PLK-G-CU-20
Table of contents
Loading...
INDUSTRIAL SEWING MACHINE
MODEL
PLK-G-CU-20
TECHNICAL MANUAL
Control Unit
A180E604P09
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____________________________
[16] Specifications_____________________________________________ [16]-1
[15]-1
- 1 -
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.
COPYRIGHT(C)2012 MITSUBISHI ELECTRIC CORPORATION
- 2 -
[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
)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
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
r
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
80
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
p
r
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
p
r
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
ON
ON
Thread trimming output [T]
Thread release output [L]
T1
T2
T3
T4
T5
LLM
setting
L1
L2
TRS(deg) TRE(ms)
ON
TRS(deg) TRE(deg)
ON
TRS(deg) TRE(ms)
ON
TRS(ms) TRE(ms)
ON
TRS(ms) TRE(ms)
ON
LRS(deg) LRE(ms)
ON
LRS(deg) LRE(deg)
ON
Wiper [W]
L3
L4
L5
LRS(deg) LRE(ms)
ON
LRS(ms) LRE(ms)
ON
LRS(ms) LRE(ms)
ON
W1(ms) W2(ms)
ON
[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
ON
3.Timing chart for [Priority of clamp]
Clamp input 1
IF1
ON
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
ON
ON
ON
ON
ON
ON
ON
ON
ON
Clamp output 2
OF2
Clamp output 3
OF3
Clamp output 4
OF4
ON
ON
ON
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
Loading...