1R 2L 2R 3L 3R

Servo alarm: NR Error # (lower 2

digits)

Axis bit

Displays of 7-segment LED (transition)

1L 1R 2L 2R 3L 3R

Note

(1) Axis bit of the spindle in which the operation error has occurred is not displayed.

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M800/M80/E80 Series Maintenance Manual

1 System Basic Configuration

Example of alarm display (Servo warning)

Note

Alarm/Warning code

S51 Parameter error 2205 Z

1L 1R 2L 2R 3L 3R

Parameter error Error # (lower 2

digits)

S52 Servo warning E0 X

1L 1R 2L 2R 3L 3R

Servo warning Error # Axis bit

S52 Aux ax servo warning 0092 0001

1L 1R 2L 2R 3L 3R

Servo warning Error # Axis bit

(1) Axis bit of the spindle in which the operation error has occurred is not displayed.

(2) Only the lower 2 digits of the parameter number are shown for [S51 Parameter error].

(3) Since the following alarms are displayed in the same state by the LEDs, it is difficult to distinguish them. Check the

details for each alarm on the diagnosis screen.

[S52 Servo warning] and [S52 Aux ax servo warning]

Axis bit

Displays of 7-segment LED (transition)

1L 1R 2L 2R 3L 3R

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Daily Maintenance and Periodic

Maintenance

M800/M80/E80 Series Maintenance Manual

2 Daily Maintenance and Periodic Maintenance

2Daily Maintenance and Periodic Maintenance

Maintenance is categorized into daily maintenance items (items to be carried at set intervals) and periodic maintenance items (replacement of parts when life is reached). Some parts may not function in a hardware manner when the life is reached, so these should be replaced before the life is reached.

For details of the inspection and maintenance of the drive section, refer to the instruction manuals for each drive unit.

Class Name Life Inspection/replacement

Daily maintenance Touchscreen Accordingly (when poor sensitive or dirty)

Escutcheon (display unit area, keyboard etc.)

Periodic maintenance Battery

(lithium battery)

Cumulative data holding time: 45,000 hours

Note

(1) Replace the battery within one month after the alarm "Z52 Battery fault 0001" appears on the NC screen.

(2) The internal data may have been damaged if the alarm "Z52 Battery fault 0003" appears.

Once/two months (Accordingly when dirty)

When battery voltage drop caution alarm occurs (Guideline: approx. 5 years)

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2 Daily Maintenance and Periodic Maintenance

2.1 Daily Maintenance

2.1.1 Touchscreen

CAUTION

Always keep the touchscreen surface clean. When it gets dirty, remove the dirt immediately. Do not perform any operation on the dirty touchscreen.

(1) Cleaning the touchscreen

When metal powder or sand dust is on the touchscreen, remove it to prevent the scratches.

Wipe the screen gently with a soft and clean cloth.

(2) Precautions for use

The touchscreen may become poor sensitive or even may not react when it gets dirty.

Operate the touchscreen with fingers. The touchscreen does not react with nails.

The use of gloves, work gloves, etc. has effects such as the deterioration of the operation feeling depending on the

material and thickness of the gloves.

The polarizing plate (display surface) of the touchscreen surface can be easily scratched, so be careful during han-

dling.

Glass is used in the touchscreen. Be careful not to drop the touchscreen or allow it to hit hard objects, as the glass

may chip or break.

The polarizing plate may be stained or discolored if drops of water, etc., adhere to it for long periods, so be sure to wipe

off any moisture immediately.

Wipe off any dirt, dust, etc., on the polarizing plate using absorbent cotton or other soft cloth.

Electronic parts are used in the touchscreen, so be careful of static electricity when handling.

Never disassemble the Touchscreen. Doing so will damage the panel.

(3) Precautions for storage

Do not store the card in locations having a high temperature or humidity. (Store within the storage temperature range.)

When storing the touchscreen as an individual unit, be sure that other objects do not touch or hit the polarizing plate

(display surface).

When storing the touchscreen for long periods, be sure to store in a dark place away from exposure to direct sunlight

or fluorescent light.

2.1.2 Escutcheon

Cleaning the escutcheon

(1) Prepare the rear side of the escutcheon to clean.

(2) Wipe the escutcheon with a soft, clean, dry cloth. If cleaning is still required, put some neutral detergent on a cloth

and wipe. Do not use alcohol, thinner, etc.

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M800/M80/E80 Series Maintenance Manual

2 Daily Maintenance and Periodic Maintenance

2.2 Periodic Maintenance

2.2.1 List of Durable Parts

Durable parts Part type

Battery for control unit Q6BAT BKO-C10811H03

Personal computer unit cooling fan 109P0424H3013

(*) Contact the Service Center, Sales Office or dealer for repairs or part replacement.

2.2.2 List of Replacing Parts

Replacing parts Part type Manufacturer

Protection fuse for operation panel I/O LM50 Daito Communication

Apparatus Co., Ltd.

Protection fuse for FCU8-DX220/230/231/651 LM50 Daito Communication

Apparatus Co., Ltd.

Protection fuse for FCU8-DX213/654/213-1/654-1 MP63 Daito Communication

Apparatus Co., Ltd.

Pair of SD/USB covers for display unit N031C089G51 -

(*) Refer to "2.2.4 Replacing Fuse" to replace the fuse.

Note

(1) Fuse for remote I/O unit (FCU8-DX651) cannot be replaced.

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2 Daily Maintenance and Periodic Maintenance

2.2.3 Durable Parts Replacement

2.2.3.1 Control Unit Battery

A lithium battery in the control unit battery holder retains parameter settings, machining programs and the like, which requires to be backed up at the power OFF.

Battery Q6BAT

Battery cumulative data holding time 45,000 hours (At 0 to 45°C; The life becomes shorter if the temperature

is high.)

Battery life Approx. 5 years (from date of battery manufacture)

Precautions for handling battery

(1) Do not disassemble the battery.

(2) Do not place the battery in flames or water.

(3) Do not pressurize and deform the battery.

(4) This is a primary battery so do not charge it.

CAUTION

Do not short-circuit, charge, overheat, incinerate or disassemble the battery.

Replacement procedures

(1) Check that the machine power is turned OFF. (If the power is not OFF, turn it OFF.)

(2) Confirm that the control unit LED, 7-segment display, etc., are all OFF.

(3) Open the front cover of the control unit.

(4) Remove the connector from the control unit BAT connector.

(5) Replace the old battery with the new battery in the battery holder.

(6) Insert the connector connected to the new battery into the BAT connector. Pay attention to the connector orientation:

do not insert backwards.

(7) Close the front cover of the control unit. At this time, confirm that the cover is closed by listening for the "click" sound

when the latch catches.

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2 Daily Maintenance and Periodic Maintenance

[M800W/M80W]

Front cover

Battery holder

Battery

connector

BAT connector

Front cover

Battery holder

Battery

BAT connector

[M800S]

BAT connector

[M80/E80]

Front cover

Battery

Battery holder

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M800/M80/E80 Series Maintenance Manual

2 Daily Maintenance and Periodic Maintenance

2.2.3.2 Personal Computer Unit Cooling Fan

Note

Blowing direction

Type 109P0424H3013

Life 60,000 hours (When the rotary speed decreased 30% less than the initial values)

(1) The life is estimated on the assumption that it is used under 60°C environment. Note that the value above is not a guar-

anteed value.

Replacement procedures

Always replace the personal computer unit cooling fan with the machine power turned OFF.

(1) Check that the machine power is turned OFF. (If the power is not OFF, turn it OFF.)

(2) Open the electric cabinet door.

(3) Remove the fan cover on the personal computer unit.

(Remove the fan cover by holding down the tab on the left side surface.)

(4) Disconnect the cooling fan connector.

(5) Remove the cooling fan from the personal computer unit cooling fan housing.

(6) Replace the cooling fan with a new one. Insert the connector from the new cooling fan into the personal computer unit.

(7) Install the fan cover taking care not to pinch the cooling fan wiring with the fan cover.

(8) Confirm that all the cables are correctly connected and close the electric cabinet door.

[FCU8-PC231] (M800W)

CAUTION

1. Do not replace the cooling fan while the power is ON.

2. Dispose the spent cooling fan according to the local laws.

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2 Daily Maintenance and Periodic Maintenance

2.2.4 Replacing Fuse

FUSE : Not lit

DOCOM : Lit

FUSE : Not lit

DOCOM : Lit

FUSE : Not lit

DOCOM : Lit

How to check for fuse blowout

Operation panel I/O unit

When FUSE LED is not lit and DOCOMLED is lit (*1), the fuse is blown out.

FCU8-DX750/760/761 FCU8-DX730/830/837

FCU8-DX731

(*1) When DOCOM LED is not lit, it is considered that the power is not supplied.

Confirm that the power is correctly supplied.

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2 Daily Maintenance and Periodic Maintenance

Remote I/O unit (FCU8-DX220/230/231)

FUSE : Not lit

24VDCIN : Lit

6A3

MP63

Indication Window :

White

When FUSE LED is not lit and 24VDCIN LED is lit (*2), the fuse is blown out.

FCU8-DX220/230/231

(*2) When 24VDCIN LED is not lit, it is considered that the power is not supplied.

Confirm that the power is correctly supplied.

Remote I/O unit (FCU8-DX213/213-1/654/654-1)

When the indication window of the fuse becomes white, the fuse is blown out.

FCU8-DX213/213-1/654/654-1

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2 Daily Maintenance and Periodic Maintenance

Replacement procedures for fuse

LM50

MP63

(1) Turn OFF the machine.

(2) Remove the fuse using tweezers, etc. and then replace it with a new fuse.

FCU8-DX750/760/761 FCU8-DX730/830/837

FCU8-DX731 FCU8-DX220/230/231 FCU8-DX213/213-1/654/654-1

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Maintenance of the Drive Unit

M800/M80/E80 Series Maintenance Manual

3 Maintenance of the Drive Unit

3Maintenance of the Drive Unit

WARNING

1. Before starting maintenance or inspections, turn the main circuit power and control power both OFF. Wait at least fifteen minutes until the CHARGE lamp turns OFF, and then confirm that the input and output voltage are zero using a tester, etc. Failure to observe this could lead to electric shocks.

2. Inspections must be carried out by a qualified technician. Failure to observe this could lead to electric shocks. Contact your nearest Mitsubishi branch or dealer for repairs and part replacement.

CAUTION

1. Never perform a megger test (measure the insulation resistance) of the drive unit. Failure to observe this could lead to faults.

2. The user must never disassemble or modify this product.

3.1 Periodic Inspections

The following periodic inspections are recommended to be done.

(1) Check that any of the screws on the terminal block is not loose. When there is a loose screw, tighten it.

(2) Check that any abnormal noise is not heard from the servo motor bearings or brake section.

(3) Check that any of the cables is not damaged or cracked. Inspect the cables periodically according to the working con-

dition, especially when the cables move along with the machine.

(4) Check the load coupling shaft for misalignment.

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3 Maintenance of the Drive Unit

3.2 Durable Parts

A guide to the part replacement cycle is shown below. Note that these will differ according to the working conditions or environmental conditions, so replace the parts if any abnormality is found. Contact Mitsubishi branch or your dealer for repairs or part replacements.

[MDS-E/EH Series]

Part name Standard replacement time Remarks

Servo drive unit Smoothing capacitor 10 years The standard replacement time is

Cooling fan 10,000 to 30,000 hours (2 to 3 years)

Battery 10,000 hours (for MDS-BAT6V1SET,

MDSBTBOX-LR2060)

Servo motor Bearings 20,000 to 30,000 hours

Encoder 20,000 to 30,000 hours

Oil seal, V-ring 5,000 hours

[MDS-EJ/EJH Series]

Part name Standard replacement time Remarks

Servo drive unit Smoothing capacitor 10 years The standard replacement time is

Cooling fan 10,000 to 30,000 hours (2 to 3 years)

Battery 10,000 hours (for MR-BAT6V1SET)

Servo motor Bearings 20,000 to 30,000 hours

Encoder 20,000 to 30,000 hours

Oil seal, V-ring 5,000 hours

a reference. Even if the standard replacement time is not reached, the part must be replaced if any abnormality is found.

[MDS-EM/EMH Series]

Part name Standard replacement time Remarks

Servo drive unit Smoothing capacitor 10 years The standard replacement time is

Cooling fan 10,000 to 30,000 hours (2 to 3 years)

Battery 10,000 hours (for MR-BAT6V1SET,

MDSBTBOX-LR2060)

Servo motor Bearings 20,000 to 30,000 hours

Encoder 20,000 to 30,000 hours

Oil seal, V-ring 5,000 hours

(1) Power smoothing capacitor:

The characteristics of the power smoothing capacitor will deteriorate due to the effect of ripple currents, etc. The capacitor life is greatly affected by the ambient temperature and working conditions. However, when used continuously in a normal air-conditioned environment, (ambient temperature is an average of 40°C or less) the service life will be ten years.

(2) Relays:

Contact faults will occur due to contact wear caused by the switching current. The service life will be reached after 100,000 cumulative switches (switching life) although this will differ according to the power capacity.

(3) Servo motor bearings:

The motor bearings should be replaced after 20,000 to 30,000 hours of rated load operation at the rated speed. This will be affected by the operation state, but the bearings must be replaced when any abnormal noise or vibration is found in the inspections.

(4) Servo motor oil seal, V-ring:

These parts should be replaced after 5,000 hours of operation at the rated speed. This will be affected by the operation state, but these parts must be replaced if oil leaks, etc., are found in the inspections.

a reference. Even if the standard replacement time is not reached, the part must be replaced if any abnormality is found.

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3 Maintenance of the Drive Unit

3.3 Adding and Replacing Units and Parts

CAUTION

1. Correctly transport the product according to its weight. Failure to observe this could result in injury.

2. Do not stack the product above the indicated limit.

3. Installation directly on or near combustible materials could result in fires.

4. Install the unit in a place which can withstand its weight.

5. Do not get on or place heavy objects on the unit. Failure to observe this could result in injury.

6. Always use the unit within the designated environment condition range.

7. Do not allow conductive foreign matter such as screws or metal chips, or combustible foreign matter such as oil enter the servo drive or servo motor.

8. Do not block the intake or exhaust ports of the servo drive of servo motor. Failure to observe this could result in faults.

9. The servo drive and servo motor are precision devices. Do not drop them or apply strong impacts.

10. Do not install or operate a servo drive or servo motor which is damaged or missing parts.

11. When the unit has been stored for a long time, contact the Service Center.

12. Connect the encoder (CN2/CN3) immediately after the installation of the servo drive unit. In addition, when a battery box is used, immediately connect to the BTA/BTB connector. (prevention of absolute position data lost)

3.3.1 MDS-E/EH Series

3.3.1.1 Replacing the Drive Unit

Arrangement of replacing parts

Contact Mitsubishi branch or your dealer for an order or a replacement of the drive unit. Place an order for the same type of a drive unit as the one to be replaced.

Replacement procedure

Replace the drive unit with the following procedures.

Procedures

(1) Turn the breaker for the input power OFF. Make sure the CHARGE lamp of the power supply unit is turned OFF.

(2) Disconnect all the connectors and the wires connected to the drive unit.

(3) Remove the two (four) screws fixing the drive unit onto the control panel. Remove the drive unit from the control panel.

(4) Make a same setting for the rotary switch and the dip switch of the new drive unit as those of the uninstalled drive unit.

(5) Install a new drive unit by following the removal procedure in reverse.

Restoration

Data backup and restoration is not required before replacing drive units because drive units’ data such as parameters are stored in the controller. However, carry out a backup of the whole system before replacement as a precautionary measure. The power for keeping the encoder’s position data of an absolute position system is supplied from the battery connected to the drive unit. Keep the power ON once for 30 minutes or more if possible, and make sure to complete the replacement within 60 minutes after charging the encoder’s capacitor.

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3 Maintenance of the Drive Unit

3.3.1.2 Replacing the Unit Fan

Replacing parts

<MDS-E Series>

Servo drive unit Spindle drive unit Power supply unit

Type

MDS-E-

V1-20 9WF0424H603 40SQ. SP-20 9WF0424H603 40SQ. CV-37 - -

V1-40 SP-40 CV-75 - -

V1-80 SP-80 CV-110 9WF0624H604 60SQ.

V1-160 SP-160 9WF0624H604 60SQ. CV-185

V1-160W 9WF0624H604 60SQ. SP-200 9WF0924H206 90SQ. CV-300 9WF0924H206 90SQ.

V1-320 9WF0924H206 90SQ. SP-240 CV-370

V1-320W SP-320 CV-450

V2-20 9WF0424H603 40SQ. SP-400 9WF0924H403 90SQ. CV-550 9WF1224H105 120SQ.

V2-40 SP-640 9WF1224H105 120SQ.

V2-80 SP2-20 9WF0424H603 40SQ.

V2-160 9WF0624H604 60SQ. SP2-40

V2-160W 9WF0924H206 90SQ. SP2-80 9WF0624H604 60SQ.

V3-20 9WF0424H603 40SQ. SP2-16080

V3-40

Fan type Size

[mm]

Type

MDS-E-

Fan type Size

[mm]

Type

MDS-E-

Fan type Size

[mm]

<MDS-EH Series>

Servo drive unit Spindle drive unit Power supply unit

Type

MDS-EH-

V1-10 - - SP-20 9WF0424H603 40SQ. CV-37 9WF0624H604 60SQ.

V1-20 9WF0424H603 40SQ. SP-40 CV-75

V1-40 SP-80 9WF0624H604 60SQ. CV-110

V1-80 SP-100 9WF0924H206 90SQ. CV-185

V1-80W 9WF0624H604 60SQ. SP-160 CV-300 9WF0924H206 90SQ.

V1-160 9WF0924H206 90SQ. SP-200 9WF0924H403 90SQ. CV-370

V1-160W SP-320 CV-450

V1-200 9WF0924H403 90SQ. SP-480 9WF1224H105 120SQ. CV-550 9WF1224H105 120SQ.

V2-10 - - SP600 CV-750

V2-20 9WF0424H603 40SQ.

V2-40

V2-80 9WF0624H604 60SQ.

V2-80W 9WF0924H206 90SQ.

Fan type Size

[mm]

Type

MDS-EH-

Fan type Size

[mm]

Type

MDS-EH-

Fan type Size

[mm]

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3 Maintenance of the Drive Unit

POINT

When the drive unit of E/EH Series which uses two cooling fans is in a n emerg e ncy st op or a l arm, o n e of fa ns (up p er one in the case of vertical layout, or either one in the case of horizontal layout) is stopped and power-saving operation is performed. If the suspended fan is restarted by canceling the emergency stop, it is not a problem with the fan.

Replacement procedure

Replace the unit fan with the following procedures.

<MDS-E/EH-V1/V2/V3/SP/SP2 Series>

(1) Turn the breaker for the input power OFF, and wait for the CHARGE lamp on the power supply unit to turn OFF before

removing the unit.

(2) Remove the fan guard from the back of the drive unit, and remove the two fan mounting screws.

(3) Remove the fan power cable.

(4) Disconnect the connection connector, and replace the fan.

Remove the two screws.

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Pull out the connection connector and disconnect the connector.

M800/M80/E80 Series Maintenance Manual

3 Maintenance of the Drive Unit

3.3.1.3 Replacing the Battery

Replacing parts

When the battery voltage is low (warning 9F), place an order for the same type of a battery as the one currently equipped with the unit. Battery type LR20 is commercially available as a size-D alkaline battery. The battery may be purchased and replaced by the user.

Type Battery equipped unit

MDS-BAT6V1SET Servo drive unit

LR20 (size-D alkaline battery) Battery unit, MDSBTBOX-LR2060

Note

(1) Four LR20 size-D alkaline batteries are needed for per battery unit, MDSBTBOX-LR2060.

CAUTION

1. When the battery voltage is low (warning 9F), do not shut OFF the power of the drive unit until replacement of the battery to protect the data.

2. Replace the MDSBTBOX-LR2060 battery with new batteries (LR20) that i s with in the r ecomm e nded s ervic e perio d.

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3 Maintenance of the Drive Unit

Replacement procedure

112 2

BTI BTO

BTA BTB

Connect the battery box with BTI.

Battery connector connection part magnified figure

Battery attaching part

Battery unit

Replace the battery with the following procedures.

CAUTION

1. Replace the batteries with new ones immediately after the battery voltage drop alarm (9F) has been output.

2. Replace the batteries while applying the drive unit’s control power.

(1) Open the battery holder cover located at the front of the drive unit.

(2) Pull out the battery connector connected with the drive unit. Remove the battery.

(3) Install a new battery and connect a cable connector to the connector position where the old battery connector was pulled

out from in step (2).

(4) Cancel the warning 9F by executing an alarm reset (pushing the NC reset button).

1 2 1 2

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3 Maintenance of the Drive Unit

Possible backup period

Possible backup period is at most one year. Thus, make sure to exchange the batteries in the one-year cycle.

How to replace the battery

(1) Remove the battery box cover (four screws).

(2) Replace the batteries with new ones. Be careful not to mistake the polarity.

(3) Attach the cover, and fix it with the four screws.

Note

(1) Replace the batteries while applying control power to the servo drive unit.

(2) When replacing the battery, do not let foreign objects enter. If the terminal area gets dirty, clean there.

(3) If the cover is ill-set, mist or foreign objects enter through the interstices and enter into the panel. Tighten the screws.

(Tightening torque: 1N•m)

Alkaline dry batteries

LR20 × 4 pieces

CAUTION

1. Replace the batteries with new ones that are in their recommended use period. (Check the recommended use period written on the batteries before using them.)

2. Replace the batteries with new ones immediately after the battery voltage drop alarm (9F) has been output.

3. Replace the batteries while applying the servo drive unit’s control power.

4. Wrong connection may cause liquid leakage, heat generation and/or explosion.

5. Do not mix new batteries with used ones or mix different types of batteries.

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3 Maintenance of the Drive Unit

3.3.2 MDS-EJ/EJH Series

3.3.2.1 Replacing the Drive Unit

Arrangement of replacing parts

Contact Mitsubishi branch or your dealer for an order or a replacement of the drive unit. Place an order for the same type of a drive unit as the one to be replaced.

Replacement procedure

Replace the drive unit with the following procedures.

Procedures

(1) Turn the breaker for the input power OFF. Make sure the CHARGE lamp of the power supply unit is turned OFF.

(2) Disconnect all the connectors and the wires connected to the drive unit.

(3) Remove the two (four) screws fixing the drive unit onto the control panel. Remove the drive unit from the control panel.

(4) Make a same setting for the rotary switch and the dip switch of the new drive unit as those of the uninstalled drive unit.

(5) Install a new drive unit by following the removal procedure in reverse.

Restoration

3.3.2.2 Replacing the Unit Fan

Replacing parts

Unit fan type

Drive unit type Fan type Size [mm]

MDS-EJ-V1-30 MMF-04C24DS BKO-CB0479H01 40SQ.

MDS-EJ-SP-20

MDS-EJ-V1-40/80/100 MMF-06F24ES-RP3 BKO-CB0500H01 60SQ.

MDS-EJ-SP-40/80

MDS-EJ-SP-100/120 MMF-08D24ES-RP1 BKO-CA1639H01 *M 80SQ.

MDS-EJ-SP-160 MMF-06F24ES-RP1 BKO-CA1638H01 *M×2 60SQ.

MDS-EJ-V2-30 MMF-06H24SS-CX1 BKO-CA2254H01 60SQ.

MDS-EJ-SP2-20

MDS-EJ-V2-40 MMF-08G24ES-CP1 BKO-CA1941H01 80SQ.

POINT

MDS-EJ-V1-10/15 does not have this unit fan.

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3 Maintenance of the Drive Unit

Replacement procedure

CON3

Direction of the fan wind

Remove the mounting screws.

Disconnect the connection connector of the fan mounted on the unit side face.

Direction of the fan wind

Cooling fan

Make sure that the cooling fan lead wires are not stuck by the cooling fan or the chassis. Also make sure not to apply any load to the base of the cooling fan lead wires.

Wire the cooling fan lead wires at the side of the cooling fan.

Replace the unit fan with the following procedures.

<MDS-EJ-V1-30, MDS-EJ-SP-20>

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3 Maintenance of the Drive Unit

<MDS-EJ-V1-40/80/100, MDS-EJ-SP-40/80>

Direction of the fan wind

Remove the mounting screws.

Disconnect the connection connector of the fan mounted on the unit side face.

Cooling fan

CON5

Direction of the fan wind

Lead out the cooling fan lead wires from here when installing the fan. Make sure that the cooling fan lead wires are not stuck by the cooling fan or the chassis.

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3 Maintenance of the Drive Unit

<MDS-EJ-SP-100/120>

Cooling fan lead wire

Cooling fan

Direction of the fan wind

Attach the harness to the position described in the figure above.

Sleeve

Connector

Insert the connector so that it will reach the end of the stopper when assembling.

Place the fan harness inside the chassis using the positioning boss for the chassis. Fold the harness to put it inside so that it will not be stuck by the cooling fan.

Keep the clearance even.

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3 Maintenance of the Drive Unit

<MDS-EJ-SP-160>

(1) Remove the mounting screws.

Insert the connector so that it will reach the end of the stopper when installing.

(2) Disconnect the connection connector of the fan mounted on the unit side face.

Direction of the fan wind

Sleeve

Direction of the fan wind

Sleeve

Connector

Installation procedure of tube for fan harness

Place the fan harness inside the chassis using the positioning boss for the chassis. Fold the harness to put it inside so that it will not be stuck by the cooling fan.

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3 Maintenance of the Drive Unit

<MDS-EJ-V2-30, MDS-EJ-SP2-20>

FAN㢼ྥ䛝

Disconnect the connection connector of the fan mounted on the unit side face.

Direction of the fan wind

Remove the mounting screws.

Disconnect the connection connector of the fan mounted on the unit side face.

Direction of the fan wind

Remove the mounting screws.

<MDS-EJ-V2-40>

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3 Maintenance of the Drive Unit

3.3.2.3 Replacing the Battery

Insert the plug to BAT after installing the battery.

Pull out the connector while pushing the unlocking lever.

Slide the case of MR-BAT6V1SET toward you while pushing the unlocking lever.

Installation

Removal

Replacing parts

When the battery voltage is low (warning 9F), place an order for the same type of a battery as the one currently equipped with the unit.

Type Battery equipped unit

MR-BAT6V1SET Servo drive unit

LR20 (size-D alkaline battery) Battery unit, MDSBTBOX-LR2060

The battery unit itself must be replaced because the battery is built into the unit. When the battery voltage is low (warning 9F), place an order for the same type of the battery unit as the one to be replaced.

CAUTION

1. When the battery voltage is low (warning 9F), do not shut OFF the power of the drive unit until replacement of the battery to protect the data.

2. Replace the MDSBTBOX-LR2060 battery with new batteries (LR20) that is within the recommended service period.

Replacement procedure

Replace the battery with the following procedures.

CAUTION

1. The power of the drive unit must be turned ON for 30min. or longer before replacing the battery.

2. Replace the batteries while applying the drive unit’s control power.

(a) Installing and removing the cell battery

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3 Maintenance of the Drive Unit

(b) Replacing the built-in battery

MR-BAT6V1SET that reached the end of the life can be reused by replacing the MR-BAT6V1 battery.

Cover

MR-BAT6V1

Open the cover while pushing the locking part.

Locking part

Replace the built-in battery with a new battery for MR-BAT6V1.

Close the cover by pushing until it is fixed with the tab of the locking part.

Tab

Cancel the warning 9F by executing an alarm reset (pushing the NC reset button).

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3 Maintenance of the Drive Unit

Possible backup period

Possible backup period is at most one year. Thus, make sure to exchange the batteries in the one-year cycle.

How to replace the battery

(1) Remove the battery box cover (four screws).

(2) Replace the batteries with new ones. Be careful not to mistake the polarity.

(3) Attach the cover, and fix it with the four screws.

Note

(1) Replace the batteries while applying control power to the servo drive unit.

(2) When replacing the battery, do not let foreign objects enter. If the terminal area gets dirty, clean there.

(3) If the cover is ill-set, mist or foreign objects enter through the interstices and enter into the panel. Tighten the screws.

(Tightening torque: 1N•m)

Alkaline dry batteries

LR20 × 4 pieces

CAUTION

1. Replace the batteries with new ones that are in their recommended use period. (Check the recommended use period written on the batteries before using them.)

2. Replace the batteries with new ones immediately after the battery voltage drop alarm (9F) has been output.

3. Replace the batteries while applying the servo drive unit’s control power.

4. Wrong connection may cause liquid leakage, heat generation and/or explosion.

5. Do not mix new batteries with used ones or mix different types of batteries.

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3 Maintenance of the Drive Unit

3.3.3 MDS-EM/EMH Series

3.3.3.1 Replacing the Drive Unit

Arrangement of replacing parts

Contact Mitsubishi branch or your dealer for an order or a replacement of the drive unit. Place an order for the same type of a drive unit as the one to be replaced.

Replacement procedure

Replace the drive unit with the following procedures.

Procedures

(1) Turn the breaker for the input power OFF. Make sure the CHARGE lamp of the power supply unit is turned OFF.

(2) Disconnect all the connectors and the wires connected to the drive unit.

(3) Remove the two (four) screws fixing the drive unit onto the control panel. Remove the drive unit from the control panel.

(4) Make a same setting for the rotary switch and the dip switch of the new drive unit as those of the uninstalled drive unit.

(5) Install a new drive unit by following the removal procedure in reverse.

Restoration

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3 Maintenance of the Drive Unit

3.3.3.2 Replacing the Fan Unit

Mounting screw

Fan unit cover

Replacing parts

Drive unit type Fan type

MDS-EM-SPV3-16040S EM-FS-18

MDS-EM-SPV3-10040 to 200120

MDS-EMH-SPV3-8040 to 10060

MDS-EM-SPV3-320120 EM-FS-30

Replacement procedure

Replace the fan unit with the following procedures.

EM-FS-26

(1) Remove the mounting screws from the fan unit cover

(2) Remove the fan unit cover.

on the top of the drive unit.

(3) Remove the fixing screws from the fan unit. Disconnect the connector on the top and pull out the fan unit.

Fixing screw

Connector

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Fan unit

M800/M80/E80 Series Maintenance Manual

3 Maintenance of the Drive Unit

(4) When installing the fan unit, insert the sheet metal of the fan unit into the fin rails.

Sheet metal

Fin rail *

* Although MDS-EM-SPV3-16040S and 320120 do not have fin rails, the installation of fan units is not affected.

3.3.3.3 Replacing the Battery

Replacing parts

Battery type

Type Battery equipped unit

MR-BAT6V1SET Multi axis drive unit

LR20 (size-D alkaline battery) Battery unit, MDSBTBOX-LR2060

Note

(1) Four LR20 size-D alkaline batteries are needed for per battery unit, MDSBTBOX-LR2060.

CAUTION

1. When the battery voltage is low (warning 9F), do not shut OFF the power of the drive unit until replacement of the battery to protect the data.

2. Replace the MDSBTBOX-LR2060 battery with new batteries (LR20) that i s with in the r ecomm e nded s ervic e perio d.

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3 Maintenance of the Drive Unit

Replacement procedure

Replace the battery with the following procedures.

CAUTION

1. Replace the batteries with new ones immediately after the battery voltage drop alarm (9F) has been output.

2. Replace the batteries while applying the drive unit’s control power.

(1) Pull out the battery connector connected with the drive unit while pushing the unlocking lever.

(2) Remove the battery unit by sliding upward while pushing the unlocking lever.

(3) Install a new battery and connect a cable connector to the connector position where the old battery connector was pulled

out from in step (2).

(4) Cancel the warning 9F by executing an alarm reset (pushing the NC reset button).

MR-BAT6V1SET

Battery connector connection part

magnified figure

2 1

Connect the battery box with BTI.

BTI

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3 Maintenance of the Drive Unit

Possible backup period

Possible backup period is at most one year. Thus, make sure to exchange the batteries in the one-year cycle.

How to replace the battery

(1) Remove the battery box cover (four screws).

(2) Replace the batteries with new ones. Be careful not to mistake the polarity.

(3) Attach the cover, and fix it with the four screws.

Note

(1) Replace the batteries while applying control power to the servo drive unit.

(2) When replacing the battery, do not let foreign objects enter. If the terminal area gets dirty, clean there.

(3) If the cover is ill-set, mist or foreign objects enter through the interstices and enter into the panel. Tighten the screws.

(Tightening torque: 1N•m)

Alkaline dry batteries

LR20 × 4 pieces

CAUTION

1. Replace the batteries with new ones that are in their recommended use period. (Check the recommended use period written on the batteries before using them.)

2. Replace the batteries with new ones immediately after the battery voltage drop alarm (9F) has been output.

3. Replace the batteries while applying the servo drive unit’s control power.

4. Wrong connection may cause liquid leakage, heat generation and/or explosion.

5. Do not mix new batteries with used ones or mix different types of batteries.

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Mitsubishi M850W, M830W, M850S, M830S, M80W Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

Manual List

Precautions for Safety

Treatment of waste

Disposal

Trademarks

Contents

System Basic Configuration

1.1 System Basic Configuration Drawing

1.2 General Connection Diagram

1.2.1 General Connection Diagram [M800W]

1.2.2 General Connection Diagram [M80W]

1.2.3 General Connection Diagram [M800S]

1.2.4 General Connection Diagram [M80]

1.2.5 General Connection Diagram [E80]

1.3 How to Check the System Configuration

1.3.1 System Configuration Screen

1.3.2 Option Display Screen

1.4 Each Unit Status Display

1.4.1 Control Unit

1.4.2 Personal Computer Unit

1.4.3 Operation Panel I/O Unit

1.4.4 Remote I/O Unit

1.4.5 Communication Expansion Unit

1.4.5.1 CC-Link Expansion Unit

1.4.5.2 PROFIBUS-DP Expansion Unit

1.4.5.3 CC-Link IE Field

1.4.5.4 EtherNet/IP

1.4.6 7-segment LEDs on the Control Unit

1.4.6.1 Normal State Display

1.4.6.2 Error Display at NC Startup

1.4.6.3 Display when an Alarm Occurs

2.1 Daily Maintenance

2.1.1 Touchscreen

2.1.2 Escutcheon

2.2 Periodic Maintenance

2.2.1 List of Durable Parts

2.2.2 List of Replacing Parts

2.2.3 Durable Parts Replacement

2.2.3.1 Control Unit Battery

2.2.3.2 Personal Computer Unit Cooling Fan

2.2.4 Replacing Fuse

Maintenance of the Drive Unit

3.1 Periodic Inspections

3.2 Durable Parts

3.3 Adding and Replacing Units and Parts

3.3.1 MDS-E/EH Series

3.3.1.1 Replacing the Drive Unit

3.3.1.2 Replacing the Unit Fan

3.3.1.3 Replacing the Battery

3.3.2 MDS-EJ/EJH Series

3.3.2.1 Replacing the Drive Unit

3.3.2.2 Replacing the Unit Fan

3.3.2.3 Replacing the Battery

3.3.3 MDS-EM/EMH Series

3.3.3.1 Replacing the Drive Unit

3.3.3.2 Replacing the Fan Unit

3.3.3.3 Replacing the Battery