Mitsubishi MELDAS M600 Series Maintenance Manual
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Mitsubishi MELDAS M600 Series Maintenance Manual

Mitsubishi MELDAS M600 Series Maintenance Manual

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BNP-B2189B (ENG)
M600 Series
MAINTENANCE MANUAL

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Summary of Contents for Mitsubishi MELDAS M600 Series

  • Page 1 BNP-B2189B (ENG) M600 Series MAINTENANCE MANUAL...
  • Page 2 Precautions for Safety Always read the specifications issued by the machine maker, this manual, related manuals and attached documents before installation, operation, programming, maintenance or inspection to ensure correct use. Understand this numerical controller, safety items and cautions before using the unit. This manual ranks the safety precautions into "Danger", "Warning"...
  • Page 3 CAUTION 3. Items related to connection Do not apply voltages other than those indicated in this manual on the conductor. Doing so may lead to destruction or damage. Incorrect connections may damage the devices, so connect the cables to the specified connectors.

  • Page 4: Table Of Contents

    CONTENTS 1. OUTLINE ..........................1 1.1 System Configuration ....................1 1.1.1 Outline drawing ....................1 1.1.2 System outline drawing ..................2 1.1.3 Configuration ....................... 3 2. EXPLANATION OF MODULE FUNCTIONS ............... 6 2.1 HR111 Card ........................ 6 2.2 HR121 Card ........................ 8 2.3 HR081 Card ........................

  • Page 5: Outline

    1. OUTLINE 1.1 System Configuration 1. OUTLINE 1.1 System Configuration 1.1.1 Outline drawing The basic configuration of the M600 system is that with the control section attached to the LCD display section. (1) Front view LCD display section LCD display section (2) Rear view Control section Control section...

  • Page 6: System Outline Drawing

    1. OUTLINE 1.1 System Configuration 1.1.2 System outline drawing With the M600 system, connections are made with the drive section through a remote I/O separated from the control section as shown below. Control section External power supply PD25 Display section 24VDC 200VAC Operation section...

  • Page 7: Configuration

    1. OUTLINE 1.1 System Configuration 1.1.3 Configuration (1) Module configuration table The M600 system is configured of the modules shown below. Type Configuration module type Function Remarks Control section HR111 card Main CPU card 6MU001 HR121 card Man-machine interface card HR081 card Control power supply card CARD PC...
  • Page 8 1. OUTLINE 1.1 System Configuration Configuration Type Function Remarks module type HDD external MK1924FCV Hard disk unit FCU6-HD101 F140 cable HR121-HDD External HDD installation fitting & With heater cover Damping rubber 4 pieces Single supply PD25 External power supply parts Di: 16 points HR371 card Card-sized I/O...
  • Page 9 1. OUTLINE 1.1 System Configuration (2) Control section module configuration PC card HR841 card HR111 card Expansion card Cassette memory ＦＡＮ ＦＡＮ CARD ＰＣ F150 cable HR121 card HR121 card F150 cable HR081 card HR841 card ＦＡＮ – 5 –...

  • Page 10: Explanation Of Module Functions

    2. EXPLANATION OF MODULE FUNCTIONS 2.1 HR111 Card 2. EXPLANATION OF MODULE FUNCTIONS 2.1 HR111 Card [Block diagram] RISC DRAM Cassette Cassette memory memory (for maintenance) CBUS#1 CBUS#2 MAC401 CPU peripheral control PLC operation FLROM  ＲＴＣ SRAM RT#0 on PC base MAC402 External I/O interface RT#1...
  • Page 11 2. EXPLANATION OF MODULE FUNCTIONS 2.1 HR111 Card [Connector layout diagram] CBUS#1 CBUS#2 DC fan (for 5V) RT#2 RT#1 RT#0 TEST1&2 ENC#2 CF10 NCSYS NCLD1 NCRST CF11 WDER TEST 1 & 2 : Test pins for maintenance and service NCREST : NC reset (do not press during normal system operation) [Explanation of settings] NCSYS: System mode selection rotary switch...

  • Page 12: Hr121 Card

    2. EXPLANATION OF MODULE FUNCTIONS 2.2 HR121 Card 2.2 HR121 Card [Block diagram] RT-BUS 2-port RAM 10.4-inch color LCD TFT/STN CF12 General purpose serial RS-232-C I/F Mouse input Full keyboard input ISA-BUS 2.5inch ＨＤＤ ＣＡＲＤ ＰＣ 3.5ｉｎｃｈ ＦＤＤ [Explanation of functions] The HR121 card is the man-machine interface for the M635/M655 system, and has the following functions.
  • Page 13 2. EXPLANATION OF MODULE FUNCTIONS 2.2 HR121 Card [Connector layout diagram] ＣＡＲＤＰＣ ＨＤＤ ＰＣＲＳＴ ＨＤ ＩＳＰ ＣＦＤ ＣＦ１２ ＬＣＤ PCRST: Personal computer reset push-button switch [Explanation of LEDs] HD: Accessing hard disk LED (green) Refer to section 3.1 for details. –...

  • Page 14: Hr081 Card

    2. EXPLANATION OF MODULE FUNCTIONS 2.3 HR081 Card 2.3 HR081 Card [Block diagram] DCIN External power supply 5V/5A DC/DC 24VDC/3A (24V/5V) LG(GND) 3.3V/2A DC/DC (24V/3.3V) LG(GND) 12V/1.2A DC/DC (24V/12V) AG(GND) Voltage detection circuit Emergency stop switch EMG∗ signal EMG∗ signal generation circuit From PD25 CF01...
  • Page 15 2. EXPLANATION OF MODULE FUNCTIONS 2.3 HR081 Card [Connector layout diagram] This connector is not used. Ｆ Ａ Ｎ Ｂ Ａ Ｔ DC output OUT Battery Control signal IN/OUT Ｃ Ｈ Ｅ Ｃ Ｋ ５ ： Ｇ Ｎ Ｄ ４:External reset input ３...

  • Page 16: Hr841 Card

    [Connector layout diagram] PCMCIA <Specifications of card corresponding with PCMCIA slot> 1) Limited to 5V specification products. (3.3V specifications cannot be used.) 2) The max. current consumption is limited to 1A/slot. 3) Mitsubishi Electric recommended IC card – 12 –...

  • Page 17: Hr273 Card

    2. EXPLANATION OF MODULE FUNCTIONS 2.5 HR273 Card 2.5 HR273 Card [Block diagram] ＬＣＤ ＣＮ１ ＣＮ２ Booster circuit (1.7〜2.4V) ＣＮ３ (26〜28V) [Explanation of functions] The HR273 card is the interface for the STN-LCD signals of the M600 system, and has the following specifications.

  • Page 18: Hr371 Card

    2. EXPLANATION OF MODULE FUNCTIONS 2.6 HR371 Card 2.6 HR371 Card [Block diagram] ＣＦ３０ Di:16 points Do:16 points ＤＯ I/F Ｍ Ａ Ｃ ３ ０ ３ Remote communication to NC ＤＩ I/F ３ Channel No. data (connector slot setting 0 to 7) +24V Power supply [Explanation of functions]...

  • Page 19: Hr325, 327, 335, 337 Cards

    2. EXPLANATION OF MODULE FUNCTIONS 2.7 HR325, 327, 335, 337 Cards 2.7 HR325, 327, 335, 337 Cards [Block diagram] Connection with control section ＣＦ１０ Ｄｉ ＳＶ１ System 1 servo 32-point ＣＦ３１ machine input ＳＶ２ System 2 servo MAC303 ＥＮＣ Auxiliary encoder input Ｄｏ...
  • Page 20 2. EXPLANATION OF MODULE FUNCTIONS 2.7 HR325, 327, 335, 337 Cards [Connector layout diagram] CR31 24IN RAL1 5OUT RAL2 [Explanation of settings] CS1: Onboard RIO No. 1 channel No. setting rotary switch CS2: Onboard RIO No. 2 channel No. setting rotary switch <Setting method>...

  • Page 21: Floppy Disk

    2. EXPLANATION OF MODULE FUNCTIONS 2.8 Floppy Disk 2.8 Floppy Disk The FDD used in the M600 system has the following specifications. This FDD is compatible with the 2HD (2MB/1.6MB) and 2DD (1MB) recording types. [FD-235HG-7332 specifications] Applicable safety standards UL, CAS, TUV 2MB mode 1.6MB mode 1MB mode...

  • Page 22: Troubleshooting

    3. TROUBLESHOOTING 3.1 List of Unit LEDs 3. TROUBLESHOOTING 3.1 List of Unit LEDs (1) NC control section CBUS1 CBUS2 OPEN RS T DCIN DCOUT ENC2 PSEMG CF12 BATALM CF11 CF10 S Y S RS T [Explanation of LED functions] Status Name Function...
  • Page 23 3. TROUBLESHOOTING 3.1 List of Unit LEDs (2) Base I/O unit, card-sized I/O Base I/O unit CR31 RIO2 RIO1 DCIN 24IN RAL1 5OUT RAL2 Card-sized I/O 5IN RAL [Explanation of LED functions] Status Name Function Color Correspondence for error When normal During error 24IN During 24VDC input supply Green...

  • Page 24: Troubleshooting

    3. TROUBLESHOOTING 3.2 Troubleshooting 3.2 Troubleshooting 3.2.1 Confirmation of trouble state Confirm "when", "when doing what", and "what kind of" trouble occurred. (1) When? What time did the trouble occur? (2) When doing what? What was the NC operation mode? •...

  • Page 25: When In Trouble

    3.2.2 When in trouble If the system does not operate as planned or if there is any trouble in the operation, confirm the following points and then contact the Mitsubishi Service Center. – Examples of trouble – • The power is not ON.
  • Page 26 3. TROUBLESHOOTING 3.2 Troubleshooting (1) Problems related to the power supply The power does not turn ON. Cause Remedy The power cord is disconnected Check the cable between the NC unit and the external or loose. power supply, and between the external power supply and socket.
  • Page 27 The LCD display, backlight power Check the cable connections. If normal, the individual or HR121 card is damaged. module may be damaged. Contact the Mitsubishi Service Center. CAUTION Do not apply voltages other than those indicated in this manual on the connector.
  • Page 28 The LCD screen is disturbed and cannot be synchronized, or the characters are unrecognizable. Cause Remedy The card PC or HR121 card is Contact the Mitsubishi Service Center. damaged. (3) Problems related to operation section A specific key switch does not function.
  • Page 29 When none of the above causes Contact the Mitsubishi Service Center. apply: (5) Problems when starting the system The NC does not start up correctly. Cause...
  • Page 30 NC control section or the cable SH41 between the broken wires or the contact is remote I/Os. defective. The HR3OO card is defective. Contact the Mitsubishi Service Center, and then replace the card. The power supply system LED is not lit. Cause Remedy The 24IN LED is not lit.

  • Page 31: Daily Maintenance And Periodic Inspection And Maintenance

    4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.1 Maintenance Tools 4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.1 Maintenance Tools (1) Measuring instruments The following measuring instruments are used to confirm that the voltage is being supplied correctly to the NC unit, to confirm that the wiring to the NC unit is correct, and to carry out simple troubleshooting.

  • Page 32: Maintenance Items

    4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.2 Maintenance Items 4.2 Maintenance Items Maintenance is categorized into daily maintenance items (items to be carried at set intervals) and periodic maintenance (replacement of parts when life is reached). Some parts (HD, FDD, etc.) will not function in a hardware manner when the life is reached, so these should be replaced before the life is reached.

  • Page 33: Replacement Methods

    4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.3 Replacement Methods 4.3 Replacement Methods 4.3.1 Cable If the cable is replaced without turning the power OFF, the normal unit or peripheral devices could be damaged, and risks could be imposed. Disconnect each cable with the following procedures.
  • Page 34 4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.3 Replacement Methods b) For a flat cable type connector with claws, open the claws in the directions of the arrows, and pull the connector off. ①  Open ②  Pull c) For a flat cable type connector without claws, hold the connector with a thumb and forefinger, and pull the connector off.

  • Page 35: Durable Parts

    All data, such as the parameters and machining programs that need to be backed up when the power is turned OFF, are saved by a lithium battery installed in the control unit's battery holder. Battery ........ With ER6 connector (Toshiba with Mitsubishi specifications) Initial battery voltage ..3.6V Voltage at which voltage ..

  • Page 36: Backlight

    4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.3 Replacement Methods (2) Backlight A cold cathode tube is used for the light source (backlight) of the LCD panel. The life of the backlight is 10,000 hours/25°C. (Time for the brightness to drop to 50% of the initial value.) The life depends on the temperature, and when used continuously at low temperatures, the life will be shorter.

  • Page 37: Cooling Fan

    The system specifications are structured so that the temperature is detected, and when below the set temperature, the cooling fan does not function. Cooling fan ..MMF-04B05DM-R (DDK with Mitsubishi specifications) Cooling fan life ... 30,000 hours a) Replacement procedures Always replace the cooling fan with the control section power turned OFF.

  • Page 38: Hard Disk (Hdd)

    HDD....MK1924FCV (Toshiba) HDD life ....5 years or 20,000 power ON hours, whichever is sooner HDD unit..... FCU6-HD101-1 (Mitsubishi Electric) a) Replacement procedures <When built into control section> Always replace the HDD with the control section power turned OFF.
  • Page 39 4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.3 Replacement Methods <When built into control section> Control section Front cover Open the front cover of the control section. HDD installation fitting Damping rubber HDD fixing fitting F140 cable PCB section PCMCIA interface PCB (HR841) Fixing screw Leave 4 pins open...
  • Page 40 4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.3 Replacement Methods <When installed outside the control section: HDD unit> Control section Operation section F140 cable Heater power cable Fixing screws HDD unit Heater power cable HDD unit Heater power cable F140 cable 1-pin indication mark Leave 4 pins open...

  • Page 41: Floppy Disk (Fdd)

    4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.3 Replacement Methods (5) Floppy disk (FDD) Due to the hardware specifications, the FDD is installed outside of the control section. The FDD is used as a set with the man-machine interface PCB HR121, and is connected with an F130 cable.

  • Page 42: Unit

    4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.3 Replacement Methods 4.3.3 Unit (1) Control unit The basic configuration of the control unit is the type with the control section installed on the display section. a) Replacement procedures Always replace the control unit with the control section power turned OFF. ①...

  • Page 43: Control Section

    4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.3 Replacement Methods (2) Control section As the basic configuration, the control section is installed on the rear side of the display section. a) Replacement procedures Always replace the control section with the control section power turned OFF. ① Check that the control section power is turned OFF.

  • Page 44: Display Section (Lcd Panel)

    4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.3 Replacement Methods (3) Display section (LCD panel) The display section's LCD panel is installed on the escutcheon side of the control section's installation fitting. a) Replacement procedures Always replace the display section's LCD panel with the control section power turned OFF. ①...

  • Page 45: Base I/O Unit

    4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.3 Replacement Methods (4) Base I/O unit The base I/O unit is generally installed on the electric cabinet side. a) Replacement procedures Always replace the base I/O unit with the control section power turned OFF. ①...

  • Page 46: External Power Supply Unit (Pd25)

    4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.3 Replacement Methods (5) External power supply unit (PD25) The external power supply unit is the 24VDC power supply for the control section used for the system mounted with an HDD. This unit is generally installed in the electric cabinet. a) Replacement procedures Always replace the external power supply unit with the control section power turned OFF.

  • Page 47: Pcmcia Card

    4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.3 Replacement Methods (6) PCMCIA card In the system mounted with the PCMCIA interface PCB HR841, up to two commercial PCMCIA cards can be connected. Install the driver for the PCMCIA card to be used before starting the system. (Refer to the software operation manual and the instruction manual of the PCMCIA card being used on how to install the software.) a) Replacement procedures...

  • Page 48: Keyboard

    4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.3 Replacement Methods (7) Keyboard The keyboard is installed on the display section periphery. a) Replacement procedures Always replace the keyboard with the control section power turned OFF. ① Check that the control section power is turned OFF. (If the power is not OFF, turn it OFF.) ②...

  • Page 49: Control Pcb

    4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.3 Replacement Methods 4.3.4 Control PCB (1) Control section power supply PCB (HR081) The control section power supply PCB is supplied with 24VDC from an external source. This PCB generates the DC voltage required for each control PCB in the control section. a) Replacement procedures Always replace the control section power supply PCB with the control section power turned OFF.

  • Page 50: Pcmcia Interface Pcb (Hr841)

    4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.3 Replacement Methods (2) PCMCIA interface PCB (HR841) The PCMCIA interface PCB is used when connecting commercial PCMCIA cards. Depending on the hardware specifications, the PCB may be built into the control section. This PCB is used as a set with the man-machine interface PCB HR121, and is connected with the F150 cable.

  • Page 51: Backlight Power Supply Pcb

    4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.3 Replacement Methods (3) Backlight power supply PCB The backlight power PCB is supplied with 12VDC from the control section power supply. This PCB generates a high voltage AC voltage for lighting the backlight of the LCD panel. a) Replacement procedures Always replace the backlight power supply PCB with the control section power turned OFF.

  • Page 52: Lcd Signal Interface Pcb (Hr273)

    4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.3 Replacement Methods (4) LCD signal interface PCB (HR273) The LCD signal interface PCB is used to distribute the signals from the control section to the LCD panel. This PCB has a voltage booster circuit inside for adjusting the contrast. a) Replacement procedures Always replace the backlight power supply PCB with the control section power turned OFF.

  • Page 53: Expansion Pcb

    4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.3 Replacement Methods (5) Expansion PCB The expansion PCB is used to expand the system for adding a serial port, etc. (Refer to corresponding modules in section 1.1.3 and section 2, for details on the expansion PCB types and functions.) Up to two expansion PCBs can be added.

  • Page 54: Cassette Memory

    4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.3 Replacement Methods (6) Cassette memory The cassette memory is a PCB used to store the user PLCs and machining programs, and is installed on CBUS1 of the control section. (Refer to corresponding modules in section 1.1.3 and section 2, for details on the cassette memory types and functions.) a) Replacement procedures Always replace the cassette memory with the control section power turned OFF.

  • Page 55: Card-Sized I/O (Hr361, Hr371)

    4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.3 Replacement Methods (7) Card-sized I/O (HR361, HR371) The card-sized I/O is a machine input/output interface PCB used for mounting relay PCBs, etc., in the electric cabinet onto the control PCB. a) Replacement procedures Always replace the card-sized I/O with the control section power turned OFF.

  • Page 56: Cleaning And Handling

    4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.4 Cleaning and Handling 4.4 Cleaning and Handling 4.4.1 Escutcheon (1) Cleaning the escutcheon ① Follow the same procedures as described for replacing the display section (LCD panel) in section 4.3.3 (3), and open the display section so that the rear side of the escutcheon can be cleaned.
  • Page 57 4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.4 Cleaning and Handling b) Precautions for storage ① Store floppy disks that are not in use and the backup floppy disks in plastic cases. ② Do not place the floppy disk where it will be subject to direct sunlight or near heating appliances.
  • Page 58 4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.4 Cleaning and Handling (4) Troubleshooting FLD error Is the floppy disk correctly mounted? Correctly mount the floppy disk. Has an FLD error occurred? The floppy disk is defective. Was the floppy disk drive used at below freezing temperatures? Carry out warming operation until the...

  • Page 59: Hard Disk

    4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.4 Cleaning and Handling 4.4.3 Hard disk (1) Handling the hard disk drive a) Precautions for use ① Correct connect the cable. ② Do not touch the connector section with hands or metal. ③...

  • Page 60: Pcmcia Card

    4. DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 4.4 Cleaning and Handling potentiometer on the LCD signal interface PCB. 4.4.5 PCMCIA card (1) Handling the PCMCIA card The general precautions for handling the PCMCIA card are as described below. Refer to the instruction manual of the PCMCIA card being used for details. a) Precautions for use ①...
  • Page 61 Revision History Revision Date of revision Revision details ＊ 97/10/2 First edition was issued. 97/11/25 Mistakes were corrected. 01/9/17 Design of the cover and the back cover were changed. MODEL, MODEL CODE, and Manual No. were added on the back cover.

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