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Mitsubishi Electric PLK-J-CU-20 Technical Manual

Industrial sewing machine.
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INDUSTRIAL SEWING MACHINE
MODEL
PLK-J-CU-20
TECHNICAL MANUAL
Control Unit
A180E780P03

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   Summary of Contents for Mitsubishi Electric PLK-J-CU-20

  • Page 1

    INDUSTRIAL SEWING MACHINE MODEL PLK-J-CU-20 TECHNICAL MANUAL Control Unit A180E780P03...

  • Page 2: Table Of Contents

    Contents [1] For safe use _______________________________________________ [1]-1 [2] Precautions for use _________________________________________ [2]-1 [3] Installation ________________________________________________ [3]-1 [4] Names of each part, wiring and grounding ______________________ [4]-1 [5] Confirmation _______________________________________________ [5]-1 [6] Main and Sub servo motor ___________________________________ [6]-1 [7] Timing chart _______________________________________________ [7]-1 [8] Customized input/output _____________________________________ [8]-1...

  • Page 3

    * The contents of this manual are subject to change without notice. * An utmost effort has been made to cover all points of operation in this manual. Contact Mitsubishi if you have any questions regarding the contents. COPYRIGHT(C) 2017 MITSUBISHI ELECTRIC CORPORATION...

  • Page 4: For Safe Use

    [1] For safe use ■ For safe use Always observe the following matters to safely use the Mitsubishi industrial electronic sewing machine PLK-J Series. Before starting Before using this control unit, read all of the technical manuals carefully, and correctly use the unit following the manual.

  • Page 5

    Removal (1) Always turn the power switch OFF and disconnect the plug from the socket (power supply line) before removing the control box. (2) Do not pull out the cord when disconnecting the plug. Always hold the plug receptacle when disconnecting the plug.

  • Page 6: Precautions For Use

    [2] Precautions for use Warning 1. Do not place foot on the foot switch when turning the power 2. Always turn the power OFF when leaving the sewing machine. 3. Do not inspect the control circuit with a tester. 4. Always turn the power switch OFF before tilting the sewing machine head, replacing the needle, or passing thread through the needle.

  • Page 7

    9. The sewing machine will coast to a stop when the power is turned OFF or a power failure occurs during sewing machine operation. 10. Always align the connector shape and direction, and securely insert the connector. 11. If the position detector's connector dislocates, or the sewing machine is completely locked, the motor will be turned OFF automatically for a set time to prevent burning.

  • Page 8: Installation

    [3] Installation 1. Installing the control box Control box ●Insert the four bolts into the holes on the top plate and install the control box. Top view of control box installation area Top plate 4-Ø9 Installation bolt (Fix at four positions) Installation bolt Damper cushion...

  • Page 9: Names Of Each Part, Wiring And Grounding

    [4] Names of each part, wiring and grounding 1.Front side Front panel Power Warning LED (green) LED (red) Heat sink Cover installation screw (M4 screw) Cover Rating plate 2.Back side CON A I/F board power CON F Power supply “Connect to I/F board (MIF) “...

  • Page 10

    3. Connecting the power connector Top plate Control box power Power connector (6-pole) Control box Caution1: Always confirm the connector shape and insertion orientation and completely insert the power connector into the control box. Always turn the power OFF before connecting the connector. Caution2: Please do not bundle the power cable and other cables together.

  • Page 11: Confirmation

    [5] Confirmation 1. Before turning the switch ON (1)Are the power and capacity correct? Refer to “section [12]”. (2)Are the connectors correctly inserted? ( * Power connector from push-button switch * Connector for connection with sewing machine Operation panel connector * Foot switch connector * Other connectors “I/F board (MIF), etc.”...

  • Page 12: Main And Sub Servo Motor

    [6] Main and Sub servo motor Main and Sub servo motor are driven by independent. Please note the timing for motion of each motors. Refer the other technical manual "Sewing Machine Head" about details. Main axis motor Main servo motor Digital tension motor Digital tension motor (P2 axis)

  • Page 13: Timing Chart

    [7] Timing chart 1. Thread trimming timing chart ·Timing for thread trimming output [T] : Program mode [Thread trimming/release timing] -- [LTM] T1~T5 Program mode [Thread trimming/release timing] -- [TRS] msec / deg Program mode [Thread trimming/release timing] -- [TRE] msec / deg ·Timing for thread release output [L] : Program mode [Thread trimming/release timing] -- [LLM]...

  • Page 14

    2. Timing chart for [Clamp of output ON/OFF delay setting] Clamp input 1 to 4 IF1 to IF4 1A to 4A 1B to 4B Clamp output 1 to 4 OF1 to OF4 3. Timing chart for [Priority of clamp] Clamp input 1 Clamp input 2 Clamp input 3 Clamp input 4...

  • Page 15

    4. Timing chart for [Clamp link setting (CF)] = ON, [Valid Number of clamp setting (FN)] = 4 Clamp input 1 Clamp output 1 Clamp output 2 Clamp output 3 Clamp output 4 Note: Halt switch is validated. 5. Timing chart for [Selection of pneumatic pressure two-step (AF2)] = ON Can not use other function in “Work holder”...

  • Page 16

    6. The divisions of clamp setting [OFB] = 4 Setting of [FN],[CF] is invalidated when above setting. Clamp(O1,O2),(O3,O4) is link movement when above setting. The presser block to be used is [F2BN] and can be set. [WHY] = OF,[OFB] = 4,[F2BN] = 2 When not using the clamp step input.

  • Page 17

    7. The divisions of clamp setting [OFB] = 4 (When using the clamp step input.) Setting of [FN],[CF] is invalidated when above setting. Clamp(O1,O2),(O3,O4) is link movement when above setting The presser block to be used is [F2BN] and can be set. The holding block that makes the motion can be set with [F2SN].

  • Page 18: Customized Input/output

    [8] Customized input/output 1. Customized input/output configuration diagram (Refer to page [8] - 3) (Refer to page [8] - 2) (Refer to page [8] - 2) (Refer to page [8] - 4) (Input port) Input Output (Output port) Physical ·Terminal block ·Terminal block control control...

  • Page 19

    2. Outline of customized input/output mode (A to E below correspond to A to E on the previous page.) (1)Customizing the input signal The ON/OFF signal input from the input port passes through the input control section (no operation, alternate operation, signal reversal), and is then stored in the physical input area corresponding to the input port.

  • Page 20

    4. Block diagram (input control section) Standard Physical input Alternate Logic changeover Operation changeover 5. Explanation of operations (input control section) The input signal passes through the A point, B point and C point of the input port, and finally is connected to the physical input Inputs the signal to the input port from an external source.

  • Page 21

    6. Block diagram (output control section) Operation ON delay selection Physical output ON delay Alternate Setting time OFF delay Logic changeover OFF delay Setting time Chopping Output port 100% ON 100%ON other then Full wave time Duty 100% ON Full wave time 66% ON(8ms ON/4ms OFF)...

  • Page 22

    B point ON delay setting (1)When "invalid" is selected, the same signal as the A point will be output to the B point. (2)When "valid" is selected, the waveform will rise after the {set value x 100μs} time (*1) set with the A point input waveform.

  • Page 23: Input / Output Signal

    [9] Input / Output signal 1. Input signal setting table Code Function Specifications Whenever FSP input is on, clamp output [1],[2],[3],[4] turned on one by one. Clamp all step ON signal However, when [Program mode > Clamp output > number of effective clamp (FN)] is set to 1, FSP input is ineffective.

  • Page 24

    < sequel to INPUT SIGNAL > Code Function Specifications Counter clear signal When CCL input is on, UP/DOWN counter is cleared. Start cancel signal When SRC input is on, sewing operation with Stringhalt is prohibited. Up counter clear signal When CCU input is on, UP counter is cleared. Down counter clear signal When CCD input is on, DOWN counter is cleared.

  • Page 25

    < sequel to INPUT SIGNAL > Code Function Specifications Machine head tilting detection When HES input is on, message [M-038] is displayed. signal SP0 to SP9 Speed dial signal Speed dial value is switched to 0 to 9. Speed up signal Speed dial value is increased +1.

  • Page 26

    2. Output signal setting table Code Function Specifications OT0 to Virtual output 0 to F When IO0 is on, OT0 output at the same time (same from OT1 to OTF ) FN1 to When FUN1 code is read while sewing operation, FN1 output is reversed. Function code output 1 to H (same from FN2 to FNH) OF1 to...

  • Page 27

    < sequel to OUTPUT SIGNAL > Code Function Specifications When the message is displayed on the operation panel, ERR output is turned Message display output Option output 1 Do not use Option output 2 Do not use SSW is turned on during power supply is on. However, input signal STP turns Halt signal being on output on SSW is turned on with blinking.

  • Page 28: What Happened? Could It Be An Error

    [10] What happened? Could it be an error? When an error occurs, the error code and corresponding message appear on the operation panel. Take a corrective action in accordance with the message. This section describes the errors and others that do not appear on the operation panel.

  • Page 29

    [Case2] Though you turn the power switch ON and a screen appears on the operation panel, the screen display is incorrect. [Checking Items and Corrective Actions] Is the problem solved when you switch the screen or turn the power switch OFF and then ON again? ▪Reinstall the system.

  • Page 30

    [Case 5] Error indication. (The red LED on the front panel of the control unit is blinking) [Red LED] Blink pattern ☼ : ON - : OFF ☼ - ☼ - ☼ - ☼ - ☼ - ☼ - ☼ - ☼ - ☼ - ☼ - Blink pattern 1 ☼...

  • Page 31

    [Action Method] How to reinstalling the system When it will reinstall the system for upgrade etc., please reinstall by according the following way by using USB flash drive. It is necessary [PLKJ_SYSTEM] folder in the USB flash drive for installing. Please check the following folder in the USB flash drive.

  • Page 32

    LED (red) (3) It will start to install, please wait a while still complete installing. The red LED on the front of the control panel will be displayed during installation. ‡If the red LED flashes, the installation has failed, please check the installation file and re-execute.

  • Page 33

    2. PAL install ① PAL system upgrade (1) Please put the key file [JPAL.PLK] into System “PLKJ_SYSTEM” folder in USB flash drive. data ‡If there is not the key file in “PLKJ_SYSTEM” Note folder, it is impossible to upgrade. ‡After the installation is completed, Notice Picture, Font, Key file...

  • Page 34

    ②Upgrade for Picture, Font, Language data (1) Please insert USB flash drive to CON W connector on PAL. (2) Turn the power on. ► Please touch the 3 diamonds mark on the screen soon after display the startup screen. ► It is appeared the install bar after sounds buzzer. ►...

  • Page 35

    3. I/F board (MIF) Install MIF system upgrade (1) Please insert USB flash drive to CON U connector on PAL. MIF System data I/F Board (MIF) CON U (2) Turn the power on. ►It is started to install automatically, please wait a while at the startup screen. ►...

  • Page 36

    4. Initialize settings the “model set initialize function” It also enters screen as follows. Please hold down the install button and turn on the power. (5) In case of "INITIALIZE", set the internal memory setting value to the initial value. ►It is not necessary to use USB flash drive.

  • Page 37: Several Power Supply

    [11] Several power supply 1.3Ø AC200V - 240V 50/60Hz White Black To control box White CON F Black Green Push button switch assay Green K14M47932202 60-9090-306-108-002 2.1Ø AC200V - 240V 50/60Hz (Except Europe) 60-9090-306-108-005 Blue Blue To control box Brown Brown CON F Green/...

  • Page 38

    3.3Ø AC380V - 415V 50/60Hz (Except Europe) Power unit PLK-B-PUC-B40 60-9090-306-108-002 60-9090-305-108-005 3-phase transformer 3Ø 800VA 60-9090-304-118-006 BKO-E3138H02 Black Black Black Black Black Black Black Brown Brown Brown Brown Brown Black To control box Blue Brown CON F Blue Blue Green/Yellow Blue Blue...

  • Page 39: Unit Wiring Diagram

    [12] Unit wiring diagram Invert SW / bobbin open/close sensor CON22 X axis HP sensor CON2 Y axis HP sensor CON3 CON24 I4/O6 Halt SW (LED) CON28 Thread release PF axis HP sensor CON4 CON8 Thread release Wiper CON27 Digital tension motor (P2 axis) CON15 P2 axis encoder CON14...

  • Page 40

    I/F unit in Back side of machine head (I/F board (MIF)) CON 16 CON T CON S Power switch box CON R CON U CON V Main servo motor Main servo encoder X stepping motor X encoder Y encoder Y stepping motor Sub servo encoder Sub servo motor Foot switch...

  • Page 41: Connectors Layout

    [13] Connectors layout About CON H Please only connect PC CON T CON S CON R CON V CON U [I/F unit in Back side of machine head] CON W (USB connector) INSTALL Button [ PAL ] [front panel of the control box] [13] ‐...

  • Page 42

    PULT1 CON12 CON1 (CON R) (CON V) (CON U) CON15 CON16 (PM) (24V) CON22 CON24 (I5) (I4/O6) CON9 CON20 (DA) (I6) CON6 (CH) CON2 (XH) CON3 (YH) CON4 (ZH) CON7 (P1H) CON25 (I7) CON10 CON14 (AD) (PENC) (O4) (O3) (O5) (O1) (O2) CON29...

  • Page 43: Pin Number Of Connectors

    [14] Pin number of connectors 1. Back side of control box/sewing machine CON G(LCD PANEL) CON A (I/F BOARD (power supply)) Signal Pin No. Signal Pin No. +12V +24V +24V TXD0 RXD0 INSTALL VBUS CON B(MAIN SERVO MOTOR) signal Pin No. CON H(OPTION PORT (PC connection))...

  • Page 44

    CON S(OPTION INPUT) CON M (MAIN SERVO ENCODER) Pin No. Signal Initial setting Signal Pin No. +12V +12V [NO] do not 1MRR +12V +12V [NO] do not 1MXR +12V +12V [NO] do not +12V +12V [NO] do not CON N(SUB SERVO ENCODER) Signal Pin No.

  • Page 45

    2. I/F BOARD (MIF) (1) INPUT CON14 Printed Signal Pin No. character CON2 DC5V power supply Printed Signal Pin No. character DC5V power supply Ground P1_AP P1 axis encoder A X axis home position P1_AN P1 axis encoder A detection P1_BP P1 axis encoder B DC12V...

  • Page 46

    Printed Signal Pin No. character General purpose input General purpose input General purpose input General purpose input General purpose input General purpose input General purpose input General purpose input General purpose input General purpose input General purpose input General purpose input General purpose input...

  • Page 47

    (2) OUTPUT CON30 CON9 Printed Printed Signal Pin No. Signal Pin No. character character Oil lubrication DC12V D12V output 2 Power supply - DA output 0 DC24V DA output 1 Power supply Ground CON15 Printed Printed Signal Pin No. Signal Pin No.

  • Page 48

    (3) PAL (CON W) and MIF board (CON U) USB connector Conditions of application ・USB memory・・・・USB1.1 or USB2.0 or USB3.0 compatible USB memory ・Barcode reader (MIF only) Inapplicable devices ・USB device requiring an external power supply (including Computer devices) ・USB hard disk drive, keyboard, mouse ・USB memory with fingerprint authentication function or with security function ・USB memory with hub function ・Media reader...

  • Page 49

    3. Ratings value of input /output (1) Ratings value of the solenoid valve output Power supply Output maximum ratings current All output DC24V O1 to O2 2 total 0.5A or less O3 to O5 DC24V 8 total 0.5A or less O7 to OB 26 total 3.0A or less DC24V...

  • Page 50: Wiring Diagram Inside Control Box

    [15] Wiring diagram inside control box CON A: I/F BOARD POWER SUPPLY CON F: MAIN POWER SUPPLY “AC200V” CON C: SUB SERVO MOTOR CON B: MAIN SERVO MOTOR REGENERATIVE CON N: SUB SERVO ENCODER RESISTOR CON M: MAIN SERVO ENCODER PWR...

  • Page 51: Specifications

    Rated output 750W Main servo motor Rated speed 3,000rpm Rated output 400W Sub servo motor Rated speed 3,000rpm Model name PLK-J-CU-20 Control box Rated output DC 24V Power source 1KVA Range of rating ±10% voltage Condition Ambient 5°C to 35°C temperature...

  • Page 52

    Printed in Japan...

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