Mitsubishi Electric Q Series User manual

A - 1

SAFETY PRECAUTIONS

(Please read these instructions before using this equipment.)

Before using this product, please read this manual and the relevant manuals introduced in this manual

carefully and pay full attention to safety to handle the product correctly.

These precautions apply only to this product. Refer to the Users manual of the QCPU module to use for a

description of the PLC system safety precautions.

In this manual, the safety instructions are rankedas "DANGER" and "CAUTION".

DANGER

Indicates that incorrect handling may cause hazardous

conditions, resulting in death or severe injury.

CAUTION

Indicates that incorrect handling may cause hazardous

conditions, resulting in medium or slight personal injury or

physical damage.

Depending on circumstances, procedures indicated by CAUTION may also be linked to serious

results.

In any case, it is important to follow the directions for usage.

Please save this manual to make it accessible when required and always forward it to the end user.

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For Safe Operations

1. Prevention of electric shocks

DANGER

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 Motion controller and servo amplifier are

charged and may lead to electric shocks.

Completely turn off the externally supplied power used in the system before mounting or

removing the module, performing wiring work, or inspections. Failing to do so 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.

Be sure to ground the Motion controller, servo amplifier and servomotor. (Ground resistance :

100 or less) 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 Motion controller, 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 Motion controller, servo amplifier or servomotor terminal blocks while the power

is ON, as this may lead to electric shocks.

Do not touch the built-in power supply, built-in grounding or signal wires of the Motion controller

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

2. For fire prevention

CAUTION

Install the Motion controller, servo amplifier, servomotor and regenerative resistor on

incombustible. Installing them directly or close to combustibles will lead to fire.

If a fault occurs in the Motion controller or servo amplifier, shut the power OFF at the servo

amplifier’s power source. If a large current continues to flow, fire 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 fire.

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 fire.

Do not damage, apply excessive stress, place heavy things on or sandwich the cables, as this

may lead to fire.

A - 3

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.

Do not touch the heat radiating fins of controller or servo amplifier, regenerative resistor and

servomotor, etc., while the power is ON and for a short time after the power is turned OFF. In this

timing, these parts become very hot and 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 Motion controller and servo amplifier power source.

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

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

Install the emergency stop circuit externally so that the operation can be stopped immediately and

the power shut off.

Use the Motion controller, servo amplifier, servomotor and regenerative resistor with the correct

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

Use the Motion controller, base unit and motion module with the correct combinations listed in the

instruction manual. Other combinations may lead to faults.

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

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

Construct a safety circuit externally of the Motion controller or servo amplifier if the abnormal

operation of the Motion controller or servo amplifier differ from the safety directive operation in the

system.

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

stop, servo OFF or power supply 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 the forced stop,

emergency stop, servo OFF or power supply OFF, use both dynamic brakes and electromagnetic

brakes.

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CAUTION

The dynamic brakes must be used only on errors that cause the forced stop, emergency stop, or

servo OFF. These brakes must not be used for normal braking.

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

and must not be used for normal braking.

The system must have a mechanical allowance so that the machine itself can stop even if the

stroke limits 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.

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

The ratings and characteristics of the parts (other than Motion controller, servo amplifier and

servomotor) used in a system must be compatible with the Motion controller, 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 electromagnetic 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 Motion controller, 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 supply module. 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.

A - 5

CAUTION

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 intelligent function module's instruction manual for the

program corresponding to the intelligent function module.

(3) Transportation and installation

CAUTION

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

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 Motion controller or servo amplifier, never hold the connected wires or

cables.

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

When transporting the Motion controller or servo amplifier, never hold the front case as it may fall

off.

When transporting, installing or removing the Motion controller or servo amplifier, never hold the

edges.

Install the unit according to the instruction manual in a place where the mass 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 Motion controller or servo amplifier and control panel

inner surface or the Motion controller and servo amplifier, Motion controller or servo amplifier and

other devices.

Do not install or operate Motion controller, servo amplifiers or servomotors that are damaged or

that have missing parts.

Do not block the intake/outtake ports of the Motion controller, servo amplifier and servomotor with

cooling fan.

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

enter the Motion controller, servo amplifier or servomotor.

The Motion controller, servo amplifier and servomotor are precision machines, so do not drop or

apply strong impacts on them.

Securely fix the Motion controller, servo amplifier and servomotor to the machine according to

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

A - 6

CAUTION

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.

Conditions

Environment

Motion controller/Servo amplifier Servomotor

Ambient

temperature According to each instruction manual. 0°C to +40°C (With no freezing)

(32°F to +104°F)

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

(-4°F to +149°F)

Atmosphere Indoors (where not subject to direct sunlight).

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

Altitude 1000m (3280.84ft.) or less above sea level

Vibration According to each instruction manual

When coupling with the synchronous 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 synchronous encoder and servomotor

shaft. Doing so may lead to shaft breakage.

When not using the module for a long time, disconnect the power line from the Motion controller

or servo amplifier.

Place the Motion controller and servo amplifier in static electricity preventing vinyl bags and store.

When storing for a long time, please contact with our sales representative.

Also, execute a trial operation.

A - 7

(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 (terminal U, V, W) and ground. 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.

DICOM

Control output

signal

DOCOM

Servo amplifie

24VDC

Control output

signal

DICOM

DOCOM

Servo amplifier

24VDC

For the sink output interface For the source output interface

Do not connect or disconnect the connection cables between each unit, the encoder cable or

PLC expansion cable while the power is ON.

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 Motion

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

Before starting test operation, set the parameter speed limit value to the slowest value, and

make sure that operation can be stopped immediately by the forced stop, etc. if a hazardous

state occurs.

A - 8

(6) Usage methods

CAUTION

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

Motion controller, 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.

Do not attempt to disassemble and repair the units excluding a qualified technician whom our

company recognized.

Do not make any modifications to the unit.

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

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

Motion controller or servo amplifier.

When using the CE Mark-compliant equipment, refer to this manual for the Motion controllers

and refer to the corresponding EMC guideline information for the servo amplifiers, inverters and

other equipment.

Use the units with the following conditions.

Item Conditions

Input power According to each instruction manual.

Input frequency According to each instruction manual.

Tolerable momentary power failure According to each instruction manual.

(7) Corrective actions for errors

CAUTION

If an error occurs in the self diagnosis of the Motion controller 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 electromagnetic brakes or install a brake mechanism externally.

Use a double circuit construction so that the electromagnetic brake operation circuit can be

operated by emergency stop signals set externally.

Servomotor RA1 EMG

24VDC

Shut off with servo ON signal OFF,

alarm, electromagnetic brake signal.

Shut off with the

emergency stop

signal (EMG).

Electromagnetic

brakes

If an error occurs, remove the cause, secure the safety and then resume operation after alarm

release.

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.)

A - 9

(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 Motion

controller 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.

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

Before touching the module, always touch grounded metal, etc. to discharge static electricity from

human body. Failure to do so may cause the module to fail or malfunction.

Do not directly touch the module's conductive parts and electronic components.

Touching them could cause an operation failure or give damage to the module.

Do not place the Motion controller 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 Motion controller or servo amplifier, always set the new module settings

correctly.

When the Motion 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 Motion controller using programming software, switch on the

power again, then perform a home position return operation.

2) Using the backup function of the programming 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 drop or impact the battery installed to the module.

Doing so may damage the battery, causing battery liquid to leak in the battery. Do not use the

dropped or impacted battery, but dispose of it.

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

Motion controller or servo amplifier.

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

damage from faults. Replacements can be made by our sales representative.

Lock the control panel and prevent access to those who are not certified to handle or install

electric equipment.

Do not burn or break a module and servo amplifier. Doing so may cause a toxic gas.

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