MITSUBISHI CONTROLLERS 500 Series
When replacing a Main
CPU (QX-611-1) board on an M520 controller you must replace the EEPROM on the
new board with the one from the old board. Then, you must clear the RAM. The
procedure for this is :
******** BEFORE YOU
START, WRITE DOWN AND SAVE ALL COMMUNICATION PARAMETERS!!! FAILURE TO DO THIS
WILL MAKE IT VERY DIFFICULT TO RELOAD THE CONTROLLER!!!****
ALSO IF YOU REPLACE
THE BOARD, MAKE SURE YOU RECONNECT THE CSH21 CABLE. OTHERWISE YOU WILL
HAVE A Y03 AMP UNEQUIPPED ALARM.
This is the same
procedure to initialize the memory.
1. Save all RAM data
to an external device. (Programs,Tool,Parameters)
2. Turn the NC off.
3. Set ...Share your problem. contact us.
4. Turn the NC on.
5. Wait for the green
LED on the CPU to turn on.
6. Turn the power
off.
7. Place ...Share your problem. contact us.
8. Format the
control.
The procedure for
formatting is:
1. Load the Machine
Parameters
2. Press the
ALARM/DIAGN button.
3. Press the PLC-I/F
soft key.
4. ...Share your problem. contact us.
5. Press the
INPUT/CALC button. (The prompts will disappear.)
6. ...Share your problem. contact us.
7. Cycle control
power.
9. The BASE
Parameters will be displayed.
10. Scroll to page
6/8.
11. ...Share your problem. contact us.
12. Go to the Data
I/O screen.
13. Select ERASE.
14. Move the cursor
to the right once and type FORMAT.
15. Press the
INPUT/CALC button.
16. FORMAT COMPLETED
should be displayed.
17. ...Share your problem. contact us.
18. Press the
INPUT/CALC button.
19. This should load
all of the fixed (canned) cycles.
20. Re-Load all
Parameters, Tool Data, and Programs.
21. Go to the Machine
Parameters (BASE).
22. Go to page 7/8.
23. ....Share your problem. contact us.
24. Press the
INPUT/CALC button.
25. Writing is done
when "EEPROM WRITING" goes off.
The function of some
of the switches on the DIP are:
SW1 MTOS
Debugger
SW2 PLC Stop
SW3 Stop EEPROM
transfer at power up.
SW4 Watchdog
Alarm disable.
On an M520
Controller, QX611-1 is Main CPU. QX084 is Power Supply. QX531 is I/O. There are
three LEDs on the QX522. The top one (green) is IOP SECTION CPU FUNCTIONING and
should always be on. If it is off, you probably have either a bad QX522 or a
bad cable. The middle one and the bottom one are FBAL1 and FBAL2. (Both red)
These should always be off. If either one or both are on you probably have a
problem with the Spindle Motor Encoder. (Not the orient encoder)This only
applies if the Spindle Encoder signal is input through the QX522. In many
cases, the feedback from both encoders is first input to the Spindle Amplifier
and is transmitted serially along the data buss to the QX611-1. In this case
the MTB may write design the software to prevent a control alarm but the LEDs
will still be on unless the software tells the QX522 not
to look for a
feedback input. Under these conditions the machine will function normally even
with the LEDs on.
There are also three
LEDs on the Power Supply. The top one (green) is Control Power On. The second
one is AC FAIL (red). This one should always be off. If it is on the AC Input
is either under or over or the 24vdc is being pulled too low. The third is
BATTERY ALARM (red). This one should always be off. It comes on when the
battery voltage drops below 2.6vdc.
The QX611-1 board has
four LED's. Normally all of these will be Green with one or more flickering. If
LED1 turns Red (Watch Dog Alarm) one of the PCBs may be defective. If LED2
turns Red (Memory Parity Error) the SRAM in the QX611-1 or one of the QX42_
cards may be defective.
If the control has a
QX524 board, it also has four LED's. The first two should always be green
meaning that data is being transferred between operation boards. If one or both
are off there is probably a defective PCB or cable. The bottom two are FBAL1
and FBAL2 and have the same indication as on QX522.
There are two memory
cassettes attached to the QX611-1 board. The one on the left contains the
Executive Software. The one on the right (QX813) contains the Ladder.
Serial Buss:
The Serial chain
starts at the CPU (QX611-1), goes to the left port on the X axis servo amp,
leaves the right port, goes to the left port of the Y axis servo amp, leaves
the right port, goes to the left port of the Z axis servo amp, leaves the right
port, goes to the left port of the Spindle amp, leaves the right port, goes to
the battery unit. The condition of the amps and the battery are monitored by
the buss and the amps are controlled by the buss. The left port on the drives
are always the Input and the right port is always the Output.
On an M500 series
controller, if you set the software limits (OT+ and OT-) in Machine Parameters
to the same value and sign (+/-) the stroke limits will be ignored. In this
case, you can then set the software limits in the User Axis Parameters to the
value you desire. There is also a User Axis Parameter (OT Check Off) which
tells the control to ignore the values set in the User Axis Parameters. But no
matter what the values are set for in User Parameters, they are superseded by
any value in Machine Parameters.
There are two types
of compensation on the M500 series controller. Type 1 and Type 2. Type 1 is
used for machining errors at lower feed rates and Type 2 is used for higher
feed rates.
In order to access
the timers on an M520 controller:
1. Go to the Machine
Parameters.
2. Press the
TOOL/PARAM button.
3. Press the PLC soft
key.
4. Page to [PLC
TIMER].
5. Page to the timer
you want.
On an M500 series
controller the control type and serial number can be found on the main
(startup) page.
To open the data
window on an M500 series control, press the WINDOW button. This icon on this
button is one rectangle (window) overlapping another. The window will open up
to the last one used. If you want the window to display some other data press
the button with two overlapping circles. When this is done three new soft key
options will be displayed. They are:
W-SLCT W-MOVE PRINT
If you press the
W-SLCT soft key you will be given eight soft key options:
WORK POSI MACHINE
NEXT HISTORY METER P_COUNT
The NEXT key will
show the next program block.
The METER button will
show the Spindle load and RPM.
The WORK button will
show the Work Coordinate page.
The HISTORY button
will show the Operation History of the NC. This is especially useful in
troubleshooting. It shows which output addresses have been activated. It lists
them with the date and time of operation. They will be Y addresses typically in
Hexadecimal. This can be very useful when trying to track down unexpected
operation of the machine. Keep in mind that the window will not update while it
is open. It must be closed then re-opened. So, if the window is open and you
press a button such as the COOLANT button, no change will be seen in the
window. If you close the window and re-open it by pressing the WINDOW button
you will then see all of the Y addresses that were activated by the coolant
function. This will only be the case if the machine are not displayed as Y
addresses but rather by name.
The buttons and the corresponding name assigned
in the window are shown below.
MONITOR
MON
CAN
C.B.
INPUT
INP
WINDOW
WND
(
(
)
)
NEXT
PAGE NXT
LAST
PAGE
BAK
TOOL
PARAM T/P
EDIT
MDI
E/M
DATA
IN/OUT I/O
GRAPHIC
GRA
DIAGN
DIG
SFP
SFP
FO
F0
SHIFT
No Change
;
EOB
;
INSERT
INS
+
+
/
/
=
=
*
*
All Alphanumeric
buttons, ABC123, etc., are displayed as they are. A is A, B is B, 9 is 9, etc.
The nine soft key buttons are shown as ME1 to ME9 for the buttons left to
right. The BACK button is the button to the left of the first soft key (ME1).
The NEXT button is the button to the right of the last soft key (ME9). The BACK
button has a left pointing arrow, the NEXT has a right pointing arrow. These
buttons are sometimes referred to as left and right chapter buttons. The Up
Arrow button is shown as CRU (Cursor Up). The Down Arrow is shown as CRD
(Cursor Down). Left Arrow and Right Arrow are CRL and CRR respectively. The
diagonal arrow button is shown as ACT.
The window can be
moved to any place on the screen. To move the window it must be highlighted in
pink. To highlight the window, press the W-MOVE soft key. Once highlighted, use
the arrow keys to move the window up, down, left or right. To scroll through
pages of history, press the Diagonal Arrow button then use the Last page and
Next page buttons to scroll.
The Date and Time
displayed on the Operation History page is the same as the NC main date and
time. If it is wrong, the main needs to be set. To do this:
1. MONITOR button.
2. C-MODAL soft key.
3. NEXT PAGE button.
4. ...Share your problem. contact us.
This
sets the date Year, Month, Day in the parentheses from left to right.
5. ...Share your problem. contact us.
This sets the time Hour, Minute, Second left to right.
6. INPUT button.
The clock does not
differentiate between AM and PM, so it is a good idea to set it up for Military
time. This is done simply by entering the hour as Military ( 13:00 for 1 PM,
14:00 for 2 PM, etc.)
Also in the C-Modal
screen you will find the Parts Counter, NC Power On Time and Time of Automatic
Operation. These can be changed and reset here using the same basic method for
changing time and date.
On the M500 series
control it is possible to do buffer correction. That is, if a programming error
occurs, it is not necessary to reset the control to correct the program. You
can correct the problem and continue on with the program. For example, if you
experience alarm P62 F-CMD NOTHING. This usually means that a line of code
containing a feed command does not have a feed rate command with it. When the
alarms occurs, press the PROGRAM soft key on Page 2 of the POSITION screen.
Now, press any of the cursor or tab keys. (Tab keys are those arrow keys
arranged in a sort of big plus sign in the lower left of the CRT/MDI normally
used to move through data fields). Doing this will establish the Buffer
Correction mode. The display area for the program being executed changes to the
buffer correction area. BUFFER EDIT is displayed. Cursor to the problem area,
in this case the line where the feed command is located and correct the
problem. The only corrections you can make is for those items in the display
area. So, in other words, you can't use Buffer Correction mode to change things
all throughout the program. After making the correction, press INPUT. The
display area returns to the program being executed and the alarm message is
cleared. Press Cycle Start, the program resumes where the alarm occurred.
When adjusting
backlash on a Mitsubishi M500 series controlled machine:
Machine Axis
Parameter 11 G0back sets compensation amount during JOG and RAPID.
Machine Axis
Parameter 12 G1back sets compensation amount in HANDLE mode and during
commanded movement (cutting feed).
If a machine leaves
bumps at the quadrants during circular interpolation, there is more than likely
a lost motion (backlash) problem. As with all controls, the adjustment is done
by Parameter and is broken down by the axis. In the case of an M500 series
control the parameter is #16 of the Machine Servo Parameters.
#
X Y Z
16
SV016 0 0 0
The setting range is
0 to 200%. Most machines have this parameter set at 0 and seldom is it required
to be more than 100%. There is no direct mathematical correlation between the
setting and the actual amount of backlash. In most cases, the best procedure is
to try different settings until a circle can be machined in a test piece
without leaving a bump. Afterwards make sure the circle is still round and
within size tolerance. Most of the time when there is a bump it is due to
overcompensation so the value in the parameter needs to be decreased.
Another parameter to
be aware of is #41(SV041). This parameter allows you to compensate one amount
in the positive direction and another amount in the negative direction. If
SV041 is set to zero, as it is in most cases, the compensation is performed
according to the value of Parameter SV106.
One very, very
important thing to know about the Ladder of an M500 series control is that most
of the time when you open it up, depending on the machine builder, comments
will not be displayed. In order to display them, press the EOB button. At the
bottom of the display a message will be shown that says DISPLAYING COMMENTS.
When you display the comments, some of the instructions will change. For
example the instruction M162 might become CL1.
Another thing to know
is that if you are trying to use the ladder to troubleshoot a problem, you can
view several rungs on the same screen even though they might be many steps apart.
For example, if you are trying to find out why the coolant won't come on you
can search and display the rung with the coolant button. This may be step 500.
If an instruction related to this one is at step 350 and you search it, it will
be displayed on the same screen with step 500 so you can view them both at the
same time.
The connectors of an
M530 I/O board from top to bottom are:
CDP12
CDP11
CDJ11
CDP11 and CDP12 are
for Inputs. CDJ11 is for Outputs.
In the unlikely event
you should need to replace the CPU (QX141-1), keep this in mind. If you replace
it with a new one, you need to backup Parameters, Tool Data and Programs. You
must also write down Latch Parameters and Bit Selects. Tool Offsets will load
in with the Tool Data but the Tool Register will not, it stays with the old
CPU. PLC timers will load back in with the Parameters as well as Position
Switch information. The Latch Parameters will stay with the old CPU.
If a program will not
execute and there are no obvious reasons such as alarms etc., check the
In-Position signal of each axis. This may also keep the spindle from running in
Manual mode. In the case of an M500 series control, the In-Position Width is
set in Machine Servo Parameter SV024. The setting range of this parameter is
0-32767. The value is um.
On an M520 Control,
User Axis Parameter #13 OT-CHECK OFF set to 1 tells the NC to ignore the values
in #14 and #15 (Soft Travel Limits). The Parameter is Axis specific so be sure
to look for the Axis name at the top of the screen.
If you have trouble
communicating with an M530 control, check for abnormal voltages at the
connectors particularly the QX524 board. A grounded wire on the external 24
volts can cause communications problems.
To set tools on an
M530 control, go to the TLM (Tool Length Measure) page. Zero Return the
machine. Cursor to the H number you want to store the height in. It can be any
number. Bring the tool down with the MPG. When you are touching the part, press
INPUT. Enter the cutter radius into one of the D numbers. It can be any number.
In your program when you call the tool, call the offsets. I.E. T1 M6 H4 D9;
If an M520 or M530
control displays EMG EMERGENCY LIN, check the 220 volts that feeds the drives.
Normal voltage
reading on the RS-232 port for the M520 and M530 controls are:
Pin 2 to GND
- 11.5 vdc
Pin 3 to GND -
0 vdc
Pin 7 to GND -
0 vdc
Pin 2 to Pin 7
- 12 vdc
Pin 3 to Pin 7
- 0 vdc
To find the software
version on an M530 control, press the DIAGN button then the NC-SPEC soft key.
Look in the lower left hand corner.
To find the PLC
version on an M520 control, look in the left hand corner of the ALARM SCREEN.
On an M530 control, look in the left hand corner of the MONITOR SCREEN.
The Ladder for an
M520 control is stored on an SRAM card which is located in the right hand CBUS
slot on the CPU board. The Mitsubishi designation is QX812. In the case of an
M530 control it may be a QX815.
If you need to change
the reference return position of an axis of an M530 control you must make an
adjustment to the Reference Point Shift Amount. This parameter is found in the
Machine Parameters under Zero (Reference) Point Return Parameters. The setting
range is 0-65535u. The value you see in this parameter is microns. To find the
shift amount in millimeters, multiply by the value in the parameter by .001.
So, if you needed to shift the ZRN position of an axis by .120", for
example, convert to microns. The conversion factor from inches to microns can
be hard to handle, it may be best to convert to millimeters then to microns.
That, or trial and error.
The procedure is:
1. Press DIAGN
IN/OUT button.
2. Press
PLC-I/F soft key.
3. ...Share your problem. contact us.
4. Press INPUT
CALC button.
5. Press TOOL
PARAM button.
6. Press ZP-RTN
soft key.
7. Press Right
Chapter key until desired axis is displayed at the top of CRT.
8. ...Share your problem. contact us.
9. Press INPUT
CALC button.
10. Cycle power.
11. Perform Reference
return.
12. Check position.
There is a condition
that can occur on M520 and M530 controls which can be very difficult to
troubleshoot. In this case the machine will be in an E-stop condition even
though the E-Stop circuit on the machine side is clear. Input address X27 which
is used by most machine builders for the E-Stop circuit will be 1 as it should
be if the E-Stop circuit is closed. The CRT will display EMG at the bottom left
and the READY lamp on the monitor will be off. This condition can be the result
of a power surge which damages the CPU board. Also the diagnostic bits normally
used for troubleshooting, R69 will all be ones and none of the drives will
indicate an alarm state.
On most machines
controlled by an M520 or M530 control, the MCC contactor is energized by a
normally open relay contacted in the CV unit if the NC is in a READY state.
There are three terminals near the bottom of the CV unit that are labeled L11,
L21 and MC1. Typically one phase of the AC line (220 vac) will be connected to
the L11 terminal and another phase will be connected to the L21 terminal. When
the NC boots up and wants to make the machine READY, it will close a relay
within the CV unit which feeds the power from the L21 terminal onto the MC1
terminal which is connected to one side of the MCC coil. The other side of the
coil is connected to either the source for the L11 terminal or to the third
phase of the incoming AC (L31, L3, T, etc.) At this point MCC should energize
sending all three phases of the AC to the main terminals of the CV unit which
charges the DC link in turn powering the servo drives and the spindle drive. If
the CV unit closes this contact and for some reason MCC does not energize (open
coil, loose wire, etc.) the following indications will normally be observed:
EMG EMERGENCY PLC
displayed at the top of the screen.
S01 SERVO ALARM : PR
0071 S1 displayed below it.
EMG displayed at the
bottom of the screen.
The CV unit will
display H.
The spindle amp will
display F3 and 71 flashing and alternating.
The servo amplifier
(if dual amp on two axis machine) will display F2 and E7 flashing and
alternating.
In order to view the
ladder on an M520 control, Bit Select parameter needs to be 1. If this
parameter is 0 on an Ecoca EL machine, when the FO button is pressed the
TEACH-IN screen will be shown regardless of the setting of the PLC-SW for
TEACH-IN.
If the cable is
removed from the battery pack (MDS-A-BT2) on an M520 controlled two axis
machine (EL, etc.), the CRT will display the following:
EMG EMERGENCY SRV
Z71 DETECTOR ERROR
0001 XZ
S01 SERVO ALARM : PR
0025 XZ
M01 OPERATION ERROR
0006 XZ
The M520 controller
has 103 timers. They are accessed through the Machine Parameters. T0 to T15
have a base value of 10 milliseconds. T16 to T103 have a value of 100
milliseconds. So, if you go to T1, for example, and the number displayed is 50,
the timer setting is 50 times 10 milliseconds or .5 seconds. If T17 displayed
50 then the timer setting would be 5 seconds.
To page through the
ladder of an M520 controller rather than searching addresses over and over:
1. Press the FO
button.
2. Press the LADDER
soft key.
3. Press the 2CIRCUIT
soft key.
4. Press the MENU
soft key.
5. Press the 6MONIT
soft key.
6. Press the SHIFT
button.
7. Press the +
button.
8. Press the INPUT
button.
Now, every time you
press the INPUT button the monitor will display the next several rungs of
ladder. On some machines you may need to press the + button without pressing
the SHIFT button. In some cases it may not work if you have already been
searching by address so you will have to press the F0 button to go back to the
LADDER soft key and start again.
BIT SELECTION
Parameters for PLC development on the 50 control per manual BNP-B2063A:
#6451.0
0 = On-board Operation OFF. On-board operation is off. Nothing will display
even if FO is pressed.
1 = On-board Operation ON. Screen is displayed for user PLC development,
ladder
monitor and ROM writing, etc.
* Note - Mitsubishi
refers to manipulation of the ladder at the CRT as On-board
programming.
#6449.0
0 = Timer Setup Value SCREEN on.
1 = Timer Setup Value PROGRAM on.
#6449.1
0 = Counter Setup Value SCREEN on.
1 = Counter Setup Value PROGRAM on.
When 6449.0 and
6449.1 are 0, the values set in the PLC TIMER and PLC COUNTER screens SETUP
PARAMETERS are used as the timer and counter setup values.
When 6449.0 and
6449.1 are 1, the programmed constant (K) values are used as the timer and
counter setup values. At the time, the programmed constant (K) values of the
timers and counters are also displayed on the PLC TIMER and PLC COUNTER screens
of machine manufacturer parameters. So, even if both bits are set to 1, the
valid setup values can be checked on the screens in the PLC-RUN state. But no
values can be set. If a value is set, the alarm E05 Setting Disabled is
displayed. When 6449.0 and 6449.1 are both set to 0, the constant (K) values
are ignored and the values set on the screen become valid but since K cannot be
omitted in programming, any numeric value must be entered in K for programming.
#6449.2
0 = Integrating Timer (T96-T103) Retention OFF (No retention)
1 = Integrating Timer (T96-T103)
Retention ON
#6449.3
0 = Counter (C0-C23) Retention OFF (No retention)
1 = Counter (C0-C23) Retention ON
When 6449.2 and
6449.3 are 0 the current values of the integrating timer and the counter are
reset to 0 when the NC power is turned off.
When 6449.2 and
6449.3 are 1 the current values of the integrating timer and the counter are
not reset to 0 even if the NC power is turned off. The values before the NC was
turned off are retained.
#6452.2 0 =
Integrating Timer (Q136-Q151) Retention OFF (No retention)
1 = Integrating Timer (Q136-Q151) Retention ON
#6452.3 0 = Counter
(B0-B103) Retention OFF (No retention)
1 = Counter (B0-B103) Retention ON
When 6452.2 and
6452.3 are 0 the current values of the Integrating and the counter are reset to
0 when the NC power is turned off.
When 6452.2 and
6452.3 are 1 the current values of the integrating timer and the counter are
not reset to 0 even if the NC power is turned off. The values before the NC was
turned off are retained.
On a Mitsubishi M520
controller the direction in which the trace is drawn for the graphic function
is set in the [TRACE SETUP] screen. The screen looks like:
[TRACE SETUP] GRAPHIC
2/2
#1 $ NO.1 (1)
2 AXIS
DIRECTION (0) (1) (+=0, -=1)
3 $ NO.2 (0)
4 AXIS
DIRECTION (0) (1) (+=0, -=1)
5 COORDINATE
CHANGE (1)
(MACHINE=0,
WORK=1)
The direction of the
trace, left to right, is determined by the placement of the 0 and the 1 for the
AXIS DIRECTION field. Using #2 as an example:
#
2 AXIS
DIRECTION (0) (1)
This will
cause the trace to be drawn from + to -.
2 AXIS
DIRECTION (1) (0)
This will
cause the trace to be drawn from - to +.
An important point to
remember about the graphic function is that the direction parameters shown
above cannot be changed if the Trace function is active. Attempting to do so
will cause E05 NOT ACCEPTABLE alarm to be issued. To determine if the Trace
function is active, go the graphic display screen (where the trace is actually
shown). Look for the TRACE soft key. If it is highlighted, the Trace function is
active. Press the TRACE soft key to deactivate the function.
If the absolute
position for an axis is lost (Z70) you may need to initialize the absolute
pulse coder. In most cases, however, you may solve the problem by loading the
machine's parameters.
If you do initialize
the pulse coders remember that if you need to change the value that is set in
the BASE (#2) parameter you have to have 1 set in the #1 SET parameter to keep
from getting the alarm E05 NOT ACCEPTABLE. In other words you should change the
value of #2 BASE immediately after setting the zero point.
The procedure for
initializing the Absolute Position Coders:
1. Access the Machine
Parameters.
2. Press the
TOOL/PARAM button.
3. Press the Scroll
button until page 5/10 of the BASE parameters
(Absolute Position) is displayed.
4....Share your problem. contact us.
5. Press Input.
ABSOLUTE will become highlighted.
6. ...Share your problem. contact us.
7. Cursor to the DATA
field ( ) which corresponds to the axis you wish
to
initialize.
8. ...Share your problem. contact us.
9. With the machine
in manual mode, move the axis to the desired zero
point.
10. ...Share your problem. contact us.
11. ...Share your problem. contact us.
12. Press INPUT.
13. The ABSOLUTE
display of the affected axis will change a few times
and if the initialization was successful will end up displaying *.
14. ...Share your problem. contact us.
15. ...Share your problem. contact us.
16. Repeat these
steps for all axes desired.
17. Cycle power.
On step 10 you must
put a value into the field of both axes, not just the one being set. This value
can be 0. If a value is not set, The SET parameter will become 1 but step 13
will not occur. The absolute display will show 1 and will stay 1 until power is
cycled.
# (2) BASE cannot be
changed unless #(1) SET = 1.
This will cause E05 NOT ACCEPTABLE to be
displayed.
