Mitsubishi Electric QD77MS User manual

MELSEC-Q/L

QD77MS/QD77GF/LD77MS/LD77MH

Simple Motion Module

User's Manual (Synchronous Control)

-QD77MS2 -QD77GF4 -LD77MS2 -LD77MH4

-QD77MS4 -QD77GF8 -LD77MS4 -LD77MH16

-QD77MS16 -QD77GF16 -LD77MS16

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.

The precautions given in this manual are concerned with this product only. Refer to the user's manual of

the CPU module to use for a description of the PLC system safety precautions.

In this manual, the safety instructions are ranked as "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.

A - 2

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 module 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 module, 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 module, 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 module, servo amplifier, servomotor connector or 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 module and servo

amplifier, as this may lead to electric shocks.

2. For fire prevention

CAUTION

Install the module, 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 module 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 module 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 module 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 module, 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 CPU module, base unit, and Simple 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 module, servo

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

Construct a safety circuit externally of the module or servo amplifier if the abnormal operation of

the module or servo amplifier differs 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 the dynamic brake.

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

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

emergency stop, servo OFF or power supply OFF, use both the dynamic brake and

electromagnetic brake.

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

servo OFF. This brake must not be used for normal braking.

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

and must not be used for normal braking.

A - 4

CAUTION

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 module, servo amplifier and servomotor)

used in a system must be compatible with the module, 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 brake 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

DANGER

Set the parameter values to those that are compatible with the module, 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 and servo amplifier. 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.

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.

A - 5

DANGER

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.

When connecting GX Works2 with the CPU module or connecting a personal computer with an

intelligent function module to modify data of a running programmable controller, configure an

interlock circuit in the program to ensure that the entire system will always operate safely.

For other forms of control (such as program modification or operating status change) of a running

programmable controller, read the relevant manuals carefully and ensure that the operation is

safe before proceeding. Especially, when a remote programmable controller is controlled by an

external device, immediate action cannot be taken if a problem occurs in the programmable

controller due to a communication failure. To prevent this, configure an interlock circuit in the

program, and determine corrective actions to be taken between the external device and CPU

module in case of a communication failure.

For the operating status of each station after a communication failure, refer to the "MELSEC-Q

QD77GF Simple Motion Module User's Manual (Network)". Incorrect output or malfunction due to

a communication failure may result in an accident.

Do not write any data to the "system area" of the buffer memory in the intelligent function module.

Also, do not use any "use prohibited" signals as an output signal from the CPU module to the

intelligent function module.

Doing so may cause malfunction of the programmable controller system.

To set a refresh device in the network parameter, select the device Y for the remote output (RY)

refresh device. If a device other than Y, such as M and L, is selected, the CPU module holds the

device status even after its status is changed to STOP.

If a communication cable is disconnected, the network may be unstable, resulting in a

communication failure of multiple stations. Configure an interlock circuit in the program to ensure

that the entire system will always operate safely even if communications fail.

Failure to do so may result in an accident due to an incorrect output or malfunction.

(3) Transportation and installation

DANGER

Shut off the external power supply (all phases) used in the system before mounting or removing a

module. Failure to do so may result in electric shock or cause the module to fail or malfunction.

A - 6

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 module or servo amplifier, never hold the connected wires or cables.

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

When transporting the module or servo amplifier, never hold the front case as it may fall off.

When transporting, installing or removing the module 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 module or servo amplifier and control panel inner

surface or the module and servo amplifier, module or servo amplifier and other devices.

Do not install or operate modules, servo amplifiers or servomotors that are damaged or that have

missing parts.

Do not block the intake/outtake ports of the 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 module, servo amplifier or servomotor.

The module, servo amplifier and servomotor are precision machines, so do not drop or apply

strong impacts on them.

Securely fix the module, servo amplifier and servomotor 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.

Environment

Conditions

Module/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 According to each instruction manual

Vibration According to each instruction manual

When coupling with the 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.

A - 7

CAUTION

When not using the module for a long time, disconnect the power line from the module or servo

amplifier.

Place the module 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.

Make sure that the connectors for the servo amplifier and peripheral devices have been securely

installed until a click is heard.

Not doing so could lead to a poor connection, resulting in erroneous input and output.

Use the programmable controller in an environment that meets the general specifications in the

user's manual for the CPU module used. Failure to do so may result in electric shock, fire,

malfunction, or damage to or deterioration of the product.

To mount the module, while pressing the module mounting lever located in the lower part of the

module, fully insert the module fixing projection(s) into the hole(s) in the base unit and press the

module until it snaps into place. Incorrect mounting may cause malfunction, failure or drop of the

module.

When using the programmable controller in an environment of frequent vibrations, fix the module

with a screw.

Tighten the screws within the specified torque range. Undertightening can cause drop of the

screw, short circuit or malfunction. Overtightening can damage the screw and/or module,

resulting in drop, short circuit, or malfunction.

Do not directly touch any conductive parts and electronic components of the module. Doing so

can cause malfunction or failure of the module.

When fumigants that contain halogen materials such as fluorine, chlorine, bromine, and iodine

are used for disinfecting and protecting wooden packaging from insects, they cause malfunction

when entering our products.

Please take necessary precautions to ensure that remaining materials from fumigant do not enter

our products, or treat packaging with methods other than fumigation (heat method). Additionally,

disinfect and protect wood from insects before packing products.

The module and the servo amplifier must not be used with parts which contain halogen-series

flame retardant materials (such as bromine) under coexisting conditions.

(4) Wiring

DANGER

Shut off the external power supply (all phases) used in the system before wiring.

Failure to do so may result in electric shock or cause the module to fail or malfunction.

A - 8

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). 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 amplifier 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.

Use applicable solderless terminals and tighten them with the specified torque.

If any solderless spade terminal is used, it may be disconnected when the terminal screw comes

loose, resulting in failure.

Do not install the control lines or communication cables together with the main circuit lines or

power cables. Keep a distance of 100mm or more between them. Failure to do so may result in

malfunction due to noise.

Prevent foreign matter such as dust or wire chips from entering the module. Such foreign matter

can cause a fire, failure, or malfunction.

A protective film is attached to the top of the module to prevent foreign matter, such as wire

chips, from entering the module during wiring. Do not remove the film during wiring. Remove it for

heat dissipation before system operation.

Place the cables in a duct or clamp them. If not, dangling cable may swing or inadvertently be

pulled, resulting in damage to the module or cables or malfunction due to poor contact.

When disconnecting the cable from the module, do not pull the cable by the cable part. For the

cable with connector, hold the connector part of the cable. Pulling the cable connected to the

module may result in malfunction or damage to the module or cable.

Use 1000BASE-T-compliant Ethernet cables for Ethernet connection. For the maximum station-

to-station distance and the overall cable distance, follow the specifications in this manual. If not,

normal data transmission is not guaranteed.

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