Mitsubishi PLK-G-CU-20 User Manual

INDUSTRIAL SEWING MACHINE

MODEL

PLK-G-CU-20

TECHNICAL MANUAL

Control Unit

A180E604P09

[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____________________________

[16] Specifications_____________________________________________ [16]-1

[15]-1

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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.

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[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

Please use this control unit in the industrial setting only. And 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 technical manual [Control unit] 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.

Enclosed units and accessories

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

[1] - 1

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.

■ NOTICE CONCERNING MARKING

(1) Electronic sewing machine PLK-G series are applied to CE conformity marking by installing the

exclusive device [PLK-G-CE]. When the products are used in the EU region, these devices are necessary to be installed.

(2) Electronic sewing machine should be use limited to the industrial areas even though above-mentioned

countermeasure is done. [Warning] Use in residential areas may cause interference.

■ 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.

The warning display shows that incorrect handling can lead to

Warning

Caution

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

This symbol indicates that the instructions must be followed.

This symbol indicates hot temperature requiring caution.

This symbol indicates a prohibited action.

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

injuries or damages to your house, household goods, and others.

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

This symbol indicates that ground wire connection is required.

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

[1] - 2

[2] Precautions for use

Warning

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

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

Control circuit

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

5. Always ground the grounding wire. Power supply

Green (Green/yellow)

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

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

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

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

6. Do not use excessive wiring.

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

[2] - 1

)

)20A

)15A

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.

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

Noise

PLK-G3-CPU

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.

XC-G2-2B-PLK

PLK-G2-PMD

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

15. Attention when power supply is turned on again Please make sure not to turn on the power supply switch until after

the LED on the front panel of the control box has completely turned off. (Please do not turn on the power supply again while displaying

the screen of the operation panel.) * Please note that if power supply is turned on again while LED still turns on,

clamp outputs (O4, O5 port) may go down.

16. When the value of the sewing area limit is changed or the limit setting is deactivated, note the collision and

with the cover and CPU removed)

fuse(one fuse)

Solenoid board located on back of machine head

2.5Afuse(two fuses

PLK-G2-PMM

8Afuse(one fuse

XC-G2-2B-PLK

PLK-G2-PMD

fuse(two fuses

take care safely. Also when using it outside the range where the mechanism can be operated, it can not assume the responsibility for all problems caused by it.

[2] - 2

1. Installing the control box

control box

Top view of control box installation area

Front view of control box installation area

Leg

Top plate

Damper cushion

Leg

[3] Installation

●Insert the four bolts into the holes

on the top plate and install the control box.

427

4-Ø9

Installation bolt (Fix at four positions)

Installation bolt

(M8×60)

Washer

Spring

washe

Nuts

control box

[3] - 1

[4] Names of each part, wiring and grounding

1.Front side

Power

LED(green)

Function button

Heat sink

Warning

LED(red)

CONR USB（TYPE A） with Protective cap

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

anel

Front

Cover installation screw (M4 screw)

2.Back side

CONA Operation panel (Connect to Operation panel)

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

CONE Various solenoids (Connect to sewing machine head section)

CONF Spindle encoder (Connect to spindle servo motor)

Cove

Rating plate

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)

CONH Foot switch (Connect to foot switch)

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

[4] - 1

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

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.”

3. Connecting the power connector

Control box

4. Connecting the 3-phase power supply

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

Push-button switch cord

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

Control box

Power connector (6-pole)

Caution1: Always confirm the connector shape and insertion

Caution2: Please do not bundle the power cable and other

Top plate

owe

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

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

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

OFF ON

Do not connect (Accurately insulate with tape.)

Green

Red

White Black

Connect these lead wires to the power supply.

[4] - 2

[5] Confirmation

1. Before turning the switch ON

(1)Are the power and capacity correct?

(2)Are the connectors correctly inserted? (

* 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?

Refer to “[12] Unit Wiring Diagram.”)

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

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

(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.

[5] - 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] - 1

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

► Press .

(5) Please turn the power off according to the display

of the message.

(6) Setting table / Step file setting (

► While holding down the [F] key on the front panel of the control box, turn the machine power ON. (Keep pushing [F]

key until red LED on the front panel is turned on.)

If setting is not necessary, goto (9).

＋

)

(7)Setting table / Step file setting

►Press .

(8)

Setting table / Step file setting mode

►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

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

press

, which above data is contained,

[*1]

[6] - 2

►After file name selection screen is displayed, choose target

filename by using up and down arrow button, then press

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

[

] folder in the USB memory.

(9)Re-turning on the power supply

► Please turn the power off according to the display of the message.

► 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

(10)Initial condition

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

displayed.

Press

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

to switch to the Standard screen, then create

[6] - 3

[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

Thread trimming output [T]

Thread release output [L]

LLM

setting

TRS(deg) TRE(ms)

TRS(deg) TRE(deg)

TRS(deg) TRE(ms)

TRS(ms) TRE(ms)

LRS(deg) LRE(ms)

LRS(deg) LRE(deg)

Wiper [W]

LRS(deg) LRE(ms)

LRS(ms) LRE(ms)

W1(ms) W2(ms)

[7] - 1

2.Timing chart for [Clamp of output ON/OFF delay setting]

Clamp input 1~8

IF1~IF8

ON ON

1A~8A 1B~8B

Clamp output 1~8

OF1~OF8

3.Timing chart for [Priority of clamp]

Clamp input 1

IF1

Clamp input 2

IF2

Clamp input 3

IF3

Clamp input 4

IF4

[WHY]=[OFF]

Clamp output 1

OF1

Clamp output 2

OF2

Clamp output 3

OF3

Clamp output 4

OF4

[WHY]=[ON]

Clamp output 1

OF1

Clamp output 2

OF2

Clamp output 3

OF3

Clamp output 4

OF4

Note: [WHY]=[ON]

* The clamp input signal [IF2],[IF3],[IF4] is invalidated when clamp output 1 is not ON. * The clamp input signal [IF2] is validated when clamp output 1 is ON. * The clamp input signal [IF3] is validated when clamp output 2 is ON. * The clamp input signal [IF4] is validated when clamp output 3 is ON.

[7] - 2

+ 37 hidden pages

Mitsubishi PLK-G-CU-20 User Manual

Contents

[1] For safe use

[2] Precautions for use

[3] Installation

[4] Names of each part, wiring and grounding

[5] Confirmation

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

[7] Timing chart