Mitsubishi Electric MELSEC System Q User manual

MELSEC System Q

Motion Controller

Installation Manual

SW3RNC-GSVE/GSVHELPE

INDUSTRIAL AUTOMATION

MIT

HI ELE

TRI

MIT

HI ELE

TRI

Art. no.: 147253

01 12 2001

IB(NA)-0300018-F

−I −

INTRODUCTION

Thank you for purchasing the Mitsubishi Motion Controller/Personal Machine Controller. This instruction

manual describes the handling and precautions of this unit. Incorrect handing will lead to unforeseen events,

so we ask that you please read this manual thoroughly and use the unit correctly.

Please make sure that this manual is delivered to the final user of the unit and that it is stored for future

reference.

Precautions for Safety

Please read this instruction manual and enclosed documents before starting installation,

operation, maintenance or inspections to ensure correct usage. Thoroughly understand the

machine, safety information and precautions before starting operation.

The safety precautions are ranked as "Warning" and "Caution" in this instruction manual.

WARNING When a dangerous situation may occur if handling is mistaken

leading to fatal or major injuries.

CAUTION When a dangerous situation may occur if handling is mistaken

leading to medium or minor injuries, or physical damage.

Note that some items described as cautions may lead to major results depending on the

situation. In any case, important information that must be observed is described.

−II −

For Sate Operations

1. Prevention of electric shocks

WARNING

Never open the front case or terminal covers while the power is ON or the unit is running, as

this may lead to electric shocks.

Never run the unit with the front case or terminal cover removed. The high voltage terminal

and charged sections will be exposed and may lead to electric shocks.

Never open the front case or terminal cover at times other than wiring work or periodic

inspections even if the power is OFF. The insides of the control unit and servo amplifier are

charged and may lead to electric shocks.

When performing wiring work or inspections, turn the power OFF, wait at least ten minutes,

and then check the voltage with a tester, etc. Failing to do so may lead to electric shocks.

Always ground the control unit, servo amplifier and servomotor with Class 3 grounding. Do

not ground commonly with other devices.

The wiring work and inspections must be done by a qualified technician.

Wire the units after installing the control unit, servo amplifier and servomotor. Failing to do

so may lead to electric shocks or damage.

Never 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.

Do not touch the control unit, servo amplifier or servomotor terminal blocks while the power

is ON, as this may lead to electric shocks.

Do not touch the internal power supply, internal grounding or signal wires of the control unit

and servo amplifier, as this may lead to electric shocks.

2. For fire prevention

CAUTION

Install the control unit, servo amplifier, servomotor and regenerative resistor on inflammable

material. Direct installation on flammable material or near flammable material may lead to

fires.

If a fault occurs in the control unit or servo amplifier, shut the power OFF at the servo

amplifier's power source. If a large current continues to flow, fires may occur.

When using a regenerative resistor, shut the power OFF with an error signal. The

regenerative resistor may abnormally overheat due to a fault in the regenerative transistor,

etc., and may lead to fires.

Always take heat measures such as flame proofing for the inside of the control panel where

the servo amplifier or regenerative resistor is installed and for the wires used. Failing to do

so may lead to fires.

−III −

3. For injury prevention

CAUTION

Do not apply a voltage other than that specified in the instruction manual on any terminal.

Doing so may lead to destruction or damage.

Do not mistake the terminal connections, as this may lead to destruction or damage.

Do not mistake the polarity (+/−), as this may lead to destruction or damage.

The servo amplifier's heat radiating fins, regenerative resistor and servo amplifier, etc., will

be hot while the power is ON and for a short time after the power is turned OFF. Do not

touch these parts as doing so may lead to burns.

Always turn the power OFF before touching the servomotor shaft or coupled machines, as

these parts may lead to injuries.

Do not go near the machine during test operations or during operations such as teaching.

Doing so may lead to injuries.

4. Various precautions

Strictly observe the following precautions.

Mistaken handling of the unit may lead to faults, injuries or electric shocks.

(1) System structure

CAUTION

Always install a leakage breaker on the control unit and servo amplifier power source.

If installation of a magnetic contactor for power shut off during an error, etc., is specified in

the instruction manual for the servo amplifier, etc., always install the magnetic contactor.

Install an external emergency stop circuit so that the operation can be stopped immediately

and the power shut off.

Use the control unit, servo amplifier, servomotor and regenerative resistor with the

combinations listed in the instruction manual. Other combinations may lead to fires or faults.

If safety standards (ex., robot safety rules, etc.,) apply to the system using the control unit,

servo amplifier and servomotor, make sure that the safety standards are satisfied.

If the operation during a control unit or servo amplifier error and the safety direction

operation of the control unit differ, construct a countermeasure circuit externally of the

control unit and servo amplifier.

In systems where coasting of the servomotor will be a problem during emergency stop,

servo OFF or when the power is shut OFF, use dynamic brakes.

Make sure that the system considers the coasting amount even when using dynamic

brakes.

In systems where perpendicular shaft dropping may be a problem during emergency stop,

servo OFF or when the power is shut OFF, use both dynamic brakes and magnetic brakes.

The dynamic brakes must be used only during emergency stop and errors where servo OFF

occurs. These brakes must not be used for normal braking.

The brakes (magnetic brakes) assembled into the servomotor are for holding applications,

and must not be used for normal braking.

Construct the system so that there is a mechanical allowance allowing stopping even if the

stroke end limit switch is passed through at the max. speed.

Use wires and cables that have a wire diameter, heat resistance and bending resistance

compatible with the system.

−IV −

CAUTION

Use wires and cables within the length of the range described in the instruction manual.

The ratings and characteristics of the system parts (other than control unit, servo amplifier,

servomotor) must be compatible with the control unit, servo amplifier and servomotor.

Install a cover on the shaft so that the rotary parts of the servomotor are not touched during

operation.

There may be some cases where holding by the magnetic brakes is not possible due to the

life or mechanical structure (when the ball screw and servomotor are connected with a

timing belt, etc.). Install a stopping device to ensure safety on the machine side.

(2) Parameter settings and programming

CAUTION

Set the parameter values to those that are compatible with the control unit, servo amplifier,

servomotor and regenerative resistor model and the system application. The protective

functions may not function if the settings are incorrect.

The regenerative resistor model and capacity parameters must be set to values that

conform to the operation mode, servo amplifier and servo power unit. The protective

functions may not function if the settings are incorrect.

Set the mechanical brake output and dynamic brake output validity parameters to values

that are compatible with the system application. The protective functions may not function if

the settings are incorrect.

Set the stroke limit input validity parameter to a value that is compatible with the system

application. The protective functions may not function if the setting is incorrect.

Set the servomotor encoder type (increment, absolute position type, etc.) parameter to a

value that is compatible with the system application. The protective functions may not

function if the setting is incorrect.

Set the servomotor capacity and type (standard, low-inertia, flat, etc.) parameter to values

that are compatible with the system application. The protective functions may not function if

the settings are incorrect.

Set the servo amplifier capacity and type parameters to values that are compatible with the

system application. The protective functions may not function if the settings are incorrect.

Use the program commands for the program with the conditions specified in the instruction

manual.

Set the sequence function program capacity setting, device capacity, latch validity range,

I/O assignment setting, and validity of continuous operation during error detection to values

that are compatible with the system application. The protective functions may not function if

the settings are incorrect.

Some devices used in the program have fixed applications, so use these with the conditions

specified in the instruction manual.

The input devices and data registers assigned to the link will hold the data previous to when

communication is terminated by an error, etc. Thus, an error correspondence interlock

program specified in the instruction manual must be used.

Use the interlock program specified in the special function unit's instruction manual for the

program corresponding to the special function unit.

−V −

(3) Transportation and installation

CAUTION

Transport the product with the correct method according to the weight.

Use the servomotor suspension bolts only for the transportation of the servomotor. Do not

transport the servomotor with machine installed on it.

Do not stack products past the limit.

When transporting the control unit or servo amplifier, never hold the connected wires or

cables.

When transporting the servomotor, never hold the cables, shaft or detector.

When transporting the control unit or servo amplifier, never hold the front case as it may fall

off.

When transporting, installing or removing the control unit or servo amplifier, never hold the

edges.

Install the unit according to the instruction manual in a place where the weight can be withstood.

Do not get on or place heavy objects on the product.

Always observe the installation direction.

Keep the designated clearance between the control unit or servo amplifier and control panel

inner surface or the control unit and servo amplifier, control unit or servo amplifier and other

devices.

Do not install or operate control units, servo amplifiers or servomotors that are damaged or

that have missing parts.

Do not block the intake/outtake ports of the servomotor with cooling fan.

Do not allow conductive matter such as screw or cutting chips or combustible matter such

as oil enter the control unit, servo amplifier or servomotor.

The control unit, servo amplifier and servomotor are precision machines, so do not drop or

apply strong impacts on them.

Securely fix the control unit and servo amplifier to the machine according to the instruction

manual. If the fixing is insufficient, these may come off during operation.

Always install the servomotor with reduction gears in the designated direction. Failing to do

so may lead to oil leaks.

Store and use the unit in the following environmental conditions.

Condition

Environment Control unit/servo amplifier Servomotor

Ambient

temperature 0°C to +55°C

(With no freezing) 0°C to +40°C

(With no freezing)

Ambient humidity According to each instruction

manual. 80%RH or less

(With no dew condensation)

Storage

temperature According to each instruction

manual. −20°C to +65°C

Atmosphere Indoors (where not subject to direct sunlight).

No corrosive gases, flammable gases, oil mist or dust must exist.

Altitude 1000m (305 Feet) or less above sea level.

Vibration According to each instruction manual.

−VI −

CAUTION

When coupling with the synchronization encoder or servomotor shaft end, do not apply

impact such as by hitting with a hammer. Doing so may lead to detector damage.

Do not apply a load larger than the tolerable load onto the servomotor shaft. Doing so may

lead to shaft breakage.

When not using the unit for a long time, disconnect the power line from the control unit or

servo amplifier.

Place the control unit and servo amplifier in static electricity preventing vinyl bags and store.

(4) Wiring

CAUTION

Correctly and securely wire the wires. Reconfirm the connections for mistakes and the

terminal screws for tightness after wiring. Failing to do so may lead to run away of the

servomotor.

After wiring, install the protective covers such as the terminal covers to the original

positions.

Do not install a phase advancing capacitor, surge absorber or radio noise filter (option FR-

BIF) on the output side of the servo amplifier.

Correctly connect the output side (terminals U, V, W). Incorrect connections will lead the

servomotor to operate abnormally.

Do not connect a commercial power supply to the servomotor, as this may lead to trouble.

Do not mistake the direction of the surge absorbing diode

installed on the DC relay for the control signal output of

brake signals, etc. Incorrect installation may lead to signals

not being output when trouble occurs or the protective

functions not functioning.

Do not connect or disconnect the connection cables

between each unit, the encoder cable or sequence

expansion cable while the power is ON.

Servo amplifier

VIN

(24VDC)

Control output

signal RA

Securely tighten the cable connector fixing screws and fixing mechanisms. Insufficient fixing

may lead to the cables combing off during operation.

Do not bundle the power line or cables.

(5) Trial operation and adjustment

CAUTION

Confirm and adjust the program and each parameter before operation. Unpredictable

movements may occur depending on the machine.

Extreme adjustments and changes may lead to unstable operation, so never make them.

When using the absolute position system function, on starting up, and when the controller or

absolute value motor has been replaced, always perform a home position return.

−VII −

(6) Usage methods

CAUTION

Immediately turn OFF the power if smoke, abnormal sounds or odors are emitted from the

control unit, servo amplifier or servomotor.

Always execute a test operation before starting actual operations after the program or

parameters have been changed or after maintenance and inspection.

The units must be disassembled and repaired by a qualified technician.

Do not make any modifications to the unit.

Keep the effect or magnetic obstacles to a minimum by installing a noise filter or by using

wire shields, etc. Magnetic obstacles may affect the electronic devices used near the control

unit or servo amplifier.

Use the units with the following conditions.

Item Conditions

Input power According to the separate instruction manual.

Input frequency According to the separate instruction manual.

Tolerable momentary

power failure According to the separate instruction manual.

(7) Remedies for errors

CAUTION

If an error occurs in the self diagnosis of the control unit or servo amplifier, confirm the

check details according to the instruction manual, and restore the operation.

If a dangerous state is predicted in case of a power failure or product failure, use a

servomotor with magnetic brakes or install a brake mechanism externally.

Use a double circuit construction so that the

magnetic brake operation circuit can be

operated by emergency stop signals set

externally.

If an error occurs, remove the cause, secure

the safety and then resume operation.

The unit may suddenly resume operation

after a power failure is restored, so do not go

near the machine. (Design the machine so

that personal safety can be ensured even if

the machine restarts suddenly.)

Servo motor

Magnetic

brakes

Shut off servo ON signal OFF,

alarm, magnetic brake signal.

Shut off with the

emergency stop

signal (EMG).

24VDC

RA1 EMG

(8) Maintenance, inspection and part replacement

CAUTION

Perform the daily and periodic inspections according to the instruction manual.

Perform maintenance and inspection after backing up the program and parameters for the

control unit and servo amplifier.

Do not place fingers or hands in the clearance when opening or closing any opening.

Periodically replace consumable parts such as batteries according to the instruction

manual.

−VIII −

CAUTION

Do not touch the lead sections such as ICs or the connector contacts.

Do not place the control unit or servo amplifier on metal that may cause a power leakage or

wood, plastic or vinyl that may cause static electricity buildup.

Do not perform a megger test (insulation resistance measurement) during inspection.

When replacing the control unit or servo amplifier, always set the new unit settings correctly.

When the controller or absolute value motor has been replaced, carry out a home position

return operation using one of the following methods, otherwise position displacement could

occur.

1) After writing the servo data to the PC using peripheral device software, switch on the

power again, then perform a home position return operation.

2) Using the backup function of the peripheral device software, load the data backed up

before replacement.

After maintenance and inspections are completed, confirm that the position detection of the

absolute position detector function is correct.

Do not short circuit, charge, overheat, incinerate or disassemble the batteries.

The electrolytic capacitor will generate gas during a fault, so do not place your face near the

control unit or servo amplifier.

The electrolytic capacitor and fan will deteriorate. Periodically change these to prevent

secondary damage from faults. Replacements can be made by the Service Center or

Service Station.

(9) Disposal

CAUTION

Dispose of this unit as general industrial waste.

Do not disassemble the control unit, servo amplifier or servomotor parts.

Dispose of the battery according to local laws and regulations.

(10) General cautions

CAUTION

All drawings provided in the instruction manual show the state with the covers and safety

partitions removed to explain detailed sections. When operating the product, always return

the covers and partitions to the designated positions, and operate according to the

instruction manual.

Revisions

*The manual number is given on the bottom left of the back cover.

Print Date *Manual Number Revision

Jul., 2000 IB(NA)-0300018-A First edition

Jan., 2001 IB(NA)-0300018-B Addition

Addition of SW3RN-GSV43P description

Mar., 2001 IB(NA)-0300018-C Addition

Addition of RS232C communication description, Section 4.5

Apr., 2001 IB(NA)-0300018-D Addition

Addition of SW3RN-GSV51P description, Section 3.6, Section 4.6,

Section 4.6.1

Correction

CONTENTS, Section 2.2 (1), Section 2.2 (2), Section 2.3, Section 2.5,

Section 3.1,

Aug., 2001 IB(NA)-0300018-E Addition

Addition of SW20RN-DOCPRNP and SW20RN-LADDERP description,

Section 3.4.2, Section 3.4.3, Section 3.4.4, Section 3.4.5, Section 3.4.6,

Chapter5

Correction

CONTENTS, Section 2.2 (1), Section 2.2 (2), Section 2.3, Section 3.1,

Section 3.2, Section 4.1, Section 4.1.1, Section 4.1.2, Section 4.2,

Dec., 2001 IB(NA)-0300018-F Addition

Addition of Windows 2000 and A10BD-PCF interface board description,

Section 4.1.3, Section 4.3.1, Section 4.3.2, Section 3.7, Section 5.5

Correction

Section 2.2, Section 2.5, Section 3.1, Section 3.3, Section 3.4.1, Section 3.4.2,

Section 3.4.3, Section 3.4.4, Section 3.4.5, Section 3.4.6, Section 4.6.1,

Section 5.1, Section 5.2, Section 5.3, Section 5.4

This manual confers no industrial property rights or any rights of any other kind, nor does it confer any patent

licenses. Mitsubishi Electric Corporation cannot be held responsible for any problems involving industrial

property rights which may occur as a result of using the contents noted in this manual.

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