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.
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
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)
Detailed specifications of hardware unit
Installation, connection, wiring, setup (startup/adjustment)
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
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
Sp
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 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"
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.
(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-
RA
RA
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
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
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 .
Contents
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
1
1
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
2
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
3
IB-1501273-F
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