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M800/M80/E80 Series Maintenance Manual
6 Replacing Each Unit

169

IB-1501273-F

6.8.2 Functional Safety Expansion Unit [M80]

Always install the functional safety expansion unit with the machine power turned OFF.

(1) Check that the machine power is turned OFF. (If the power is not OFF, turn it OFF.)
(2) Open the operation panel.
(3) Open the cover of the control unit.
(4) Fix the functional safety expansion unit to the control unit with two screws.
(5) Close the cover of the control unit.
(6) Confirm that all the cables are correctly connected and close the operation panel.

(1) Check that the machine power is turned OFF. (If the power is not OFF, turn it OFF.)
(2) Open the operation panel.
(3) Open the cover of the control unit.
(4) Remove two screws fixing the functional safety expansion unit to the control unit.
(5) Close the cover of the control unit.
(6) Confirm that all the cables are correctly connected and close the operation panel.

CAUTION

1. Incorrect connections could cause devices to damage. Connect the cables to designated connectors.

2. Do not replace the expansion unit/card while the power is ON.

3. Do not connect or disconnect the cables between units while the power is ON.

Installation procedures

Removal procedures

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Summary of Contents for E80 Series

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Page 2: ...icable 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 specifi...

Page 3: ...nation for screen operation etc M800 M80 E80 C80 Series Programming Manual Lathe System 1 2 IB 1501275 G code programming for lathe system Basic functions etc M800 M80 E80 C80 Series Programming Manual Lathe System 2 2 IB 1501276 G code programming for lathe system Functions for multi part system high accuracy function etc M800 M80 E80 C80 Series Programming Manual Machining Center System 1 2 IB 1...

Page 4: ...800 M80 E80 Series PLC Programming Manual IB 1501271 Electrical design Sequence programming PLC support functions etc M800 M80 E80 C80 Series PLC Interface Manual IB 1501272 Electrical design Interface signals between NC and PLC M800 M80 E80 Series Maintenance Manual IB 1501273 Cleaning and replacement for each unit Other items related to maintenance C80 Series Maintenance Manual IB 1501454 Cleani...

Page 5: ...tallation method of GX Works2 GX Works2 Version 1 Operating Manual Common SH 080779ENG 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 GX Works2 Version 1 Operating Manual Simple Project SH 080780ENG Explanation for methods for such as creating and monitoring p...

Page 6: ...tem and maintenance related descriptions for Q series CPU module etc GX Works3 Operating Manual SH 081215 Outline of functions programming etc Manual No Purpose and Contents M800 M80 Series Smart safety observation Specification manual BNP C3072 022 Explanation for smart safety observation function C80 Series Smart safety observation Specification manual BNP C3077 022 M800 M80 Series CC Link Maste...

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Page 8: ... indicate prohibition and compulsory The meaning of each pictorial sign is as follows 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 This sig...

Page 9: ... in electric shocks Contact your nearby Service Center for replacing parts and ser vicing 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 ob...

Page 10: ...lace 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 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 m...

Page 11: ... 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 p...

Page 12: ...se 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 st...

Page 13: ...suppress rush currents The wires from the surge absorber should be connected without extensions 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 CAUTION If the battery low warning is issued save the machining programs tool data and parameters in an input output device...

Page 14: ...e 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 termi nal Do n...

Page 15: ...ld 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...

Page 16: ...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 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 in...

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Page 18: ...ric 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 product when no longer needed according to item 1 above The user should make an effort to reduce waste in this manner b When disposing a product that cann...

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Page 20: ... 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 ac...

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Page 22: ... 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 I...

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Page 24: ...andling 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 ...

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Page 26: ...nance 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 Dura...

Page 27: ...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 Pro...

Page 28: ...1 1 IB 1501273 F System Basic Configuration ...

Page 29: ...he drive unit configuration refer to the drive unit s manual M800W M80W Windows based display non Windows based display Motor group Servo Spindle drive unit Manual pulse generator Manual pulse penerator Remote I O unit Remote I O unit Display unit Operation panel I O unit Keyboard unit Synchronous feed encoder Personal computer unit Control unit Grahpic control unit Note ...

Page 30: ...o the drive unit s manual Control unit is added onto back of display unit Motor group Servo Spindle drive unit Manual pulse generator Manual pulse penerator Remote I O unit Remote I O unit Display unit Operation panel I O unit Control unit Operation panel I O unit is added onto back of keyboard unit Keyboard unit Synchronous feed encoder Note ...

Page 31: ...relay contact Machine control relay contact 24VDC Manual pulse generator 5V 12V Machine operation panel made by the machine tool builder Dotted lines indicate the sections prepared by the machine tool builder Angle brackets indicates attached cable of unit No fuse breaker 24VDC stabilized power supply Function expansion unit Note 1 Handy terminal FCU8 EX56x FCU8 EX54x FCU8 MA041 MU042 MA041 M850W ...

Page 32: ...operation panel made by the machine tool builder Dotted lines indicate the sections prepared by the machine tool builder Angle brackets indicates attached cable of unit No fuse breaker 24VDC stabilized power supply Function expansion unit Note 1 Handy terminal FCU8 EX56x FCU8 EX54x FCU8 MA041 MU042 MA041 M850W MU042 M830W RIO8 AIO J026 J027 J220 EXT2 EXT4 RIO4 RIO6 RIO7 RIO5 Communication expansio...

Page 33: ...it 24VDC Energy measuring units Drive units Stored in control unit To the next remote I O or terminator connector To the next remote I O or terminator connector Emergency stop switch SD memory card 24VDC 24VDC 24VDC 24VDC Machine control relay contact Machine control relay contact 24VDC Manual pulse generator 5V 12V Machine operation panel made by the machine tool builder Dotted lines indicate the...

Page 34: ... unit Remote I O unit 24VDC Energy measuring units Drive units Stored in control unit To the next remote I O or terminator connector To the next remote I O or terminator connector Emergency stop switch SD memory card 24VDC 24VDC 24VDC 24VDC Machine control relay contact Machine control relay contact 24VDC Manual pulse generator 5V 12V Machine operation panel made by the machine tool builder Dotted...

Page 35: ... control unit To the next remote I O or terminator connector To the next remote I O or terminator connector Emergency stop switch SD memory card 24VDC 24VDC 24VDC 24VDC Machine control relay contact Machine control relay contact 24VDC Manual pulse generator 5V 12V Machine operation panel made by the machine tool builder Dotted lines indicate the sections prepared by the machine tool builder Angle ...

Page 36: ...3 J024 J025 12V J020 J021 J022 L1 L2 L3 NFB DCOUT FG ACIN CP MC ON OFF MC MC J350 351 J350 351 J350 351 J350 351 FCU8 EX54x EXT1 EXT3 G430 device Skip signal input Communication expansion unit Control unit Max 32 units for each port Remote I O unit Remote I O unit Remote I O unit Remote I O unit 24VDC Energy measuring units Drive units Stored in control unit To the next remote I O or terminator co...

Page 37: ...1 33 DO CJ32 34 RIO1 DCIN RIO2 J350 351 J350 351 R2 TM R2 TM R2 TM G430 J210 FCU8 KB92x FCU8 KB941 KB931 G460 24VDC MITSUBISHI CNC Machine Operation Panel Note 1 Drive unit Control unit Synchronous feed encoder No fuse breaker NFB AC reactor Circuit protector CP Ethernet device Ethernet device 24VDC RS 232C device Communication expansion unit Menu key Display unit Memory mediums Front memory I F c...

Page 38: ...071 DI CJ31 33 DO CJ32 34 RIO1 DCIN RIO2 DI CJ31 33 DO CJ32 34 RIO1 DCIN RIO2 J350 351 J350 351 R2 TM R2 TM R2 TM G430 J210 FCU8 KB92x FCU8 KB941 KB931 G460 24VDC MITSUBISHI CNC Machine Operation Panel Note 1 Drive unit Control unit Synchronous feed encoder No fuse breaker NFB AC reactor Circuit protector CP Ethernet device Ethernet device 24VDC RS 232C device Communication expansion unit Menu key...

Page 39: ...070 071 DI CJ31 33 DO CJ32 34 RIO1 DCIN RIO2 DI CJ31 33 DO CJ32 34 RIO1 DCIN RIO2 J350 351 J350 351 R2 TM R2 TM R2 TM G430 J210 FCU8 KB92x FCU8 KB941 KB931 G460 24VDC MITSUBISHI CNC Machine Operation Panel Note 1 Drive unit Control unit Synchronous feed encoder No fuse breaker NFB AC reactor Circuit protector CP Ethernet device Ethernet device 24VDC RS 232C device Communication expansion unit Menu...

Page 40: ... DI CJ31 33 DO CJ32 34 RIO1 DCIN RIO2 DI CJ31 33 DO CJ32 34 RIO1 DCIN RIO2 J350 351 J350 351 R2 TM R2 TM R2 TM G430 J210 FCU8 KB92x FCU8 KB941 KB931 G460 24VDC MITSUBISHI CNC Machine Operation Panel Note 1 Drive unit Control unit Synchronous feed encoder No fuse breaker NFB AC reactor Circuit protector CP Ethernet device Ethernet device 24VDC RS 232C device Communication expansion unit Menu key Di...

Page 41: ... 1 System Configuration Screen Select the menu Config on the diagnosis Diagn screen to display the hardware configuration card name and sub num ber software configuration software number and sub number and PLC program configuration file name file label and execution type Software configuration Hardware configuration Diagn 1 2 4 3 ...

Page 42: ...alled lang This displays a list of installed languages ENG English SWE Swedish JPN Japanese HUN Hungarian DEU German POL Polish FRA French CHI1 Simplified Chinese ITA Italian RUS Russian SPA Spanish TUR Turkish CHI2 Traditional Chinese CZE Czech KOR Korean POR Portuguese DUT Dutch 3 NC serial No This displays the NC model name serial No system type and unit type NC TYPE NC type MODEL NAME System t...

Page 43: ...he expansion unit type refer to the description of expansion unit WN511 Existing expansion units are dis played from the top in the above or der DISPLAY DU191 Display unit The unit type varies by model KEYBOARD KB046 Keyboard unit The unit type varies by the keyboard unit being connected ECOMON1 to ECOMON16 EMU4 BD1 EMU4 HD1 EcoMonitorLight unit The unit type varies de pending on the connected Eco...

Page 44: ...M80W M80 E80 60 b File name This displays the file name of PLC pro gram file data of GX Developer GX Woks2 Max 8 characters c File label This displays this file label of PLC pro gram file data of GX Developer GX Woks2 Max 32 characters d Execution type This displays the execution type of PLC program HIGH High speed PLC program MIDDLE Middle speed PLC program INTIAL Initial state of PLC program WAI...

Page 45: ...COUT Lit Green The followings are all successfully output 5V and 3 3V generated from 24V 2 5V 1 8V 1 5V 1 15V and 1 1V on the main card Not lit The followings may have caused an error No 24V power supply from the external power supply Failure in any of the power output circuits Failure of LED or IC which helps turn the LED ON 3 READY Lit Green Servo ON or ready ON state Not lit Servo OFF or ready ...

Page 46: ...V generated from 24V 2 5V 1 8V 1 5V 1 15V and 1 1V on the main card Not lit The followings may have caused an error No 24V power supply from the external power supply Failure in any of the power output circuits Failure of LED or IC which helps turn the LED ON 3 READY Lit Green Servo ON or ready ON state Not lit Servo OFF or ready OFF state 4 ERR Lit Red H W is not operating properly The followings...

Page 47: ...UT Lit Green Internal voltage is normally output Not lit The followings may have caused an error No 24V power supply from the external power supply Failure in any of the power output circuits Failure of LED or IC which helps turn the LED ON 3 LCDON Lit Green 12VDC for the backlight of display unit is normally output Not lit The followings may have caused an error Failure of 12VDC output in control...

Page 48: ...0W LED No Name Function Color State Normal At fault 1 DCIN 24VDC input observation Green Lit Not lit 2 DCOUT DC internal power supply output obser vation Green Lit Not lit 3 12V 12VDC output observation Green Lit Not lit 4 5V 5VDC output observation Green Lit Not lit 5 3 3V 3 3VDC output observation Green Lit Not lit 5 1 2 4 3 ...

Page 49: ...nput of DCIN connector Green Lit Not lit Lit when a current is applied 5 5VIN 5V power supply circuit status Green Lit Not lit Lit when the circuit is normally operated 6 3VIN 3 3V power supply circuit status Green Lit Not lit Lit when the circuit is normally operated 7 12VON 12V power supply circuit status Green Lit Not lit Lit when the circuit is normally operated 8 ALM1 RIO communication error ...

Page 50: ... 3 12VON 12V power supply circuit status Green Lit Not lit Lit when the circuit is normally operated 4 5VIN 5V power supply circuit status Green Lit Not lit Lit when the circuit is normally operated 5 3VIN 3 3V power supply circuit status Green Lit Not lit Lit when the circuit is normally operated 6 ALM1 RIO communication error Red Not lit Lit Lit when RIO communication error has occurred 7 ALM2 R...

Page 51: ...r Red Not lit Lit Lit when RIO communication error has occurred 10 FUSE2 Fuse status Green Lit Not lit Not lit when a fuse has been blown out 11 DOCOM2 Energization status of 24VDC input DOCOM of CJ42 connector Green Lit Not lit Lit when a current is applied No Name Function Color State Supplement Normal At fault ...

Page 52: ...X230 FCU8 DX231 FCU8 DX213 FCU8 DX213 1 FCU8 DX654 FCU8 DX654 1 FCU8 DX202 FCU8 DX408 FCU8 DX409 No Name Function Color State Supplement Normal At fault 1 RIOVER RIO communication status Green Lit during RIO 2 0 communication Not lit during RIO 1 0 communication 2 ALM RIO communication error Red Not lit Lit Lit when RIO communication error has occurred 3 FUSE Fuse status Green Lit Not lit Not lit ...

Page 53: ...t lit when a relay has been blown out H3 Safety relay output SYR02 status Green Lit Not lit Not lit when a relay has been blown out H4 Safety relay output SYR03 status Green Lit Not lit Not lit when a relay has been blown out 2 ALM RIO communication error Red Not lit Lit Lit when RIO communication error has occurred 3 DCIN Energization status of 24VDC input of DCIN connector Green Lit Not lit Lit ...

Page 54: ...n Lit CC Link module in the normal state Not lit Watchdog timer error 2 LRUN Green Lit Data link in process of execution 3 SD Green Lit During data transmission 4 RD Green Lit During data reception 5 ERR Red Lit Switch setting error LERR is also lit overlapping of mas ter parameter error communication error Flashing Other station data link error when it is master station 6 LERR Red Lit Data link c...

Page 55: ...f STA ERR Name Color State Details 1 RUN Green Green Lit Lit when PROFIBUS DP module is normally operated 2 RDY Yellow Green yellow Flashing Boot standby Module status Yellow Lit Boot error Lit No power supply module failure 3 STA Green Green Lit regularly Configuration successful communication unestablished 4 ERR Red Green Lit randomly Configuration failure stuck error Communication status Green ...

Page 56: ...rmed Flashing Data link cyclic transmission stopped Not lit Data link not performed disconnected 4 MST Green Lit Operating as master station Not lit Operating as local station 5 ERR Red Not lit Normal operation Flashing 500 ms interval A data link faulty station detected Flashing 200 ms interval Failure occurring Lit Error in all stations detected or occurring 6 RUN Green Lit Hardware running norm...

Page 57: ...odule status Flashing Not lit Waiting for initialization Lit Not lit Normal operation Not lit Flashing Recoverable failure Not lit Lit Unrecoverable failure The hardware needs to be re placed 2 NS Green Red Flashing green red alternately In self diagnosis Communication status Not lit Not lit No IP address Flashing Not lit No connection Lit Not lit Normal operation Not lit Flashing Connection time ...

Page 58: ...ub CPU NCLD2 is displayed on the left and that of the main CPU NCLD1 is displayed on the right by two 7 segment LEDs Take a note of the displayed contents and contact the Service Center cf In case of SRAM clear the 7 segment LEDs change as follows RSW2 C NCLD2 NCLD1 Main CPU Sub CPU LED display Cause E Undefined interruption occurred F Bus error address error or interrupt exception ASIC d Memory t...

Page 59: ...te When Alarm Stop code occurs flashes three times Alarm code is shown in three diﬀerent stages Example Z53 CNC overheat 0003 When Alarm Stop code occurs flashes three times Flashes when an alarm occurs in the 1st part system Flashes when an alarm occurs in the 2nd part system When an alarm doesn t occur in the 1st part system This means that indicated alarm belongs to the 1st part system Alarm co...

Page 60: ...indication Emergency stop EXIN Emergency stop WAIT M01 Cutting block start interlock 0110 M01 In synchronous correction mode 0120 Display of the 7 segment LEDs and their meanings Alarm code for the first time Alarm warning Left side LED Operation error Stop code Emergency stop Program error System alarm waring MCP alarm waring Servo alarm waring Note ...

Page 61: ... error 0002 of M01 Operation error and 5002 of M50 Operation warning Alarm Warning code Displays of 7 segment LEDs transition 1L 1R 2L 2R 3L 3R M01 H W stroke end axis exists 0006 XYZ 1L 1R 2L 2R 3L 3R Operation error Error lower 3 digits Axis bit M01 No operation mode 0101 1L 1R 2L 2R 3L 3R Operation error Error lower 3 digits No meaning M00 Aux ax R ret invld at ini 0025 0004 1L 1R 2L 2R 3L 3R A...

Page 62: ...stroke end axis exists 0202 1L 1R 2L 2R 3L 3R Stop code Error lower 2 digits No meaning T03 Single block stop signal ON 0301 1L 1R 2L 2R 3L 3R Stop code Error lower 2 digits No meaning T04 Collation stop 0401 1L 1R 2L 2R 3L 3R Stop code Error lower 2 digits No meaning T10 Fin wait 0001 1L 1R 2L 2R 3L 3R Stop code Error lower 2 digits No meaning Alarm Warning code Displays of 7 segment LED transiti...

Page 63: ...data er ror Error Axis bit Z71 Abs encoder failure 0002 X 1L 1R 2L 2R 3L 3R Encoder failure Error Axis bit Z72 Position check error 0001 Z 1L 1R 2L 2R 3L 3R Position check error Error Axis bit Z73 Absolute position data warning 0003 XYZ 1L 1R 2L 2R 3L 3R Absolute position data warning Error Axis bit Z70 Aux ax abs position error 0001 0001 1L 1R 2L 2R 3L 3R Auxiliary axis absolute position error Er...

Page 64: ...R 2L 2R 3L 3R System warning Warning code Type Z52 Battery fault 0001 1L 1R 2L 2R 3L 3R System warning Warning code No meaning Z53 CNC overheat 0003 1L 1R 2L 2R 3L 3R System warning Warning code Unit bit Z55 RIO communication stop 0007 1L 1R 2L 2R 3L 3R System warning Warning code Unit bit Z57 System warning 0010 1L 1R 2L 2R 3L 3R System warning Warning code Type Z58 ROM write not completed 1L 1R ...

Page 65: ...alarm Error lower 2 digits Error code Y03 Drive unit unequipped XYZS 1L 1R 2L 2R 3L 3R Drive unit unequipped Axis bit No meaning Y05 Initial parameter error 1039 1L 1R 2L 2R 3L 3R Initial parameter error Parameter lower 2 digits No meaning Y06 mcp_no setting error 1L 1R 2L 2R 3L 3R mcp_no setting error No meaning No meaning Y02 Aux ax system alarm 0051 0004 1L 1R 2L 2R 3L 3R mcp_no setting error N...

Page 66: ...ameter error 3225 S 1L 1R 2L 2R 3L 3R Initial parameter error Error lower 2 digits Axis bit S03 Servo alarm NR 0052 Y 1L 1R 2L 2R 3L 3R Servo alarm NR Error lower 2 digits Axis bit S04 Servo alarm AR 006F Y 1L 1R 2L 2R 3L 3R Servo alarm AR Error lower 2 digits Axis bit S01 Aux ax servo alarm 0016 0004 1L 1R 2L 2R 3L 3R Auxiliary axis servo alarm Error lower 2 digits Axis bit S02 Aux ax servo alarm...

Page 67: ...g alarms are displayed in the same state by the LEDs it is difficult to distinguish them Check the details for each alarm on the diagnosis screen S52 Servo warning and S52 Aux ax servo warning Alarm Warning code Displays of 7 segment LED transition 1L 1R 2L 2R 3L 3R S51 Parameter error 2205 Z 1L 1R 2L 2R 3L 3R Parameter error Error lower 2 digits Axis bit S52 Servo warning E0 X 1L 1R 2L 2R 3L 3R S...

Page 68: ...2 41 IB 1501273 F Daily Maintenance and Periodic Maintenance ...

Page 69: ... of the inspection and maintenance of the drive section refer to the instruction manuals for each drive unit 1 Replace the battery within one month after the alarm Z52 Battery fault 0001 appears on the NC screen 2 The internal data may have been damaged if the alarm Z52 Battery fault 0003 appears Class Name Life Inspection replacement Daily maintenance Touchscreen Accordingly when poor sensitive o...

Page 70: ... water etc adhere to it for long periods so be sure to wipe off any moisture immediately Wipe off any dirt dust etc on the polarizing plate using absorbent cotton or other soft cloth Electronic parts are used in the touchscreen so be careful of static electricity when handling Never disassemble the Touchscreen Doing so will damage the panel 3 Precautions for storage Do not store the card in locati...

Page 71: ...se for remote I O unit FCU8 DX651 cannot be replaced Durable parts Part type Battery for control unit Q6BAT BKO C10811H03 Personal computer unit cooling fan 109P0424H3013 Replacing parts Part type Manufacturer Protection fuse for operation panel I O LM50 Daito Communication Apparatus Co Ltd Protection fuse for FCU8 DX220 230 231 651 LM50 Daito Communication Apparatus Co Ltd Protection fuse for FCU...

Page 72: ...FF turn it OFF 2 Confirm that the control unit LED 7 segment display etc are all OFF 3 Open the front cover of the control unit 4 Remove the connector from the control unit BAT connector 5 Replace the old battery with the new battery in the battery holder 6 Insert the connector connected to the new battery into the BAT connector Pay attention to the connector orientation do not insert backwards 7 ...

Page 73: ...ly Maintenance and Periodic Maintenance 46 IB 1501273 F M800W M80W M800S M80 E80 Front cover Battery holder Battery Battery connector BAT connector Front cover Battery holder Battery BAT connector Front cover Battery holder Battery BAT connector ...

Page 74: ...nit Remove the fan cover by holding down the tab on the left side surface 4 Disconnect the cooling fan connector 5 Remove the cooling fan from the personal computer unit cooling fan housing 6 Replace the cooling fan with a new one Insert the connector from the new cooling fan into the personal computer unit 7 Install the fan cover taking care not to pinch the cooling fan wiring with the fan cover ...

Page 75: ...unit When FUSE LED is not lit and DOCOMLED is lit 1 the fuse is blown out 1 When DOCOM LED is not lit it is considered that the power is not supplied Confirm that the power is correctly supplied How to check for fuse blowout FCU8 DX750 760 761 FCU8 DX730 830 837 FCU8 DX731 FUSE Not lit DOCOM Lit FUSE Not lit DOCOM Lit FUSE Not lit DOCOM Lit ...

Page 76: ...is lit 2 the fuse is blown out 2 When 24VDCIN LED is not lit it is considered that the power is not supplied Confirm that the power is correctly supplied Remote I O unit FCU8 DX213 213 1 654 654 1 When the indication window of the fuse becomes white the fuse is blown out FCU8 DX220 230 231 FCU8 DX213 213 1 654 654 1 FUSE Not lit 24VDCIN Lit 6 A 3 MP63 Indication Window White ...

Page 77: ...aintenance 50 IB 1501273 F 1 Turn OFF the machine 2 Remove the fuse using tweezers etc and then replace it with a new fuse Replacement procedures for fuse FCU8 DX750 760 761 FCU8 DX730 830 837 FCU8 DX731 FCU8 DX220 230 231 FCU8 DX213 213 1 654 654 1 LM50 LM50 LM50 LM50 MP63 ...

Page 78: ...3 51 IB 1501273 F Maintenance of the Drive Unit ...

Page 79: ...long with the machine 4 Check the load coupling shaft for misalignment WARNING 1 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 Inspections must be carr...

Page 80: ...V ring These parts should be replaced after 5 000 hours of operation at the rated speed This will be affected by the operation state but these parts must be replaced if oil leaks etc are found in the inspections Part name Standard replacement time Remarks Servo drive unit Smoothing capacitor 10 years The standard replacement time is a reference Even if the standard replacement time is not reached ...

Page 81: ...absolute position system is supplied from the battery connected to the drive unit Keep the power ON once for 30 minutes or more if possible and make sure to complete the replacement within 60 minutes after charging the encoder s capacitor CAUTION 1 Correctly transport the product according to its weight Failure to observe this could result in injury 2 Do not stack the product above the indicated l...

Page 82: ...403 90SQ CV 550 9WF1224H105 120SQ V2 40 SP 640 9WF1224H105 120SQ V2 80 SP2 20 9WF0424H603 40SQ V2 160 9WF0624H604 60SQ SP2 40 V2 160W 9WF0924H206 90SQ SP2 80 9WF0624H604 60SQ V3 20 9WF0424H603 40SQ SP2 16080 V3 40 Servo drive unit Spindle drive unit Power supply unit Type MDS EH Fan type Size mm Type MDS EH Fan type Size mm Type MDS EH Fan type Size mm V1 10 SP 20 9WF0424H603 40SQ CV 37 9WF0624H60...

Page 83: ...rive unit and remove the two fan mounting screws 3 Remove the fan power cable 4 Disconnect the connection connector and replace the fan POINT When the drive unit of E EH Series which uses two cooling fans is in an emergency stop or alarm one of fans upper one in the case of vertical layout or either one in the case of horizontal layout is stopped and power saving oper ation is performed If the sus...

Page 84: ... LR20 is commercially available as a size D alkaline battery The battery may be purchased and replaced by the user 1 Four LR20 size D alkaline batteries are needed for per battery unit MDSBTBOX LR2060 Type Battery equipped unit MDS BAT6V1SET Servo drive unit LR20 size D alkaline battery Battery unit MDSBTBOX LR2060 CAUTION 1 When the battery voltage is low warning 9F do not shut OFF the power of t...

Page 85: ...attery 3 Install a new battery and connect a cable connector to the connector position where the old battery connector was pulled out from in step 2 4 Cancel the warning 9F by executing an alarm reset pushing the NC reset button CAUTION 1 Replace the batteries with new ones immediately after the battery voltage drop alarm 9F has been output 2 Replace the batteries while applying the drive unit s c...

Page 86: ...battery do not let foreign objects enter If the terminal area gets dirty clean there 3 If the cover is ill set mist or foreign objects enter through the interstices and enter into the panel Tighten the screws Tightening torque 1N m CAUTION 1 Replace the batteries with new ones that are in their recommended use period Check the recommended use period written on the batteries before using them 2 Rep...

Page 87: ...y following the removal procedure in reverse Restoration Data backup and restoration is not required before replacing drive units because drive units data such as parameters are stored in the controller However carry out a backup of the whole system before replacement as a precautionary measure The power for keeping the encoder s position data of an absolute position system is supplied from the ba...

Page 88: ...ection of the fan wind Remove the mounting screws Disconnect the connection connector of the fan mounted on the unit side face Direction of the fan wind Cooling fan Make sure that the cooling fan lead wires are not stuck by the cooling fan or the chassis Also make sure not to apply any load to the base of the cooling fan lead wires Wire the cooling fan lead wires at the side of the cooling fan ...

Page 89: ... Direction of the fan wind Remove the mounting screws Disconnect the connection connector of the fan mounted on the unit side face Direction of the fan wind Cooling fan Lead out the cooling fan lead wires from here when installing the fan Make sure that the cooling fan lead wires are not stuck by the cooling fan or the chassis ...

Page 90: ...ion of the fan wind Attach the harness to the position described in the figure above Sleeve Connector Insert the connector so that it will reach the end of the stopper when assembling Place the fan harness inside the chassis using the positioning boss for the chassis Fold the harness to put it inside so that it will not be stuck by the cooling fan Keep the clearance even ...

Page 91: ...r so that it will reach the end of the stopper when installing Place the fan harness inside the chassis using the positioning boss for the chassis Fold the harness to put it inside so that it will not be stuck by the cooling fan Sleeve 2 Disconnect the connection connector of the fan mounted on the unit side face 1 Remove the mounting screws Installation procedure of tube for fan harness ...

Page 92: ... 30 MDS EJ SP2 20 MDS EJ V2 40 FAN㢼ྥ䛝 Disconnect the connection connector of the fan mounted on the unit side face Direction of the fan wind Remove the mounting screws Disconnect the connection connector of the fan mounted on the unit side face Direction of the fan wind Remove the mounting screws ...

Page 93: ... procedures Replacement procedure for the cell battery MR BAT6V1SET a Installing and removing the cell battery Type Battery equipped unit MR BAT6V1SET Servo drive unit LR20 size D alkaline battery Battery unit MDSBTBOX LR2060 CAUTION 1 When the battery voltage is low warning 9F do not shut OFF the power of the drive unit until replacement of the battery to protect the data 2 Replace the MDSBTBOX L...

Page 94: ...an alarm reset pushing the NC reset button MR BAT6V1 MR BAT6V1SET that reached the end of the life can be reused by replacing the MR BAT6V1 battery Open the cover while pushing the locking part Replace the built in battery with a new battery for MR BAT6V1 Close the cover by pushing until it is fixed with the tab of the locking part Cover Locking part Tab ...

Page 95: ...battery do not let foreign objects enter If the terminal area gets dirty clean there 3 If the cover is ill set mist or foreign objects enter through the interstices and enter into the panel Tighten the screws Tightening torque 1N m CAUTION 1 Replace the batteries with new ones that are in their recommended use period Check the recommended use period written on the batteries before using them 2 Rep...

Page 96: ...ws fixing the drive unit onto the control panel Remove the drive unit from the control panel 4 Make a same setting for the rotary switch and the dip switch of the new drive unit as those of the uninstalled drive unit 5 Install a new drive unit by following the removal procedure in reverse Restoration Data backup and restoration is not required before replacing drive units because drive units data ...

Page 97: ...nit type Fan type MDS EM SPV3 16040S EM FS 18 MDS EM SPV3 10040 to 200120 EM FS 26 MDS EMH SPV3 8040 to 10060 MDS EM SPV3 320120 EM FS 30 1 Remove the mounting screws from the fan unit cover on the top of the drive unit 2 Remove the fan unit cover 3 Remove the fixing screws from the fan unit Disconnect the connector on the top and pull out the fan unit Mounting screw Fan unit cover Fixing screw Fa...

Page 98: ...ttery type 1 Four LR20 size D alkaline batteries are needed for per battery unit MDSBTBOX LR2060 4 When installing the fan unit insert the sheet metal of the fan unit into the fin rails Although MDS EM SPV3 16040S and 320120 do not have fin rails the installation of fan units is not affected Type Battery equipped unit MR BAT6V1SET Multi axis drive unit LR20 size D alkaline battery Battery unit MDS...

Page 99: ...ward while pushing the unlocking lever 3 Install a new battery and connect a cable connector to the connector position where the old battery connector was pulled out from in step 2 4 Cancel the warning 9F by executing an alarm reset pushing the NC reset button CAUTION 1 Replace the batteries with new ones immediately after the battery voltage drop alarm 9F has been output 2 Replace the batteries w...

Page 100: ...battery do not let foreign objects enter If the terminal area gets dirty clean there 3 If the cover is ill set mist or foreign objects enter through the interstices and enter into the panel Tighten the screws Tightening torque 1N m CAUTION 1 Replace the batteries with new ones that are in their recommended use period Check the recommended use period written on the batteries before using them 2 Rep...

Page 101: ...M800 M80 E80 Series Maintenance Manual 3 Maintenance of the Drive Unit 74 IB 1501273 F ...

Page 102: ...4 75 IB 1501273 F Failure Diagnosis ...

Page 103: ...ouble occurred Also check how many years the machine has been operated and how many hours a day it is used 4 2 Failure Diagnosis Procedure Investigate the cause of the failure according to the following procedures Start Diagnosis Based on the Alarm Refer to 4 3 Diagnosis Based on the I F Diagnosis Screen Refer to 4 4 Diagnosis Based on the Self Diagnosis Screen Refer to 4 5 Diagnosis Based on the ...

Page 104: ... message PLC message and Alarm history 4 3 1 How To Check the Alarm Information A list of currently occurring alarms or messages can be displayed on this screen The displayed messages include the NC alarms stop codes alarm messages operator messages etc A history of alarm information can be displayed also NC message PLC message Diagn 1 2 3 4 ...

Page 105: ...larm message Using the PLC programs this displays messages such as details of machine abnor malities This varies depending on the MTB specifications Up to 4 messages are displayed 4 Operator message Using the PLC programs this displays operator information messages This varies de pending on the MTB specifications Macro alarm messages are also displayed in this field Up to 4 messages are displayed ...

Page 106: ...s When two or more alarms occur at the same time up to five alarms are recorded With multi part system 1st part system is given priority and recorded Following 2nd part system 3rd part system Number of history 512 alarms Whole Range of record NC alarm alarm warning PLC alarm message 1 The following alarms are not recorded on the alarm warning screen Operation alarm External interlock axis exists M...

Page 107: ...ata select in the maintenance diagnostic data collection setting Menus Menus Details This displays the first page of the alarm history The history sequentially displays 16 alarms per page from the latest alarm If there are two or more NC alarms of same day and time the alarms are sequentially displayed from the alarm and warning of the 1st part system To display the old history press the key To di...

Page 108: ...ual To confirm by Guidance display on the NC screen Confirm details with the alarm guidance alarm message details displayed on the NC screen by pressing the key or key While the alarm history screen is displayed the guidance of the alarm displayed on the screen is displayed It might be different from the alarm which currently occurs To confirm by Alarm manual Confirm the details with M800 M80 E80 ...

Page 109: ...isplayed project 2 Device No and input output signal value bi nary hexadecimal dis play This displays the data from the device Nos designated in the setting area in numerical order The data is displayed as binary bit units and hexadecimal values Individual device Nos can be displayed separately in the left area and right area Se lect the display area with the and key when operations such as displa...

Page 110: ...his changes the setting area to an input standby status The signal is forcibly output one shot A confirmation message appears and the machine turns into standby status The force OP one shot output of all I O signals are canceled 1 The device and I O signal of the next project are displayed If the last project is displayed the top project is displayed How to read the device No and display data Disp...

Page 111: ...n setting the device No an error will occur if a number exceeding the specifications or an illegal address is set 2 The input output signals of X Y R and ZR are the same for all projects The valid area device Nos change in page units when is pressed Changing of the pages stops within the range of device numbers of which the device has Displaying the data of a arbitrary device No X0020 1 Press the ...

Page 112: ...utput area The released data is erased from this area Modally outputting data 1 to device X0048 1 Press the menu Modal output The mode changes to the modal output mode and the cursor appears at the modal output area 2 Using the and keys move the cursor to the set ting position 3 Set the device and data and press the INPUT key Modal output is executed and the cursor disappears The data that was in ...

Page 113: ...hot output for all projects 4 The devices other than X Y R and ZR are one shot output for the currently displayed project One shot outputting data 1 to device X0042 1 Press the menu Next Project The display is switched to the I O signal of the next proj ect Press the menu key to switch the project in order 2 Press the menu 1 shot output 3 Set the device and data and press the INPUT key The input d...

Page 114: ...2047 2048 1 bit For temporary memory Alarm message interface SB SB0 to SB3FF 1024 1 bit Special relay for linking B B0 to BDFFF 57344 1 bit Link relay SM SM0 to SM2047 2048 1 bit Special relay V V0 to V511 512 1 bit Edge relay SW SW0 to SW3FF 1024 16 bit Special register for linking SD SD0 to SD2047 2048 16 bit Special register TI TI0 to TI2047 2048 1 bit Timer contact TO TO0 to TO2047 2048 1 bit ...

Page 115: ...splays the hardware state of the NC unit and display unit 1 2 Operation state De pends on part system This displays the state when the operation seems to be stopped in spite that the alarm does not occur 2 3 System lock This displays the valid term by the system lock when the system lock is valid This will not displayed when the system lock specification is invalid Once the expiry date is passed c...

Page 116: ...ays the cumulated count of occurrence for Y51 SV commu er Recv frame xx04 Press the menu Servo clear to clear the cumulated count to 0 Servo comm err Num2 This displays the count of occurrence for Y51 SV commu er Data ID error xx03 after the power ON Servo comm err Acc2 This displays the cumulated count of occurrence for Y51 SV commu er Data ID er ror xx03 Press the menu Servo clear to clear the c...

Page 117: ...axis is moving in direction 1 appears for the axis if the exter nal deceleration speed is valid and the feedrate is clamped exceeding the set value of the external deceleration speed In the above case the 1st axis and the 3rd axis are in external deceleration speed Even when the number of usable axes is less than 8 in 1 part system this displays 8 axes fixed ExtDcc When the control axis is moving ...

Page 118: ...ause or block stop is performed during automatic operation with the state the expiry date is over NC cannot restart For the display position of warning and alarm messages refer to the Instruction Manual While the warning is occurring you can check the number of days remaining before the expiry date Open Diagn Alarm message NC message screen then you can check the number of days The number of remai...

Page 119: ...code is pressed Decryption Code automatically appears in Dir and PASSCODE DATA in File If you enter RLS in Dir the screen will be displayed in the same way 6 Press Trnsfr A B 7 When a confirmation message appears press either Y or INPUT If the decryption code has successfully been set Setting complete normally appears If the warning message is on the screen this message will be removed If the alar...

Page 120: ...a can be output externally on the I O screen on the maintenance Mainte screen Sampling specifications 1 The maximum number of sampled data items is the total number of data When the number of sampled channels is increased the number of data per channel will decrease 2 If the free capacity of DRAM is insufficient the maximum number of data items decreases Sampling cycle 1 776 ms x Setting value Num...

Page 121: ...e position to the command position is called droop This error is proportional to command speed value This follows the setting and display unit 1003 iunit Speed r min This displays the actual rotation speed of motor Feedrate mm s This displays the feedrate on the machine end Load current This displays the FB value of the motor current in terms of continuous current during stalling Max current 1 Thi...

Page 122: ...ace This displays the grid space for the reference position return Command unit Grid amnt This displays the distance from the dog off point to the grid point when the dog type reference position return is displayed The grid mask amount is not included Com mand unit Machine position This displays the NC basic machine coordinate system position Command unit Motor end FB This displays the feedback va...

Page 123: ...Bit4 Position loop gain changeover command Bit6 Excessive error detection width changeover command Bit7 Alarm reset command Control input 1H This indicates the control signal input from NC to servo bit8 to bitF Bit8 Current limit selection command Control input 2L This indicates the control signal input from NC to servo bit0 to bit7 Control input 2H This indicates the control signal input from NC ...

Page 124: ...r LS Linear scale MP MP scale ESS Semi closed high speed serial encoder ECS Ball screw end high speed serial encoder INC Incremental Power OFF posn This displays the coordinate at NC power OFF in the basic machine coordinate sys tem Command unit Power ON posn This displays the coordinate at NC power ON in the basic machine coordinate system Command unit Current posn This displays the current coord...

Page 125: ...splayed when the method is SEMI Mach end detect No This displays the machine end detector serial No Motor This displays the motor type Work time This displays the READY ON work time Units 1 hr Alarm history 1 Time 1 Alarm This displays servo alarms that occurred in latest order with the following formats Time Work time when the alarm occurred Alarm No Number of the servo alarms that occurred 8 Tim...

Page 126: ...ms of continuous current during stalling An absolute value of the current command peak value sampled after the power ON is dis played Max current 2 This displays the motor current command in terms of continuous current during stalling An absolute value of the current command peak value sampled in most recent 2 seconds is displayed Max current 3 This displays the FB value of the motor current in te...

Page 127: ...t 1 Motor end FB This displays the feedback value of the speed detector Command unit 1 FB error i This displays the error of the motor end FB and machine end FB 1 DFB compen amnt i This displays the compensation pulse amount during dual feedback control 1 Tap error mm 2 This displays the current value of the synchronous error between the tapping spindle and the drilling axis during synchronous tap...

Page 128: ...ync err P deg This displays the maximum value of the distance in which the guide bushing spindle ad vances beyond the reference spindle during guide bushing spindle synchronization 99999 999 deg GB sync err P deg This displays the maximum value of the distance in which the guide bushing spindle lags behind the reference spindle during guide bushing spindle synchronization 99999 999 deg GB sync err...

Page 129: ...t 2H This indicates the control signal input from spindle to NC bit8 to bitF Bit9 In speed monitor BitA In door closed controller BitB In door closed self drive unit Control output 3L This indicates the control signal input from spindle to NC bit0 to bit7 Control output 3H This indicates the control signal input from spindle to NC bit8 to bitF Control output 4L This indicates the control signal in...

Page 130: ...work time Units 1 hr Alarm history 1 Time 1 Alarm This displays servo alarms that occurred in latest order with the following formats Time Work time when the alarm occurred Alarm No Number of the servo alarms that occurred 8 Time 8 Alarm Maint hist 1 This displays the maintenance dates Year One digit Month 1 to 9 X Oct Y Nov Z Dec 4 Maint status This displays the maintenance status Data name Detai...

Page 131: ... displays PN bus voltage 0 to 999V Min PN bus volt V This displays the minimum PN bus voltage after the NC power ON 0 to 999V Min PN current This displays the bus current when PN bus voltage is at minimum driving regen erative 0 to 999 Bus current This displays the bus current driving regenerative 0 to 999 Max current1 This displays the maximum driving current after the NC power ON 0 to 999 Max cu...

Page 132: ...ed FAN1 rot state The detected rotation speed of the unit cooling fan is displayed by converting it into percentage format converted with the rated speed of the fan as 100 FAN2 rot state The detected rotation speed of the unit cooling fan is displayed by converting it into percentage format converted with the rated speed of the fan as 100 Alarm history 1 Time 1 Alarm This displays servo alarms tha...

Page 133: ...rvo control section before pitch error compensation relative position compensation and backlash compensation is dis played If this error occurs the parameters that should be the same for the synchronous axes are different Command error Command s command m Δ Command s Slave axis commanded position Command m Master axis commanded position Δ Command s command m at start of synchronous control FB erro...

Page 134: ...vo unit Spindle unit or Power unit 2 Using the menu Next axis tab keys and select the axis device from which to clear the alarm history 3 Press the menu Alarm his clr The menu is highlighted and a message appears to confirm the erasing The alarm history1 Time appears at the head 4 Press the Y key All alarm history data for the selected axis device are cleared to 0 Diagn ...

Page 135: ...s Details 1 Index No This displays the registration No of the NC memory data When one of the 2 Data contents is set the number is highlighted indicating that the normal display of the data contents has stopped 2 Data contents Part system No Designate the part system No 1 1st part system Designate 0 to designate the data common for the part systems Section sub section axis Designate the section No ...

Page 136: ...con stantly displayed The Index No highlight indicating data is being set is released The cursor appears in Part system No of that line This writes the data in the setting area to the NC memory indicated by address data at the cursor posi tion 1 The Data No highlight indicating data is being set is released and constant display is started After writing the cursor moves to Part system No of the nex...

Page 137: ...y stop observation SLS Safety limited speed observation SLP Safety limited position observation SSM Safe speed monitor SCA Safe cam SOS Safe operating stop observation SS1 Safe stop 1 SS2 Safe stop 2 STO Safe torque OFF SBC Safe brake control 2 NC DRV safety communi cation This displays the safety communication status of the drive unit To perform the safety drive communication the smart safety obs...

Page 138: ...the configuration diagnosis display of the smart safety observation This switches the screen to the signal monitor display of the smart safety observation This switches the screen to the drive monitor display of the smart safety observation This switches the screen to the version display of the smart safety observation This switches the drive monitor diagnosis information to the servo unit informa...

Page 139: ...y items Display items Details 1 Device No and input out put signal value binary hexadecimal display This displays the duplex safety PLC signals A B from the designated device No in order The input output signal is displayed in binary and hexadecimal bitwise The device to be displayed can be switched individually for the left area and right ar ea The operation target right or left can be switched w...

Page 140: ...020 1 Press the tab key or to select the area where the data is displayed 2 Set the device No X0020 and then press the INPUT key 1 Setting a device No which exceeds the specification or setting an illegal address causes a setting error The operation target device Nos change in page unit when is pressed Changing of the pages stops within the range of device numbers of which the device has Displayin...

Page 141: ...th servo drive NC axis PLC axis and spindle drive can be monitored Only the safety drive communication parameter enabled axes are displayed on this screen Display items Display items Details Safety command 1L This displays the data sent to the drive Bit Details 1L 0 STO command 0 No command 1 With command 1 2 3 4 5 Safety command 1H 6 7 1H 8 9 A B C D E F ...

Page 142: ...ommand 1 With command 3 SBC command for SBT 1CH side 0 No command 1 With command 4 SBC command for SBT 2CH side 0 No command 1 With command 5 Safety command 2H 6 7 2H 8 9 A B C D E F Safety status 1L This displays the data received from the drive Bit Details 1L 0 STO status 0 No operation 1 In operation 1 2 3 4 5 Safety status 1H 6 7 1H 8 9 A B C D E F Display items Details ...

Page 143: ...BT 1CH side 0 No operation 1 In opera tion 4 SBC status for SBT 2CH side 0 No operation 1 In opera tion 5 Safety status 2H 6 7 2H 8 9 A B C D E F Safe position FB This displays the encoder position information from the drive to NC Saf detector connect This displays the safety encoder connection status 0 No connection 1 With connection Safety status 2L This displays the data received from the drive...

Page 144: ...rsion of the NC system Parameters This displays the safety parameter changed date and time comment and CRC Lad 1 2 This displays the safety PLC ladder 1 2 changed date and time comment and CRC Servo axis up to 32 axes This displays the safety software version of servo axis The version only for axis of the safety servo unit is displayed Change the display item with or Spindle up to 8 spindles This ...

Page 145: ...by pressing Mainte Servo diagn on the diag nosis Diagn screen The number of alarms of servo spindle drive unit DA output information PLG diagnosis spindle The maintenance diagnosis information of servo spindle unit such as alarm cause counter This operation is protected according to the operation level Servo unit Spindle unit 1 Display of the DA output data Mainte 1 2 3 1 2 3 ...

Page 146: ...e drive unit power was turned ON The number of times can be cleared for each axis with All cnt clr accu Displays the number of times in which the alarm occurrence condition was met since the drive unit power was turned ON freq Displays the peak hold value when the alarm occurrence condition is met per constant cycle 3 DA output This displays the data for each axis or unit DA Address 1 Servo parame...

Page 147: ...s set to 0 this menu is not displayed Even when the parameter 1039 spinno is set to other than 0 this menu will be grayed out and non selectable while displaying the servo unit diagnosis information This clears the number of alarms of the axis at the cursor position to 0 This clears the number of alarms at the cursor position to 0 Note When the cursor is on AL cause cnt accu or freq this menu is g...

Page 148: ... parameter 1 and parameter 2 PLC I O history 2048 This shows the change history of the input output signals between the machine PLC ladder and the NC Changed time device names and status 1 OFF ON 0 ON OFF AC power ON OFF history 64 This shows the history information when the power is ON OFF Occurrence time and NC power ON OFF Touch history 2048 This shows the touchscreen input history information ...

Page 149: ...pling data is not to be collected Specify the part system in HEX When 0 is set sampling is carried out for all spindles This setting is ignored if a non existent spindle is specified Servo Specify the servo axes where sampling data is not to be collected Specify the part system in HEX This setting is not system specific When 0 is set sampling is carried out for all axes This setting is ignored if ...

Page 150: ...1 Data collection starts even if Alarm history is set to 1 Not collect 4 11 2 Stopping the Data Collection The data collection stops when any of the following operations is performed 1 When the menu Stop is pressed the confirmation message appears 2 Press the Y or INPUT key to stop the data collection Press the menu Start to restart the data collection When the data collection is stopped by pressi...

Page 151: ...alarm history 11052 LOG Sort Order 0 Ascending by date and time for all history History data of each history type is output collectively in time ascending or der If two or more histories have the same time and date they are displayed in the order of key history touchscreen history alarm history PLC I O signal history tool offset change history workpiece offset change history and AC alarm history 1...

Page 152: ...ss the menu Area change to set the destination of the device B file In this manual the destination is HD D NCFILE as an example B Dev HD Directory Select a destination directory File name Input a file name to save Note If you omit the file name the file is named with the same name as the device A 4 Press the menu Trnsfr A B to output the file Procedures to output the history data files 1 2 2 㺃㺃㺃 S...

Page 153: ...name the file is named with the same name as the device A 4 Press the menu Trnsfr A B to output the file 1 On the Mainte screen select Mainte and then Psswd input to input the password issued by the MTB 2 Select the menu Edit Open on the edit screen 3 Input the following strings in the input area according to the history data to browse and then press the INPUT key LOG ALLLOG LOG for all history da...

Page 154: ... error or 1477 SrvAlmDly Delayed display and storage of servo spindle alarm in this case and saving of these alarms in the alarm history is delayed and they also are not recorded The parameter 1476 ComErrDly or 1477 SrvAlmDly only enables the display history of the alarms to be postponed therefore the NC is in the emergency stop state while the alarm display is being delayed Set the minimum value ...

Page 155: ...understand from the information Narrow the cause by combining the information NC side PC side Applica tion side 1 Application name in which the error occurred Application name Process ID A Application name in which the error occurred 2 The time the error detection function started C The elapsed time from when the NC power is turned ON to the error occurrence 3 The time error occurred The time erro...

Page 156: ...1 Up to ten lines are displayed at a time When the display item exceeds ten lines the following lines can be displayed with the Page down key Display Items Display Items Description 1 Connect NC address This displays IP address of the connection destination control unit 2 PC IP address PC Subnet PC Gateway This displays IP address subnet mask gateway settings 3 IP address This displays IP address ...

Page 157: ...e dialog which notifies the change of the network set ting is displayed To establish the communication between the selected control unit and the display unit the Ethernet parameter is temporarily changed 2 Press the INPUT key After a while the NC screen is displayed If the NC screen is not displayed remove the control unit from external network and carry out the procedure 1 again Note In the step ...

Page 158: ...P address is reset Message Description Searching The system is searching the connectable NC control unit to establish the commu nication between the control unit and the display unit Please wait until the search is completed Socket error The system could not find the connectable control unit because of the network interference Turn OFF the NC power supply and review the wiring for the network conn...

Page 159: ...t the causes for example in the following cases Communication is disconnected Communication is not carried out properly The communication expansion units in the table below are available with this function The statistical information of communication packets can be checked on the I F diagnosis screen of NC Conditions for use Data can be input or output to the I F diagnosis screen The password issu...

Page 160: ...a refer to 4 14 2 Diagnosis Com mand Device EXT1 EXT3 Device EXT2 EXT4 Details SD1133 to SD1134 SD1633 to SD1634 The number of times that packet data has been received through the port 1 4 bytes SD1135 to SD1136 SD1635 to SD1636 The number of times that packet data has been received through the port 1 4 bytes The cumulative number until it is cleared 1 SD1137 to SD1138 SD1637 to SD1638 The number ...

Page 161: ...a has been transmitted 4 bytes It is cleared by turning the power OFF SD1135 to SD1136 SD1635 to SD1636 The number of times that packet data has been transmitted 4 bytes The cumulative number until it is cleared 1 SD1137 to SD1138 SD1637 to SD1638 The number of times that packet data has been received 4 bytes It is cleared by turning the power OFF SD1139 to SD1140 SD1639 to SD1640 The number of ti...

Page 162: ...t the number of times of Reset request is not increasing Reset request is not necessary for EtherNet IP on the NC When the number increases it means there is the device which requests an unnecessary Reset The device which requests the unnecessary Reset might be infected with a virus Check that the device functions properly Device EXT1 EXT3 Device EXT2 EXT4 CC Link IE Field EtherNet IP SD1164 SD166...

Page 163: ...e SD device for issuing the diagnosis command on the I F diagnosis screen and execute the command After this command is executed the screen transitions as follows before the execution is completed If EXXX is displayed on the device for execution result of the diagnosis command when the operation is completed it means that an error occurs XXX is any hexadecimal number For detailed information of er...

Page 164: ...play of each error and its meaning are as follows Value Details E001 HEX Notification of invalid command input This error code is displayed when an invalid command is input EFFF HEX Notification that an uncorrectable error occurs When this error occurs this function might be in the state that the diagnosis command cannot be used Contact the Service Center Also the result of command execution proce...

Page 165: ...M800 M80 E80 Series Maintenance Manual 4 Failure Diagnosis 138 IB 1501273 F ...

Page 166: ...5 139 IB 1501273 F Troubleshooting ...

Page 167: ...the operation procedure What were the previous and next steps What screen is displayed on the display unit of MTB What is the state of the peripheral devices Did the trouble occur during input output operations What was the machine side state Did the trouble occur while replacing the tools Did hunting occur in the control axis 5 How frequently does the trouble occur If the trouble occurs infrequen...

Page 168: ...n in the power voltage or noise from the communication cable Is the power voltage always correct Is the power frequency always correct Does the voltage fluctuate depending on the time Does the voltage drop momentarily when a peripheral device starts operation Was there an instantaneous power failure before the trouble Have measures against noise been taken for each unit Are the communication and p...

Page 169: ...M800 M80 E80 Series Maintenance Manual 5 Troubleshooting 142 IB 1501273 F ...

Page 170: ...6 143 IB 1501273 F Replacing Each Unit ...

Page 171: ...t be restored For the input output function for separate files refer to the Instruction Manual HD Hard disk This is not displayed on M800S M80 E80 Series and non Windows based display unit of M800W M80W Series Memory card Front side SD card DS M800S M80 E80 Back side SD card of the display unit M800W M80W Control unit side SD card USB memory Screen display File name Data type System data SRAM BIN ...

Page 172: ...isplayed Note Press the to cancel this process 2 Press the Y y or INPUT key The backup starts Executing and are displayed for the state of file un der processing Note If any NC data file exists in the backup folder the con firmation message Overwrite this file Y N ap pears In this case press the Y y or INPUT key to start backup If the tool data is being sorted the operation message File access err...

Page 173: ...he memory card or DS 3 On the Windows based display unit if the size the size in the actual memory of custom data exceeds 48MB the op eration message Skipped custom data due to over capacity appears and the custom data cannot be backed up Note that the size in the actual memory and the size on Windows may differ 3 The backup is completed without error The states of backup complete files turn to Co...

Page 174: ...of the backup data The System data file does not exist in the transfer source The ladder larger than 256 KB is stored and all backup is executed when the large capacity PLC specification is valid and then the specification is switched to invalid 4 APLC data can be restored only when the APLC release specification is valid 5 When smart safety observation is valid entering the safety password is req...

Page 175: ...at the position where the cursor moved to the operation message Select directory to restore appears Select the file again and then press the INPUT key key Auto1 Auto2 Auto3 Manual Auto1 key Auto1 Manual Auto3 Auto2 Auto1 6 Press the Y y or INPUT key The restoration starts Executing and are displayed for the state of file un der processing Note If PLC is in operation the message PLC running Does it...

Page 176: ...onnect all the cables back to the control unit Always connect the cables to the designated connectors 6 Confirm that all the cables are correctly connected and close the door of the electric cabinet or operation panel 1 Wire the control unit optical cable as shown below Refer to M800S M80 E80 Series Connection and Setup Manual and M800W M80W Series Connection and Setup Manual when handling and wir...

Page 177: ...acing Each Unit 150 IB 1501273 F FCU8 MU542 FCU8 MA542 FCU8 MU541 FCU8 MA541 M800S FCU8 MU511 FCU8 MU512 FCU8 MU501 FCU8 MU502 M80 FCU8 MU513 FCU8 MU514 E80 Mounting screw size M4 FCU8 MU042 FCU8 MA041 M800W FCU8 MU044 M80W Mounting screw size M5 ...

Page 178: ...ews fixing the display unit and take the display unit off 5 Install a new display unit with fixing screws 6 Connect all the cables back to the display unit Always connect the cables to the designated connectors 7 Confirm that all the cables are correctly connected and close the operation panel door Replacement procedures CAUTION 1 Incorrect connections could cause devices to damage Connect the cab...

Page 179: ...Unit 152 IB 1501273 F FCU8 DU121 8 4 type display unit Fixed on the front side Fixing screw Cheese head screw M3 4 pcs Fixing screws are provided with the unit Fixed on the back side Fixture M3 nut 4 pcs 4 pcs of the screw caps a are provided with the unit a ...

Page 180: ...nit 153 IB 1501273 F FCU8 DU141 10 4 type display unit Fixed on the front side Fixing screw Cheese head screw M3 4 pcs Fixing screws are provided with the unit Fixed on the back side Fixture M3 nut 4 pcs 4 pcs of the screw caps a are provided with the unit a ...

Page 181: ...Unit 154 IB 1501273 F FCU8 DU181 15 type display unit Fixed on the front side Fixing screw Cheese head screw M3 8 pcs Fixing screws are provided with the unit Fixed on the back side Fixture M3 nut 8 pcs 8 pcs of the screw caps a are provided with the unit a ...

Page 182: ...6 Replacing Each Unit 155 IB 1501273 F FCU8 DU191 19 type display unit Fixing screw Use M4 10 with spring washer and plain washer 10 screws FCU8 DU192 19 type display unit Fixing screw Use M4 10 with spring washer and plain washer 10 screws ...

Page 183: ...unit and take the personal computer unit off 5 Install a new personal computer unit with fixing screws 6 Connect all the cables connected to the personal computer unit Always connect the cables to the designated connec tors 7 Confirm that all the cables are correctly connected and close the operation panel door FCU8 PC231 M800W Mounting screw size M4 Replacement procedures CAUTION 1 Incorrect conn...

Page 184: ... fixing the keyboard unit and take the keyboard unit off 5 Install a new keyboard unit with fixing screws 6 Connect all the cables connected to the keyboard unit Always connect the cables to the designated connectors 7 Confirm that all the cables are correctly connected and close the operation panel door Replacement procedures CAUTION 1 Incorrect connections could cause devices to damage Connect t...

Page 185: ...h Unit 158 IB 1501273 F FCU8 KB024 KB025 KB026 KB028 Fixed on the front side Fixing screw Cheese head screw M3 4 pcs Fixing screws are provided with the unit Fixed on the back side Fixture M3 nut 4 pcs 4 pcs of the screw caps a are provided with the unit a ...

Page 186: ...acing Each Unit 159 IB 1501273 F FCU8 KB029 Fixed on the front side Fixing screw Cheese head screw M3 4 pcs Fixing screws are provided with the unit Fixed on the back side Fixture M3 nut 4 pcs 4 pcs of the screw caps a are provided with the unit a ...

Page 187: ...ng Each Unit 160 IB 1501273 F FCU8 KB041 KB046 Fixed on the front side Fixing screw Cheese head screw M3 4 pcs Fixing screws are provided with the unit Fixed on the back side Fixture M3 nut 4 pcs 4 pcs of the screw caps a are provided with the unit a ...

Page 188: ...lacing Each Unit 161 IB 1501273 F FCU8 KB047 Fixed on the front side Fixing screw Cheese head screw M3 4 pcs Fixing screws are provided with the unit Fixed on the back side Fixture M3 nut 4 pcs 4 pcs of the screw caps are provided with the unit a ...

Page 189: ...acing Each Unit 162 IB 1501273 F FCU8 KB048 Fixed on the front side Fixing screw Cheese head screw M3 4 pcs Fixing screws are provided with the unit Fixed on the back side Fixture M3 nut 4 pcs 4 pcs of the screw caps a are provided with the unit a ...

Page 190: ...acing Each Unit 163 IB 1501273 F FCU8 KB083 Fixed on the front side Fixing screw Cheese head screw M3 6 pcs Fixing screws are provided with the unit Fixed on the back side Fixture M3 nut 6 pcs 6 pcs of the screw caps a are provided with the unit a ...

Page 191: ...tion panel I O unit with fixing screws Fix so that the operation panel I O unit connector slot is placed at the lower part 6 Connect all the cables back to the operation panel I O unit Always connect the cables to the designated connectors 7 Confirm that all the cables are correctly connected and close the operation panel door FCU8 DX830 FCU8 DX837 FCU8 DX730 M800W M80W Mounting screw size M3 Repl...

Page 192: ...ottom for the horizontally arranged keyboard and at the right for the vertically arranged keyboard 6 Connect all the cables back to the operation panel I O unit Always connect the cables to the designated connectors Insert NCKB cable by fitting Δ1st pin position with the connector 7 Confirm that all the cables are correctly connected and close the operation panel door FCU8 DX731 FCU8 DX750 FCU8 DX...

Page 193: ...the remote I O unit off 5 Install a new remote I O unit with fixing screws Or install a new remote I O unit to DIN rail and lock it by pulling up the slide bar of the remote I O unit 6 Connect all the cables back to the remote I O unit 7 Confirm that all the cables are correctly connected and close the operation panel door FCU8 DX220 FCU8 DX230 FCU8 DX231 FCU8 DX202 FCU8 DX213 FCU8 DX213 1 FCU8 DX...

Page 194: ...M800 M80 E80 Series Maintenance Manual 6 Replacing Each Unit 167 IB 1501273 F FCU8 DX651 Mounting screw size M5 ...

Page 195: ...xed with the tabs 7 Connect the cable to the function expansion unit 8 Confirm that all the cables are correctly connected and close the electric cabinet door 1 Check that the machine power is turned OFF If the power is not OFF turn it OFF 2 Open the electric cabinet door 3 Disconnect the cable from the function expansion unit 4 Press the tabs on the top and bottom of the function expansion unit 5...

Page 196: ...es are correctly connected and close the operation panel 1 Check that the machine power is turned OFF If the power is not OFF turn it OFF 2 Open the operation panel 3 Open the cover of the control unit 4 Remove two screws fixing the functional safety expansion unit to the control unit 5 Close the cover of the control unit 6 Confirm that all the cables are correctly connected and close the operatio...

Page 197: ...ove the expansion unit by pulling it frontward 6 Install the cover to the expansion slot 7 Close the electric cabinet door Always install the expansion unit FCU8 EX56x with the machine power turned OFF 1 Check that the machine power is turned OFF If the power is not OFF turn it OFF 2 Open the operation panel 3 Disconnect the LAN cable and SIO cable of control unit to facilitate the installation 4 ...

Page 198: ...e LAN cable and SIO cable of control unit to facilitate the removal 4 Disconnect the cable from the expansion unit 5 Remove three screws fixing the expansion unit to the control unit 6 Install the back cover of the control unit 7 Connect the LAN cable and SIO cable to the control unit 8 Confirm that all the cables are correctly connected and close the operation panel Removal procedures M800S M80 E...

Page 199: ...e built in disk of the display unit to eject the built in disk of the display unit 5 Insert a new built in disk of the display unit Insert it so that the nameplate sticker of the built in disk of the display unit faces to the PCB 6 Close the back cover of the personal computer unit 7 Close the electric cabinet door M800W CAUTION 1 Incorrect connections could cause devices to damage Connect the cab...

Page 200: ...r is turned OFF 2 Open the electric cabinet door 3 Open the cover on the back side of the control unit 4 Insert eject the SD card Insert it so that the top surface faces to the observer s right side 5 Close the back cover 6 Close the electric cabinet door 1 Do not eject an SD card during the data reading writing 2 MITSUBISHI is unable to guarantee the machine operation when a commercially availabl...

Page 201: ...e power turned OFF 1 Check that the machine power is turned OFF 2 Open the electric cabinet door 3 Insert remove the USB memory 4 Close the electric cabinet door 1 Do not remove a USB memory during the data reading writing 2 Do not connect devices other than USB memories When using a commercially available USB memory performance check must be made by MTB Replacement of front side USB memory Replac...

Page 202: ...C machine operation panel and take the MITSUBISHI CNC machine operation panel off 5 Install a new MITSUBISHI CNC machine operation panel with fixing screws 6 Connect all the cables connected to the MITSUBISHI CNC machine operation panel Always connect the cables to the designated connectors 7 Confirm that all the cables are correctly connected and close the operation panel door Replacement procedu...

Page 203: ... 176 IB 1501273 F FCU8 KB921 KB922 KB923 KB924 KB925 KB926 Fixed on the front side Fixing screw Cheese head screw M3 4 pcs Fixing screws are provided with the unit Fixed on the back side Fixture M3 nut 4 pcs 4 pcs of the screw caps a are provided with the unit a ...

Page 204: ...Each Unit 177 IB 1501273 F FCU8 KB931 FCU8 KB941 Fixed on the front side Fixing screw Cheese head screw M3 4 pcs Fixing screws are provided with the unit Fixed on the back side Fixture M3 nut 4 pcs 4 pcs of the screw caps a are provided with the unit a ...

Page 205: ...M800 M80 E80 Series Maintenance Manual 6 Replacing Each Unit 178 IB 1501273 F ...

Page 206: ... 11 Diagnosis Data Collection Setting 6 1 Data Backup and Restoration 6 8 Function Expansion Unit Deleted the following chapter Included in 4 3 2 Alarm History 1 3 How to Check the Alarm Screen Corrected the chapter No The existing chapter No was corrected according to the addition or deletion of the above chapter Reviewed the contents in the following chapters 1 1 System Basic Configuration Drawi...

Page 207: ...neral Connection Diagram 1 4 1 Control Unit 1 4 4 Remote I O Unit 2 2 2 List of Replacing Parts 2 2 4 Replacing Fuse 4 5 1 Self Diagnosis Screen 4 7 1 Servo Unit 4 7 2 Spindle Unit 4 7 3 Power Supply Unit 4 11 Diagnosis Data Collection Setting 6 1 Data Backup and Restoration 6 2 Control Unit 6 7 Remote I O Unit Also corrected wrong indications Nov 2017 IB NA 1501273 D The descriptions were revised...

Page 208: ... series Added the following chapters 4 11 5 Display Delay Function for Communication Errors and Servo Spindle Alarms 4 14 Field Network Diagnostics Function Changed the titles of the following chapters 1 4 6 7 segment LEDs on the Control Unit 4 7 1 Drive Monitor Screen Servo Unit 4 7 2 Drive Monitor Screen Spindle Unit 4 7 3 Drive Monitor Screen Power Supply Unit 4 7 4 Drive Monitor Screen Synchro...

Page 209: ... S A TEL 34 935 65 2236 FAX 34 935 89 1579 TEL 1 714 699 2625 FAX 1 847 478 2650 San Francisco CA Service Satellite Poland Service Center Seattle WA Service Satellite UL KRAKOWSKA 50 32 083 BALICE POLAND Denver CO Service Satellite TEL 48 12 347 6500 FAX 48 12 630 4701 Canada Region Service Center Tronto Hungary Service Center 4299 14TH AVENUE MARKHAM ONTARIO L3R OJ2 CANADA MADARASZ IRODAPARK MADA...

Page 210: ...JAYA SELANGOR DARUL EHSAN MALAYSIA China DongGuang Service Partner TEL 60 3 7960 2628 FAX 60 3 7960 2629 Johor Bahru Service Satellite China Dalian Service Center DONGBEI 3 5 DALIAN ECONOMIC TECHNICAL DEVELOPMENTZONE LIAONING PROVINCE 116600 CHINA TEL 86 411 8765 5951 FAX 86 411 8765 5952 THAILAND MITSUBISHI ELECTRIC FACTORY AUTOMATION THAILAND CO LTD KOREA Thailand Service Center Bangkok 12TH FLO...

Page 211: ...ses simultaneous revision is not possible Please contact your Mitsubishi Electric dealer with any questions or comments regarding the use of this product Duplication Prohibited This manual may not be reproduced in any form in part or in whole without written permission from Mitsubishi Electric Corporation COPYRIGHT 2015 2019 MITSUBISHI ELECTRIC CORPORATION ALL RIGHTS RESERVED ...

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