Mitsubishi Electric PLK - G Technical Manual

Industrial Sewing Machine

TECHNICAL MANUAL

Electronic Pattern Sewing Machine PLK - G Series

Control Unit

A180E604P02

Contents

[1] For safe use_________________________________________________ [1]-1 [2] Precautions for use __________________________________________

[2]-1

[3] Installation__________________________________________________

[3]-1

[4] Names of each part, wiring and grounding _______________________

[4]-1

[5] Confirmation ________________________________________________

[5]-1

[6] Initial Settings of System Software (Model/Language Settings) ______

[6]-1

[7] Timing chart ________________________________________________

[7]-1

[8] Customized input/output ______________________________________

[8]-1

[9] Input/Output signal___________________________________________

[9]-1

[10] What happened? Could it be an error? _________________________

[10]-1

[11] Several power supply________________________________________

[11]-1

[12] Unit wiring diagram _________________________________________

[12]-1

[13] Connectors layout __________________________________________

[13]-1

[14] Pin number of connectors____________________________________

[14]-1

[15] Wiring diagram inside control box _____________________________

[15]-1

[16] Specifications ______________________________________________ [16]-1

- 1 -

- 2 -

Thank you for purchasing the Mitsubishi industrial sewing machine PLK-G Series. Please read this technical manual before starting to ensure correct and long-term use.

* The contents of this manual may not be reproduced in part or whole. * The contents of this manual are subject to change without notice. * An utmost effort has been made to cover all points of operation in this manual.

Contact Mitsubishi if you have any questions regarding the contents.

[1] - 1

[1] For safe use

■ For safe use

Always observe the following matters to safely use the Mitsubishi industrial electronic sewing machine PLK-G Series.

Before starting

Before using this control unit, read all of the technical manuals carefully, and correctly use the unit following the manual. Also read the "Mitsubishi Industrial Sewing Machine Technical Manual <Sewing Machine Head>" for details on the general configuration and sewing machine head.

Application and purpose

This control unit is designed to drive and control the Mitsubishi industrial electronic sewing machine PLK-G Series. Do not use this control unit for other applications or purposes. Do not use this control unit until it has been confirmed that safety measures have been accurately taken for the installed electronic sewing machine head section.

Working environment

Do not use this control unit in the following type of environment. (1) Power voltage

* Where the voltage fluctuation exceeds ±10% of the rated voltage. * Where the specified power capacity (refer to page [4]-2 “5. Power capacity”) cannot be ensured.

(2) Magnetic noise

* Where strong fields or magnetic fields are generated, such as near a high-output high frequency

oscillating machine or high frequency welder.

(3) Temperature and humidity

* Where the ambient temperature is 35°C or more and 5°C or less. * Where the unit will be subject to direct sunlight, or outdoors. * Near sources of heat, such as heating appliances. * Where the relative humidity is 45% or less, or 85% or more, and where dew may condense.

(4) Atmosphere

* In an atmosphere containing dust or corrosive gases, etc. * In a flammable gas or explosive environment.

(5) Vibration

* If excessive vibration could occur when installed on the sewing machine, separately install the

control box.

■ Installation

Control box

Correctly install the control box according to this manual.

Accessories

Always disconnect the control unit from the main power supply before installing the accessories listed in this manual. (Turn the power switch OFF, and disconnect the plug from the socket (power supply line).)

Cable

(1) Lay the connection cables so that excessive force will not be applied during operation. Do not

excessively bend the cables. (2) Cables laid near operating machine sections must be separated by at least 25mm. (3) Before connecting the power cable to the control box, confirm that the power voltage matches the

specifications given on the control box's rating nameplate and factory shipment voltage nameplate.

Connect the cable to the indicated positions, and then supply the power. When using a power unit,

connect the cable to the power unit and supply the power. In addition, when using a power unit,

confirm that the power voltage matches the specifications given on the power unit's rating nameplate.

Turn the power switch OFF before making any connections.

Grounding

Always ground the power cord's grounding wire.

[1] - 2

Enclosed units and accessories

Connect the electrical enclosed units and accessories only to the positions indicated in the manual.

Removal

(1) Always turn the power switch OFF and disconnect the plug from the socket (power supply line) before

removing the control box.

(2) Do not pull out the cord when disconnecting the plug. Always hold the plug receptacle when

disconnecting the plug.

(3) Note that a high voltage is applied inside the control panel, so always turn the power OFF and wait

at least ten minutes before opening the control box cover.

■ Maintenance, inspection and repairs

(1) Follow this manual when carrying out maintenance or inspections related to this control unit. (2) This unit must be repaired, serviced and inspected only by a worker that has received special training. (3) Always turn the power OFF before replacing the needle or bobbin, etc., on the head. (4) Use genuine replacement parts for repairs and maintenance.

■ Other safety measures

(1) Keep fingers away from all moving machine parts (especially around the sewing machine needle,

etc.). (2) Never drop the control unit, or place objects in the clearances. (3) Do not operate the sewing machine without the protective parts such as the cover, or protection

devices such as the safety breaker. (4) If any damage is observed in the control unit, if the unit does not operate correctly, or if the operation

is suspicious, always suspend operation. Only operate the machine after the supervisor has adjusted,

repaired or inspected the machine. (5) The user must not make improvements or changes without instruction from Mitsubishi.

■ Caution displays and danger displays

(1)In this manual, the dangers and danger levels that arise with incorrect handling are classified using the

following displays.

Warning

The warning display shows that incorrect handling can lead to death or serious injuries.

Caution

The caution display shows that incorrect handling can lead to injuries or damages to your house, household goods, and others.

(2)The meanings of these symbols are as follows.

This symbol indicates that the instructions must be followed.

This symbol indicates an electrical hazard or caution (electric shock caution).

This symbol indicates hot temperature requiring caution.

This symbol indicates that ground wire connection is required.

This symbol indicates a prohibited action.

* Always deliver this manual to the end user. * Store this manual nearby where it can be referred to when necessary.

[2] - 1

[2] Precautions for use

Warning

1. Do not place foot on the foot switch when turning the power ON.

2. Always turn the power OFF when leaving the sewing machine.

3. Do not inspect the control circuit with a tester.

The tester voltage could be applied on the semiconductor parts, and cause damage.

4. Always turn the power switch OFF before tilting the sewing machine head, replacing the needle, or passing thread through the needle.

5. Always ground the grounding wire.

Always ground the provided grounding wire (green(green/yellow)).

6. Do not use excessive wiring.

7. A high voltage is applied inside creating a hazardous state, so always turn the power OFF and wait ten minutes before opening the cover.

High voltage risk

8. Radiation fins and other parts may be hot. Do not touch the parts.

Control circuit

Green (Green/yellow)

Power supply

[2] - 2

9. The sewing machine will coast to a stop when the power is turned OFF or a power failure occurs during sewing machine operation.

10. Always align the connector shape and direction, and securely insert the connector.

11. If the position detector's connector dislocates, or the sewing machine is completely locked, the motor will be turned OFF automatically for a set time to prevent burning. (Note that the motor may not turn OFF if there is incomplete locking or an overload.) When the fault has been recovered, turn the power OFF and ON once to resume normal operation. The same type of operation will take place if a detector fault or disconnection occurs.

12．Use the machine away from strong noise sources such as high

frequency welders.

13. When connecting the external switch to an optional connector, etc., keep the signal wire as short as possible. A long wire could cause malfunctions.

Use a shielded wire for the signal wire when possible.

14. If the fuse blows, remove the cause, and replace the blown fuse with one having the same capacity.

(View from the front with cover removed) (View from the front

with the cover and CPU removed)

Solenoid board located on back of machine head

15．Attention when power supply is turned on again

Please make sure that turning on the power supply switch, after the LED of the front panel on the controlbox is completely turned off.

(Please do not turn on the power supply again while displaying the screen of the oepration panel.)

Noise

PLK-G2-PMD

XC-G2-2B-PLK

PLK-G2-CPU

PLK-G2-PMD

PLK-G2-PMM

8Afuse(one fuse

)

2.5Afuse(two fuses

)20A

fuse(two fuses

)20A

fuse(two fuses

)15A

fuse(one fuse)

XC-G2-2B-PLK

[3] - 1

[3] Installation

1. Installing the control box

●Insert the four bolts into the holes on the top plate and install the control box.

Top view of control box installation area

Front view of control box installation area

427

Top plate

Damper cushion

control box

4-Ø9

Leg

Nuts

Spring

washe

Washer

Installation bolt

(M8×60)

Leg

control box

Installation bolt (Fix at four positions)

[4] - 1

[4] Names of each part, wiring and grounding

1.Front side

2.Back side

Heat sink

Power

LED(green)

Warning

LED(red)

CONR USB（TYPE A） with Protective cap

CONS RS-232C（MINI DIN） with Protective cap

Front

anel

CONA Operation panel (Connect to Operation panel)

CONE Various solenoids (Connect to sewing machine head section)

CONF Spindle encoder (Connect to spindle servo motor)

CONG XY axis encoder (Connect to XY axis stepping motor)

CONH Foot switch (Connect to foot switch)

CONJ XY axis stepping motor (Connect to sewing machine head stepping motor)

Cover installation screw (M4 screw)

Cove

Function button

CONB Power supply (Connect to power switch box)

CONC DC power for solenoid (Connect to sewing machine head section)

COND Spindle servo motor (Connect to spindle servo motor)

CONK PF axis stepping motor (Connect to sewing machine head PF axis stepping motor)

Rating plate

Caution: Be sure to connect all connectors

before turning ON the power. Connect each connector fully to ensure sufficient contact. Refer to “[12] Unit Wiring Diagram.”

[4] - 2

3. Connecting the power connector

Caution1: Always confirm the connector shape and insertion

orientation and completely insert the power connector into the control box. Always turn the power OFF before connecting the connector.

Caution2: Please do not bundle the power cable and other

cables together. It may cause of malfunction by the influence of the power supply noise etc.

4. Connecting the 3-phase power supply

3-phase power supply R-phase S-phase T-phase

Push-button switch cord

Warning

Always connect the green wire to the grounding terminal.

Consult with your electrician for details on the grounding wire.

5. Power capacity

Use a fuse or safety breaker on the power supply.

Power supply Recommended current capacity value

3-phase 200V

10A

6. Using the 3-phase 200V control box with single-phase 200 to 220V

Connect power supply to the "red" and "white" lead wires for the push-button switch. The black wire is not used, so insulate it by wrapping insulation tape, etc., around it. Always ground the green grounding wire.

Connect to ground

Connection connector to control box Push-button switch

Top plate

Control box

owe

Power connector (6-pole)

Control box

Red(black) White(brown) Black(blue) Green(green/yellow)

Green

Red

White Black

Do not connect (Accurately insulate with tape.)

Connect these lead wires to the power supply.

OFF ON

[5] - 1

[5] Confirmation

1. Before turning the switch ON

(1)Are the power and capacity correct?

(2)Are the connectors correctly inserted? (

Refer to “[12] Unit Wiring Diagram.”)

* Power connector from push-button switch * Connector for connection with sewing machine * Motor connector * Motor encoder connector * Foot switch connector * Other connectors (solenoid, etc.)

(3)Does the hand pulley turn easily?

2. After turning the switch ON

(1)Is the front panel power LED (green) on?

(2)Is the front panel warning LED (red) on or flickering?

(3)Is there any heating, odors or abnormal noise from the motor or control box?

● When you turn ON the power, a click noise comes from inside the control box. This noises are not abnormal.

Turn the sewing machine OFF and contact your dealer if there is any heating, odors or abnormal noise.

For actions to be taken when the warning LED (red) is on or flickering, refer to “[10] What Happened? Could it Be an Error?”

[6] - 1

[6] Initial Settings of System Software (Model/Language Settings)

1.Model/Language Settings

The model to be used and the language to be displayed need to be set. When you turn on the machine power with the system in an initial state, the “Model/Language Setting” screen appears. Perform the procedures below.

(1)When the power supply is turned on first time, [Model/Language setting] screen is displayed.

►For language setting, press .

►For model setting, press

(2)Language setting

►press .

►Choose Language button, then press .

(3)Model setting

►press .

►Choose Model button, then press .

[6] - 2

(4)Setting table / Step file setting

►For Setting table/ step file setting, press .

If setting is not necessary, goto (5).

►Choose one of following buttons.

Reads Setting table and Step file

Reads Setting table only

Reads Step file only

Reads System file ,Setting table and Step file

►Connect USB memory

[*1]

, which above data is contained,

to the connector on the front panel of the control box, then, press

►After file name selection screen is displayed, choose target

filename by using up and down arrow button, then press

. Goto (6)

[*1] Setting table and Step file must be saved in the

[

] folder in the USB memory.

(5) Model / Language setting screen is displayed again.

► press

Note Do not press at this time.

[6] - 3

(6)Re-turning on the power supply

►Turn the power off.

► After check the LED lamp on the front panel of the control box

Is completely off, turn the power on.

Check the LED lamp is OFF

(7)Initial condition

► At initial condition, the message like a right picture is

displayed. Press

to switch to the Standard screen, then create

or read sewing pattern data. ( Refer to technical manual [ Operation panel ].)

[7] - 1

[7] Timing chart

1.Thread trimming timing chart

·Timing for thread trimming output [T] :

Program mode [Thread trimming/release timing] -- [LTM] T1~T5 Program mode [Thread trimming/release timing] -- [TRS] msec / deg Program mode [Thread trimming/release timing] -- [TRE] msec / deg

·Timing for thread release output [L] :

Program mode [Thread trimming/release timing] -- [LLM] L1~L5 Program mode [Thread trimming/release timing] -- [LRS] msec / deg Program mode [Thread trimming/release timing] -- [LRE] msec / deg

·Timing for wiper output [W] :

Program mode [Wiper] -- [W1] msec Program mode [Wiper] -- [W2] msec

Needle down position DN

Needle up position UP

LTM

setting

TRS(deg) TRE(ms)

TRS(deg) TRE(deg)

TRS(deg) TRE(ms)

TRS(ms) TRE(ms)

Thread trimming output [T]

TRS(ms) TRE(ms)

LLM

setting

LRS(deg) LRE(ms)

LRS(deg) LRE(deg)

LRS(deg) LRE(ms)

LRS(ms) LRE(ms)

Thread release output [L]

LRS(ms) LRE(ms)

Wiper [W]

W1(ms) W2(ms)

+ 36 hidden pages

Mitsubishi Electric PLK - G Technical Manual

Specifications and Main Features

Frequently Asked Questions

User Manual