CNC REMOTE I/O UNIT FCU6-DX561 CONNECTION AND MAINTENANCE MANUAL BNP-B2302*(ENG)
Precautions for Safety Always read the specifications issued by the machine maker, this manual, related manuals and enclosed documents before starting installation, operation, programming, maintenance or inspection to ensure correct usage. Thoroughly understand the basics, safety information and precautions of this numerical controller before using the unit. DANGER , WARNING and CAUTION .
CAUTION 1. Items related to noise Always treat the shield cables indicated in this manual with grounding measures such as cable clamps. Separate the signal wire from the drive line/power line when wiring. 2. Items related to installation Install the unit on noncombustible material. Installation directly on or near combustible material may lead to fires. Always observe the installation direction. Do not install or operate a unit that is damaged or that have missing parts.
FCU6-DX561 CONNECTION AND MAITENANCE MANUAL CONTENTS I. CONNECTION MANUAL 1. OUTLINE ..................................................................................................................... 2. CONFIGURATION ....................................................................................................... 2.1 System Configuration .......................................................................................... 3. INSTALLATION ........................................................
II. MAINTENANCE MANUAL 1. EXPLANATION OF MODULE FUNCTIONS ................................................................ 1.1 FX2N-80BMT-NC Card ....................................................................................... 2. FAULT DIAGNOSIS..................................................................................................... 2.1 List of Unit LEDs.................................................................................................. 2.2 Troubleshooting...................
I.
1. OUTLINE 1. OUTLINE This manual explains the items required for installing and connecting the remote I/O unit (FCU6-DX561). The FCU6-DX561 is a remote I/O unit with PLC functions. This unit is used as to monitor both the machine signals and the spindle speed. Read this manual thoroughly and understand the product's functions and performance before starting use. Refer to the following documents for explanations on the functions.
2. CONFIGURATION 2.1 System Configuration 2. CONFIGURATION 2.1 System Configuration Communication terminal Operation panel, etc.
3. INSTALLATION 3.1 General Specification 3. INSTALLATION 3.1 General Specification Unit name Remote I/O unit Type name FCU6-DX561 Power specifications General specifications During operation Ambient temperature During storage Ambient humidity 0 to 55°C * Note –20 to 60°C During operation 45 to 75% RH (with no dew condensation) During storage 45 to 80% RH (with no dew condensation) 4.9m/s2 or less (during operation) Vibration resistance Shock resistance Working atmosphere 29.
3. INSTALLATION 3.2 Noise Countermeasures 3.2 Noise Countermeasures 3.2.1 Connection of FG (Frame Ground) The frame should basically be grounded at one ground point. Connect the control unit and base I/O unit's and remote I/O unit's 0V (RG) to the FG on the 24VDC stabilized power supply side. Control unit FCU6-MU -MA FG cable 0 R220 cable (24VDC) Remote I/O unit FCU6-DX561 FG FG 0V DC24V 24VDC (+) (+) Short bar 4 ST No.
3. INSTALLATION 3.2 Noise Countermeasures 3.2.2 Shield Clamping of Cables (1) Cables requiring ground connection with lead wire The FG wire of the RIO cable (R211) connected between the base I/O and each remote I/O unit must be connected to the grounding plate near the unit. Remote I/O unit FCU6-DX561 Base I/O unit FCU6-DX3/DX4/HR377/378 0 Remote I/O unit FCUA-DX1 0 ENC SKIP 4 ST No.
3. INSTALLATION 3.2 Noise Countermeasures 3.2.3 Connecting Spark Killers Connect a spark killer on the coil or contact in parallel for noise countermeasures. Use spark killers which are 0.033 to 0.1µF, 10 to 120Ω.
3. INSTALLATION 3.3 Installation 3.3 Installation Each unit is installed in the sealed structure cabinet as a principle. When installing into the cabinet, refer to the following drawings to consider the unit's heat dissipation and wiring, and secure enough space for ventilation. (1) Install the unit vertically so that the front is visible. (2) Refer to the following drawings to consider the unit's heat dissipation and wiring, and secure enough space for ventilation.
3. INSTALLATION 3.4 Mounting Conditions 3.4 Mounting Conditions (1) Parts, highly susceptible to dust, are mounted with a high density inside the unit. Always use a sealed structure for the cabinet, and provide the following treatments. • Always plug the cable inlet with packing, etc., to prevent dust and oil from entering. • Take care so that outdoor air does not enter the heat dissipation holes, etc. • Plug all clearances. • Always install door packing. • If there is a back lid, always install packing.
4. SYSTEM CONNECTION 4.1 General System Diagram 4. SYSTEM CONNECTION 4.
5. CONNECTION OF UNIT 5.1 Names of Each Part 5. CONNECTION OF UNIT The methods for connecting to each unit and device are briefly explained in this chapter. Front view 5.1 Names of Each Part DCIN (1) DC IN (1) 24VDC input connector (2) Connector 1 for encoder (speed signal) connection (Note) (3) Connector 2 for encoder (speed signal) connection (Note) (4) Station No.
5. CONNECTION OF UNIT 5.2 Unit Connection System Diagram 5.
5. CONNECTION OF UNIT 5.3 Connection of Base I/O Unit 5.3 Connection of Base I/O Unit The RIO1 connector is used for connection to the base I/O unit. Connect the R211 cable from the RIO1 connector on this unit to the RIO1 connector on the base I/O unit. Control unit (FCU6-MU/MA) Remote I/O unit (FCU6-DX561) CBUS 1 CBUS 2 OPEN 4 ST No.
5. CONNECTION OF UNIT 5.4 Connection of RIO Unit 5.4 Connection of RIO Unit The RIO2 connector is used to connect several remote I/O units. Connect the R211 cable from the RIO2 connector on this unit to RIO1 on the remote I/O unit. When connecting several remote I/O units, connect the R211 cable from the RIO2 connector on the remote I/O unit to the RIO1 connector on the next remote I/O unit. Connect the terminator (R-TM) to the RIO2 connector on the final remote I/O unit.
5. CONNECTION OF UNIT 5.5 Connection of Power Supply 5.5 Connection of Power Supply Supply the 24VDC power supply for the control circuit to the DCIN connector (DCIN). The 24VDC power for the input/output circuit is supplied from an external source. Supply to each connector (DI-L/-R, DO-L). Remote I/O unit (1) DCIN power connection (for control circuit) (FCU6-DX561) Y 24VDC (+) 0V FG FG DCIN Stabilized power supply (2) DI-L/-R power connection (for DI circuit) (For source input) 4 3 5 0 EF 12 STNo.
5. CONNECTION OF UNIT 5.6 Connection of Encoder Speed Signal 5.6 Connection of Encoder Speed Signal Encoder 1 10 ENC１ ENC1/2 (Note) Refer to following drawing.
5. CONNECTION OF UNIT 5.6 Connection of Encoder Speed Signal [Outline of connection] ENC1/2 PC 100Ω 1kΩ PC∗ 1kΩ GND Spindle amplifier [Signal assignment table] 1st channel 2nd channel 3rd channel 4th channel X00 X01 X02 X03 [Input specifications] Item Input voltage Input sensitivity Input response time Specifications Line receiver input (X00 to X03) (5VDC) OFF → ON 4.5mA or more, ON → OFF 1.5mA or less X00 to X03 require 50µs or more for the second trigger to be validated.
5. CONNECTION OF UNIT 5.7 Connection of Machine Input/Output Signal 5.7 Connection of Machine Input/Output Signal Machine input/output signal types and number of points Input Output 44 points 32 points R300 cable/ R301 cable Number of occupied serial link stations 2 DI-L DI-R Machine signal R300 cable/ R301 cable DO-L Machine signal [Outline of connection] X00 to X07 and Y00 to Y37 below are indicated as octal values.
5. CONNECTION OF UNIT 5.7 Connection of Machine Input/Output Signal [Signal assignment table] (Note) DI-L X00 to X03 are used for the encoder input, and cannot be assigned to the DI-L connector. Machine side control panel, etc.
5. CONNECTION OF UNIT 5.7 Connection of Machine Input/Output Signal [Outline of input circuit] The digital signal input circuit includes the sink type and source type. These can be selected with each connector unit. DI_24V Connection method Sink input (X04 to X57) 680kΩ DI_COM X X04 to X07:3.3kΩ 1/2W X10 to X57:4.3kΩ 1/2W DI_0V Connection method Source input (X04 to X57) X DI_24V 680kΩ DI_COM DI_0V X04 to X07:3.3kΩ 1/2W X10 to X57:4.
5. CONNECTION OF UNIT 5.7 Connection of Machine Input/Output Signal [Outline of output circuit] The digital signal output circuit is a source type. Connection method Source output (Y00 to Y37) DO_24V DO_COM DO_0V Y [Output specifications] Item Rated voltage, current Response time Resistance load Maximum Inductive load load Lamp load Output saturation voltage Circuit insulation Specifications (per point) 5VDC to 30VDC, 0.1A 0.2ms (at 24VDC, 0.
APPENDIX 1 UNIT OUTLINE DRAWINGS AND INSTALLATION DIMENSIONS APPENDIX 1 UNIT OUTLINE DRAWINGS AND INSTALLATION DIMENSIONS 50 10 To p Heat dissipation allowance 2-M5x0.8 screw DC IN 4 3 5 67 8 9 A 0 EF 12 ENC1 ENC2 ST No. B CD POWER RUN CPU-E ST OP RUN 380 360 PROG.
Application Remote I/O unit (FCU6-DX561) - Spindle amplifier (MDS-B/C1-SP ) MDS-B-SPJ2- DIO connector - terminal block I/O communication connector 24VDC power connector DIO connector Type FCUACS000 FCUACS301 FCUACN211 FCUACN220 FCUACN300 3M □ □ □ □ I-22 Connector (3M) 7940-6500SC × 2 pcs. Connector (Tyco Electronics AMP) 2-178288-3 × 1 pc. Connector (Tyco Electronics AMP) 1-178288-3 × 1 pc. Connector (3M) 7940-6500SC × 4 pcs. 3M Connector (3M) 10120-3000VE × 2 pcs.
APPENDIX 3 CABLE MANUFACTURING DRAWINGS APPENDIX 3 CABLE MANUFACTURING DRAWING As a rule, most F/R cables used with this product are not sold by Mitsubishi. Thus, manufacture the required cables using the cable manufacturing drawings on the following pages as a reference. Note that the cable-compatible connectors can be purchased from Mitsubishi.
APPENDIX 3 CABLE MANUFACTURING DRAWINGS Appendix No. Appendix 3.1 Appendix 3.2 Cable type R000 cable R211 cable Encoder Remote I/O Application : 2ch Max. length 30m Appendix 3.3 Appendix 3.4 Appendix 3.5 R220 cable R300 cable R301 cable +24V input DI/DO DI/DO Appendix 3.
APPENDIX 3 CABLE MANUFACTURING DRAWINGS Appendix 3.1 FCUA-R000 Cable Manufacturing Drawing Appendix 3.1 FCUA-R000 Cable Manufacturing Drawing Application: Remote I/O unit (FCU6-DX561) to spindle connection Option (compatible connector set) FCUA-CS000 Assembly drawing List of parts used No. 1 2 1 2 1 3 2 3 R000 Part name/model Maker Connector Sumitomo 3M 10120-6000EL Connector case Sumitomo 3M 10320-3210-000 Wire material Note (1) UL20276 AWG28 × 10P Qty.
APPENDIX 3 CABLE MANUFACTURING DRAWINGS Appendix 3.2 FCUA-R211 Cable Manufacturing Drawing Appendix 3.
APPENDIX 3 CABLE MANUFACTURING DRAWING Appendix 3.3 FCUA-R220 Cable Manufacturing Drawing Appendix 3.3 FCUA-R220 Cable Manufacturing Drawing Application: Supply of 24V to remote I/O unit (FCU6-DX561) Option (compatible connector set) FCUA-CN220 (Note that this corresponds only to the connector on the remote I/O unit side.) List of parts used No.
APPENDIX 3 CABLE MANUFACTURING DRAWING Appendix 3.4 R300 Cable Manufacturing Drawing Appendix 3.4 R300 Cable Manufacturing Drawing Application: DIO – Machine electric cabinet List of parts used No. 1 2 Part name/model Maker Connector Sumitomo 3M 7940-6500SC Wire material Note (1) B40-S Qty. 1 (1) Assembly drawing First wire is colored Remote I/O unit (FCU6-DX561) side DI-L/-R DO-L 1 Max.
APPENDIX 3 CABLE MANUFACTURING DRAWING Appendix 3.5 R301 Cable Manufacturing Drawing Appendix 3.5 R301 Cable Manufacturing Drawing Application: DIO – Machine electric cabinet List of parts used No. Part name/model Maker Connector Sumitomo 3M 7940-6500SC Strain relief Sumitomo 3M 3448-7940 Wire material Note (1) B40-S 1 2 3 Qty. 2 1 (1) Assembly drawing First wire is colored Remote I/O unit (FCU6-DX561) side DI-L/-R DO-L 1 3 2 Max.
APPENDIX 3 CABLE MANUFACTURING DRAWING Appendix 3.6 R-TM Manufacturing Drawing Appendix 3.6 R-TM Manufacturing Drawing Application: Terminator for MC link B remote I/O unit (FCU6-DX561) termination Assembly drawing List of parts used 101 102 No. 1 103 Ｄ－３ ＡＭ Ｐ １ ２ ３ 2 Qty.
APPENDIX 4 PRECAUTIONS FOR COMPLYING WITH UL/c-UL STANDARDS APPENDIX 4 PRECAUTIONS FOR COMPLYING WITH UL/c-UL STANDARDS Observe the following matters to comply with the UL/c-UL Standards. (1) Selecting the external 24VDC power supply unit The remote I/O unit (FCU6-DX561) complies with UL Standards on the condition that the external power supply unit for supplying 24VDC is a UL-approved part. Use a UL-approved part for the power supply unit supplying 24VDC to this unit.
II.
1. EXPLANATION OF MODULE FUNCTIONS 1.1 FX2N-80BMT-NC Card 1. EXPLANATION OF MODULE FUNCTIONS 1.1 FX2N-80BMT-NC Card CN1 [Block diagram] CPU SW1 Run EEPROM BPU-G/A SRAM IO-G/A DO I/F DO-L DC-DC 24V→5V DCIN ENC2 Stop DI-L ENC1 Encoder I/F DI-R DI I/F RIO2 IO-G/A RIO1 RIO-G/A [Explanation of functions] The FX2N-80BMT-NC card is based on the MELSEC PLC FX2N Series, and has two remote I/O controllers mounted. This functions as the remote I/O's slave station.
1. EXPLANATION OF MODULE FUNCTIONS 1.1 FX2N-80BMT-NC Card [Connector layout diagram] RIO2 U:DI-R L:DI-L DCIN SW2 POWER RUN CPU-E U:ENC2 L:ENC1 DO-L PROG. PORT RIOERR1 RIOERR2 RIO1 SW1 [Explanation of settings] SW1 RUN-STOP slide switch Starts running when the switch is set to RUN, and stops when set to OFF. SW2 Remote I/O station No. setting rotary switch 0 to 7: Corresponds to the RIO station No.
2. FAULT DIAGNOSIS 2.1 List of Unit LEDs 2. FAULT DIAGNOSIS 2.1 List of Unit LEDs DCIN ENC1 ENC2 0 EF 12 4 3 5 8 67 9 A STNo. BC D POWER RU N CPU-E STOP RU N PROG.
2. FAULT DIAGNOSIS 2.2 Troubleshooting 2.2 Troubleshooting 2.2.1 Confirmation of trouble state Confirm "when", "when doing what", and "what kind of" trouble occurred. (1) When? What time did the trouble occur? (2) When doing what? What was the NC operation mode? (3) What kind of trouble? • What was displayed on the setting display unit's Alarm Diagnosis screen? Display the Alarm Diagnosis screen, and check the alarm details.
2. FAULT DIAGNOSIS 2.2 Troubleshooting 2.2.2 When in trouble If the system does not operate as planned or if there is any trouble in the operation, confirm the following points and then contact the Mitsubishi Service Center. − Examples of trouble − • • • • • • • • The power does not turn ON. The external power turns ON, but the control power does not turn ON. The power turns OFF. The communication alarm display "RIOERR1"/"RIOERR2" LED turns ON. The 5VDC output display "POWER" LED turns OFF.
2. FAULT DIAGNOSIS 2.2 Troubleshooting (1) Problems related to the power supply The power does not turn ON. Cause The door interlock is applied. Remedy If the control panel door is not completely closed, close it. If the door interlock is applied even when the door is closed, the door interlock circuit is damaged. The external power supply's input Check that the input voltage is within 200 to 230AC voltage is not as specified. +10%/–15%. (Note) The power supply for this unit is 24VDC.
2. FAULT DIAGNOSIS 2.2 Troubleshooting (2) Problems related to remote I/O unit (FCU6-DX561) If any of the following problems occur, all points of the machine input/output data for the remote I/O unit (FCU6-DX561) will turn OFF or may become unreliable. Thus, detect "Mismatch of input" with the PLC for another unit (NC). The communication alarm display "RIOERR1"/"RIOERR2" LED turns ON.
2. FAULT DIAGNOSIS 2.2 Troubleshooting The operation display "RUN" LED does not turn ON. Cause The RUN/STOP switch is set to STOP. Remedy Set the RUN/STOP switch to RUN. An error was detected by the unit's Check for circuit errors and syntax errors with the peripheral self-diagnosis function. device's program check function. If the operation is stopped with a watch dog timer error, refer to the section "The CPU error display "CPU-E" turns ON (flickers)." on the previous page.
2. FAULT DIAGNOSIS 2.2 Troubleshooting 2.2.3 Behavior of independent faults The EN954-1 Category 3 machine system must be designed so that the safety functions are not disabled when one of the safety-related parts fails independently. Precautions for the designs and examples of the behavior when an independent fault occurs are listed below.
3. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 3.1 Maintenance Tools 3. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 3.1 Maintenance Tools (1) Measuring instruments The following measuring instruments are used to confirm that the voltage is being supplied correctly to the unit, to confirm that the wiring to the unit is correct, and to carry out simple troubleshooting. Table 3.
3. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 3.2 Replacement Methods 3.2 Replacement Methods 3.2.1 Cable If the cable is replaced without turning the power OFF, the normal unit or peripheral devices could be damaged, and risks could be imposed. Disconnect each cable with the following procedures. a) For the following type of connector, press the tabs with a thumb and forefinger in the direction of the arrow, and pull the connector off.
3. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 3.2 Replacement Methods b) For a flat cable type connector with claws, open the claws in the directions of the arrows, and pull the connector off. (1) Open (2) Pull c) For a flat cable type connector without claws, hold the connector with a thumb and forefinger, and pull the connector off. (1) Hold with thumb and forefinger. (2) Pull CAUTION Do not connect or disconnect the connection cables between each unit while the power is ON.
3. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 3.2 Replacement Methods 3.2.2 Unit Usually, the unit is installed on the electric cabinet side. Always replace the unit with the machine power turned OFF. 1) 2) 3) 4) 5) 6) Disconnect all cables connected to the unit. Loosen screw A. (The screw does not need to be removed.) While supporting the unit with a hand, remove screw B. Lift the unit upward and remove it.
Revision history Revision Date of revision ∗ 00/12/01 Revision details First edition issued
MITSUBISHI ELECTRIC CORPORATION HEAD OFFICE : MITSUBISHI DENKI BLDG., 2-2-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN MODEL REMOTE I/O UNIT・FCU6-DX561 MODEL CODE 008-165 Manual No. BNP-B2302* (ENG) Specifications subject to change without notice. (0110) MEE Printed in Japan on recycled paper.
