Mitsubishi Bnpb2203d MELDASMAGIC64 CONNECTION MANUAL User Ab25794e 8899 4345 81b7 Fa0ac8a9c1ab
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CNC 64 CONNECTION MANUAL BNP-B2203D(ENG) MELDASMAGIC is a registered trademark of Mitsubishi Electric Corporation. Microsoft and MS-DOS are registered trademarks of Microsoft Corporation U.S.A. Windows is a registered trademark of Microsoft Corporation U.S.A. IBM is a registered trademark of International Business Machines Corporation U.S.A. Other company and product names are trademarks or registered trademarks of the respective companies. i Introduction This manual is the MELDASMAGIC64 Connection Manual. MELDASMAGIC64 installation and connection methods are explained centered on the NC Card. Refer to the materials below for explanations concerning functions. MELDASMAGIC64 Setup Instruction Manual................................................................................ BNP-B2191 MELDASMAGIC64 Maintenance Manual ...................................................................................... BNP-B2207 MELDAS AC Servo and Spindle MDS-A/B Series Specifications Manual..................................... BNP-B3759 MELDAS AC Servo and Spindle MDS-C1 Series Specifications Manual...................................... BNP-C3000 MELDAS AC Servo and Spindle MDS-CH Series Specifications Manual ..................................... BNP-C3016 MELDAS AC Servo MDS-B-SVJ2 Series Specification Manual .................................................... BNP-B3937 MELDAS AC Servo MDS-B-SPJ2 Series Specification Manual .................................................... BNP-B2164 General items (1) Read this manual carefully before using MELDASMAGIC64. Please have a full understanding of product functions and performance, and use this product correctly. (2) All efforts possible have been made to describe any special handling in this manual. Items not described in this manual must be interpreted as "Not Possible". (3) When the details described in this instruction manual change, the sub-No. of the cover page instruction manual No. (*, A, B) will be changed. (4) The details described in this manual may change without notice. Mitsubishi may not be held responsible for errors in the contents described. About MELDASMAGIC64 (1) MELDASMAGIC64 includes the ISA NC Card compatible with the ISA bus, and the PCI NC Card compatible with the PCI bus. Either card can be selected. The user can structure a custom-made NC unit by inserting the NC Card supplied from Mitsubishi into the selected personal computer's expansion slot (ISA bus or PCI bus). NC Card ISA NC Card (ISA bus specifications) PCI NC Card (PCI bus specifications) HR621 FCU6-HR655 HR623 (2) The NC Card supplied by Mitsubishi realizes the equivalent environmental resistance (ambient temperature, noise resistance and vibration resistance) as conventional NC units. However, some environmental resistance equivalent to conventional NC units is not always guaranteed regarding personal computers presumed to be normally used in an office. Therefore, when selecting a personal computer, study this manual well and select an appropriate model responding to the required uses and applications. When required, execute the appropriate countermeasures. ii (3) Take care to the working environment when using MELDASMAGIC64. Working environment PCI NC Card Applicable personal computer Compatible OS ISA NC Card IBM PC/AT or compatible machine • • • • • • • Windows 98SE Windows 2000 Windows XP Windows 95 Windows 98 Windows 98SE Windows NT Workstation 4.0 • For Windows 95 Pentium 100MHz or faster (Pentium 150MHz or faster recommended) • For Windows 98, Windows 98SE, Windows NT Workstation 4.0 CPU Pentium 200MHz or faster (Pentium 233MHz or faster recommended) • For Windows 2000, Windows XP Pentium 300MHz or faster • For Windows 95, Windows 98 16MB or larger (24MB or larger recommended) • For Windows 98SE, Windows NT Workstation 4.0 24MB or larger (32MB or larger recommended) Memory • For Windows 2000 64MB or larger (128MB or larger recommended) • For Windows XP 128MB or larger Hard disk 20MB or more open space recommended Floppy disk One 3.5-type 1.44MB drive PCI bus (PCI bus Standards 2.0 or Expansion slot ISA bus higher) +3.3V (*1) 0.2A or more Electric 2.5A or more characteristics +5.0V +12.0V 0.7A or more 0.5A or more Time for +5.0V power voltage to drop from +4.5V to +4.0V when the Power drop characteristics power is turned OFF takes 1ms or more. (*1) When using the PCI NC Card, always use a personal computer that supplies +3.3V power to the PCI bus. (4) Heat radiation-countermeasures for personal computer A rise in the personal computer's internal temperature could cause NC Card damage or malfunction. Select a personal computer with a fan for circulating the heat in the personal computer, or a personal computer to which a fan can be mounted. (5) Personal computer vibration If the expansion slot on the personal computer vibrates greatly, a connector connection fault could occur and result in incorrect operations. Select a personal computer with a fitting for fixing the NC Card, or a personal computer that can be fixed.iii Precautions for Safety Always read the specifications issued by the machine maker, this manual, related manuals and enclosed documents before starting installation, operation, programming, maintenance or inspection to ensure correct usage. Thoroughly understand the basics, safety information and precautions of this numerical controller before using the unit. This manual ranks the safety precautions into "DANGER", "WARNING" and "CAUTION". DANGER When there is a great risk that the user could be subject to fatalities or serious injuries if handling is mistaken. WARNING When the user could be subject to fatalities or serious injuries if handling is mistaken. CAUTION When the user could be subject to injuries or when physical damage Note that even if the items is ranked as " CAUTION", incorrect handling could lead to serious results. Important information is described in all cases, so please observe the items. DANGER Not applicable in this manual. 1. Items related to prevention of electric shocks WARNING Do not open the front cover while the power is ON or during operation. Failure to observe this could result in electric shocks. Do not operate the device with the front cover removed. The high voltage terminals and charged sections will be exposed, and could result in electric shocks. Do not remove the front cover even when the power is OFF except for wiring work or periodic inspections. The controller and servo drive unit are charged internally and could result in electric shocks. Always wait at least 15 minutes after turning the power OFF and check the voltage with a tester, etc., before starting wiring work or inspections. Failure to observe this could result in electric shocks. Ground the 200V Series input controller, servo drive unit and servomotor with Class C or higher protective grounding, and the 400V Series input with Class D or higher protective grounding. All wiring work and inspections must be carried out by a qualified electrician. Wire the controller, servo drive unit and servomotor after installation. Failure to observe this could result in electric shocks. Do not operate the switches with wet hands, as this may lead to electric shocks. Do not damage, apply excessive stress, place heavy things on or sandwich the cables, as this may lead to electric shocks. iv 2. Items related to prevention of fires CAUTION Install the controller, servo drive unit, servomotor and regenerative resistor on non-combustible material. Installation directly on or near combustible materials could result in fires. If trouble occurs in the servo drive unit, shut off the power at the servo drive unit's input power side. Fires could result if large current continues to flow. When using the regenerative resistor, shut off the power with an error signal. The regenerative resistor could abnormally overheat and cause fires due to a regenerative transistor fault, etc. Incorrect wiring or connections could damage the device. 3. Items related to prevention of damage CAUTION Do not apply voltages other than those indicated in the Controller Connection Manual or Specifications Manual for Servo Drive Unit. Failure to observe this could lead to rupture, or damage, etc. Do not mistake the terminal connections. Failure to observe this could lead to rupture, or damage, etc. Do not mistake the polarity (+, –). Failure to observe this could lead to rupture, or damage, etc. Persons wearing medical devices, such as pacemakers, must not be near this unit. The medical device could be affected by electromagnetic waves. The servo drive unit fins, regenerative resistor and servomotor, etc., will be hot during operation and for a while after operation is stopped. Touching these sections could result in burns. v 4. General Precautions Always observe the following precautions. Incorrect handling could result in faults, injuries, or electric shocks, etc. (1) Transportation and installation CAUTION Correctly transport the product according to its weight. Use servomotor's suspension bolts only to transport the servomotor. Do not use suspension bolts of the servomotor on the machine to transport the machine. Do not stack products above the indicated limit. Do not hold cables, shaft or detector when transporting the servomotor. Do not suspend or hold the controller or servo drive unit by the connected wires or cables when transporting. Do not hold the front cover when transporting the controller or servo drive unit. The device could drop. When installing, always observe the installation direction and install on a place which can withstand the weight. Do not get on the product, or place heavy objects on it. Provide the specified distance between the controller, servo drive unit and inner surface of the control panel and between other devices. Do not install or operate a controller, servo drive unit or servomotor that is damaged or that has missing parts. Take care not to cut hands on the heat radiating fins or metal edges. Do not block the intake/outtake ports of the servomotor with cooling fan. Do not allow conductive foreign matter such as screws or metal chips or combustible foreign matter such as oil enter the controller, servo drive unit or servomotor. The controller, servo drive unit and servomotor are precision devices so do not drop or apply strong impacts on them. Do not install the controller operation board where it may be subject to cutting oil. vi (2) Wiring CAUTION Correctly wire this product. Failure to do so could result in servomotor runaway, etc. Do not install a phase advancing capacitor, surge absorber or radio noise filter on the output side of the servo drive unit. Correctly connect the output side (terminals U, V, W). The servomotor will not operate if incorrectly connected. Do not directly connect a commercial power supply to the servomotor. Failure to observe this could lead to faults. When using an inductive load such as relays, always connect a diode in parallel to the load as a noise measure. 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 installed on the DC relay for the control output signal. The signal will not be output due to fault and the protective circuit, such as emergency stop, will be disabled. Do not connect or disconnect the connection cables between each unit while the power is ON. Securely tighten the cable connector fixing screw or fixing mechanism. Insufficient fixing could result in dislocation during operation. Always treat the shield cables indicated in this manual with grounding measures such as cable clamps. Separate the signal wire from the drive line/power line when wiring. Use wires and cables having a wire diameter, heat resistance level and bending capacity that match the system. Ground the device according to the requirements of the country where the device is to be used. Wire the heat radiating fins and wires so that they do no contact. (3) Adjustments CAUTION Check and adjust each parameter before staring operation. Unpredictable operations could occur depending on the machine. Do not make marked adjustments or changes as the operation could become unstable. vii (4) Usage methods CAUTION Install an external emergency stop circuit so that the operation can be stopped and the power turns OFF immediately. A contactor, etc., must be used in addition to the shutoff function in the controller. Turn OFF the power immediately if any smoke, abnormal noise or odor is generated from the controller, servo drive unit or servomotor. Only a qualified technician may disassemble or repair this product. Do not modify this product. Use a noise filter, etc., to reduce the effect of electromagnetic disturbances. Electronic devices used near the servo drive unit could be affected by the electromagnetic disturbances. Use the controller, servo drive unit, servomotor and regenerative resistor in the designated combination. Failure to observe this could result in fires or faults. The brakes (magnetic brakes) assembled in the servomotor are used for holding, and must not be used for normal braking. There may be cases when the magnetic brakes cannot hold the state because of the life or machine structure (when ball screw and servomotor are coupled via a timing belt, etc.). Install a stopping device on the machine side so that safety can be ensured. After maintenance or inspection, always carry out a trial operation before starting actual operation. Do not move the machine's movable range during automatic operation. Do not place hands, feet or face near the spindle during rotation. Use the power (input voltage, input frequency, tolerable instantaneous power failure time) under the power specification conditions given in the Specifications. Turn the NC Card's power ON before turning the base I/O unit's power ON. If the base I/O unit's power is turned ON first, the current will be led to the NC Card from the connection cable. This will prevent the personal computer or the cards in the personal computer from starting up properly. (5) Measures during a fault CAUTION If a hazardous situation could arise during a power failure or product fault, use the servomotor with magnetic brakes or provide an external brake mechanism for holding purposes. Use a double circuit structure for the magnetic brake's operation circuit so that the brakes will activate even when the external emergency stop signal is issued. If an alarm occurs, remove the cause, and secure surrounding safety before resetting the alarm and restarting operation. The machine could suddenly restart when power is restored after an instantaneous power failure. Do not near the machine in this case. (Design the machine so that operator safety can be ensured even if the machine restarts.) viii (6) Maintenance, inspection and part replacement CAUTION The electrolytic capacitor's capacity will drop due to deterioration. To prevent secondary damage due to capacitor's faults, Mitsubishi recommends replacing the electrolytic capacitor after approx. five years when used in a general environment. Contact the Service Center or Service Station for replacements. Do not perform a megger test (insulation resistance measurement) during inspection. Save the machining programs, tool data and parameters with an input/output device before replacing the battery. Do not short-circuit, charge, overheat, incinerate or disassemble the battery. The hard disk unit has a service life, and must be replaced when the life is reached. Always back up the customer's data stored on the hard disk unit. The customer's data stored on the hard disk unit cannot be guaranteed. (7) Disposal CAUTION Handle this product as general industrial waste. Note that some of the MDS Series products use alternate Freon. These corresponding models must not be handled as general industrial waste and must always be returned to the Service Center or Service Station. (Corresponding models have heat radiating fins on the back of the unit.) Do not disassemble the controller, servo drive unit or servomotor parts. Collect and dispose of the spent batteries according to local laws. (8) General precautions CAUTION To explain the details, drawings given in this instruction manual, etc., may show the unit with the cover or safety partition removed. When operating the product, always install the cover or partitions at their original position, and operate as indicated in the instruction manual, etc. ix CONTENTS 1. Outline.................................................................................................................................. 1 2. Configuration ...................................................................................................................... 2.1 System Configuration ..................................................................................................... 2.2 List of Configuration Units .............................................................................................. 2 2 3 3. Installation ........................................................................................................................... 3.1 General Specifications ................................................................................................... 3.2 General System Diagram ............................................................................................... 3.3 Installation ...................................................................................................................... 3.3.1 Installation Direction and Spacing........................................................................... 3.3.2 Prevention of Foreign Matter Entry......................................................................... 3.3.3 Heat Radiation Countermeasures .......................................................................... 3.3.4 Noise Countermeasures......................................................................................... 5 5 6 8 8 9 10 12 4. NC Card Connection ........................................................................................................... 4.1 NC Card Connection System Diagram........................................................................... 4.2 NC Card Part Names ..................................................................................................... 4.2.1 Names of HR621 Card Parts.................................................................................. 4.2.2 Names of HR623 Card Parts.................................................................................. 4.2.3 Names of FCU6-HR655 Unit Parts......................................................................... 4.3 Control Unit Connector Pin Assignment ......................................................................... 4.4 ISA NC Card Mounting ................................................................................................... 4.4.1 Before Mounting the ISA NC Card.......................................................................... 4.4.2 ISA NC Card Mounting Procedure.......................................................................... 4.5 PCI NC Card Mounting................................................................................................... 4.5.1 Before Mounting the PCI NC Card ......................................................................... 4.5.2 PCI NC Card Mounting Procedure ......................................................................... 15 15 16 16 17 18 19 23 23 24 27 27 28 5. Base I/O Unit Connection ................................................................................................... 5.1 Base I/O Unit Outline ..................................................................................................... 5.2 Base I/O Connection System Drawing ........................................................................... 5.3 Base I/O Unit Part Names .............................................................................................. 5.4 Base I/O Unit Connector Pin Assignment....................................................................... 5.5 Base I/O Unit Input/Output Specifications ...................................................................... 5.5.1 Rotary Switch Settings ........................................................................................... 5.5.2 RIO1 Terminator ..................................................................................................... 5.5.3 CF31, CF32 Input Circuit........................................................................................ 5.5.4 CF33, CF34 Output Circuit ..................................................................................... 5.5.5 Specifications of ADD ON PCB Connected to CR31 .............................................. 5.5.6 Connection of Base I/O Unit Power Supply ............................................................ 5.5.7 Examples of DI/DO Connection.............................................................................. 5.5.8 Connection of Servo Drive Unit .............................................................................. 5.5.9 Connection of Spindle Encoder .............................................................................. 5.5.10 Connection of Sensor Signal ................................................................................ 31 31 32 33 35 38 38 38 39 39 39 40 41 42 42 43 6. Relay Card Connection....................................................................................................... 6.1 Relay Card Outline ......................................................................................................... 6.2 Relay Card Connection System Diagram....................................................................... 6.3 Relay Card Part Names ................................................................................................. 6.4 Relay Card Connector Pin Assignment .......................................................................... 6.5 Relay Card Input/Output Specifications.......................................................................... 6.5.1 Relay Card Power Connection ............................................................................... 6.5.2 Emergency Stop Connection .................................................................................. 6.5.3 Connection of Spindle Encoder .............................................................................. 6.5.4 Manual Pulse Generator Connection ..................................................................... 6.5.5 RS-232C Device Connection.................................................................................. 6.6 Installation on the Base I/O Unit..................................................................................... 44 44 44 45 46 48 48 48 49 49 49 50 x 7. Remote I/O Unit Connection .............................................................................................. 7.1 Outline of Remote I/O Unit ............................................................................................. 7.2 Names of Each Remote I/O Unit Section ....................................................................... 7.3 Connection of Remote I/O Power................................................................................... 7.4 Outline of Digital Signal Input Circuit .............................................................................. 7.5 Outline of Digital Signal Output Circuit ........................................................................... 7.6 Outline of Analog Signal Output Circuit .......................................................................... 7.7 Outline of Analog Signal Input Circuit............................................................................. 7.8 Connection of FCUA-DX10*/13*/14* Unit and Machine Control Signal .......................... 7.9 Connection of FCUA-DX11* Unit and Machine Control Signal....................................... 7.10 Connection of FCUA-DX12* Unit and Machine Control Signal..................................... 7.11 Connection of FCUA-DX13* Unit and Handle .............................................................. 7.12 Outline of FCUA-DX13* Unit Pulse Input Circuit .......................................................... 7.13 Connection of FCUA-DX14* Unit and Analog Input/Output Signal ............................... 7.14 Setting of Channel No. when Using Multiple Remote I/O Units.................................... 7.15 Remote I/O Unit Input/Output Signal Cables................................................................ 51 51 52 53 54 56 57 58 59 61 63 65 66 67 68 70 Appendix 1 Outline Drawings ................................................................................................ Appendix 1.1 ISA NC Card Outline Drawing (HR621) ....................................................... Appendix 1.2 ISA NC Card Outline Drawing (HR623) ....................................................... Appendix 1.3 PCI NC Card Outline Drawing (FCU6-HR655) ............................................ Appendix 1.4 Base I/O Unit Outline Drawing ..................................................................... Appendix 1.5 Relay Card (independent installation) Outline Drawing ............................... Appendix 1.6 Base I/O Unit + Relay Card (add-on) Outline Drawing................................. Appendix 1.7 Remote I/O Unit Outline Drawing................................................................. Appendix 1.8 Manual Pulse Generator (HD60) Outline Drawing ....................................... Appendix 1.9 Spindle Encoder (OSE-1024-3-15-68) Outline Drawing............................... Appendix 1.10 Grounding Plate and Clamp Fitting Outline Drawings.................................. 71 71 71 72 73 74 75 76 77 78 79 Appendix 2 Cable Manufacturing Drawings ......................................................................... 80 Appendix 2.1 SH21 cable (Servo drive unit) ...................................................................... 82 Appendix 2.2 SH41 cable (Remote I/O unit)...................................................................... 83 Appendix 2.3 R031 cable (Analog signal input/output) ...................................................... 84 Appendix 2.4 R041 cable (Manual pulse generator).......................................................... 85 Appendix 2.5 R042 cable (Manual pulse generator).......................................................... 86 Appendix 2.6 R211 cable (Remote I/O unit) ..................................................................... 87 Appendix 2.7 R220 cable (+24VDC input)......................................................................... 88 Appendix 2.8 R300 cable (Machine input/output) .............................................................. 89 Appendix 2.9 R301 cable (Machine input/output) .............................................................. 90 Appendix 2.10 F010 cable (NC Card).................................................................................. 91 Appendix 2.11 F011 cable (NC Card) .................................................................................. 92 Appendix 2.12 F020 cable (Manual pulse generator) ........................................................ 93 Appendix 2.13 F021 cable (Manual pulse generator) ........................................................ 94 Appendix 2.14 F022 cable (Manual pulse generator) ........................................................ 95 Appendix 2.15 F040 cable (Spindle encoder) ...................................................................... 96 Appendix 2.16 F041 cable (Spindle encoder) ...................................................................... 97 Appendix 2.17 F070 cable (+24VDC input) ......................................................................... 98 Appendix 2.18 F390 cable (RS232C) .................................................................................. 99 Appendix 2.19 ENC-SP1 cable (Spindle drive unit) ........................................................... 100 Appendix 2.20 Table of Connector Sets ............................................................................. 101 Appendix 3 Parts for EMC Measures..................................................................................... Appendix 3.1 Shield Clamp Fitting..................................................................................... Appendix 3.2 Ferrite Core.................................................................................................. Appendix 3.3 Surge Protector............................................................................................ Appendix 3.4 Selection of Stabilized Power Supply........................................................... xi 102 102 103 104 107 1. Outline 1. Outline This manual explains MELDASMAGIC64 installation and connection methods centered on the NC Card. By installing this NC Card in a personal computer expansion slot (ISA bus or PCI bus), and connecting a servo drive unit, servomotor, etc., a custom-made NC unit can be constructed. This manual assumes that all functions are added, but the actually delivered device may not have all functions. Refer to the following documents for explanations on the functions. MELDASMAGIC64 Setup Instruction Manual........................................................................ BNP-B2191 MELDASMAGIC64 Maintenance Manual .............................................................................. BNP-B2207 MELDAS AC Servo and Spindle MDS-A/B Series Specifications Manual ............................ BNP-B3759 MELDAS AC Servo and Spindle MDS-C1 Series Specifications Manual.............................. BNP-C3000 MELDAS AC Servo and Spindle MDS-CH Series Specifications Manual ............................. BNP-C3016 MELDAS AC Servo MDS-B-SVJ2 Series Specification Manual ............................................ BNP-B3937 MELDAS AC Servo MDS-B-SPJ2 Series Specification Manual ............................................ BNP-B2164 1 2. Configuration 2.1 System Configuration 2. Configuration 2.1 System Configuration Prepared by machine tool manufacturer NC CARD Panel computer Desktop personal computer or Prepared by machine tool manufacturer Mouse Keyboard NC RD CA Floppy disk drive ISA NC Card HR621/HR623 PCI NC Card FCU6-HR655 Base I/O unit (FCU6-DX2**, 3**, 4**) F010 cable External power (24VDC supply) F070 cable (R220 cable) F011 cable SH21 cable Externalpower (24VDC supply) Relay card (HR682) F070 cable (R220 cable) SH41 cable (R211 cable) F070 cable (R220 cable) Servo drive unit/ spindle drive unit MDS-B-V1/V2 MDS-C1-V1/V2 MDS-B-SVJ2 MDS-B-SP MDS-B-SPJ2 MR-J2-CT R300/R301 cable F020/F021/F022 cable Remote I/O unit Manual pulse generator #1 #2 #3 Machine electric cabinet External emergency stop switch RS-232C device (Note) Only the DC code (X ON/OFF) method handshake is possible Servomotor/spindle motor 2 2. Configuration 2.2 List of Configuration Units 2.2 List of Configuration Units 1. NC Card Type HR621 NC Card installed in an ISA bus personal computer HR623 NC Card installed in an ISA bus personal computer FCU6-HR655 NC Card installed in an PCI bus personal computer 2. Configuration elements HR621 HR623 HR183 HR655 Details CPU PCB CPU PCB CPU PCB I/F PCB I/O unit (1) Type HR682 HANDLE, ENC, RS-232C, emergency stop switch input I/F RS-232C uses only the DC code (X ON/OFF) method handshake. FCU6-DX210 DI (sink/source)/DO (sink) = 48/48 With servo, RIO, SKIP, ENC I/F FCU6-DX310 DI (sink/source)/DO (sink) = 80/64 With servo, RIO, SKIP, ENC I/F FCU6-DX320 DI (sink/source)/DO (sink) = 80/64 With servo, RIO, SKIP, ENC I/F Analog output 1 point FCU6-DX330 DI (sink/source)/DO (sink) = 48/48 With servo, RIO, SKIP, ENC I/F Manual pulse 2ch FCU6-DX340 DI (sink/source)/DO (sink) = 48/48 With servo, RIO, SKIP, ENC I/F Analog input 4 points, analog output 1 point FCU6-DX220 DI (sink/source)/DO (sink) = 64/64 With servo, RIO, SKIP, ENC I/F FCU6-DX410 DI (sink/source)/DO (sink) = 96/80 With servo, RIO, SKIP, ENC I/F FCU6-DX420 DI (sink/source)/DO (sink) = 96/80 With servo, RIO, SKIP, ENC I/F Analog output 1 point FCU6-DX430 DI (sink/source)/DO (sink) = 64/64 With servo, RIO, SKIP, ENC I/F Manual pulse 2ch FCU6-DX440 DI (sink/source)/DO (sink) = 64/64 With servo, RIO, SKIP, ENC I/F Analog input 4 points, analog output 1 point FCU6-DX211 DI (sink/source)/DO (source) = 48/48 With servo, RIO, SKIP, ENC I/F FCU6-DX311 DI (sink/source)/DO (source) = 80/64 With servo, RIO, SKIP, ENC I/F FCU6-DX321 FCU6-DX331 FCU6-DX341 FCU6-DX221 FCU6-DX411 FCU6-DX421 FCU6-DX431 FCU6-DX441 Configuration elements HR682 HR325 Aluminum die cast HR325 RX323-1 Aluminum die cast HR325 RX323 Aluminum die cast HR325 RX331 Aluminum die cast HR325 RX341 Aluminum die cast HR327 Aluminum die cast HR327 RX323-1 Aluminum die cast HR327 RX323 Aluminum die cast HR327 RX331 Aluminum die cast HR327 RX341 Aluminum die cast HR335 Aluminum die cast HR335 RX324-1 Aluminum die cast DI (sink/source)/DO (source) = 80/64 HR335 With servo, RIO, SKIP, ENC I/F RX324 Analog output 1 point Aluminum die cast DI (sink/source)/DO (source) = 48/48 HR335 With servo, RIO, SKIP, ENC I/F RX331 Manual pulse 2ch Aluminum die cast DI (sink/source)/DO (source) = 48/48 HR335 With servo, RIO, SKIP, ENC I/F RX341 Analog input 4 points, analog output Aluminum die cast 1 point DI (sink/source)/DO (source) = 64/64 HR337 With servo, RIO, SKIP, ENC I/F Aluminum die cast DI (sink/source)/DO (source) = 96/80 HR337 With servo, RIO, SKIP, ENC I/F RX324-1 Aluminum die cast DI (sink/source)/DO (source) = 96/80 HR337 With servo, RIO, SKIP, ENC I/F RX324 Analog output 1 point Aluminum die cast DI (sink/source)/DO (source) = 64/64 HR337 With servo, RIO, SKIP, ENC I/F RX331 Manual pulse 2ch Aluminum die cast DI (sink/source)/DO (source) = 64/64 HR337 With servo, RIO, SKIP, ENC I/F RX341 Analog input 4 points, analog output Aluminum die cast 1 point 3 Details With metal spacers. Add-on to FCU6-DX2** possible. Base PCB: DI (sink/source)/DO (sink) = 48/48 Add-on PCB: DI (sink/source)/DO (sink) = 32/16 Base PCB: DI (sink/source)/DO (sink) = 48/48 Add-on PCB: DI (sink/source)/DO (sink) = 32/16 Analog output 1 point Base PCB: DI (sink/source)/DO (sink) = 48/48 Add-on PCB: Manual pulse generator 2ch Base PCB: DI (sink/source)/DO (sink) = 48/48 Add-on PCB: Analog input 4 points, analog output 1 point Base PCB: DI (sink/source)/DO (sink) = 64/64 Add-on PCB: DI (sink/source)/DO (sink) = 32/16 Base PCB: DI (sink/source)/DO (sink) = 64/64 Add-on PCB: DI (sink/source)/DO (sink) = 32/16 Analog output 1 point Base PCB: DI (sink/source)/DO (sink) = 64/64 Add-on PCB: Manual pulse generator 2ch Base PCB: DI (sink/source)/DO (sink) = 64/64 Add-on PCB: Analog input 4 points, analog output 1 point Base PCB: DI (sink/source)/DO (source) = 48/48 Add-on PCB: DI (sink/source)/DO (source) = 32/16 Base PCB: DI (sink/source)/DO (source) = 48/48 Add-on PCB: DI (sink/source)/DO (source) = 32/16 Analog output 1 point Base PCB: DI (sink/source)/DO (source) = 48/48 Add-on PCB: Manual pulse generator 2ch Base PCB: DI (sink/source)/DO (source) = 48/48 Add-on PCB: Analog input 4 points, analog output 1 point Base PCB: DI (sink/source)/DO (source) = 64/64 Add-on PCB: DI (sink/source)/DO (source) = 32/16 Base PCB: DI (sink/source)/DO (source) = 64/64 Add-on PCB: DI (sink/source)/DO (source) = 32/16 Analog output 1 point Base PCB: DI (sink/source)/DO (source) = 64/64 Add-on PCB: Manual pulse generator 2ch Base PCB: DI (sink/source)/DO (source) = 64/64 Add-on PCB: Analog input 4 points, analog output 1 point 2. Configuration 2.2 List of Configuration Units 2. I/O unit (2) Type RX323-1 RX323 FCUA-DX100 DI (sink/source)/DO (sink)=32/16 DI (sink/source)/DO (sink)=32/16 Analog output 1 point DI (sink/source)/DO (source)=32/16 DI (sink/source)/DO (source)=32/16 Analog output 1 point Manual pulse generator 2ch Analog input 4 points, Analog output 1 point DI (sink/source)/DO (sink)=32/32 FCUA-DX110 DI (sink/source)/DO (sink)=64/48 FCUA-DX120 DI (sink/source)/DO (sink)=64/48 Analog output 1 point FCUA-DX130 DI (sink/source)/DO (sink)=32/32 Manual pulse 2ch FCUA-DX140 DI (sink/source)/DO (sink)=32/32 Analog input 4 points, Analog output 1 point FCUA-DX101 DI (sink/source)/ DO (source)=32/32 DI (sink/source)/ DO (source)=64/48 RX324-1 RX324 RX331 RX341 FCUA-DX111 FCUA-DX121 DI (sink/source)/ DO (source)=64/48 Analog output 1 point FCUA-DX131 DI (sink/source)/ DO (source)=32/32 Manual pulse 2ch DI (sink/source)/ DO (source)=32/32 Analog input 4 points, Analog output 1 point FCUA-DX141 3. Configuration elements RX323-1 RX323 Add-on PCB Add-on PCB RX324-1 Add-on PCB RX324 Add-on PCB RX331 RX341 Add-on PCB Add-on PCB RX311 Case RX311 RX321-1 Case RX311 RX321 Base PCB: DI (sink/source)/DO (sink)=32/32 Case RX311 RX331 Case RX311 RX341 Case RX312 Case RX312 RX322-1 Case RX312 RX322 Case RX312 RX331 Case RX312 RX341 Base PCB: DI (sink/source)/DO (sink)=32/32 Add-on PCB: DI (sink/source)/ DO (sink)=32/16 Base PCB: DI (sink/source)/DO (sink)=32/32 Add-on PCB: DI (sink/source)/ DO (sink)=32/16 Analog output 1 point Base PCB: DI (sink/source)/DO (sink)=32/32 Add-on PCB: Manual pulse generator 2ch Base PCB: DI (sink/source)/DO (sink)=32/32 Add-on PCB: Analog input 4 points, analog output 1 point Base PCB: DI (sink/source)/DO (source)=32/32 Base PCB: DI (sink/source)/DO (source)=32/32 Add-on PCB: DI (sink/source)/ DO (source)=32/16 Base PCB: DI (sink/source)/DO (source)=32/32 Add-on PCB: DI (sink/source)/ DO (source)=32/16 Analog output 1 point Base PCB: DI (sink/source)/DO (source)=32/32 Add-on PCB: Manual pulse generator 2ch Base PCB: DI (sink/source)/DO (source)=32/32 Add-on PCB: Analog input 4 points, analog output 1 point Case Peripheral devices Type Configuration elements HD60C Manual pulse generator HD60C-1 Manual pulse generator Grounding plate D Grounding plate E 4. Details Details Without MELDAS logo With MELDAS logo Grounding plate D set Grounding plate E set Operation unit options Type FCU6-HR211 FCU6-HR251 I/O branch plate IC card interface Configuration elements HR211 card HR251 card 4 Details 3. Installation 3.1 General Specifications 3. Installation 3.1 General Specifications NC Card peripheral environment conditions Type name HR621/HR623 General specifications Unit name FCU6-HR655 NC Card 0~55°C During operation 40~75% RH (with no dew condensation) During storage 40~75% RH (with no dew condensation) -20~60°C Working atmosphere No corrosive gas or dust 3.3VDC ± 5% Power specifications – 5VDC ± 2% Power voltage 12VDC ± 2% 3.3V Current consumption 24VDC ± 5% Ripple ± 5% (P-P) 0.2A (max) – 2.5A (max) 0.5A (max) – 0.7A (max) 24V Power drop characteristics – – 0.5A (max) Personal computer 5V: 4.5V →4.0V is 1ms or more (*1) – 19W Unit size (*2) – 5V 12V Heating value (*1) Relay card During operation Ambient temperature During storage Ambient humidity HR682 22W 248.9×107.6×20 (mm) 12W 174.63×106.68×21 (mm) 115×156×30 (mm) (*2) If these characteristics are not satisfied, the NC Card cannot back up the absolute position information of the machine position when the power is turned OFF. Excluding spacers Environmental conditions in electric cabinet Type name FCU6-DX210, FCU6-DX211 Power specifications General specifications Unit name During operation Ambient temperature During storage Ambient humidity 0~55°C -20~60°C During operation 45~75% RH (with no dew condensation) During storage 45~80% RH (with no dew condensation) Vibration resistance 4.9m/s2 or less (during operation) Shock resistance 29.4m/s2 or less (during operation) Working atmosphere No corrosive gas or dust 24VDC ± 5% Ripple ± 5% (P-P) Power voltage Current consumption Heating value 5V 1A (max), 24V 3.6A (max) (*3) 5V 1A (max), 24V 4.8A (max) (*3) 90W (*3) 110W (*3) Mass 2.0kg Unit size (*3) FCU6-DX220, FCU6-DX221 Base I/O unit 220×168×35 (mm) When all DO points are ON 5 3. Installation 3.2 General System Diagram 3.2 General System Diagram RST 3-phase 200V-230VAC : Machine tool manufacturer -prepared parts No-fuse breaker (NFB) ON OFF MC MC MC Stabilized power supply No-fuse braker (NFB) Display unit No-fuse braker Noise (NFB) filter Transformer 200VAC: 100VAC +24VDC FG FG Keyboard Pointing device RS-232C device Personal computer main unit Relay card HR682 NC Card HR621/HR623/ FCU6-HR655 F011 CF61 CF61 RS232C HANDLE DCIN EMG1 F390 (Not e) The power voltage depends on the personal computer specifications. 24VDC F040/F041 ENC#2 F010 CF10 (Note) Only the DC code (X ON/OFF) method handshake is possible for the RS-232C. F020/F021/F022 2nd spindle encoder Manual pulse generator (max. 3 channels) F070 (FCUA-R220) F070 (FCUA-R220) 24VDC Emergency stop switch CF10 24VDC CF31 CF32 Base I/O unit CF33 FCU6-DX2**CF34 F070 (FCUA-R220) DCIN (DX3**) (DX4**) SV1 SV2 RIO1 RIO ENC1 R301 DI R301 DI R301 DO R301 DO Machine electric cabinet F040/F041 Sensor contact, max. 8 points SKIP 1st spindle encoder RIO2 (for expansion) Cable clamp FG SH21 NC servo/spindle drive unit MDS-B-V1/V2 MDS-B-SVJ2 MDS-B-SP MDS-B-SPJ2 MDS-C1-V1/V2 Auxiliar y axis MR-J2- CT SH21 Terminator R- TM Remote I/O unit FCUA-DX1** DCIN RIO1 RIO2 SH41(FCUA-R211) F070 (FCUA-R220) 24VDC Machine control relay/contact R R To the next SH41 remote (FCUA-R211) I/O unit Terminator R- TM Note) The remote I/O unit can be extended up to six stations. Note that when an add-on PCB is mounted (DX3**, DX4**), the remote I/O unit can be extended up to 5 stations. CAUTION Separate the signal wire from the drive line/power line when wiring. 6 3. Installation 3.2 General System Diagram Example of connection when using V1/V2 in the drive section RS T Connection to base I/O unit SV1 and SV2 Note (1) Servo drive unit MDS-B/C1 Series SH21 cable Note (2) SH21 cable CN1A CN1B Terminator A-TM Servo drive unit MDS-B/C1 Series SH21 cable CN4 AC servomotor SM PG P N R0 S0 U V W E CN2 CN4 U V W E PG MDS-A-BT-4(4 axes) MDS-A-BT-2(2 axes) P N R0 S0 MC1 AC servomotor SM Battery unit CN1A CN1B Power supply unit CN2 R S T E Motor end detector Motor end detector MC B-AL (Note) (1) Drive section connections differ according to the configuration of the servo drive unit and motor used. (2) When connecting the spindle drive unit, set the axis No. to the value after the last servo axis. (3) Connect the last axis (the axis to be connected to the battery unit) to the power supply unit. (4) When using a terminator, connect to the last axis. (5) Always wire the control unit's signal wire away from the drive section's drive lines/power lines. CAUTION Separate the signal wire from the drive line/power line when wiring. 7 3. Installation 3.3 Installation 3.3 Installation 3.3.1 Installation Direction and Spacing Each unit is installed in a sealed structure electric cabinet as a principle. Observe the following points when installing into the electric cabinet. (1) Install each unit vertically, so that it is visible from the front. (2) Consider the heat radiation and wiring of each unit. Refer to the following drawing, and secure space for ventilation. (3) Install the personal computer main unit paying particular attention to the specification conditions of the selected personal computer. Top 100mm or more (heat radiation space) Remote I/O unit Servo drive unit Base I/O unit Relay card MI TSUB ISHI MI TSUB ISHI 0 Spindle drive unit 30mm or more 0 ENC1 SKIP DCIN CF10 SV2 SV1 CR31 CF31 CF32 CF33 CF34 HANDLE RI02 DCIN RI01 EMG2 CF61 RS232C EMG1 ENC#2 10mm or more 10mm or more 10mm or more 150mm or more (heat radiation and wiring space) 10mm or more 15mm or more (wiring space) 10mm or more 15mm or more (wiring space) Bottom (Note) The relay card can be added on to the base I/O unit. Refer to "6.6 Installation to the Base I/O Unit" for the installation method when adding on. CAUTION Always observe the direction of installation. 8 3. Installation 3.3 Installation 3.3.2 Prevention of Foreign Matter Entry (1) The inside of each unit is densely mounted, and is sensitive to dust, etc. Always design a sealed structure electric cabinet, and execute the following measures. Carry out dust-proofing and oil-proofing measures such as sealing the cable inlets with packing. Be particularly careful that outside air does not enter the electric cabinet through heat radiation holes, etc. Seal all gaps. Securely install the door packing. Always install packing around any back cover (when present). Oil can easily accumulate in screw holes on top of the electric cabinet and penetrate into the electric cabinet. Therefore, carry out special countermeasures such as using oil-proof packing. Metal fittings Cable Packing Cable inlet (example) (2) After installing each unit, avoid any tool machining in the area surrounding those units. Cutting chips, etc., may adhere to electronic parts and cause a failure. (3) Design the electric cabinet so the internal temperature will rise no more than 10°C (target value 5°C or less) over the ambient temperature, and will stay within the temperature conditions of the personal computer, NC Card, etc. (Refer to "3.3.3 Heat Radiation Countermeasures" for details.) Use a panel cooler when required. (4) The personal computer display unit may not operate normally due to external magnetic fields. Separate magnetism producing sources (transformers, fans, magnetic switches, solenoid relays, magnet stands, magnetic workpieces, power lines flowing a large current, etc.) from the display unit by 200mm or more. Note that the magnetism produced by these magnetism producing sources differs individually, and will also differ according to the installation direction, etc. Therefore, the display unit may not operate properly even when separated by 200mm or more from these sources. When determining the layout of magnetism producing sources, also consider the direction, etc., of the magnetism produced, and finally confirm by actual operation of the machine. CAUTION Make sure that conductive foreign matter (screws, metal pieces, etc.) and flammable foreign matter (oil, etc.) does not enter inside any unit. 9 3. Installation 3.3 Installation 3.3.3 Heat Radiation Countermeasures In normal NC units, the electric cabinet thermal design is so the electric cabinet ambient temperature is a 0 to 45°C usage condition, and the electric cabinet internal temperature rise is 10°C. However, these conditions do not necessarily apply in MELDASMAGIC64. This is because the operation of all Mitsubishi-supplied units, including the NC Card, is guaranteed up to 55°C, but the operation of the personal computer is not necessarily guaranteed up to 55°C. Thus, the electric cabinet ambient temperature must first be determined as shown below. (1) Determine the electric cabinet ambient temperature Ta. Ex. 0 to 35°C (2) Determine the internal temperature rise ∆T. Ex. 5°C (3) Select a personal computer. When Ta max. = 35°C and ∆T = 5°C, the personal computer must have a guaranteed operating temperature of 40°C or more (45°C or more for a margin of safety). (4) In this example, the average temperature in the electric cabinet will be 40°C or less according to (1) and (2). (Note) 1. When heat accumulates in upper areas, etc., of the unit, circulate the air inside the electric cabinet using a circulation fan. 2. Use an electric cabinet cooler when required. Use an electric cabinet cooler type that does not take outside air into the electric cabinet. 3. If the personal computer's heat builds up in the personal computer, circulate the air in the personal computer with a fan. Back fan Front fan NC card 10 3. Installation 3.3 Installation Please refer to following method for heat radiation countermeasures method. Example of heat radiation countermeasures (1) Electric cabinet ambient temperature : Ta (2) Internal temperature rise value : ∆Td (The value for the conventional NC is 10°C, but this temperature must be set to 10°C or less (target value 5°C) for the MELDASMAGIC64.) (3) Average temperature in electric cabinet : Ta+ ∆Td Procedures for heat design and verification Calculate total heat generation of each mounted unit (W) (1) Refer to "3.1 General Specifications" for the heat generated by each unit. (2) Enclosed electric cabinet (thin steel plate) cooling capacity calculation equation W1 = U × A × ∆Td U : 6W/m2 × °C with internal circulation fan 4W/m2 × °C W≤W1 Comparison of W and W1 without internal circulation fan A : Effective heat radiation area (m2) (Area where heat can be radiated from W>W1 electric cabinet) Selection of heat exchanger When calculating the effective heat radiation area, do not include the parts that Mounting design contact other objects. (3) Points of caution for heat radiation Collection of internal temperature rise countermeasures when designing mounting distribution data state * Consider convection in electric cabinet (eliminate heat spots) ∆Tm ≤ ∆Td * Collect hot air at suction port in heat Evaluation exchanger panel. (4) Evaluation standards for internal temperature rise distribution data ∆Tm > ∆Td ∆Tm (average value) ≤ ∆Td Improvements ∆Tm max (maximum value) ≤ (∆Td + 5) °C R (inconsistency ∆Tm max - ∆Tm min) ≤ 6°C (Evaluate existence of heat spots) Completion ∆Tm: Internal temperature rise measurement value Mounting example and introduction to temperature (∆T) measurement locations (reference) Calculate electric cabinet’s cooling capacity (W1) : Temperature rise measurement points (example) Internal air flow Relay panel, etc. Air inlet Heat exchanger External air flow Air outlet 11 3. Installation 3.3 Installation 3.3.4 Noise Countermeasures (1) Connection of frame ground (FG) The frame should basically be grounded at one earth point. When relaying through the grounding plate in the middle of the connection route, separate the desktop personal computer/panel personal computer from the remote I/O unit, and the base I/O unit from the servo drive unit/spindle drive unit, etc. The NC Card FG is connected to the personal computer electric cabinet with card installation metal fittings. Desktop personal computer/ panel personal computer Remote I/O unit Base I/O unit 0 0 HR682 Note 3 Note 1 DCIN HANDLE E M G2 CF61 E M G1 RS232C ENC#2 Note 1 Servo drive unit/spindle drive unit, etc. Spindle motor Note 2 Servomotor Note 2 Main ground Note 1: This is not required when directly connecting to the main ground. Note 2: Connect the motor's grounding cable to the servo drive unit and spindle drive unit. Note 3: A spacer is used when mounting the HR682 card on the base I/O unit, but when not mounting on the base I/O unit, connect the card to the main ground using the FG terminal. 12 3. Installation 3.3 Installation (2) Shield clamping of cables The shield of the shield cable connected to the base I/O unit, servo drive unit and spindle drive unit must be connected to the grounding plate to stabilize operation while preventing malfunctioning due to noise. The shield can be connected to the grounding plate with lead wires or clamp fittings. Refer to the following drawings to treat the shield cable. Example of connection with lead wire Example of lead wire treatment Grounding cable Soldering Unit Unit Cable Signal wire Cable Shield Caution When soldering the grounding cable to the shield, if the soldered section is close to the shield, the signal wire's sheath could melt by the soldering heat resulting in a short-circuit. Solder at a place 10 to 20mm away from the mesh section. Grounding cable Example of connection with clamp fitting Shield Clamp fitting Cable Unit Grounding plate Cable Less than 0.8m Shield (1) Peel part of the cable sheath and expose the shield as shown in the drawing. Press the exposed part against the grounding plate with the cable clamp fittings. (2) If the cable is thin, clamp several together in a bunch. (3) Use adequate force when tightening the cable so that the wire material is not damaged. (4) Connect each grounding plate together and ground them at one point. Clamp fitting Grounding plate When manufacturing the clamp fittings and grounding plate, refer to "Appendix 1.10 Grounding Plate and Clamp Fitting Outline Drawings". These can also be ordered from Mitsubishi. CAUTION Execute ground treatment by cable clamps, etc., for the shielded cable indicated in this instruction manual. 13 3. Installation 3.3 Installation Cables which require shield clamp with a connector cases are shown following table. Fold the wire material shield over the sheath, and wrap copper foil tape over it. Connect the wrapped copper foil tape to the connector case GND plate. Connector name Unit name NC Card (HR621/HR623/ FCU6-HR655) CF10 CF61 Treatment of cable ends Connection destination Connection origin Connection destination Base I/O unit Relay card (NC Card) Not required (NC Card) Not required Not required Not required Base I/O unit CF10 (FCU6-DX2∗∗, 3∗∗, SV1 4∗∗) SV2 ENC1 SKIP PI01 PI02 NC Card Servo drive unit Servo drive unit Spindle encoder Skip Remote I/O unit Remote I/O unit (Base I/O unit) Not required (Base I/O unit) Required (Base I/O unit) Required (Base I/O unit) Required (Base I/O unit) Required (Base I/O unit) Required (Base I/O unit) Required Not required Not required Not required Not required Not required Not required Not required Relay card (HR682) NC Card Spindle encoder Manual pulse generator RS-232C (I/O device) (Relay card) Not required (Relay card) Required (Relay card) Required (Relay card) Required Not required Not required Not required Not required CF61 ENC#2 HANDLE RS232C (Note) (Note) RS-232C uses only the DC code (X ON/OFF) method handshake. (3) Connecting Spark Killers Connect a spark killer on the coil or relay contact in parallel for noise countermeasures. Use spark killers which are 0.033~0.1µF, 10~120Ω. Contact SK SK E 14 Coil 4. NC Card (HR621/HR623/FCU6-HR655) Connection 4.1 NC Card Connection System Diagram 4. NC Card (HR621/HR623/FCU6-HR655) Connection 4.1 NC Card Connection System Diagram The NC Card is connected to the personal computer with the expansion slot (ISA bus or PCI bus). The base I/O unit and relay card are connected with a cable. Base I/O unit (FCU6-DX2**/3**/4**) Expansion slot (ISA bus/PCI bus) Personal computer NC Card (HR621/HR623/ FCU6-HR655) CF10 F010 cable CF10 Relay card (HR682) CF61 F011 cable CF61 CAUTION Turn the NC Card's power ON before turning the base I/O unit's power ON. If the base I/O unit's power is turned ON first, the current will be led to the NC Card from the connection cable. This will prevent the personal computer or the cards in the personal computer from starting up properly. 15 4. NC Card (HR621/HR623/FCU6-HR655) Connection 4.2 NC Card Part Names NC Card Part Names Names of HR621 Card Parts TEST (8) ISP BAT (6) (7) (13) SEMG CIO NCLED (5) (14) (4) (15) (1) RWDG DPADR IOPADR (11) (2) CF10 (10) IRQ (12) S.O.DIMM2 CF61 CF62 S.O.DIMM1 CF10 4.2.1 CF61 4.2 (3) (9) ISABUS ISABUS List of connectors No. (1) Name CF61 (2) (3) (4) (5) (6) (7) CF10 ISABUS BAT CIO ISP TEST (8) (9) CF62 S.O. DIMM1, 2 Function details This is used in the connection with the relay card (HR682). An F011 cable is connected. This is used in the connection with the base I/O unit (DX2**, 3**, 4**). An F010 cable is connected. This is connected to the personal computer expansion slot (ISA bus). This is a battery holder. A Toshiba battery CR2450 is installed. This is a connector for expansion. Not used. Not used. Not used. This is the MAGIC 64 memory module connector. Do not remove the memory module. List of rotary switches No. (10) (11) (12) (Note) Name DPADR IOPADR IRQ Function details This is used in the address assignment setting of the personal computer expansion region. This is used in the address assignment setting of the personal computer I/O port region. This is used in the level setting of the interrupt request signal to the personal computer CPU. Refer to "4.4 ISA NC Card Mounting" for details on setting rotary switches. LED list No. Name (13) NCLED (14) SEMG (15) RWDG Function details This is the 7-segment LED for the NC status display. This LED changes when at startup, during alarms, etc. This is the chip LED for the NC system When lit (red) : System in emergency stop. emergency stop display. When not lit : Normal This is the chip LED for the remote When lit (red) : Watchdog alarm. communication watchdog display. When not lit : Normal CAUTION Do not apply voltages on the connector other than those indicated in this manual. Doing so may lead to destruction or damage. Incorrect connections may damage the devices, so connect the cables to the specified connectors. Do not connect or disconnect the connection cables between each unit while the power is ON. Do not connect or disconnect any PCB while the power is ON. 16 4. NC Card (HR621/HR623/FCU6-HR655) Connection 4.2 NC Card Part Names Names of HR623 Card Parts SEMG WDER (15) (14) BAT CIO NCLD1 (13) (5) ISP TEST (6) (12) (4) (7) IRQ IOPADR DPADR (1) CF61 3VALM 5VSALM 3VSALM (16)(17)(18) CF61 4.2.2 (10) (11) CF10 CF10 (2) (3) ISABUS ISABUS List of connectors No. (1) Name CF61 (2) (3) (4) (5) (6) (7) CF10 ISABUS BAT CIO ISP TEST Function details This is used in the connection with the relay card (HR682). An F011 cable is connected. This is used in the connection with the base I/O unit (DX2**, 3**, 4**). An F010 cable is connected. This is connected to the personal computer expansion slot (ISA bus). This is a battery holder. A Toshiba battery CR2450 is installed. This is a connector for expansion. Not used. Not used. List of rotary switches No. (10) Name DPADR Function details This is used in the address assignment setting of the personal computer expansion region. (11) (12) IOPADR IRQ This is used in the address assignment setting of the personal computer I/O port region. This is used in the level setting of the interrupt request signal to the personal computer CPU. (Note) Refer to "4.4 ISA NC Card Mounting" for details on setting rotary switches. LED list No. Name (13) NCLD1 (14) SEMG (15) WDER (16) 5VSALM (17) 3VSALM (18) 3VALM Function details This is the 7-segment LED for the NC status display. This LED changes when at startup, during alarms, etc. This is the chip LED for the NC system emergency stop display. This is the chip LED for the remote communication watchdog display. When lit (red) When not lit When lit (red) When not lit : System in emergency stop. : Normal : Watchdog alarm. : Normal This is the chip LED for the circuit power 5VDC low alarm display. This is the chip LED for the circuit power 3VDC low alarm display. When lit (red) When not lit When lit (red) When not lit : 5VDC low : Normal : 3VDC low : Normal This is the chip LED for the circuit power 3VDC low alarm display. When lit (red) : 3VDC low When not lit : Normal CAUTION Do not apply voltages on the connector other than those indicated in this manual. Doing so may lead to destruction or damage. Incorrect connections may damage the devices, so connect the cables to the specified connectors. Do not connect or disconnect the connection cables between each unit while the power is ON. Do not connect or disconnect any PCB while the power is ON. 17 4. NC Card (HR621/HR623/FCU6-HR655) Connection 4.2 NC Card Part Names 4.2.3 Names of FCU6-HR655 Unit Parts (11)(12)(13)(14)(15)(16) NCLD SEMG WDER 5VSALM 3VSALM 3VALM (5) CF61 CF61 (1) CF62 (9) BAT BAT BAT (8 ) (4) (7) (10) CF10 CF10 (2) TEST ISP SW1 CF63 (6) (3) PCIBUS PCIBUS List of connectors No. (1) (2) (3) (4) (5) (6) (7) (8) Name CF61 CF10 PCIBUS BAT CF62 CF63 TEST ISP Function details This is used in the connection with the relay card (HR682). An F011 cable is connected. This is used in the connection with the base I/O unit (DX2**, 3**, 4**). An F010 cable is connected. This is connected to the personal computer expansion slot (PCI bus). This is a battery holder. A Toshiba battery CR2032 is installed. This is used to input AC FAIL from an external source. (Note 1) This is used to supply power from an external source. (Note 1) Not used. Not used. (Note 1) When multiple FCU6-HR655 cards are inserted, the power supplied from the personal computer or panel computer may be insufficient. Supply the power from an external source to CF63 in this case. Input a FAIL signal to CF62 when using an external power supply. List of switches No. (9) Name CDNO (10) SW1 Function details This is used to set the PCI NC Card's station No. This sets the power supply method. Set "L" when supplying from the PCI bus, and set "M" when supplying power to CF63 from an external power supply. (Note 2) Refer to "4.5 PCI NC Card Mounting" for details on setting rotary switches. LED list No. Name (11) SEMG (12) WDER (13) 5VSALM (14) 3VSALM (15) 3VALM (16) NCLD Function details This is the chip LED for the NC system When lit (red) : System in emergency stop. emergency stop display. When not lit : Normal This is the chip LED for the remote When lit (red) : Watchdog alarm. communication watchdog display. When not lit : Normal This is the chip LED for the circuit power When lit (red) : 5VDC low 5VDC low alarm display. When not lit : Normal This is the chip LED for the circuit power When lit (red) : 3VDC low 3VDC low alarm display. When not lit : Normal This is the chip LED for the circuit power When lit (red) : 3VDC low 3VDC low alarm display. When not lit : Normal This is the 7-segment LED for the NC status display. This LED changes when at startup, during alarms, etc. CAUTION Do not apply voltages on the connector other than those indicated in this manual. Doing so may lead to destruction or damage. Incorrect connections may damage the devices, so connect the cables to the specified connectors. Do not connect or disconnect the connection cables between each unit while the power is ON. Do not connect or disconnect any PCB while the power is ON. 18 4. NC Card (HR621/HR623/FCU6-HR655) Connection 4.3 NC Card Connector Pin Assignment 4.3 NC Card Connector Pin Assignment 1 I/O 2 I/O 3 4 I 5 I 6 I 7 I 8 I 9 I 10 I 11 I 12 13 I 14 I 15 I 16 17 O 18 I 19 I 20 O 21 22 O 23 I 24 I 25 O Base I/O unit CF10 1 25 50 26 Plug: 10150-6000EL Shell: 10350-3210-000 Recommended manufacturer: Sumitomo 3M TXRX1 TXRX2 GND SKIP1 SKIP2 SKIP3 SKIP4 SKIP5 SKIP6 SKIP7 SKIP8 GND ENC1A ENC1B ENC1Z GND SVTXD2 SVALM2 SVRXD2 SVEMG2 GND SVTXD1 SVALM1 SVRXD1 SVEMG1 26 I/O TXRX1* 27 I/O TXRX2* GND 28 I SKIP1* 29 I SKIP2* 30 I SKIP3* 31 I SKIP4* 32 I SKIP5* 33 I SKIP6* 34 I SKIP7* 35 I SKIP8* 36 GND 37 I ENC1A* 38 I ENC1B* 39 I ENC1Z* 40 GND 41 42 O SVTXD2* I SVALM2* 43 I SVRXD2* 44 45 O SVEMG2* GND 46 47 O SVTXD1* I SVALM1* 48 I SVRXD1* 49 50 O SVEMG1* RIO1 RIO2 SKIP ENC1 SV2 SV1 (Note) I/O in the table is from the viewpoint of the NC Card. Relay card CF61 13 26 1 14 1 2 3 4 5 6 7 8 9 10 11 12 13 O O O I I I I O I I I TD0 LED1 LED3 EMGIN GND HA1A HA2A HA3A DR0 GND EN2A EN2B EN2Z 14 15 16 17 18 19 20 21 22 23 24 25 26 I O O I I I I I I I I RD0 LED2 EMGOUT* EMGIN* GND HA1B HA2B HA3B DC0 GND EN2A* EN2B* EN2Z* RS-232C LED (for debugging) Emergency stop HANDLE RS-232C ENC#2 (Note) I/O in the table is from the viewpoint of the Plug: 10126-6000EL NC Card. Shell: 10326-3210-000 Recommended manufacturer: Sumitomo 3M CAUTION Do not apply voltages other than those indicated in this manual on the connector. Doing so may lead to destruction or damage. Incorrect connections may damage the devices, so connect the cables to the specified connectors. 19 4. NC Card (HR621/HR623/FCU6-HR655) Connection 4.3 NC Card Connector Pin Assignment ISA bus (NC Card side) 1C 31A (1D) (31B) 18C (18D) 1A (1B) * Pin Nos. inside the ( ) are rear side pin Nos. 1A 2A 3A 4A 5A 6A 7A 8A 9A 10A 11A 12A 13A 14A 15A 16A 17A 18A 19A 20A 21A 22A 23A 24A 25A 26A 27A 28A 29A 30A 31A I/O I/O I/O I/O I/O I/O I/O I/O O I I I I I I I I I I I I I I I I I I NC SD7 SD6 SD5 SD4 SD3 SD2 SD1 SD0 IOCHRDY AEN* NC NC NC SA16 SA15 SA14 SA13 SA12 SA11 SA10 SA9 SA8 SA7 SA6 SA5 SA4 SA3 SA2 SA1 SA0 1B 2B I 3B 4B O 5B 6B 7B 8B 9B 10B 11B 12B 13B I 14B I 15B 16B 17B 18B 19B 20B 21B O 22B 23B O 24B 25B 26B 27B 28B I 29B 30B 31B 1C 2C 3C 4C 5C 6C 7C 8C 9C 10C 11C 12C 13C 14C 15C 16C 17C 18C GND RSTDRV +5V IRQ9 NC NC NC NC +12V GND NC NC IOW* IOR* NC NC NC NC NC NC IRQ7 NC IRQ5 NC NC NC NC BALE +5V NC GND I I I I I I I I I I I/O I/O I/O I/O I/O I/O I/O I/O SBHE* LA23 LA22 LA21 LA20 LA19 LA18 LA17 MEMR* MEMW* SD8 SD9 SD10 SD11 SD12 SD13 SD14 SD15 1D 2D 3D 4D 5D 6D 7D 8D 9D 10D 11D 12D 13D 14D 15D 16D 17D 18D O MEMCS16* NC O IRQ10 NC NC NC NC NC NC NC NC NC NC NC NC +5V NC GND (Note) I/O in the table is from the viewpoint of the NC Card. 20 4. NC Card (HR621/HR623/FCU6-HR655) Connection 4.3 NC Card Connector Pin Assignment PCI bus (NC Card side) 1B (1A) 49B 52B (49A)(52A) 62B (62A) * Pin Nos. inside the ( ) are rear side pin Nos. 1A 2A 3A 4A 5A 6A 7A 8A 9A 10A 11A 12A 13A 14A 15A 16A 17A 18A 19A 20A 21A 22A 23A 24A 25A 26A 27A 28A 29A 30A 31A 32A 33A 34A 35A 36A 37A 38A 39A 40A 41A 42A 43A 44A 45A 46A 47A 48A 49A I I I O I I/O I/O I/O I/O I I/O I/O I/O I/O I O O I/O I/O I/O I/O I/O TRST* 12V TMS TDI +5V INTA* N.C. +5V N.C. ⎯ N.C. GND GMD N.C. RST* ⎯ N.C. GND N.C. AD30 +3.3V AD28 AD26 GND AD24 IDSEL +3.3V AD22 AD20 GND AD18 AD16 +3.3V FRAME* GND TRDY* GND STOP* +3.3V N.C. N.C. GND PAR AD15 +3.3V AD13 AD11 GND AD9 1B 2B 3B 4B 5B 6B 7B 8B 9B 10B 11B 12B 13B 14B 15B 16B 17B 18B 19B 20B 21B 22B 23B 24B 25B 26B 27B 28B 29B 30B 31B 32B 33B 34B 35B 36B 37B 38B 39B 40B 41B 42B 43B 44B 45B 46B 47B 48B 49B I O O O I I/O I/O I/O I/O I I/O I/O I/O I/O I I O I O O I I/O I/O I/O N.C. TCK GND TDO 5V 5V N.C. N.C. PRSNT1* N.C. PRSNT2* GND GND N.C. GND PCLK GND N.C. N.C. AD31 AD29 GND AD27 AD25 +3.3V C/BE3* AD23 GND AD21 AD19 +3.3V AD17 C/BE2* GND IRDY* +3.3V DEVSEL* GND LOCK* PERR* +3.3V SERR* +3.3V C/BE1* AD14 GND AD12 AD10 GND 50A 51A 52A 53A 54A 55A 56A 57A 58A 59A 60A 61A 62A Connector key Connector key I I/O I/O I/O I/O C/BE0 +3.3V AD6 AD4 GND AD2 Ad0 N.C. N.C. +5V +5V 50B 51B 52B 53B 54B 55B 56B 57B 58B 59B 60B 61B 62B Connector key Connector key I/O I/O I/O I/O I/O AD8 AD7 +3.3V AD5 AD3 GND AD1 N.C. N.C. +5V +5V (Note 1) 10A and 16A are for +5V (for I/O). (Note 2) I/O in the table is from the viewpoint of the NC Card. 21 4. NC Card (HR621/HR623/FCU6-HR655) Connection 4.3 NC Card Connector Pin Assignment AC FAIL CF62 2 1 1 2 I AC FAIL* GND (Note) I/O in the table is from the viewpoint of the NC Card. External power supply CF63 6 1 2 3 4 5 6 1 +5V +5V GND GND +12V GND (Note) I/O in the table is from the viewpoint of the NC Card. 22 4. NC Card (HR621/HR623/FCU6-HR655) Connection 4.4 ISA NC Card Mounting 4.4 4.4.1 ISA NC Card Mounting Before Mounting the ISA NC Card (1) Before mounting the ISA NC Card, confirm that the control section items below are present. HR621/623 card (ISA bus-compatible NC Card): 1 pc. FCU6-DX2**, DX3** or DX4** unit (Base I/O unit: with aluminum die cast): 1 pc. HR682 card (relay card: L-shaped PCB, with metal spacers): 1 pc. CR2450 (Toshiba button battery): 1 pc. F010 cable (half-pitch 50-pole shielded cable): 1 pc. F011 cable (half-pitch 26-pole shielded cable): 1 pc. (2) Insert a battery to the ISA NC Card as shown below. + Battery holder 45° - Insert at a 45° angle. The positive (+) polarity side should face up. Press in horizontally. The insertion should complete smoothly. Do not press in from above. A reverse insertion prevention function is attached so the battery can only be inserted with the proper polarity in the holder. Insert in the direction of the arrow. ISA NC Card (HR621) Insert in the direction of the arrow. Battery holder 20 ISA NC Card (HR623) CAUTION Do not short-circuit, charge, overheat, incinerate or disassemble the battery. Dispose of the spent battery according to local laws. 23 4. NC Card (HR621/HR623/FCU6-HR655) Connection 4.4 ISA NC Card Mounting 4.4.2 ISA NC Card Mounting Procedure Install the software and mount the NC Card following the Setup Instruction Manual (BNP-B2191). The software will not be installed correctly if the software installation and NC Card mounting procedure are mistaken. Mount the NC Card onto the personal computer with the following procedures. (1) Set the DPADR, IOPADR and IRQ rotary switches according to the personal computer memory region, I/O port region and interrupt request signals designated when installing the software. (Note) Before touching the NC Card, touch an exposed metal section of the personal computer to discharge any static electricity. Pay attention not to touch the NC Card, personal computer chip or circuit. Location of ISA NC Card (HR621) rotary switches DPADR IOPADR IRQ Location of ISA NC Card (HR623) rotary switches DPADR IOPADR IRQ Roles of each rotary switch DPADR : This is used in the address setting of the personal computer expansion region. IOPADR : This is used in the address setting of the personal computer I/O port region. IRQ : This is used in the level setting of the interrupt request signal to the personal computer CPU. DPADR setting IOPADR setting IRQ setting Switch Expansion region Switch I/O port region Switch 0 1 2 3 4 5 6 7 8 9 A B C D E F h0D_8000~h0D_FFFF h0D_0000~h0D_7FFF h0C_8000~h0C_FFFF h0C_0000~h0C_7FFF RESERVED RESERVED RESERVED RESERVED RESERVED RESERVED RESERVED RESERVED RESERVED RESERVED RESERVED RESERVED 0 1 2 3 4 5 6 7 8 9 A B C D E F h0120-h0123 h0140-h0143 h0160-h0163 h0180-h0183 h01A0-h01A3 h01C0-h01C3 h01E0-h01E3 h0200-h0203 h0220-h0223 h0240-h0243 h0260-h0263 h0280-h0283 h02A0-h02A3 h02C0-h02C3 h02E0-h02E3 h0300-h0303 0 1 2 4 8 24 Interrupt request signal None IRQ5 IRQ7 IRQ9 IRQ10 4. NC Card (HR621/HR623/FCU6-HR655) Connection 4.4 ISA NC Card Mounting (2) Following the instructions in the personal computer manual, remove the personal computer cover. (Note) Follow the precautions instructed in the personal computer manual. Confirm that the personal computer power is OFF, and that the power cable is disconnected. (3) After confirming that there is a vacant ISA bus slot, remove the slot cover of the selected ISA bus slot. (Note) Do not misplace the slot cover screw as it is used to fix the ISA NC Card onto the personal computer. (4) Holding the card installation metal fittings and the ends of the ISA NC Card, so as to push in the NC Card upper end, insert the card all the way into the personal computer ISA bus slot. (Note) The ISA BUS slot insertion orientation is predetermined. Insert the card so that the card mounting fitting comes to the slot cover position. Press in Press in ISA NC Card Card mounting fitting Personal computer ISA bus slot (5) Using the fixing screw of the slot cover removed in mounting step 3, fix the ISA NC Card to the personal computer. (Note) Securely tighten the screw. Screw NC Ca rd 25 4. NC Card (HR621/HR623/FCU6-HR655) Connection 4.4 ISA NC Card Mounting (6) Following the instructions in the personal computer manual, install the personal computer cover removed in mounting step 2. (7) Reconnect the personal computer power cables. (Note) Do not turn the personal computer ON yet. (8) Connect the two relay cables (F010 and F011) to the two connectors (CF10 and CF61) on the card installation metal fitting section of the ISA NC Card. (Note) Connect the F010 cable to the CF10 connector, and the F011 cable to the CF61 connector. (9) Connect the F010 and F011 cables to the base I/O unit and relay card. (Note) Connect the F010 cable to the CF10 connector on the base I/O unit, and the F011 cable to the CF61 connector on the relay card. This completes the ISA NC Card (HR621/623) mounting. (10) Install the MELDASMAGIC64 software into the personal computer while the ISA NC Card is mounted. (Note) Install the software and mount the NC Card following the Setup Instruction Manual (BNP-B2191). 26 4. NC Card (HR621/HR623/FCU6-HR655) Connection 4.5 PCI NC Card Mounting 4.5 4.5.1 PCI NC Card Mounting Before Mounting the PCI NC Card (1) Before mounting the PCI NC Card, confirm that the control section items below are present. FCU6-HR655 unit (PCI bus-compatible NC Card): 1 pc. FCU6-DX2**, DX3** or DX4** unit (Base I/O unit: with aluminum die cast): 1 pc. HR682 card (relay card: L-shaped PCB, with metal spacers): 1 pc. CR2032 (Toshiba button battery): 1 pc. F010 cable (half-pitch 50-pole shielded cable): 1 pc. F011 cable (half-pitch 26-pole shielded cable): 1 pc. (2) Insert a battery to the PCI NC Card as shown below. + - Insert with the + polarity facing upward, and catch with the hook. Insert in the direction of the arrow. Battery holder + BAT BAT - + Press in vertically. - Check the battery's polarity indicated on the holder's metal section before inserting. PCI NC Card (HR183+655) CAUTION Do not short-circuit, charge, overheat, incinerate or disassemble the battery. Dispose of the spent battery according to local laws. 27 4. NC Card (HR621/HR623/FCU6-HR655) Connection 4.5 PCI NC Card Mounting 4.5.2 PCI NC Card Mounting Procedure Install the software and mount the NC Card following the Setup Instruction Manual (BNP-B2191). The software will not be installed correctly if the software installation and NC Card mounting procedure are mistaken. Mount the NC Card onto the personal computer with the following procedures. (1) Set the rotary switch CDNO and slide switch SW1. (Note) Before touching the NC Card, touch an exposed metal section of the personal computer to discharge any static electricity. Pay attention not to touch the NC Card, personal computer chip or circuit. Location of PCI NC Card (FCU6-HR655) switches CDNO CF62 BAT BAT CF63 SW1 Roles of each switch CDNO (rotary switch): Use to set the PCI NC Card's station No. SW1 (slide switch): Use to set the PCI NC Card's power supply (internal/external). CDNO setting Switch 0 1 2 3 4 5 6 7 8 9 A B C D E F Card 1st card 2nd card 3rd card 4th card 5th card 6th card 7th card 8th card 9th card 10th card 11th card 12th card 13th card 14th card 15th card 16th card SW1 setting Switch Supply method L Internal supply M External supply Details +5V/+12V is supplied by PCI bus. +5V/+12V is supplied by stabilized power supply. AC FAIL The default setting is "L". CF62 BBAATT The default setting is "0". L SW1 M +12V/+5V Stabilized power supply CF63 Connect a stabilized power supply to the CF62 and CF63 connectors when using an external power supply. 28 4. NC Card (HR621/HR623/FCU6-HR655) Connection 4.5 PCI NC Card Mounting (2) Following the instructions in the personal computer manual, remove the personal computer cover. (Note) Follow the precautions instructed in the personal computer manual. Confirm that the personal computer power is OFF, and that the power cable is disconnected. (3) After confirming that there is a vacant PCI bus slot, remove the slot cover of the selected PCI bus slot. (Note) Do not misplace the slot cover screw as it is used to fix the PCI NC Card onto the personal computer. (4) Holding the card installation metal fittings and the ends of the PCI NC Card, so as to push in the NC Card upper end, insert the card all the way into the personal computer PCI bus slot. (Note) There is a set orientation for inserting the PCI NC Card into the PCI bus slot. Insert the card so that the card installation fitting comes to the slot cover's position. Press in Press in Card mounting fitting PCI NC Card Personal computer PCI bus slot (5) Using the fixing screw of the slot cover removed in mounting step 3, fix the PCI NC Card to the personal computer. (Note) Securely tighten the screw. Screw NC Ca rd 29 4. NC Card (HR621/HR623/FCU6-HR655) Connection 4.5 PCI NC Card Mounting (6) Following the instructions in the personal computer manual, install the personal computer cover removed in mounting step 2. (7) Reconnect the personal computer power cables. (Note) Do not turn the personal computer ON yet. (8) Connect the two relay cables (F010 and F011) to the two connectors (CF10 and CF61) on the card installation metal fitting section of the PCI NC Card. (Note) Connect the F010 cable to the CF10 connector, and the F011 cable to the CF61 connector. (9) Connect the F010 and F011 cables to the base I/O unit and relay card. (Note) Connect the F010 cable to the CF10 connector on the base I/O unit, and the F011 cable to the CF61 connector on the relay card. This completes the PCI NC Card (FCU6-HR655) mounting. (10) Install the MELDASMAGIC64 software into the personal computer while the PCI NC Card is mounted. (Note) Do not change the personal computer's station No. or the power supply method while installing the software. Install the software and mount the NC Card following the Setup Instruction Manual (BNP-B2191). 30 5. Base I/O Unit (FCU6-DX2**/3**/4**) Connection 5.1 Base I/O Unit Outline 5. Base I/O Unit (FCU6-DX2**/3**/4**) Connection 5.1 Base I/O Unit Outline The base I/O unit is used in the connection of the machine input/output (DI/DO), servo drive unit, spindle encoder, skip and remote I/O unit. There must be one base I/O unit for each NC Card. Depending on the base I/O unit type, connection is possible with analog input, analog output and a manual pulse generator. The following shows a list of base I/O units and add-on PCBs. Name Type Base I/O FCU6-DX210 unit FCU6-DX211 FCU6-DX220 FCU6-DX221 FCU6-DX310 FCU6-DX311 FCU6-DX410 FCU6-DX411 No. of machine input/ output points DI (sink/source)/DO (sink)=48/48 DI (sink/source)/DO (source)=48/48 DI (sink/source)/DO (sink)=64/64 DI (sink/source)/DO (source)=64/64 DI (sink/source)/DO (sink)=80/64 DI (sink/source)/DO (source)=80/64 DI (sink/source)/DO (sink)=96/80 DI (sink/source)/DO (source)=96/80 Other interfaces SV1, SV2, ENC1, SKIP, RIO1, RIO2, CR31 (for add-on PCB) SV1, SV2, ENC1, SKIP, RIO1, RIO2 Add-on PCB: RX323-1 (DO is sink type) : RX324-1 (DO is source type) SV1, SV2, ENC1, SKIP, RIO1, RIO2, Analog output 1 point FCU6-DX321 DI (sink/source)/DO (source)=80/64 Add-on PCB: RX323 (DO is sink type) FCU6-DX420 DI (sink/source)/DO (sink)=96/80 : RX324 (DO is source type) FCU6-DX421 DI (sink/source)/DO (source)=96/80 FCU6-DX320 DI (sink/source)/DO (sink)=80/64 Add-on PCB FCU6-DX330 FCU6-DX331 FCU6-DX430 FCU6-DX431 FCU6-DX340 FCU6-DX341 FCU6-DX440 FCU6-DX441 RX323-1 RX323 RX324-1 RX324 RX331 RX341 DI (sink/source)/DO (sink)=48/48 DI (sink/source)/DO (source)=48/48 DI (sink/source)/DO (sink)=64/64 DI (sink/source)/DO (source)=64/64 DI (sink/source)/DO (sink)=48/48 DI (sink/source)/DO (source)=48/48 DI (sink/source)/DO (sink)=64/64 DI (sink/source)/DO (source)=64/64 DI (sink/source)/DO (sink)=32/16 DI (sink/source)/DO (sink)=32/16 DI (sink/source)/DO (source)=32/16 DI (sink/source)/DO (source)=32/16 None None SV1, SV2, ENC1, SKIP, RIO1, RIO2, HANDLE2ch Add-on PCB: RX331 SV1, SV2, ENC1, SKIP, RIO1, RIO2, Analog input 4 points, analog output 1 point Add-on PCB: RX341 None Analog output 1 point None Analog output 1 point HANDLE2ch Analog input 4 points, analog output 1 point (Note) Refer to "7. Remote I/O Unit Connection" for add-on PCB connections. 31 5. Base I/O Unit Connection 5.2 Base I/O Connection System Drawing 5.2 Base I/O Connection System Drawing Base I/O unit NC card CF10 SH21 cable SV1 F010 cable CF10 SV2 SH21 cable F040 cable ENC1 SKIP Servo drive unit (spindle and NC servo axis) Servo drive unit (auxiliary axes) Encoder 1ch (1st spindle encoder) Sensor signal (skip) SH41 (FCUA-R211) cable Remote I/O unit, part system 1 RIO1 RIO2 CF31 CF32 CF33 CF34 CR31 SH41 (FCUA-R211) cable Remote I/O unit, part system 2 (future expansion) R301 cable R301 cable R301 cable R301 cable Enclosed cable DI (machine input) DI (machine input) DO (machine output) DO (machine output) Add-on PCB > > SW1 SW2 0 1 DCIN F070 (FCUA-R220) cable External power (24VDC) (Note) Refer to "7. Remote I/O Unit Connection" for add-on PCB connections. CAUTION Turn the NC Card's power ON before turning the base I/O unit's power ON. If the base I/O unit's power is turned ON first, the current will be led to the NC Card from the connection cable. This will prevent the personal computer or the cards in the personal computer from starting up properly. 32 5. Base I/O Unit Connection 5.3 Base I/O Unit Part Names 5.3 Base I/O Unit Part Names 78 9 78 9 (9) BC D E A (8) CR31 (14) 45 6 (12) F0 1 2 3 A (4) SKIP 45 6 (5) F0 1 2 3 B C DE (15) CS2 CS1 ENC1 (1) CF10 SV2 SV1 (2) (3) CF31 CF32 (10) CF33 CF34 (11) (7) CS1：オンボードRIO第1局局番設定ロータリスイッチ CS2：オンボードRIO第2局局番設定ロータリスイッチ RI02 RI01DCIN (13) 24IN (6) RAL1 (16) 5OUT RAL2 (17) List of connectors Unit name FCU6-DX210 No. (1) (2) (3) (4) (5) Name CF10 SV1 SV2 ENC1 SKIP (6) RIO1 (7) RIO2 (8) CF31 (9) CF32 (10) CF33 (11) CF34 (12) (13) CR31 DCIN FCU6-DX211 FCU6-DX220 FCU6-DX221 Function This is used in the connection with the NC Card. An F010 cable is connected. This is connected to the servo drive unit 1st part system (for spindles and NC servo axes). This is connected to the servo drive unit 2nd part system (for auxiliary axes). This is connected to the encoder 1st channel (1st spindle encoder). This is the sensor signal (skip) input connection. Up to eight points can be used. This is connected to the remote I/O unit 1st part system. The max. No. of occupied stations is eight. Because two stations are occupied in the base I/O unit, the remaining six occupied stations can be used. Note that when an add-on PCB is used, the remaining five occupied stations can be used. This is connected to the remote I/O unit 2nd part system. The max. No. of occupied stations is eight. Eight occupied stations can be used. For future expansion. This is used in the connection of the station No. (normally station No. 0) machine input signal set by the CS1 rotary switch. DI: 32 (sink/source) DI: 32 (sink/source) DI: 32 (sink/source) DI: 32 (sink/source) This is used in the connection of the station No. (normally station No. 1) machine input signal set by the CS2 rotary switch. DI: 16 (sink/source) DI: 16 (sink/source) DI: 32 (sink/source) DI: 32 (sink/source) This is used in the connection of the station No. (normally station No. 0) machine output signal set by the CS1 rotary switch. DO: 32 (sink type) DO: 32 (source type) DO: 32 (sink type) DO: 32 (source type) This is used in the connection of the station No. (normally station No. 1) machine output signal set by the CS2 rotary switch. DO: 16 (sink type) DO: 16 (source type) DO: 32 (sink type) DO: 32 (source type) This is a connector for an add-on PCB. It cannot be used unless using an add-on PCB. 24VDC must be supplied by external power. Refer to "3.1 General Specifications" for power specifications. CAUTION Do not apply voltages on the connector other than those indicated in this manual. Doing so may lead to destruction or damage. Incorrect connections may damage the devices, so connect the cables to the specified connectors. Do not connect or disconnect the connection cables between each unit while the power is ON. Do not connect or disconnect any PCB while the power is ON. 33 5. Base I/O Unit Connection 5.3 Base I/O Unit Part Names List of rotary switches No. Name Function (14) CS1 This is used in the station No. setting of the CF31 and CF33 machine input/output signals. (15) CS2 This is used in the station No. setting of the CF32 and CF34 machine input/output signals. Rotary switch setting value Station No. 0 0 Device assignment DI DO X00~X1F Y00~Y1F 1 2 3 4 5 6 1 2 3 4 5 6 X20~X3F X40~X5F X60~X7F X80~X9F XA0~XBF XC0~XDF 7 8~F 7 XE0~XFF YE0~YFF Cannot be used Y20~Y3F Y40~Y5F Y60~Y7F Y80~Y9F YA0~YBF YC0~YDF LED list No. Name 24IN (16) Function When lit (green) : 24VDC being supplied. When not lit : 24VDC supply OFF. This is the LED for the 24VDC input display. This is the LED for the onboard remote I/O 1st station (CS1 setting station No.) communication alarm display. This is the LED for the circuit power 5VDC output 5OUT display. RAL1 (17) RAL2 When lit (red) When not lit When lit (green) When not lit This is the LED for the onboard remote I/O 2nd station When lit (red) (CS2 setting station No.) communication alarm display. When not lit 34 : Communication alarm. : Normal : Outputting 5VDC. : 5VDC output OFF. : Communication alarm. : Normal 5. Base I/O Unit Connection 5.4 Base I/O Unit Connector Pin Assignment 5.4 Base I/O Unit Connector Pin Assignment NC Card 1 25 CF10 50 Connector pin assignment: Refer to "4.3 NC Card Connector Pin Assignment" (Base I/O unit: CF10). 26 Plug : 10150-6000EL Shell : 10350-3210-000 Recommended manufacturer: Sumitomo 3M Servo drive unit SV1 1 10 20 11 Plug : 10120-6000EL Shell : 10320-3210-000 Recommended manufacturer: Sumitomo 3M 1 2 3 4 5 6 7 8 9 10 O I I GND SVTXD1 SVALM1 SVRXD1 GND O SVEMG1 O +5V 11 12 O 13 I 14 I 15 16 17 O 18 19 20 GND SVTXD1* SVALM1* SVRXD1* GND SVEMG1* I/O in the table is from the viewpoint of the base I/O unit. (Note) Servo drive unit SV2 10 1 20 11 Plug : 10120-6000EL Shell : 10320-3210-000 Recommended manufacturer: Sumitomo 3M 1 2 3 4 5 6 7 8 9 10 O I I GND SVTXD2 SVALM2 SVRXD2 GND O SVEMG2 O +5V 11 12 13 14 15 16 17 18 19 20 O I I GND SVTXD2* SVALM2* SVRXD2* GND O SVEMG2* I/O in the table is from the viewpoint of the base I/O unit. (Note) Spindle encoder ENC1 1 5 9 6 Connector : CDE-9PF Contact : CD-PC-111 Case : HDE-CTH Recommended manufacturer: Hirose Electric 35 1 2 3 4 5 (Note) I I I ENC1A ENC1B ENC1Z GND GND 6 7 8 9 I I I O ENC1A* ENC1B* ENC1Z* +5V I/O in the table is from the viewpoint of the base I/O unit. 5. Base I/O Unit Connection 5.4 Base I/O Unit Connector Pin Assignment Sensor signal SKIP 8 1 15 9 Connector : CDA-15P Contact : CD-PC-111 Case : HDA-CTH Recommended manufacturer: Hirose Electric Remote I/O unit 1 2 3 RIO1 1 2 3 4 5 6 7 8 (Note) I I GND SKIP IN1 SKIP IN3 I I SKIP IN5 SKIP IN7 GND 9 10 11 12 13 14 15 I I I I GND SKIP IN2 SKIP IN4 SKIP IN6 SKIP IN8 GND I/O in the table is from the viewpoint of the base I/O unit. 1 I/O TXRX1 2 I/O TXRX1* Connector : 1-178288-3 3 GND Contact : 1-175218-5 Recommended manufacturer: Tyco Electronics AMP (Note) I/O in the table is from the viewpoint of the base I/O unit. Remote I/O unit 1 RIO2 2 3 1 I/O TXRX2 2 I/O TXRX2* Connector : 1-178288-3 GND 3 Contact : 1-175218-5 Recommended manufacturer: Tyco Electronics AMP (Note) +24VDC input 1 DCIN 2 3 I/O in the table is from the viewpoint of the base I/O unit. 1 I +24V 2 GND Connector : 2-178288-3 3 FG Contact : 1-175218-5 Recommended manufacturer: Tyco Electronics AMP (Note) I/O in the table is from the viewpoint of the base I/O unit. CAUTION Do not apply voltages other than those indicated in this manual on the connector. Doing so may lead to destruction or damage. Incorrect connections may damage the devices, so connect the cables to the specified connectors. 36 5. Base I/O Unit Connection 5.4 Base I/O Unit Connector Pin Assignment DI/DO A20 A1 B20 B1 CF31, 32, 33, 34 Connector : 7940-6500SC Recommended manufacturer: Sumitomo 3M CF31 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 I I I I I I I I I I I I I I I I B X0 X1 X2 X3 X4 X5 X6 X7 X8 X9 XA XB XC XD XE XF I I I COM +24V +24V 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 CF32 I I I I I I I I I I I I I I I I I A X10 X11 X12 X13 X14 X15 X16 X17 X18 X19 X1A X1B X1C X1D X1E X1F 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 COM GND GND I I I I I I I I I I I I I I I I B X20 X21 X22 X23 X24 X25 X26 X27 X28 X29 X2A X2B X2C X2D X2E X2F I I I COM +24V +24V 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 I I I I I I I I I I I I I I I I I A (X30) (X31) (X32) (X33) (X34) (X35) (X36) (X37) (X38) (X39) (X3A) (X3B) (X3C) (X3D) (X3E) (X3F) COM GND GND The values in parentheses are used only for DX220 and DX221. CF33 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 O O O O O O O O O O O O O O O O B Y0 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 Y9 YA YB YC YD YE YF I I +24V +24V 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 CF34 O O O O O O O O O O O O O O O O A Y10 Y11 Y12 Y13 Y14 Y15 Y16 Y17 Y18 Y19 Y1A Y1B Y1C Y1D Y1E Y1F I I GND GND 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 O O O O O O O O O O O O O O O O B Y20 Y21 Y22 Y23 Y24 Y25 Y26 Y27 Y28 Y29 Y2A Y2B Y2C Y2D Y2E Y2F I I +24V +24V 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 O O O O O O O O O O O O O O O O A (Y30) (Y31) (Y32) (Y33) (Y34) (Y35) (Y36) (Y37) (Y38) (Y39) (Y3A) (Y3B) (Y3C) (Y3D) (Y3E) (Y3F) I I GND GND The values in parentheses are used only for DX220 and DX221. (Note) 37 I/O in the table is from the viewpoint of the base I/O unit. 5. Base I/O Unit Connection 5.5 Base I/O Unit Input/Output Specifications 5.5 Base I/O Unit Input/Output Specifications 5.5.1 Rotary Switch (CS1 and CS2) Settings Normal settings CS1 CS2 0 1 The base I/O unit No. of occupied stations is two (when an add-on PCB is not used). (Note) Also refer to "7.14 Setting of Channel No. When Using Multiple Remote I/O Units" for rotary switch (CS1 and CS2) settings of the base I/O unit. Relation between rotary switches and DI/DO connectors CS1 CS2 DI: CF31, DO: CF33 DI: CF32, DO: CF34 Relation between rotary switches and device assignments Setting value 0 1 2 3 4 5 6 7 8 ~F Device assignment DI DO 0 X00~X1F Y00~Y1F 1 X20~X3F Y20~Y3F 2 X40~X5F Y40~Y5F 3 X60~X7F Y60~Y7F 4 X80~X9F Y80~Y9F 5 XA0~XBF YA0~YBF 6 XC0~XDF YC0~YDF 7 XE0~XFF YE0~YFF Cannot be used Station No. No. of I/O points (max) 32 points 32 points 32 points 32 points 32 points 32 points 32 points 32 points Station No. settings of add-on PCBs When using an add-on PCB, set the station No. using the rotary switch on the add-on PCB. This rotary switch corresponds to connectors CR21 and CR22 of the add-on PCB. The setting values, station Nos. and device assignments are as shown in the table above. (Note) Refer to "5.1 Base I/O Unit Outline" for types of add-on PCBs. One station is occupied when using RX331 (manual pulse generator) and RX341 (analog input/output) also. 5.5.2 RIO1 Terminator Connect a terminator to the final end of the remote I/O unit connected to the RIO1. When not using any remote I/O unit, connect a terminator to the base I/O unit RIO1. Terminator type: R-TM Recommended manufacturer: Tyco Electronics AMP X AMP D-3 38 5. Base I/O Unit Connection 5.5 Base I/O Unit Input/Output Specifications 5.5.3 CF31, CF32 Input Circuit Refer to "7.4 Outline of Digital Signal Input Circuit" for the base I/O unit CF31 and CF32 input circuits. 1 2 3 4 5 6 5.5.4 Unit name Card name Input type COM pin connection No. of input points Pin used for input FCU6-DX210 HR325 Sink/source +24V/GND 48 points X00~X2F FCU6-DX211 HR335 Sink/source +24V/GND 48 points X00~X2F FCU6-DX220 HR327 Sink/source +24V/GND 64 points X00~X3F FCU6-DX221 HR337 Sink/source +24V/GND 64 points X00~X3F CF33, CF34 Output Circuit Refer to "7.5 Outline of Digital Signal Output Circuit" for the base I/O unit CF33 and CF34 output circuits. 1 2 3 4 5 6 5.5.5 Unit name Card name Output type Output current No. of output points Pin used for output FCU6-DX210 HR325 Sink type 60mA/point 48 points Y00~Y2F FCU6-DX211 HR335 Source type 60mA/point 48 points Y00~Y2F FCU6-DX220 HR327 Sink type 60mA/point 64 points Y00~Y3F FCU6-DX221 HR337 Source type 60mA/point 64 points Y00~Y3F Specifications of ADD ON PCB Connected to CR31 Refer to "7. Remote I/O Unit Connection" for add-on PCB specifications. One add-on PCB can be installed on the base I/O unit, and it occupies one station. Reference items are as in the following table. Name 1 RX323-1 2 RX323 3 RX324-1 4 RX324 5 RX331 6 RX341 7.9 7.10 7.9 7.10 7.11 7.13 Reference item Connection of FCUA-DX11* unit and machine control signal Connection of FCUA-DX12* unit and machine control signal Connection of FCUA-DX11* unit and machine control signal Connection of FCUA-DX12* unit and machine control signal Connection of FCUA-DX13* unit and handle Connection of FCUA-DX14* unit and analog input/output signal Reference connector name FCUA-DX110: DI-R, DO-R FCUA-DX120: DI-R, DO-R FCUA-DX111: DI-R, DO-R FCUA-DX121: DI-R, DO-R FCUA-DX13*: HANDLE FCUA-DX14*: AIO Refer to "7.6 Outline of Analog Signal Output Circuit" for the analog output specifications. Refer to "7.7 Outline of Analog Signal Input Circuit" for the analog input specifications. 39 5. Base I/O Unit Connection 5.5 Base I/O Unit Input/Output Specifications 5.5.6 Connection of Base I/O Unit Power Supply Supply the +24V power to the base I/O unit from the DCIN connector. Base I/O unit Stabilized power DCIN +24V +24V GND GND FG NC (Prepare separately.) (Note) A +24V power supply must be input for both the sink type and source type. CAUTION Do not apply voltages other than those indicated in this manual on the connector. Doing so may lead to destruction or damage. Incorrect connections may damage the devices, so connect the cables to the specified connectors. 40 5. Base I/O Unit Connection 5.5 Base I/O Unit Input/Output Specifications 5.5.7 Examples of DI/DO Connection There are two types of MELDASMAGIC64 DI/DO; the base I/O unit and remote I/O unit. Normally, one base I/O unit is used, a remote I/O unit is connected to RIO1 or RIO2 (for future expansion), and the No. of I/O points is configured in combination with the user specifications. Refer to "7. Remote I/O Unit Connection" for information about remote I/O units. When not using an add-on PCB RIO1 SH41(FCUA-R211) cable Maximum configuration Base I/O unit FCU6-DX2** Remote I/O unit: FCUA-DX11*/12*/13*/14*×3 units No. of occupied stations: 2 (dependent on RIO1) RIO2 No. of occupied stations: 2 No. of occupied stations: 2 No. of occupied stations: 2 Total No. of occupied stations (RIO1): Base I/O unit (2 stations) + 3 remote I/O units (2 stations + 2 stations + 2 stations) = 8 stations (For future expansion) SH41(FCUA-R211) cable Maximum configuration Remote I/O unit: FCUA-DX11*/12*/13*/14*×4 units No. of occupied stations: 2 No. of occupied stations: 2 No. of occupied stations: 2 No. of occupied stations: 2 Total No. of occupied stations (RIO2): Remote I/O unit (2 stations + 2 stations + 2 stations + 2 stations) = 8 stations When using an add-on PCB RIO1 Base I/O unit FCU6-DX3** /4** No. of occupied stations: 3 (dependent on RIO1) RIO2 SH41(FCUA-R211) cable Maximum configuration Remote I/O unit: FCUA-DX10*×1 unit + Remote I/O unit: FCUA-DX11*/12*/13*/14* No. of occupied No. of occupied No. of occupied ×2 units stations: 1 stations: 2 stations: 2 Total No. of occupied stations (RIO1): Base I/O unit (3 stations) + remote I/O unit (1 station + 2 stations + 2 stations) = 8 stations SH41(FCUA-R211) cable (For future expansion) Maximum configuration Remote I/O unit: FCUA-DX11*/12*/13*/14*×4 units No. of occupied stations: 2 No. of occupied stations: 2 No. of occupied stations: 2 No. of occupied stations: 2 Total No. of occupied stations (RIO2): Remote I/O unit (2 stations + 2 stations + 2 stations + 2 stations) = 8 stations CAUTION Do not apply voltages other than those indicated in this manual on the connector. Doing so may lead to destruction or damage. Incorrect connections may damage the devices, so connect the cables to the specified connectors. 41 5. Base I/O Unit Connection 5.5 Base I/O Unit Input/Output Specifications 5.5.8 Connection of Servo Drive Unit Connect the servo drive unit to the base I/O unit SV1 (for spindles and NC servo axes) and SV2 (for peripheral axes). Servo drive unit Base I/O unit SH21 cable SV1 CN1A Servo drive unit SH21 cable SV2 CN1A (Spindles and NC servo axes) (For auxiliary axes) Refer to "MELDAS AC Servo and Spindle MDS-A/B Series Specifications Manual (BNP-B3759) MDS-C1 Series Specifications Manual (BNP-C3000)" for servo drive unit details. Cable manufacturing drawing: “Appendix 2.1 SH21 cable” Connector pin assignment: “5.4 Base I/O unit connector pin assignment” - servo drive unit (SV1, SV2) 5.5.9 Connection of Spindle Encoder Connect the spindle encoder to ENC1 on the base I/O unit. When connecting two channels, connect the second channel to ENC#2 on the relay card (HR682). (Channel 1) Base I/O unit 1st spindle encoder ENC1 F040/F041 cable (Channel 2) Relay card 2nd spindle encoder ENC#2 F040/F041 cable Outline drawing: Appendix 1 Cable manufacturing drawing: “Appendix 2.15 F040 cable”, “Appendix 2.16 F041 cable” Connector pin assignment: “5.4 Base I/O unit connector pin assignment” - encoder (ENC1) “6.4 Relay card connector pin assignment” - encoder (ENC#2) 42 5. Base I/O Unit Connection 5.5 Base I/O Unit Input/Output Specifications 5.5.10 Connection of Sensor Signal (skip) Connect the sensor signal (skip) to SKIP on the base I/O unit. The sensor signal is used for processing the high-speed signals. Always shield the cable. (1) Sensor signal (skip) cable Base I/O unit SKIP SKIP IN1 2 2.2kΩ SKIP IN2 10 2.2kΩ SKIP IN3 3 2.2kΩ SKIP IN4 11 2.2kΩ SKIP IN5 5 2.2kΩ SKIP IN6 13 2.2kΩ SKIP IN7 6 Stabilized power +24V 2.2kΩ SKIP IN8 14 FG GND 2.2kΩ 1,8,9,15 Control circuit FG (2) Input conditions Use the input signal within the following condition range. 1 2 3 4 5 6 Input voltage when external contact is ON Input current when external contact is ON Input voltage when external contact is OFF Input current when external contact is OFF Input signal hold time (Ton) Internal response time 7 Machine side contact capacity 25.2V or more 9mA or more 4V or less 1mA or less 2ms or more 0.08ms or less +30V or more, 16mA or more To n +24V GND t Ton _ > 2ms Connector pin assignment: “5.4 Base I/O unit connector pin assignment” – sensor signal (SKIP) CAUTION Do not apply voltages other than those indicated in this manual on the connector. Doing so may lead to destruction or damage. Incorrect connections may damage the devices, so connect the cables to the specified connectors. 43 6. Relay Card (HR682) Connection 6.1 Relay Card Outline 6. Relay Card (HR682) Connection 6.1 Relay Card Outline The relay card is used in the connection of the spindle encoder, manual pulse generator, RS-232C and external emergency stop. There must be one relay card for each NC Card. Name Type HR682 Relay card No. of machine input/ output points No DI/DO Other interfaces EMG, ENC#2, HANDLE 3ch and RS-232C. With metal spacers. Add-On to FCU6-DX2** possible. RS-232C uses only the DC code (X ON/OFF) method handshake. 6.2 Relay Card Connection System Diagram Relay card NC Card CF61 F011 cable F040 cable CF61 ENC#2 F020 cable HANDLE Encoder 2ch (2nd spindle encoder) Manual pulse generator 3ch F390 cable RS-232C 1ch RS232C F070 cable Emergency stop switch EMG1 F070 cable DCIN External power (24VDC) (Note) RS-232C uses only the DC code (X ON/OFF) method handshake. 44 6. Relay Card (HR682) Connection 6.3 Relay Card Part Names 6.3 Relay Card Part Names Relay card (8) (9) (10) DCIN EMG LED2 5VON LED3 LED1 (7) (6) (3) (11) HANDLE (5) (1) EMG1 CF61 RS232C ENC#2 (2) (4) List of connectors No. (1) (2) (3) Name CF61 ENC#2 HANDLE (4) RS232C (5) (6) EMG1 DCIN Function details This is used in the connection with the NC Card. An F011 cable is connected. This is connected to the encoder 2nd channel (2nd spindle encoder). This is connected to the manual pulse generator. Up to 3 channels can be connected. This is connected to the RS-232C. One channel can be connected. Note that only the DC code (X ON/OFF) method handshake is possible. This is connected to the external emergency stop switch. 24VDC is supplied by external power. Refer to "3.1 General Specifications" for power specifications. LED list No. Name (7) 5VON (8) (9) LED1 LED2 (10) LED3 (11) EMG Function details This is the LED for the circuit power 5VDC output display. Not in use Not in use Not in use This is the LED for the NC system emergency stop display. When lit (green): Outputting 5VDC. When not lit: 5VDC output OFF. When lit (red): System in emergency stop When not lit: Normal CAUTION Do not apply voltages on the connector other than those indicated in this manual. Doing so may lead to destruction or damage. Incorrect connections may damage the devices, so connect the cables to the specified connectors. Do not connect or disconnect the connection cables between each unit while the power is ON. Do not connect or disconnect any PCB while the power is ON. 45 6. Relay Card (HR682) Connection 6.4 Relay Card Connector Pin Assignment 6.4 Relay Card Connector Pin Assignment NC Card 13 1 CF61 26 Connector pin assignment: Refer to "4.3 NC Card connector pin assignment" (Relay card: CF61). 14 Plug : 10126-6000EL Shell : 10326-3210-000 Recommended manufacturer: Sumitomo 3M Spindle encoder 1 5 ENC#2 9 1 2 3 4 5 6 Connector : CDE-9PF Contact : CD-PC-111 Case : HDE-CTH Recommended manufacturer: Hirose Electric I I I (Note) ENC2A ENC2B ENC2Z GND GND 6 7 8 9 I I I O ENC2A* ENC2B* ENC2Z* +5V I/O in the table is from the viewpoint of the relay card. Manual pulse generator HANDLE 8 15 1 9 Connector : CDA-15P Contact : CD-PC-111 Case : HDA-CTH Recommended manufacturer: Hirose Electric 46 1 2 3 4 5 6 7 8 I I I I I I (Note) HA1A HA1B HA2A HA2B HA3A HA3B 9 10 11 12 13 14 15 GND +12V GND +12V GND +12V I/O in the table is from the viewpoint of the relay card. 6. Relay Card (HR682) Connection 6.4 Relay Card Connector Pin Assignment RS-232C device RS232C 1 2 O 3 I 4 5 6 O 7 8 9 10 11 12 13 1 13 14 25 Connector : CDA-25P Contact : CD-PC-111 Case : HDA-CTH Recommended manufacturer: Hirose Electric FG TD RD DR GND 14 15 16 17 18 19 20 21 22 23 24 25 I DC (Note) I/O in the table is from the viewpoint of the relay card. This connector shows the minimum required pin assignment for the RS-232C interface. Refer to "Appendix 2.18 F390 Cable" for details on manufacturing the cable. 1 +24VDC input 2 3 1 2 3 DCIN +24V GND FG (Note) Connector : 2-178288-3 Contact : 1-175218-5 Recommended manufacturer: Tyco Electronics AMP Emergency stop 1 2 I/O in the table is from the viewpoint of the relay card. 3 1 2 3 EMG1 I (Note) Connector : 2-178288-3 Contact : 1-175218-5 Recommended maker: Tyco Electronics AMP EMG GND FG I/O in the table is from the viewpoint of the relay card. CAUTION Do not apply voltages other than those indicated in this manual on the connector. Doing so may lead to destruction or damage. Incorrect connections may damage the devices, so connect the cables to the specified connectors. 47 6. Relay Card (HR682) Connection 6.5 Relay Card Input/Output Specifications 6.5 Relay Card Input/Output Specifications 6.5.1 Relay Card Power Connection Supply the external power (24VDC) input by the DCIN connector. Relay card Stabilized power supply DCIN 24VDC 24VDC GND GND NC FG (Prepare separately) 6.5.2 Emergency Stop Connection The emergency stop input is connected to the EMG1 connector. Stabilized power supply Emergency stop switch EMG1 2.2kΩ R 1 24VDC 2 GND 3 FG FG (Prepare separately) Input conditions Input voltage when external contact is ON Input current when external contact is ON Input voltage when external contact is OFF Input current when external contact is OFF Input signal hold time (Tson) Machine side contact capacity 18V or more 9mA or more 4V or more 1mA or more 40ms or more +30V or more, 16mA or more Tson +24V GND t > 40ms Tson _ CAUTION Do not apply voltages other than those indicated in this manual on the connector. Doing so may lead to destruction or damage. Incorrect connections may damage the devices, so connect the cables to the specified connectors. 48 6. Relay Card (HR682) Connection 6.5 Relay Card Input/Output Specifications 6.5.3 Connection of Spindle Encoder Refer to "5.5.9 Connection of Spindle Encoder" for details. 6.5.4 Manual Pulse Generator Connection Connect the manual pulse generator to the relay card HANDLE connector. The manual pulse generator can be connected to a max. of three channels. Relay card F020/F021/F022 cable HANDLE F021/F022 cable F022 cable (Channel 1) (Channel 2) (Channel 3) Manual pulse generator connection cables Cable name 1 Channel 2 3 F020 cable F021 cable F022 cable : Connection possible Outline drawing: "Appendix 1.8 Manual Pulse Generator (HD60) Outline Drawing" Cable manufacturing drawing: "Appendix 2.12 F020 Cable", "Appendix 2.13 F021 Cable" and "Appendix 2.14 F022 Cable" Connector pin assignment: "6.4 Relay Card Connector Pin Assignment" - Manual Pulse Generator (HANDLE) 6.5.5 RS-232C Device Connection Connect the RS-232C device to the RS-232C connector on the relay card using an F390 cable. The pin assignment for the RS-232C connector differs from a commercially-available RS-232C cable. Refer to the following related sections for details on manufacturing the cable. Note that only the DC code (X ON/OFF) method handshake is possible. Cable manufacturing drawing: "Appendix 2.18 F390 Cable" Connector pin assignment: "6.4 Relay Card Connector Pin Assignment" - RS-232C Device (RS232C) CAUTION Do not apply voltages other than those indicated in this manual on the connector. Doing so may lead to destruction or damage. Incorrect connections may damage the devices, so connect the cables to the specified connectors. 49 6. Relay Card (HR682) Connection 6.6 Installation on the Base I/O Unit 6.6 Installation on the Base I/O Unit A relay card (HR682) can be added on to the base I/O unit. When adding on, install the card using the following procedure. Adding on is only possible with the FCU6-DX2** base I/O unit. Note that adding on is not possible with the FCU6-DX3** and 4**. 1. Remove screw 1 from the base I/O unit. (Fig. 1) 2. Remove screw 2 of the relay card and spacer 1 (screw holes at both ends are female). (Fig. 2) 3. Install the attached spacer 2 (screw holes on one side are male) to the hole of screw 1 that was removed from the base I/O unit. (Fig. 3) 4. Mount the relay card on the base I/O unit, and fix with screw 1 that was removed in step 1. (Fig. 4) 5. Turn the unit over, and fix the screws at the three holes to the three spacer locations. (Fig. 5) This completes the installation of the relay card to the base I/O unit. 0 CF31 CF3 0 CF32 CF34 Remove screw 2 and spacer 1. Remove screw 1. Fig. 2 Fig. 1 0 0 0 CF31 CF3 CF32 Install spacer 2. CF34 CF31 CF3 0 CF32 CF34 Install screw 1. Fig. 3 Fig. 4 Turn the unit over, and fix the screws at the three locations. Fig. 5 50 7. Remote I/O Unit Connection (FCUA-DX1**) 7.1 Outline of Remote I/O Unit 7. Remote I/O Unit Connection (FCUA-DX1**) 7.1 Outline of Remote I/O Unit The eight types of signals that can be input/output from the remote I/O unit (FCUA-DX1**) are shown below according to the type and No. of contacts. Use with serial link connections (MC link B) to the NC Card. When the remote I/O unit is connected with serial links, multiple units can be used as long as the total No. of occupied stations (channels) is within 8 channels. (Refer to "7.14 Setting of Channel No. When Using Multiple Remote I/O Units" for station No. setting details.) Unit name Machine control signals that can be input/output No. of occupied serial link channels FCUA-DX100 Digital input signal (DI) : 32 points (photo coupler insulation) sink/source type Digital output signal (DO) : 32 points (non-insulation) sink type 1 FCUA-DX101 Digital input signal (DI) : 32 points (photo coupler insulation) sink/source type Digital output signal (DO) : 32 points (non-insulation) source type 1 FCUA-DX110 Digital input signal (DI) : 64 points (photo coupler insulation) sink/source type Digital output signal (DO) : 48 points (non-insulation) sink type 2 FCUA-DX111 Digital input signal (DI) : 64 points (photo coupler insulation) sink/source type Digital output signal (DO) : 48 points (non-insulation) source type 2 FCUA-DX120 Digital input signal (DI) : 64 points (photo coupler insulation) sink/source type Digital output signal (DO) : 48 points (non-insulation) sink type Analog output (AO) : 1 point 2 FCUA-DX121 Digital input signal (DI) : 64 points (photo coupler insulation) sink/source type Digital output signal (DO) : 48 points (non-insulation) source type Analog output (AO) : 1 point 2 FCUA-DX130 Digital input signal (DI) : 32 points (photo coupler insulation) sink/source type Digital output signal (DO) : 32 points (non-insulation) sink type Handle input : 2 channels 2 FCUA-DX131 Digital input signal (DI) : 32 points (photo coupler insulation) sink/source type Digital output signal (DO) : 32 points (non-insulation) source type Handle input : 2 channels 2 FCUA-DX140 Digital input signal (DI) Digital output signal (DO) Analog input (AI) Analog output (AO) : : : : 32 points (photo coupler insulation) sink/source type 32 points (non-insulation) sink type 4 points 1 point 2 FCUA-DX141 Digital input signal (DI) Digital output signal (DO) Analog input (AI) Analog output (AO) : : : : 32 points (photo coupler insulation) sink/source type 32 points (non-insulation) source type 4 points 1 point 2 51 7. Remote I/O Unit Connection (FCUA-DX1**) 7.2 Names of Each Remote I/O Unit Section Names of Each Remote I/O Unit Section FCUA-DX10* FCUA-DX11*/FCUA-DX12* Front view Front view (1) (1) (2) (2) (8) (3) (3) (4) (4) (9) Bottom view (10) (1) (Front) (Front) Bottom view (5) Bottom view (6) (7) (Rear) Bottom view (6) (7) (Rear) (Rear) (1) DI-L (machine input signal connector) (2) DS (transfer speed changeover switch) (3) (3) (4) (4) (5) (6) (11) (2) (3) (3) (7) (Rear) Front view (1) (5) (7) Front view (Front) (5) (6) FCUA-DX14* (2) (3) (Front) FCUA-DX13* For changeover of transfer speed. Normally set to left side. DS Not used (3) CS (channel No. changeover switch) 3 4 5 E 7 8 9 A CS 6 (4) DO-L (machine output signal connector) F 0 1 2 7.2 Selection of channel No. B C D (5) RIO1 (serial connection connector #1) (6) RIO2 (serial connection connector #2) Enlarged drawing of DS and CS (7) DCIN (+24VDC power input connector) (8) DI-R (machine input signal connector) (9) DO-R (machine output signal connector) (10) HANDLE (manual pulse generator signal input connector) (11) AIO (analog signal input/output connector) 52 (Note) Baud rate changeover Left side : 2.8Mbps Right side : 1.4Mbps 7. Remote I/O Unit Connection (FCUA-DX1**) 7.3 Connection of Remote I/O Power 7.3 Connection of Remote I/O Power +24VDC is required to run the remote I/O unit. Prepare a stabilized power supply that satisfies the following conditions. Output voltage +24V ±5% Ripple ±5% (P-P) Max. output current FCUA-DX10* 2.4A or more FCUA-DX11* 3.8A or more FCUA-DX12* 3.8A or more FCUA-DX13* 3.4A or more FCUA-DX14* 3.4A or more The +24VDC power for the control circuit is supplied from the connector DCIN on the bottom of the unit or from connectors DI-L, DI-R, DO-L or DO-R on the front. When supplying from the front connector, supply to all corresponding pins. When manufacturing the R300 cable, use the single-end connector CN300 (optional, with one end), and when manufacturing the R301 cable, use the connector set CS301 (optional, with two ends). Machine control panel, electric cabinet, etc. Front Remote I/O unit DI-L DI-R R300 cable or R301 cable DI-L +24VDC RA 0V PL DI-R B1 B1 B2 B2 A1 A1 A2 A2 B1 B1 B2 B2 A1 A1 A2 A2 DO-L DO-R DO-L (Front) DO-R Supply to either method Y DCIN Base R220 cable 1 2 3 Y +24VDC 0V +24VDC 0V FG FG (Rear) Stabilized power (prepare separately) CAUTION Do not apply voltages other than those indicated in this manual on the connector. Doing so may lead to destruction or damage. Incorrect connections could damage the device, so always connect the cable to the designated connector. 53 7. Remote I/O Unit Connection (FCUA-DX1**) 7.4 Outline of Digital Signal Input Circuit 7.4 Outline of Digital Signal Input Circuit The input circuit can be selected from sink type or source type in card units. Input circuit (Machine side) DI-R/DI-L 2.2kΩ 0V 2.2kΩ 0V 2.2kΩ 0V 2.2kΩ 0V 2.2kΩ 0V Control circuit +24VDC A3,B3 COM Sink type (Machine side) DI-R/DI-L +24VDC 2.2kΩ +24VDC 2.2kΩ +24VDC 2.2kΩ +24VDC 2.2kΩ +24VDC 2.2kΩ Control circuit A3,B3 COM 0V Source type 54 7. Remote I/O Unit Connection (FCUA-DX1**) 7.4 Outline of Digital Signal Input Circuit Input conditions The input signals must be used within the following condition ranges. Sink type Input voltage at external contact ON 6V or less Input current at external contact ON 9mA or more Input voltage at external contact OFF 20V or more, 25.2V or less Input current at external contact OFF 2mA or less Tolerable chattering time (T1) 3ms or less Input signal hold time (T2) 40ms or more Input circuit operation delay time (T3, T4) 3ms ≤ T3 Machine side contact capacity +30V or more, 16mA or more T4 ≤ 16ms Source type Input voltage at external contact ON 18V or more, 25.2V or less Input current at external contact ON 9mA or more Input voltage at external contact OFF 4V or less Input current at external contact OFF 2mA or less Tolerable chattering time (T1) 3ms or less Input signal hold time (T2) 40ms or more Input circuit operation delay time (T3, T4) 3ms ≤ T3 Machine side contact capacity +30V or more, 16mA or more T4 ≤ 16ms T2 T2 T1 T1 T3 T1 T4 T1 T3 Sink type T4 Source type 55 7. Remote I/O Unit Connection (FCUA-DX1**) 7.5 Outline of Digital Signal Output Circuit 7.5 Outline of Digital Signal Output Circuit The digital signal output circuit uses a sink type (DX1*0) or source type (DX1*1). Use within the specification ranges shown below. Output circuit (Machine side) DO-R/DO-L +24VDC RA Control circuit R PL Sink type (DX1*0) DO-R/DO-L (Machine side) +24VDC RA Control circuit R PL Source type (DX1*1) Output conditions Insulation method Non-insulation Rated load voltage +24VDC Max. output current 60mA/1 point (fixed value) Output delay time 40µs (Note) An output voltage of more than 60mA per point cannot be flowed. * When using an inductive load such as a relay, always connect a diode (voltage resistance 100V or more, 100mA or more) in parallel to the load. * When using a capacity load such as a ramp, always connect a protective resistor (R=150 Ω) serially to the load to suppress rush currents. (Make sure that the current is less than the above tolerable current including the momentary current.) CAUTION When using an inductive load such as a relay, always connect a diode in parallel to the load. When using a capacity load such as a ramp, always connect a protective resistor serially to the load to suppress rush currents. 56 7. Remote I/O Unit Connection (FCUA-DX1**) 7.6 Outline of Analog Signal Output Circuit 7.6 Outline of Analog Signal Output Circuit The analog signal output circuit can be used only for the FCUA-DX120/DX121/DX140/DX141. Output circuit R R 220Ω AO DAC AO* Output conditions Output voltage 0V~±10V (±5%) Resolution (polarity included) 12 bit (±10V × n/4096) (n = 20 to 211) Load conditions 10kΩ load resistance Output impedance 220Ω 57 7. Remote I/O Unit Connection (FCUA-DX1**) 7.7 Outline of Analog Signal Input Circuit 7.7 Outline of Analog Signal Input Circuit The analog signal output circuit can be used only for the FCUA-DX140/DX141. Input circuit 150Ω ADC AI AI* Input conditions Max. input voltage rating ±15V Resolution (polarity included) 12 bit (±10V × n/2048) (n = 20 to 211) Precision Within ±25mV AD input sampling time (conversion delay) 14.2ms (AI0)/42.6ms (AI1~3) 58 7. Remote I/O Unit Connection (FCUA-DX1**) 7.8 Connection of FCUA-DX10*/13*/14* Unit and Machine Control Signal 7.8 Connection of FCUA-DX10*/13*/14* Unit and Machine Control Signal Type of machine input/output signal and No. of points Input Output 32 points 32 points FCUA-DX10* or FCUA-DX13* or FCUA-DX14* R300 cable/ R301 cable DI-L Machine signal R300 cable/ R301 cable DCIN DO-L RIO2 Machine signal RIO1 The single-end connector CN300 (optional, with one end) includes the DI-L and DO-L connectors. The connector set CS301 (optional) includes the DI-L and DO-L connectors, and two connectors for ∗ connection with the terminal block . ∗ IDEC IZUMI Corporation I/O terminal BX1F-T40 DI-L A3 B3 +24VDC DI-L FCUA-DX100/130/140 A3 B3 COM 0V +24VDC Input circuit sink type 2.2kΩ 0V FCUA-DX101/131/141 Input circuit source type COM 2.2kΩ B1 B2 B1 B2 A1 A2 A1 A2 +24VDC DO-L DO-L Output circuit source type RA RA Output circuit sink type PL Machine control panel B1 B2 A1 A2 PL 0V Control circuit Machine control panel RIO1 1 2 3 Stabilized power +24VDC Control circu it RIO1 DCIN RIO2 B1 B2 A1 A2 Stabilized power 0V FG RIO2 DCIN 1 2 3 +24VDC 0V FG CAUTION Incorrect connections could damage the device, so always connect the cable to the designated connector. Do not connect or disconnect the connection cables between each unit while the power is ON. 59 7. Remote I/O Unit Connection (FCUA-DX1**) 7.8 Connection of FCUA-DX10*/13*/14* Unit and Machine Control Signal FCUA-DX10*/13*/14* Machine side control panel, etc. DI-L When using more than two remote I/O units, the signal assignments will change. Refer to the "PLC Interface Manual (BNP-B2211)" for details. +24VDC DI-L 0V B X00 X01 X02 X03 X04 X05 X06 X07 X08 X09 X0A X0B X0C X0D X0E X0F A X10 X11 X12 X13 X14 X15 X16 X17 X18 X19 X1A X1B X1C X1D X1E X1F COM +24V +24V B COM 0V 0V A 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 DO-L B A Y00 Y10 Y01 Y11 Y02 Y12 Y03 Y13 Y04 Y14 Y05 Y15 Y06 Y16 Y07 Y17 Y08 DO-L Y18 Y09 Y19 Y0A Y1A Y0B Y1B Y0C Y1C Y0D Y1D Y0E Y1E Y0F Y1F +24VDC DO-L RA PL 0V +24V +24V B 0V 0V 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 A Base I/O unit RI01 1 2 TX RX TX RX * +24VDC 3 LG RI02 2 1 TX RX TX RX * X AMP X D-3 3 LG AMP 1 +24V DCIN 2 3 0V FG Y AMP D-3 0V D-3 R-TM Remote I/O unit DCIN (CN220) Connector: 2-178288-3 Contact : 1-175218-5 Manufacturer: Tyco Electronics AMP RIO1/RIO2 (CN211) DI-L/DO-L(CN300) Connector: 1-178288-3 Contact : 1-175218-2 Manufacturer: Tyco Electronics AMP 60 Crimp type connector: 7940-6500SC Manufacturer: Sumitomo 3M Terminator (R-TM) X D-3 AMP Manufacturer: Tyco Electronics AMP 7. Remote I/O Unit Connection 7.9 Connection of FCUA-DX11* Unit and Machine Control Signal 7.9 Connection of FCUA-DX11* Unit and Machine Control Signal Type of machine input/output signal and No. of points Input Output 64 points 48 points FCUA- DX11* R300 cable/ R301 cable DI-L DI- R Machine signal R300 cable/ R301 cable DO- R DO-L DCIN RIO2 Machine signal RIO1 The single-end connector CN300 (optional, with one end) includes the DI-L (DI-R) and DO-L (DO-R) connectors. The connector set CS301 (optional) includes the DI-L (DI-R) and DO-L (DO-R) connectors, ∗ and two connectors for connection with the terminal block . ∗ IDEC IZUMI Corporation I/O terminal BX1F-T40 FCUA- DX110 DI- L/R A3 B3 +24VDC DI- L/R COM A3 B3 0V Input circuit sink type 2.2kΩ 0V +24VDC FCUA- DX111 2.2kΩ B1 B2 A1 A2 B1 B2 A1 A2 +24VDC DO- L/R DO- L/R Output circuit source type RA RA Output circuit sink type PL Machine control panel Input circuit source type COM B1 B2 A1 A2 PL 0V Control circuit Machine control panel RIO1 Control circu it RIO1 DCIN RIO2 B1 B2 A1 A2 1 2 3 1 2 3 Stabilized power +24VDC DCIN RIO2 Stabilized power 0V FG +24VDC 0V FG CAUTION Incorrect connections could damage the device, so always connect the cable to the designated connector. Do not connect or disconnect the connection cables between each unit while the power is ON. 61 7. Remote I/O Unit Connection 7.9 Connection of FCUA-DX11* Unit and Machine Control Signal When using two or more remote I/O units, the signal allocation will differ. Refer to the "PLC interface manual" for details. Machine side control panel, etc. +24VDC FCUA-DX11* DI-L DI-R DO-L DO-R DI-L 0V DI-R +24VDC 0V DO-L +24VDC 0V DO-R +24VDC 0V +24VDC Base I/O unit 0V R-TM Remote I/O unit DCIN (CN220) RIO1/RIO2 (CN211) Connector : 2-178288-3 Contact : 1-175218-5 Manufacturer : Tyco Electronics AMP DI-L/DO-L (CN300) Connector : 1-178288-3 Contact : 1-175218-2 Manufacturer : Tyco Electronics AMP 62 Crimp type connector: 7940-6500SC Manufacturer: Sumitomo 3M Terminator (R-TM) Manufacturer: Tyco Electronics AMP 7. Remote I/O Unit Connection 7.10 Connection of FCUA-DX12* Unit and Machine Control Signal 7.10 Connection of FCUA-DX12* Unit and Machine Control Signal Type of machine input/output signal and No. of points Input Output Analog output 64 points 48 points 1 point FCUA-DX12* R300 cable/ R301 cable DI-L DI-R Machine signal R300 cable/ R301 cable DCIN DO-R DO-L RIO2 Machine signal RIO1 The single-end connector CN300 (optional, with one end) includes the DI-L (DI-R) and DO-L (DO-R) connectors. The connector set CS301 (optional) includes the DI-L (DI-R) and DO-L (DO-R) connectors, and two connectors for connection with the terminal block ∗. ∗ IDEC IZUMI Corporation I/O terminal BX1F-T40 FCUA- DX120 DI- L/R A3 +24VDC CO M A3 CO M 0V B3 Input circuit sink type 2.2kΩ FCUA- DX121 DI- L/R Input circuit source type B3 +24VDC 2.2kΩ 0V B1 B2 A1 A2 B1 B2 A1 A2 +24VDC DO- L/R DO- L/R Output circuit source type RA RA Output circuit sink type PL Machine control panel B1 B2 A1 A2 B4 A4 0V Control circuit Machine control panel R DO - R Analog out PL R DAC Analog out 220Ω RIO1 RIO2 DCIN B1 B2 A1 A2 Control circu it R DO- R B4 A4 R RIO1 1 2 3 Stabilized power +24VDC Stabilized power 0V FG DAC 220Ω RIO2 DCIN 1 2 3 +24VDC 0V FG CAUTION Incorrect connections could damage the device, so always connect the cable to the designated connector. Do not connect or disconnect the connection cables between each unit while the power is ON. 63 7. Remote I/O Unit Connection 7.10 Connection of FCUA-DX12* Unit and Machine Control Signal When using two or more remote I/O units, the signal allocation will differ. Refer to the "PLC interface manual" for details. Machine side control panel, etc. +24VDC FCUA-DX12* DI-L DI-R DO-L DO-R DI-L 0V DI-R +24VDC 0V +24VDC DO-L 0V DO-R +24VDC 0V +24VDC Base I/O unit 0V R-TM Remote I/O unit DCIN (CN220) Connector : 2-178288-3 Contact : 1-175218-5 Manufacturer : Tyco Electronics AMP RIO1/RIO2 (CN211) Connector : 1-178288-3 Contact : 1-175218-2 Manufacturer : Tyco Electronics AMP 64 DI-L/DO-L (CN300) Crimp type connector: 7940-6500SC Manufacturer: Sumitomo 3M Terminator (R-TM) Manufacturer: Tyco Electronics AMP 7. Remote I/O Unit Connection 7.11 Connection of FCUA-DX13* Unit and Handle 7.11 Connection of FCUA-DX13* Unit and Handle To connect the manual pulse generator, the R041 or R042 cable is connected to "HANDLE". Up to two manual pulse generators can be connected. When manufacturing the R041 or R042 cable, use the connector set CS000 (optional, with two ends). (Refer to Appendix 2.4 R041 Cable, and Appendix 2.5 R042 Cable for cable details.) To Connect one manual pulse generator Manual pulse generator FCUA-HD60 Rear view FCUA-DX13* NO.1 HANDLE 12V 0V A B 4-M3 R041 cable To connect two manual pulse generators Manual pulse generator FCUA-HD60 Rear view 20 10 11 1 Pin No. NO.1 NO.2 12V 0V A B 12V 0V A B HANDLE 4-M3 R042 cable SEL* FCUA-DX13* When connecting the second manual pulse generator, connect the SEL* signal to the No. 1's 0V. CAUTION Incorrect connections could damage the device, so always connect the cable to the designated connector. Do not connect or disconnect the connection cables between each unit while the power is ON. 65 7. Remote I/O Unit Connection 7.12 Outline of FCUA-DX13* Unit Pulse Input Circuit 7.12 Outline of FCUA-DX13* Unit Pulse Input Circuit When connecting a device (pulse generator) other than the manual pulse generator to the FCUA-DX13* unit, use within the following specifications. Input/output conditions Input pulse signal format 2 signals of A-phase and B-phase potential difference 90 degrees (Refer to waveform below) Input voltage H level 3.5V or more, L level 1.0V or less Max. frequency of input pulse 100kHz Output voltage 12V ± 10% Max. output current 300mA Input waveform The difference of the input waveform potential must be ± 45 degrees or less. A(B) phase e: Rising edge potential difference of A-phase or B-phase B(A) phase T: A or B-phase cycle (min. 10µs) e T Input/output circuit FCUA-DX13* Connector pin No. +5V 470 Ω HA2 HB2 3 470 Ω 13 Input 220 Ω +5V 4700pF 220 Ω 4700pF +5V 470 Ω HA1 HB1 Output 4 470 Ω 14 +12V 6 0V 1 220 Ω +5V 4700pF 220 Ω 4700pF Control circuit HC14 phase or equivalent The R041-3M (for one unit) and R042-3M (for two units) are available for the handle cables. 66 7. Remote I/O Unit Connection 7.13 Connection of FCUA-DX14* Unit and Analog Input/Output Signal 7.13 Connection of FCUA-DX14* Unit and Analog Input/Output Signal For the analog input/output signal, the R031 cable is connected to "AIO". Up to four input points and one output point of the analog input/output signal can be connected. When manufacturing the R031, use the connector set CS000 (optional, with two ends). (Refer to the Appendix 2.3. R031 cable.) FCUA-DX14 AIO R031 cable 20 10 11 1 Pin No. Input/output circuit FCUA-DX14* Connector pin No. AI0 Input 2 AI1 12 AI2 3 AI3 13 150 Ω 150 Ω 150 Ω ADC 150 Ω R Output AO 7 R 220 Ω DAC GND 1 GND 11 GND 5 GND 15 CAUTION Incorrect connections could damage the device, so always connect the cable to the designated connector. Do not connect or disconnect the connection cables between each unit while the power is ON. 67 7. Remote I/O Unit Connection 7.14 Setting of Channel No. when Using Multiple Remote I/O Units 7.14 Setting of Channel No. when Using Multiple Remote I/O Units When the remote I/O unit is connected with serial links (MC link B), multiple units can be used as long as the total No. of occupied channels is within 8 channels. Unit name FCUA-DX10* FCUA-DX11* FCUA-DX12* FCUA-DX13* FCUA-DX14* No. of occupied serial link channels 1 2 2 2 2 When using multiple remote I/O units, a characteristic station No. must be set for each unit. The FCUA-DX10* unit has one station No. setting switch, and FCUA-DX11*, DX12*, DX13* and DX14* units have two switches. Each of these switches must be set to a characteristic station No. The device address in each unit is determined according to the station No. Use the station No. setting switch to set the device address. Relation between rotary switches and device assignments Setting value 0 1 2 3 4 5 6 7 8~F Station No. 0 1 2 3 4 5 6 7 Device assignment DI DO X00~X1F Y00~Y1F X20~X3F Y20~Y3F X40~X5F Y40~Y5F X60~X7F Y60~Y7F X80~X9F Y80~Y9F XA0~XBF YA0~YBF XC0~XDF YC0~YDF XE0~XFF YE0~YFF Cannot be used No. of I/O points (max) 32 points 32 points 32 points 32 points 32 points 32 points 32 points 32 points Device assignment Rotary switch Station setting value No. DI DO 0 0 X00~X1F Y00~Y1F 1 1 X20~X3F Y20~Y3F 2 2 X40~X5F Y40~Y5F 3 3 X60~X7F Y60~Y7F 4 4 X80~X9F Y80~Y9F (Note) Refer to the next page for a configuration example. Device assignment Rotary switch Station setting value No. DI DO 0 0 X00~X1F Y00~Y1F 1 1 X20~X3F Y20~Y3F 2 2 X40~X5F Y40~Y5F 3 3 X60~X7F Y60~Y7F 4 4 X80~X9F Y80~Y9F 5 5 XA0~XBF YA0~YBF 6 6 XC0~XDF YC0~YDF 7 7 XE0~XFF YE0~YFF (Note) Refer to the next page for a configuration example. 68 7. Remote I/O Unit Connection 7.14 Setting of Channel No. when Using Multiple Remote I/O Units Configuration for on the previous page FCU6-DX22* unit CS2 CS1 FCUA-DX11* unit or FCUA-DX12* unit FCUA-DX10* unit 0 1 No. of occupied channels: 2 + + 2 3 No. of occupied channels: 1 4 No. of occupied channels: 2 Total No. of occupied cannels: 5 Configuration for on the previous page FCUA-DX11* unit or FCUA-DX12* unit: 3 units FCU6-DX21* unit + 0 1 No. of occupied channels: 2 + 2 3 No. of occupied channels: 2 + 4 5 6 7 No. of occupied No. of occupied channels: 2 channels: 2 Total No. of occupied channels: 8 (Max. configuration) (Note) In MELDASMAGIC64, the base I/O unit normally occupies station Nos. 0 and 1. Both of the examples above are configuration examples when connected to RIO1 (Part system 1) connectors. 69 7. Remote I/O Unit Connection 7.15 Remote I/O Unit Input/Output Signal Cables 7.15 Remote I/O Unit Input/Output Signal Cables There are two types of remote I/O unit digital input/output signal cables; the R300 and R301. The R300 cable has one end cut off. The R301 cable is a cable for connecting to the terminal block ∗. R300-3M and R301-3M are available If a cable longer than 3m is required, use the connector set CN300 or CS301. The R041-3M (for one unit) and R042-3M (for two units) are available for the handle cables. For the analog input/output cable, the R031 cable must be manufactured by the user. ∗ IDEC IZUMI Corporation I/O terminal BX1F-T40A Machine control panel, power distribution panel, etc. R300 cable BX1F-T40A IDEC 2 4 6 8 10 12 14 16 18 20 2224 26 28 30 32 34 36 38 40 PL 1 3 5 7 9 1113 15 17 19 2123 25 2729 31 33 35 37 39 RA R301 cable Connector pin correspondence table Terminal block BX1F 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 DX1** A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 Terminal block BX1F 2 4 6 DX1** B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B18 B19 B20 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 70 Appendix 1 Outline Drawings Appendix 1.1 ISA NC Card Outline Drawing (HR621) Appendix 1 Outline Drawings Appendix 1.1 ISA NC Card Outline Drawing (HR621) 248.9 CF61 CF10 100 120 DPADR IOPADR IRQ ISABUS Appendix 1.2 CF61 CIO NCLED CF10 BAT ISABUS ISA NC Card Outline Drawing (HR623) 248.9 CF61 120 100 IRQ IOPADR DPADR CF10 CIO CF61 NCLD1 CF10 BAT ISABUS ISABUS 71 Appendix 1 Outline Drawings Appendix 1.3 PCI NC Card Outline Drawing (FCU6-HR655) Appendix 1.3 PCI NC Card Outline Drawing (FCU6-HR655) 174.63 CDNO NCLD CF61 CF10 TESTISP SW1 CF63 PCIBUS 72 PCIBUS 106.71 CF61 BAT 120 CF10 CF62 Appendix 1 Outline Drawings Appendix 1.4 Base I/O Unit Outline Drawing Appendix 1.4 Base I/O Unit Outline Drawing 6 4-M5 screw hole E D C AB E C D AB 8 79 79 8 56 234 F10 56 234 0 1 F ENC1 SKIP CF10 SV2 SV1 156 CF31 CF32 CF33 CF34 6 RIO2 RIO1DCIN 6 208 6 220 Add-on PCB 73 168 CR31 Appendix 1 Outline Drawings Appendix 1.5 Relay Card (independent installation) Outline Drawing Appendix 1.5 Relay Card (independent installation) Outline Drawing 70 51 5 19 90 73 4-M3 screw hole EMG1 17 HANDLE 146 156 DCIN 46 46 CF61 RS232C 5 10 10 ENC#2 91 19 91 5 115 Spacer Screw diameter: M3×0.5 Outline diameter: Ø8 or less Length: 6mm or more 74 Appendix 1 Outline Drawings Appendix 1.6 Base I/O Unit + Relay Card (add-on) Outline Drawing Appendix 1.6 Base I/O Unit + Relay Card (add-on) Outline Drawing B CDE A 78 9 CD 3 456 3 4 56 78 9 AB F01 2 F01 2 E 6 4-M5 screw hole ENC1 SKIP DCIN CF10 SV2 SV1 HANDLE RIO2 RIO1DCIN EMG1 CF61 RS232C 6 ENC#2 6 208 220 75 6 168 CF31 CF32 CF33 CF34 156 CR31 Appendix 1 Outline Drawings Appendix 1.7 Remote I/O Unit Outline Drawing Appendix 1.7 Remote I/O Unit Outline Drawing 168 135 Heat dissipation allowance 100 Top 150 70 Wiring allowance 135 Bottom Installation hole 6 2-M5-0.8 screw 6 156 DX 34 76 6 Heat dissipation, wiring allowance 6 40 Appendix 1 Outline Drawings Appendix 1.8 Manual Pulse Generator (HD60) Outline Drawing Appendix 1.8 Manual Pulse Generator (HD60) Outline Drawing 3-M4 stud bolts L10 16 24 Ø80 ± 1 Ø60 ± 0.5 Rubber shield t2.0 Ø60 ± 0.5 +12V 12V0V 0V AA BB 8.89 27 ± 0.5 3 - Ø4.8 hole ec t io Uniform Ø62 0° ris (T n) 12 Ø77 ± 0.5 3.6 +2 0 Ø72 ± 0.2 Panel cut drawing 77 7.60 Installation other than M3 x 6 not possible Appendix 1 Outline Drawings Appendix 1.9 Spindle Encoder (OSE-1024-3-15-68) Outline Drawing Appendix 1.9 Spindle Encoder (OSE-1024-3-15-68) Outline Drawing 68 Caution plate 56 56 68 Ø 50 Ø 68 -0.009 -0.025 Detector (1024P/rev) 4 - Ø5.4 hole 20 28 2 5 3 19.5 33 102 135 0 Ø14.3 -0.11 Encoder side : 97F3102E20-29P (or equivalent) Applicable cable side : MS3106A20-29S -0.012 5 -0.042 +0.14 1.15 0 1.15 3 +0.1 0 -0.009 -0.025 Ø50 Ø16 Ø15 -0.006 -0.017 2 +0.14 0 Cross-section BB 26 The effective depth of the key way is 21mm 2 Enlarged view of key A 1chA K B 2chZ L C 3chB M D N 1chA P 2chZ F R 3chB G S E H J 78 0V Case grounding +5V T Appendix 1 Outline Drawings Appendix 1.10 Grounding Plate and Clamp Fitting Outline Drawings Appendix 1.10 Grounding Plate and Clamp Fitting Outline Drawings The shield wire generally only needs to be grounded to the connector's case frame. However, the effect can be improved by directly grounding to the grounding plate as shown on the right. Install the grounding plate near each unit. Peel part of the cable sheath as shown on the right to expose the shield sheath. Press that section against the grounding plate with the clamp fitting. Note that if the cable is thin, several can be clamped together. Install the grounding plate directly onto the cabinet or connect a grounding wire so that sufficient frame grounding is achieved. If the AERSBAN- SET, containing the grounding plate and clamp fitting, is required, please contact Mitsubishi. Cable Presser Grounding plate 40 Clamp fitting (Fitting A,B) Shield sheath Clamp section drawing • Outline drawing Presser outline drawing 17.5 2-Ø5 hole 24 0 -0.2 7 Installation hole 20+0.3 0 6 35 29 7 3 24 3 0 -0.2 a c b ± 0.3 3 12 Grounding plate outline drawing 6 Clamp metal fitting outline drawing 22 35 11 30 Note 1 M4 screw 10 24+0.3 0 MAX L Note 1) Screw hole for wiring to cabinet's grounding plate Note 2) The grounding plate thickness is 1.6mm a b c Enclosed fittings AERSBAN-DSET 100 86 30 Two clamp fittings A Clamp fitting A 70 AERSBAN-ESET 70 56 – One clamp fitting B Clamp fitting B 45 (Note) a, b and c in the table are symbols in the outline drawing of the grounding plate. 79 L (Note) L in the table is a symbol in the outline drawing of the clamp metal fittings. Appendix 2 Cable Manufacturing Drawings Appendix 2 Cable Manufacturing Drawings Cable type name table No. 1 2 3 4 5 6 Appendix No. Appendix 2.1 Appendix 2.2 Appendix 2.3 Appendix 2.4 Appendix 2.5 Appendix 2.6 Cable type SH21 cable SH41 cable R031 cable R041 cable R042 cable R211 cable Application Servo drive unit Remote I/O Analog input/output Manual pulse generator: 1ch Manual pulse generator: 2ch Remote I/O Max. length * 30m * 50m 30m 50m 50m * 50m 7 8 9 10 11 12 Appendix 2.7 Appendix 2.8 Appendix 2.9 Appendix 2.10 Appendix 2.11 Appendix 2.12 R220 cable R300 cable R301 cable F010 cable F011 cable F020 cable DC +24V input, emergency stop DI/DO: Single-end connector DI/DO: Double-end connector I/O interface: Base I/O unit I/O interface: Relay card Manual pulse generator: 1ch 30m 50m 50m 20m 15m 50m 13 14 15 16 17 18 19 Appendix 2.13 Appendix 2.14 Appendix 2.15 Appendix 2.16 Appendix 2.17 Appendix 2.18 Appendix 2.19 F021 cable F022 cable F040 cable F041 cable F070 cable F390 cable ENC-SP1 cable Manual pulse generator: 2ch Manual pulse generator: 3ch Spindle encoder: Straight Spindle encoder: Right angle DC +24V input, emergency stop RS232C: 1ch Spindle drive unit 50m 50m * 50m * 50m 30m 15m 50m Remarks * For the cables marked with * in the Max. length column: The cable length (L1) is the length from the NC Card to the base I/O unit and relay card. The cable length (L2) is the length from the base I/O unit and relay card to each unit. Keep the total cable length (L1 + L2) within the maximum cable length. Maximum cable length L1 NC card L2 Base I/O unit F010 SV1 SV2 RIO1 RIO2 SH21 SH41 (R211) ENC1 F040/041 Spindle encoder F040/041 Spindle encoder Servo drive unit Remote I/O unit Relay card F011 ENC#2 Symbols for writing cable manufacturing drawing The following symbols are used in the cable manufacturing drawing. 1. indicates twist. 2. indicates the shield sheath. 3. indicates shield clamping to the ground plate. 4. In the cable manufacturing drawings, the partner of the twisted pair cable is given a priority, so the pin Nos. of the connectors at both end are not necessary in number of order. 5. Equivalent parts can be used for the connector, contact and wire material. 80 Appendix 2 Cable Manufacturing Drawings As a rule, the cables used with this product are not available from Mitsubishi, excluding the cables connected between the Mitsubishi devices. Thus, manufacture the required cables using the cable manufacturing drawings on the following pages as a reference. Note that the cable-compatible connectors are available from Mitsubishi as the cable set (Appendix 2.20). If crimp tools are not available when manufacturing the power supply cable (F070, R220) and RIO communication cable (SH41, R211), the cables can be manufactured by soldering a wire and connector as shown in the following procedure. 2. Insert the wire into the contact. Hold the sheath keep. 1. Carry out preparatory soldering. (Remove 3.5mm of the sheath.) Soldering iron Contact Wire Solder 3. Lightly press down one side of the wire barrel using radio pliers. Wire barrel 4. Firmly press down the other side of the wire barrel. (Press firmly enough that the wire will not come out when pulled lightly.) This is a barrier to prevent mis-insertion. Do not bend. Radio pliers 5. Firmly press down the sheath keeps in the same manner as the wire barrel. 6. Apply the soldering iron, and melt the preparatory solder inside. Better results will be achieved if an additional, small amount of solder is applied then. Sheath keep Soldering iron Contact section 7. Lastly, insert the soldered contact into the housing. Be careful that the solder does not flow into the contact section. Pay attention to the insertion direction. 81 Appendix 2 Cable Manufacturing Drawings 2.1 SH21 Cable (Servo drive unit) Cable type name: SH21 cable Appendix 2.1 Application: Base I/O unit – Servo drive unit connection Servo drive unit – Servo drive unit connection, etc. Assembly drawing (1)(2) List of parts used (1)(2) No. (3) Part name 1 Plug 2 Shell 3 Wire material SH21 Recommended part type Sumitomo 3M 10120-6000EL Sumitomo 3M 10320-3210-000 Toyokuni Electric Cable UL20276 AWG28 × 10P Qty 2 2 (1) SH21 Connection diagram Maximum cable length: 30m 1 11 1 11 2 12 2 12 3 13 3 13 4 14 4 14 5 15 5 15 6 16 6 16 7 17 7 17 8 18 8 18 9 19 9 19 10 20 10 20 Case frame Case frame FG FG Manufacturing precautions (1) The wire material shall be a shielded, 10-pair stranded cable equivalent to UL20276 Standard AWG28 (0.08mm2). (2) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications. (3) Attach the nameplate with protective cover stamped with the cable name in the position designated in the assembly drawing. (4) Fold the wire material shield over the sheath, and wrap copper foil tape over it. Connect the copper foil tape wrapped around the sheath to a connector GND plate. (5) Part No. 1 (plug) and part No. 2 (shell) are solderless types. If soldering types are required, use parts equivalent to 10120-3000VE for the plug and 10320-52FO-008 for the shell (both parts manufactured by Sumitomo 3M). 82 Appendix 2 Cable Manufacturing Drawings 2.2 SH41 Cable (Remote I/O unit) Cable type name: SH41 cable Appendix 2.2 Application: Base I/O unit – Remote I/O unit connection Remote I/O unit – Remote I/O unit connection Assembly drawing List of parts used No. (1)(2) (1)(2) (3) Part name Connector 2 Contact 3 Wire material X 1 SH41 Recommended part type Tyco Electronics AMP 1-178288-3 Tyco Electronics AMP 1-175218-2 Takeuchi Densen 2 MVVS 3C × 0.3mm 2 (MIC 3C × 0.3 mm ) Qty 2 6 (1) SH41 Connection diagram Maximum cable length: 50m TXRX 1 1 TXRX TXRX* 2 2 TXRX* GND 3 3 GND Manufacturing precautions (1) The wire material shall be a shielded, 3-core cable equivalent to AWG22 (0.3mm2). (2) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications. (3) Attach the nameplate with protective cover stamped with the cable name in the position designated in the assembly drawing. (4) Protect both ends of the wire with an insulating bush. 83 Appendix 2 Cable Manufacturing Drawings 2.3 R031 Cable (Analog signal input/output) Cable type name: R031 cable Appendix 2.3 Application: Analog signal input/output Option (compatible connector set) FCUA-CS000 (Note that this is only compatible with the remote I/O unit side.) Assembly drawing Remote I/O unit side Analog input/output signal (1)(2) No. (4) (3) List of parts used Part name 1 Plug 2 Shell R031 3 4 Wire material Crimp terminal Recommended part type Sumitomo 3M 10120-3000VE Sumitomo 3M 10320-52F0-008 UL1061-2464 AWG22 × 6P J.S.T. Mfg V1.25-4 Qty 1 1 (1) 10 R031 Connection diagram Maximum cable length: 30m Remote I/O unit side Analog input/output signal 2 1 AI0 GND 12 11 AI1 GND 3 5 AI2 GND 13 15 AI3 GND 7 AO GND Case frame FG Manufacturing precautions (1) The wire material shall be a shielded, 6-pair stranded cable equivalent to UL1061-2464 Standard AWG22 (0.3mm2). (2) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications. (3) Attach the nameplate with protective cover stamped with the cable name in the position designated in the assembly drawing. (4) Fold the wire material shield on the remote I/O unit side over the sheath, and wrap copper foil tape over it. Connect the copper foil tape wrapped around the sheath to a connector GND plate. (5) Stamp the name of each signal on the crimp terminal side mark tube and install. (6) Insulate the crimp terminals of unused signal wires with vinyl tape, etc. (7) Part 1 (plug) is usually used for wire material of AWG 24 (0.2mm2) or less in the catalog specifications, but AWG 22 (0.3mm2) can also be used. 84 Appendix 2 Cable Manufacturing Drawings 2.4 R041 Cable (Manual pulse generator) Cable type name: R041 cable Appendix 2.4 Application: Remote I/O unit – Manual pulse generator connection (when one manual pulse generator is connected) Assembly drawing Remote I/O unit side Manual pulse generator side (1)(2) (3) Option (compatible connector set) FCUA-CS000 (Note that this is only compatible with the remote I/O unit side.) (4) List of parts used No. Part name 1 Plug 2 Shell R041 3 R041 4 Wire material Crimp terminal Recommended part type Sumitomo 3M 10120-3000VE Sumitomo 3M 10320-52F0-008 UL1061-2464 AWG22 × 6P J.S.T. Mfg V1.25-4 Qty 1 1 (1) 5 Connection diagram Maximum cable length: 30m Remote I/O unit side Manual pulse generator side 1 11 GND 4 14 HA1 HB1 5 15 GND 6 16 +12V Case frame FG Manufacturing precautions (1) The wire material shall be a shielded, 6-pair stranded cable equivalent to UL1061-2464 Standard AWG22 (0.3mm2). (2) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications. (3) Attach the nameplate with protective cover stamped with the cable name in the position designated in the assembly drawing. (4) Fold the wire material shield on the remote I/O unit side over the sheath, and wrap copper foil tape over it. Connect the copper foil tape wrapped around the sheath to a connector GND plate. (5) Stamp the name of each signal on the crimp terminal side mark tube and install. (6) Part 1 (plug) is usually used for wire material of AWG 24 (0.2mm2) or less in the catalog specifications, but AWG 22 (0.3mm2) can also be used. 85 Appendix 2 Cable Manufacturing Drawings 2.5 R042 Cable (Manual pulse generator) Cable type name: R042 cable Appendix 2.5 Application: Remote I/O unit – Manual pulse generator connection (when two manual pulse generator is connected) Assembly drawing Manual pulse generator side Remote I/O unit side (4) Option (compatible connector set) FCUA-CS000 (Note that this is only compatible with the remote I/O unit side.) (1)(2) List of parts used (3) No. R042 R042 Part name 1 Plug 2 Shell 3 Wire material 4 Crimp terminal Recommended part type Sumitomo 3M 10120-3000VE Sumitomo 3M 10320-52F0-008 Wire material UL1061-2464 AWG22 × 6P J.S.T. Mfg V1.25-4 Qty 1 1 (1) 9 Connection diagram Maximum cable length: 30m Remote I/O unit side Manual pulse generator side 1 11 GND 2 SEL* 3 13 HA2 HB2 Channel 2 4 14 HA1 HB1 Channel 1 5 15 GND 6 16 +12V Case frame FG (When using channel 2, connect the SEL* signal to the GND.) Manufacturing precautions (1) The wire material shall be a shielded, 6-pair stranded cable equivalent to UL1061-2464 Standard AWG22 (0.3mm2). (2) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications. (3) Attach the nameplate with protective cover stamped with the cable name in the position designated in the assembly drawing. (4) Fold the wire material shield on the remote I/O unit side over the sheath, and wrap copper foil tape over it. Connect the copper foil tape wrapped around the sheath to a connector GND plate. (5) Stamp the name of each signal on the crimp terminal side mark tube and install. (6) Part 1 (plug) is usually used for wire material of AWG 24 (0.2mm2) or less in the catalog specifications, but AWG 22 (0.3mm2) can also be used. 86 Appendix 2 Cable Manufacturing Drawings 2.6 R211 Cable (Remote I/O unit) Cable type name: R211 cable Appendix 2.6 Application: Base I/O unit – Remote I/O unit connection Remote I/O unit – Remote I/O unit connection Option (compatible connector set) FCUA-CN211 (Note that there is a single-end connector and contact, with no crimp terminal.) Assembly drawing (1)(2) (1)(2) (3) List of parts used X No. Part name R211 (5) R211 (4) 1 Connector 2 Contact 3 Wire material 4 5 Recommended part type Tyco Electronics AMP 1-178288-3 Tyco Electronics AMP 1-175218-2 Takeuchi Densen 2 MVVS 3C × 0.5 mm 2 (MIC 3C × 0.5 mm ) Crimp terminal Crimp terminal J.S.T. Mfg V1.25-3 J.S.T. Mfg V1.25-5 Qty 2 6 (1) 1 1 Connection diagram Maximum cable length: 50m TXRX TXRX* GND 1 2 3 1 2 3 FG TXRX TXRX* GND FG Manufacturing precautions (1) The wire material shall be a shielded, 3-core cable equivalent to AWG20 (0.5mm2). (2) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications. (3) Attach the nameplate with protective cover stamped with the cable name in the position designated in the assembly drawing. (4) Protect both ends of the wire with an insulating bush. (5) Connect the crimp terminal attached to the shield to the frame ground of the base I/O unit or remote I/O unit. Note that for noise resistance improvement, in some cases only one end is connected, both ends are connected or neither end is connected. 87 Appendix 2 Cable Manufacturing Drawings 2.7 R220 Cable (+24VDC input) Cable type name: R220 cable Appendix 2.7 Application: +24V supply to the base I/O unit, relay card and remote I/O unit Input of emergency stop signal to the relay card Assembly drawing (1)(2) Option (compatible connector set) FCUA-CN220 (Note that this is only compatible with the base I/O unit, relay card and remote I/O unit side connectors.) (4) (3) List of parts used Y R220 No. R220 Part name 1 Connector 2 Contact 3 4 Wire material Crimp terminal Recommended part type Tyco Electronics AMP 1-178288-3 Tyco Electronics AMP 2-175218-5 DDK 2 JPVV-SB 1P × 0.5 mm J.S.T. Mfg V1.25-3 Qty 1 3 (1) 3 Connection diagram Maximum cable length: 30m +24V GND FG 1 2 3 +24V GND FG Manufacturing precautions (1) The wire material shall be a shielded, 1-pair stranded cable equivalent to AWG18 (0.75mm2). If the cable length exceeds 15m, select wire material equivalent to AWG16. (2) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications. (3) Attach the nameplate with protective cover stamped with the cable name in the position designated in the assembly drawing. (4) Stamp the name of each signal on the crimp terminal side mark tube and install. (5) Protect both ends of the wire with an insulating bush. (6) Use shield processing wire material equivalent to AWG18 (0.75mm2). 88 Appendix 2 Cable Manufacturing Drawings 2.8 R300 Cable (Machine input/output) Cable type name: R300 cable Appendix 2.8 Application: Base I/O unit and remote I/O unit – Machine electric cabinet connection Option (compatible connector set) FCUA-CN300 (Note that this is only compatible with the base I/O unit and remote I/O unit side connectors.) List of parts used No. Part name 1 Connector 2 Wire material Recommended part type Sumitomo 3M 7940-6500SC Oki Electric Cable B40-S Qty 1 (1) Assembly drawing Maximum cable length: 50m The No.1 pin cable is colored. Base I/O unit and remote I/O unit side (1) (2) Machine electric cabinet side R300 R300 Manufacturing precautions (1) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications. (2) Attach the nameplate with protective cover stamped with the cable name in the position designated in the assembly drawing. 89 Appendix 2 Cable Manufacturing Drawings 2.9 R301 Cable (Machine input/output) Cable type name: R301 cable Appendix 2.9 Application: Base I/O unit and remote I/O unit – Recommended terminal block Option (compatible connector set) FCUA-CS301 List of parts used No. Part name 1 Connector 2 Wire material 3 Strain relief Recommended part type Sumitomo 3M 7940-6500SC Oki Electric Cable B40-S Sumitomo 3M 3448-7940 Qty 2 (1) 1 Assembly drawing Maximum cable length: 50m The No.1 pin cable is colored. Base I/O unit and remote I/O unit side (1) (1)(3) (2) Recommended terminal block side R301 R301 Manufacturing precautions (1) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications. (2) Attach the nameplate with protective cover stamped with the cable name in the position designated in the assembly drawing. (3) The recommended terminal block is the IDEC IZUMI I/O terminal BX1F-T40. 90 Appendix 2 Cable Manufacturing Drawings 2.10 F010 Cable (NC Card) Cable type name: F010 cable Appendix 2.10 Application: NC Card – Base I/O unit connection Assembly drawing (1)(2) (1)(2) (3) List of parts used No. Part name 1 Plug 2 Shell 3 Wire material F010 Recommended part type Sumitomo 3M 10150-6000EL Sumitomo 3M 10350-321-000 Toyokuni Electric Cable UL20276 AWG28 × 25P Qty 2 2 (1) F010 Connection diagram Maximum cable length: 20m TXRX1 TXRX1* 1 26 1 26 TXRX2 TXRX2* 2 27 2 27 GND GND 3 28 3 28 SKIP1 SKIP1* 4 29 4 29 SKIP2 SKIP2* 5 30 5 30 SKIP3 SKIP3* 6 31 6 31 SKIP4 SKIP4* 7 32 7 32 SKIP5 SKIP5* 8 33 8 33 SKIP6 SKIP6* 9 34 9 34 SKIP7 SKIP7* 10 35 10 35 SKIP8 SKIP8* 11 36 11 36 GND GND 12 37 12 37 ENC1A ENC1A* 13 38 13 38 ENC1B ENC1B* 14 39 14 39 ENC1Z ENC1Z* 15 40 15 40 GND GND 16 41 16 41 SVTXD2 17 SVTXD2* 42 17 42 SVALM2 18 SVALM2* 43 18 43 SVRXD2 19 SVRXD2* 44 19 44 SVEMG2 20 SVEMG2* 45 20 45 GND GND 21 46 21 46 SVTXD1 22 SVTXD1* 47 22 47 SVALM1 23 SVALM1* 48 23 48 SVRXD1 24 SVRXD1* 49 24 49 SVEMG1 25 SVEMG1* 50 25 50 FG Case frame Case frame Manufacturing precautions (1) The wire material shall be a shielded, 25-pair stranded cable equivalent to UL20276 Standard AWG28 (0.08mm2). (2) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications. (3) Attach the nameplate with protective cover stamped with the cable name in the position designated in the assembly drawing. (4) Fold the wire material shield over the sheath, and wrap copper foil tape over it. Connect the copper foil tape wrapped around the sheath to a connector GND plate. (5) Part No. 1 (plug) and part No. 2 (shell) are solderless types. If soldering types are required, use parts equivalent to 10150-3000VE for the plug and 10350-52FO-008 for the shell (both parts manufactured by Sumitomo 3M). FG 91 Appendix 2 Cable Manufacturing Drawings 2.11 F011 Cable (NC Card) Cable type name: F011 cable Appendix 2.11 Application: NC Card – Relay card connection Assembly drawing (1)(2) (3) List of parts used (1)(2) No. F011 Part name 1 Plug 2 Shell 3 Wire material Recommended part type Sumitomo 3M 10126-6000EL Sumitomo 3M 10326-3210-000 Toyokuni Electric Cable UL20276 AWG28 × 15P Qty 2 2 (1) F011 Connection diagram Maximum cable length: 15m TD0 RD0 1 14 1 14 LED1 LED2 2 15 2 15 LED3 3 EMGOUT* 16 3 16 EMGIN EMGIN* 4 17 4 17 GND GND 5 18 5 18 HA1A HA1B 6 19 6 19 HA2A HA2B 7 20 7 20 HA3A HA3B 8 21 8 21 DR0 DC0 9 22 9 22 GND GND 10 23 10 23 EN2A EN2A* 11 24 11 24 EN2B EN2B* 12 25 12 25 EN2Z EN2Z* 13 26 13 26 Case frame Case frame FG FG Manufacturing precautions (1) The wire material shall be a shielded, 15-pair stranded cable equivalent to UL20276 Standard AWG28 (0.08mm2). (2) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications. (3) Attach the nameplate with protective cover stamped with the cable name in the position designated in the assembly drawing. (4) Fold the wire material shield over the sheath, and wrap copper foil tape over it. Connect the copper foil tape wrapped around the sheath to a connector GND plate. (5) Part No. 1 (plug) and part No. 2 (shell) are solderless types. If soldering types are required, use parts equivalent to 10126-3000VE for the plug and 10326-52FO-008 for the shell (both parts manufactured by Sumitomo 3M). 92 Appendix 2 Cable Manufacturing Drawings 2.12 F020 Cable (Manual pulse generator) Cable type name: F020 cable Appendix 2.12 Application: Relay card – Manual pulse generator connection (when one manual pulse generator is connected) Assembly drawing List of parts used No. (4) Relay card side Manual pulse generator side Part name 1 Connector 2 Contact F020 3 4 (5) (1)(2)(3) F020 5 Connector case Wire material Crimp terminal Recommended part type Hirose Electric CDA-15P Hirose Electric CD-PC-111 Hirose Electric HAD-CTH Sumitomo Electric B-22 (19) U × 2SJ-1 × 9 J.S.T. Mfg V1.25-3 Qty 1 4 1 (2) 4 Connection diagram Maximum cable length: 50m Manual pulse generator side Relay card side 1HA 1HB +12V GND 1 2 10 9 1ch FG Case frame Manufacturing precautions (1) The wire material shall be a shielded, 2-pair stranded cable equivalent to AWG22 (0.3mm2). (2) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications. (3) Attach the nameplate with protective cover stamped with the cable name in the position designated in the assembly drawing. (4) Fold the wire material shield on the relay card side over the sheath, and wrap copper foil tape over it. Connect the copper foil tape wrapped around the sheath to a connector GND plate. (5) Stamp the name of each signal on the crimp terminal side mark tube and install. 93 Appendix 2 Cable Manufacturing Drawings 2.13 F021 Cable (Manual pulse generator) Cable type name: F021 cable Appendix 2.13 Application: Relay card – Manual pulse generator connection (when two manual pulse generators are connected) Assembly drawing List of parts used No. (4) Relay card side Manual pulse generator side 1 Connector 2 Contact F021 3 4 F021 (1)(2)(3) 5 F021 Part name Connector case Wire material Crimp terminal Recommended part type Hirose Electric CDA-15P Hirose Electric CD-PC-111 Hirose Electric HAD-CTH Sumitomo Electric B-22 (19) U × 2SJ-1 × 9 J.S.T. Mfg V1.25-3 Qty 1 8 1 (4) 8 (5) Connection diagram Maximum cable length: 50m Relay card side 1HA Manual pulse generator side 1 1HB 2 +12V 10 GND 9 2HA 3 2HB 4 +12V 12 GND 11 1ch 2ch Case frame FG Manufacturing precautions (1) The wire material shall be a shielded, 4-pair stranded cable equivalent to AWG22 (0.3mm2). (2) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications. (3) Attach the nameplate with protective cover stamped with the cable name in the position designated in the assembly drawing. (4) Fold the wire material shield on the relay card side over the sheath, and wrap copper foil tape over it. Connect the copper foil tape wrapped around the sheath to a connector GND plate. (5) Stamp the name of each signal on the crimp terminal side mark tube and install. 94 Appendix 2 Cable Manufacturing Drawings 2.14 F022 Cable (Manual pulse generator) Cable type name: F022 cable Appendix 2.14 Application: Relay card – Manual pulse generator connection (when three manual pulse generators are connected) Assembly drawing List of parts used No. (4) Relay card side Manual pulse generator side 1 Connector 2 Contact F022 3 4 F022 (1)(2)(3) Part name 5 Connector case Wire material Crimp terminal Recommended part type Hirose Electric CDA-15P Hirose Electric CD-PC-111 Hirose Electric HAD-CTH Sumitomo Electric B-22 (19) U × 2SJ-1 × 9 J.S.T. Mfg V1.25-3 Qty 1 12 1 (6) 12 F022 F022 (5) Connection diagram Maximum cable length: 50m Relay card side 1HA Manual pulse generator side 1 1HB 2 +12V 10 GND 9 2HA 3 2HB 4 +12V 12 GND 11 3HA 5 3HB 6 +12V 14 GND 13 1ch 2ch 3ch Case frame FG Manufacturing precautions (1) The wire material shall be a shielded, 6-pair stranded cable equivalent to AWG22 (0.3mm2). (2) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications. (3) Attach the nameplate with protective cover stamped with the cable name in the position designated in the assembly drawing. (4) Fold the wire material shield on the relay card side over the sheath, and wrap copper foil tape over it. Connect the copper foil tape wrapped around the sheath to a connector GND plate. (5) Stamp the name of each signal on the crimp terminal side mark tube and install. 95 Appendix 2 Cable Manufacturing Drawings 2.15 F040 Cable (Spindle encoder) Cable type name: F040 cable Appendix 2.15 Application: Base I/O unit – Spindle encoder (straight) connection Relay card – Spindle encoder (straight) connection Assembly drawing List of parts used No. Base I/O unit and relay card side (4) Spindle encoder (straight) side 1 Connector 2 Contact 3 Connector case 4 Wire material 5 Connector 6 Cable clamp F040 (1)(2)(3) F040 (5)(6) Part name Recommended part type Hirose Electric CDE-9PF Hirose Electric CD-PC-111 Hirose Electric HDE-CTH Bando Electric Wire 2 DPVVSB 6P × 0.2 mm ITT Canon MS3106B20-29S ITT Canon MS3057-12A Qty 1 9 1 (1) 1 1 Connection diagram Maximum cable length: 50m Base I/O unit and relay card side ENC1A (ENC2A) ENC1A*(ENC2A*) ENC1B (ENC2B) ENC1B*(ENC2B*) ENC1Z (ENC2Z) ENC1Z*(ENC2Z*) GND Spindle encoder side (straight) 1 6 2 7 3 8 4 GND 5 +5V 9 A N C R B P K H (Note) Signal names in parentheses are equivalent to the channel 2 signal names. Case frame FG Manufacturing precautions (1) The wire material shall be a shielded, 6-pair stranded cable equivalent to AWG24 (0.2mm2). (2) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications. (3) Attach the nameplate with protective cover stamped with the cable name in the position designated in the assembly drawing. (4) Fold the wire material shield on the base I/O unit and relay card side over the sheath, and wrap copper foil tape over it. Connect the wound copper foil tape to the connector's GND plate. 96 Appendix 2 Cable Manufacturing Drawings 2.16 F041 Cable (Spindle encoder) Cable type name: F041 cable Appendix 2.16 Application: Base I/O unit – Spindle encoder (right angle) connection Relay card – Spindle encoder (right angle) connection Assembly drawing List of parts used No. Base I/O unit and relay card side (4) Spindle encoder (right angle) side 1 Connector 2 Contact 3 Connector case 4 Wire material 5 Connector 6 Cable clamp F041 F041 (1)(2)(3) (5)(6) Part name Recommended part type Hirose Electric CDE-9PF Hirose Electric CD-PC-111 Hirose Electric HDE-CTH Bando Electric Wire 2 DPVVSB 6P × 0.2 mm ITT Canon MS3108B20-29S ITT Canon MS3057-12A Qty 1 9 1 (1) 1 1 Connection diagram Maximum cable length: 50m Base I/O unit, Relay card side ENC1A (ENC2A) ENC1A*(ENC2A*) ENC1B (ENC2B) ENC1B*(ENC2B*) ENC1Z (ENC2Z) ENC1Z*(ENC2Z*) GND Spindle encoder side (right angle) 1 6 2 7 3 8 4 GND 5 +5V 9 A N C R B P K H (Note) Signal names in parentheses are equivalent to the channel 2 signal names. Case frame FG Manufacturing precautions (1) The wire material shall be a shielded, 6-pair stranded cable equivalent to AWG24 (0.2mm2). (2) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications. (3) Attach the nameplate with protective cover stamped with the cable name in the position designated in the assembly drawing. (4) Fold the wire material shield on the base I/O unit and relay card side over the sheath, and wrap copper foil tape over it. Connect the wound copper foil tape to the connector's GND plate. 97 Appendix 2 Cable Manufacturing Drawings 2.17 F070 Cable (+24VDC input) Cable type name: F070 cable Appendix 2.17 Application: +24V supply to the base I/O unit, relay card and remote I/O unit Input of emergency stop signal to the relay card Assembly drawing (1)(2) (3) Option (compatible connector set) FCUA-CN220 (Note that this is only compatible with the base I/O unit, relay card and remote I/O unit side connectors.) (4) List of parts used Y F070 No. F070 Part name Recommended part type Tyco Electronics AMP 1-178288-3 1 Connector 2 Contact 3 Wire material Tyco Electronics AMP 2-175218-5 Sumitomo Electric B-18 (19) U × 2SJ-1 × 9 4 Crimp terminal J.S.T. Mfg V1.25-3 Qty 1 2 (1) 2 Connection diagram Maximum cable length: 30m +24V GND +24V 1 2 3 GND Manufacturing precautions (1) The wire material shall be a shielded, 1-pair stranded cable equivalent to AWG18 (0.75mm2). If the cable length exceeds 15m, select wire material equivalent to AWG16. (2) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications. (3) Attach the nameplate with protective cover stamped with the cable name in the position designated in the assembly drawing. (4) Stamp the name of each signal on the crimp terminal side mark tube and install. (5) Protect both ends of the wire with an insulating bush. (6) Use shield processing wire material equivalent to AWG18 (0.75mm2). 98 Appendix 2 Cable Manufacturing Drawings 2.18 F390 Cable (RS232C) Cable type name: F390 cable Appendix 2.18 Application: Relay card – RS-232C device connection (cross cable) List of parts used Assembly drawing No. Relay card side Connector name: RS232C (4) RS-232C device side Connector name: CH1 1 Connector 2 Contact 3 F390 4 F390 (1)(2)(3) Part name Connector case Wire material Recommended part type Hirose Electric CDB-25P Hirose Electric CD-PC-111 Hirose Electric HDB-CTH Bando Electric Wire 2 DPVVSB 6P × 0.2 mm Qty 2 14 2 (1) (1)(2)(3) Connection diagram CH1 RS232C SD RD ER DR 2 3 4 5 6 20 3 2 4 5 6 20 GND 7 7 FG Manufacturing precautions (1) The wire material shall be a shielded, 6-pair stranded cable equivalent to AWG24 (0.2mm2). (2) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications. (3) Attach the nameplate with protective cover stamped with the cable name in the position designated in the assembly drawing. (4) Fold the wire material shield on the base I/O unit and relay card side over the sheath, and wrap copper foil tape over it. Connect the wound copper foil tape to the connector's GND plate. 99 Appendix 2 Cable Manufacturing Drawings 2.19 ENC-SP1 Cable (Spindle drive unit) Cable type name: ENC-SP1 cable Appendix 2.19 Application: Base I/O unit – Spindle drive unit connection Relay card – Spindle drive unit connection Assembly drawing List of parts used No. (4) Base I/O unit and relay card side Spindle drive unit side 1 Connector 2 Contact ENC-SP1 3 4 (5)(6) (1)(2)(3) ENC-SP1 Part name Connector case Wire material 5 Plug 6 Shell Recommended part type Hirose Electric CDE-9PF Hirose Electric CD-PC-111 Hirose Electric HDE-CTH Bando Electric Wire 2 DPVVSB 6P × 0.2 mm Sumitomo 3M 10120-6000EL Sumitomo 3M 10320-3210-000 Qty 1 8 1 (1) 1 1 Connection diagram Maximum cable length: 50m Base I/O unit, Relay card side ENC1A (ENC2A) ENC1A*(ENC2A*) ENC1B (ENC2B) ENC1B*(ENC2B*) ENC1Z (ENC2Z) ENC1Z*(ENC2Z*) GND GND +5V Spindle drive unit side 2 12 3 13 4 14 1 5 1 6 2 7 3 8 4 5 9 Case frame (Note) Signal names in parentheses are equivalent to the channel 2 signal names. FG Manufacturing precautions (1) The wire material shall be a shielded, 6-pair stranded cable equivalent to AWG24 (0.2mm2). (2) The parts used shall be Mitsubishi recommended parts. Equivalent parts may be used providing they are compatible with the specifications. (3) Attach the nameplate with protective cover stamped with the cable name in the position designated in the assembly drawing. (4) Fold the wire material shield on the base I/O unit and relay card side over the sheath, and wrap copper foil tape over it. Connect the wound cooper foil tape to the connector's GND plate. (5) Part No. 5 (plug) and part No. 6 (shell) are solderless types. If soldering types are required, use parts equivalent to 10120-3000VE for the plug and 10320-52FO-008 for the shell (both parts manufactured by Sumitomo 3M). (6) Do not connect a +5V power supply. 100 Appendix 2 Cable Manufacturing Drawings Appendix 2.20 Table of Connector Sets Appendix 2.20 Connector type FCUA-CS000 Table of Connector Sets Application Packing details Double-ended: Base I/O unit – Servo drive unit Servo drive unit – Servo drive unit Single-ended (* side): Remote I/O unit ( * ) – Analog input/output Remote I/O unit ( * ) – Manual pulse generator Base I/O unit – Spindle drive unit ( * ) Relay card – Spindle drive unit ( * ) Plug (Sumitomo 3M) 10120-3000VE × 2pcs. 3M Shell (Sumitomo 3M) 10320-52F0-008 × 2pcs. 3M Connector (Sumitomo 3M) Strain relief 7940-6500SC × 4pcs. (Sumitomo 3M) 3448-7940 × 2pcs. FCUA-CS301 Remote I/O unit – terminal block Base I/O unit – terminal block Connector (Tyco Electronics AMP) 1-178288-3 × 1pc. Base I/O unit - remote I/O unit Remote I/O unit - remote I/O unit X FCUA-CN211 Gold contact (Tyco Electronics AMP) 1-175218-2 × 3pcs. Connector (Tyco Electronics AMP) 2-178288-3 × 1pc. 24VDC power input External emergency stop input Y FCUA-CN220 Connector (Sumitomo 3M) 7940-6500SC × 2pcs. FCUA-CN300 Base I/O unit – Machine electric cabinet Remote I/O unit – Machine electric cabinet 101 Tin contact (Tyco Electronics AMP) 1-175218-5 × 3pcs. Appendix 3 Parts for EMC Measures Appendix 3.1 Shield Clamp Fitting Appendix 3 Parts for EMC Measures Appendix 3.1 Shield Clamp Fitting The effect can be increased by directly connecting the cable's shield sheath to the grounding plate. Install the grounding plate near the outlet (within 10cm) of each panel, and press against the grounding plate with the clamp fitting. If the cables are thin, several can be bundled and clamped together. To provide sufficient frame grounding, install the grounding plate directly on the cabinet or connect with a grounding wire. If the AERSBAN-SET, containing the grounding plate and clamp fitting, is required, please contact Mitsubishi. Peel the cable sheath at the clamp section Cable Grounding plate Cable 40 Clamp fitting (Fitting A, B) Shield sheath Clamp section drawing Outline drawing Grounding plate Clamp fitting 17.5 MAX L 10 3 24 +0. 0 35 6 7 3 0 24 -0.2 A C B±0.3 30 2-φ5 hole Installation hole Note 1 M4 screw 22 6 Unit: mm 11 35 Note 1) Screw hole for wiring to cabinet’s grounding plate Note 2) The grounding plate thickness is 1.6mm AERSBAN-DSET AERSBAN-ESET A B C (mm) (mm) (mm) 100 86 30 70 56 – Enclosed fitting L (mm) Two clamp fittings A Clamp fitting A 70 One clamp fitting B Clamp fitting B 45 102 Appendix 3 Parts for EMC Measures Appendix 3.2 Ferrite Core Appendix 3.2 Ferrite Core The ferrite core is mounted integrally with the plastic case. This can be installed with one touch without cutting the interface cable or power supply cable. This ferrite core is effective against common mode noise, allowing measures against noise without affecting the quality of the signal. Recommended ferrite core: TDK ZCAT Series ZCAT3035-1330 (-BK) ZCAT type ZCAT-A, ZCAT-AP type ZCAT-C type Part name ZCAT1518-0730-M(-BK)*1 ZCAT1518-0730(BK)*2 ZCAT2017-0930-M(-BK) ZCAT2032-0930-M(-BK)*1 ZCAT2032-0930(-BK)*2 ZCAT2132-1130-M(-BK)*1 ZCAT2132-1130(-BK)*2 ZCAT3035-1330-M(-BK)*1 ZCAT3035-1330(-BK)*2 ZCAT1525-0430AP-M(-BK) ZCAT1325-0530A-M(-BK)*1 ZCAT1325-0530A(-BK) ZCAT1730-0730A-M(-BK) ZCAT2035-0930A-M(-BK)*1 ZCAT2035-0930A(-BK) ZCAT2235-1030A-M(-BK) ZCAT2436-1330A-M(-BK) ZCAT2017-0930B-M(-BK) ZCAT2749-0430C-M(-BK) ZCAT4625-3430D(-BK) ZCAT4625-3430DT(-BK)*3 ZCAT6819-5230D(-BK) ZCAT6819-5230DT(-BK)*3 ZCAT-B type ZCAT-D type A (mm) B (mm) øC (mm) øD (mm) E (mm) 22±1 22±1 21±1 36±1 36±1 36±1 36±1 39±1 39±1 25±1 25±1 25±1 30±1 35±1 35±1 35±1 36±1 21±1 49±1 45.5±1 45.5±1 67.5±1 67.5±1 18±1 18±1 17±1 32±1 32±1 32±1 32±1 34±1 34±1 20±1 20±1 20±1 23±1 28±1 28±1 28±1 29±1 17±1 27±1 24.5±1 24.5±1 18.5±1 18.5±1 7±1 7±1 9±1 9±1 9±1 11±1 11±1 13±1 13±1 4±1 5±1 5±1 7±1 9±1 9±1 10±1 13±1 9±1 4.5±1 34±1 34±1 52±1 52±1 15±1 15±1 20±1 19.5±1 19.5±1 20.5±1 20.5±1 30±1 30±1 15±1 12.8±1 12.8±1 16.5±1 19.5±1 19.5±1 21.5±1 23.5±1 20±1 19.5±1 12±1 13±1 16±1 17±1 – – – – – – – – – 11.5±1 11.2±1 11.2±1 15±1 17.4±1 17.4±1 20±1 22±1 28.5±1 – – – – – Applicable cable outer diameter (mm) 7max. 7max. 9max. 9max. 9max. 11max. 11max. 13max. 13max. 2.5 to 4(USB) 3 to 5(USB) 3 to 5(USB) 4 to 7(USB/IEEE1394) 6 to 9 6 to 9 8 to 10 10 to 13 9max. 4.5max. For 26 core flat cable For 26 core flat cable For 40 core flat cable For 40 core flat cable • ZCAT-C type and ZCAT-D type *1 The M stamp is attached. *2 A fixing band is attached at shipment. *3 Double sided tape type. (Double sided tape is attached at shipment) • ZCAT-B type: Cabinet fixing type installation hole ø4.8 to 4.9mm, plate thickness 0.5 to 2mm • ZCAT-AP and ZCAT-C type: Structure that prevents easy opening after case is closed. 103 Weight (g) 6 6 11 22 22 22 22 63 63 7 7 7 12 22 22 27 29 12 26 32 32 58 58 Appendix 3 Parts for EMC Measures Appendix 3.3 Surge Protector Appendix 3.3 Surge Protector (1) Surge protector Make sure that surge does not directly enter the AC line of the general-purpose stabilized power supply (prepared by customer) supplied to the control unit and DIO. The following product or equivalent is recommended for the surge protector. 1) Part name Manufacturer : RAV-781BYZ-2 : Okaya Electric Industries Circuit voltage 50/60Hz Vrms Max. tolerable circuit voltage Clamp voltage V±10% Surge resistance level 8/20µs Surge withstand voltage 1.2/50µs Static capacity Operating temperature range 250V 3ø 300V 783V 2500A 20kV 75pF –20 to +70°C Circuit drawing (1) Black (2) Black (3) Black 28.5±1 5.5±1 11±1 Outline drawing 28±1 4.5±0.5 200± 30 0 UL-1015 AW G16 41±1 Unit: mm * Refer to the manufacturer's catalog for detailed characteristics, outline and connection methods of the surge protector. 104 Appendix 3 Parts for EMC Measures Appendix 3.3 Surge Protector 2) Part name Manufacturer : RAV-781BXZ-4 : Okaya Electric Industries Circuit voltage 50/60Hz Vrms Max. tolerable circuit voltage Clamp voltage V±10% Surge resistance level 8/20µs Surge withstand voltage 1.2/50µs Static capacity Operating temperature range 250V 3ø 300V 700V 2500A 2kV 75pF –20 to +70°C Circuit drawing (1) Black (2) Black (3) Black Green 28.5±1 5.5±1 11±1 Outline drawing 28±1 4.5±0.5 200± 30 0 UL-1015 AWG16 41±1 Unit: mm * Refer to the manufacturer's catalog for detailed characteristics, outline and connection methods of the surge protector. 105 Appendix 3 Parts for EMC Measures Appendix 3.3 Surge Protector (2) Surge protector installation example Transformer No-fuse breaker NC control section Other device Power supply for panel, etc. Earth leakage From power breaker for panel supply No-fuse breaker MC Control panel (Relay panel, etc.) Reactor Input 200/ 230VAC NC drive section A Other device Power supply for panel, etc. Circuit protector Surge protector (1) Surge protector (2) B Grounding Grounding plate Surge protector installation method (1) Thick wires will enhance the lighting surge absorption effect, so keep the wire as thick and short as possible. -Wire materialWire diameter: 2mm2 or more Wire length: Connection length (A) to surge protector (1) is 2m or less. Connection length (B) to surge protector (2) is 2m or less. (2) When carrying out an insulation voltage resistance test with an overvoltage (100VAC, 1500VAC) applied on the power supply line, remove the serge protector (2) since it will function under the applied voltage. (3) A short-circuit accident will occur if a surge exceeding the tolerance is applied on the surge protector. Thus, always insert a circuit protector to protect the power supply line. The current does not flow constantly to surge protectors (1) and (2), so the circuit protector can also be used for the other devices. 106 Appendix 3 Parts for EMC Measures Appendix 3.4 Selection of Stabilized Power supply Appendix 3.4 Selection of Stabilized Power Supply Consider the following characteristics when selecting the stabilized power supply. (prepared by customer) Use a power supply that complies with CE Marking or that follows the standards given below. Stabilized power supply selection items Item Voltage fluctuation Output Ripple noise fluctuation Spike noise Output current Output holding time ±5% Max. 120mV Max. 500mV — Min. 20ms Conditions ±5% or less of 24VDC output ±5% or less of 24VDC output Refer to this manual Instantaneous off time Standards Safety Standards : UL1950, CSA C22.2 No. 234 approved, IEC950 compliant Noise Terminal Voltage : FCC Class A, VCCI-1 Class High Harmonics Current Restrictions : IEC1000-3-2 107 Revision History Date of revision Manual No. Feb. 1998 BNP-B2203* Sept. 1999 BNP-B2203A Revision details First edition created. • Design of the cover and the back cover were changed. Oct. 2003 BNP-B2203D • MODEL, MODEL CODE, and Manual No. were added on the back cover. • PCI bus specifications (FCU6-HR655) card added. • Miswrite is corrected Notice Every effort has been made to keep up with software and hardware revisions in the contents described in this manual. However, please understand that in some unavoidable cases simultaneous revision is not possible. Please contact a Mitsubishi business office with any questions or comments regarding the use of this product. Duplication Prohibited This instruction manual may not be reproduced in any form, in part or in whole, without written permission from Mitsubishi Electric Corporation. © 1997-2003 MITSUBISHI ELECTRIC CORPORATION ALL RIGHTS RESERVED MITSUBISHI ELECTRIC CORPORATION HEAD OFFICE : MITSUBISHI DENKI BLDG., 2-2-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN MODEL MAGIC64 MODEL CODE 008-096 Manual No. BNP-B2203D(ENG) Specifications subject to change without notice. (0310)MEE Printed in Japan on recycled paper.
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