TECHNICAL MANUAL Simplified Operation Panel

INDUSTRIAL SEWING MACHINE MODEL PLK-G10 TECHNICAL MANUAL Simplified Operation Panel A180E670P01

... Contents... 1. For safe use 1 2. Precautions for use 3 3. Initial settings (Language / Model settings) 5 4. Operation procedure 7 4-1.Outline of the Control Switch Panel... 7 4-2.Change in "Program mode" 1... 9 4-3.Change in "Program mode" 2... 11 4-4.Change in "Speed setting mode"... 13 4-5.Bobbin winding mode... 14 4-6.Counter mode... 15 4-7.Reading / Writing mode (Reading the sewing data)... 18 4-8.Reading / Writing mode (Writing the sewing data)... 19 4-9.Reading / Writing mode (Erasing the sewing data)... 21 4-10.Reading / Writing mode (Reading the combination data)... 23 4-11.Reading / Writing mode (Erasing the combination data)... 25 4-12.Reading / Writing mode (Reading the setting table)... 26 4-13.Reading / Writing mode (Reading the step file)... 27 4-14.Tool mode (Switching the pattern of combination)... 28 4-15.Tool mode (Deactivating the combination function)... 29 4-16.Tool mode (Moving the needle up and down)... 30 4-17.Tool mode (Version display)... 31 5. Reinstalling the System 32 6. Error / Message (display) list 35-1 -

Thank you for purchasing the Mitsubishi industrial sewing machine PLK-G Series. Please read this technical manual before starting to ensure correct and long-term use. * The contents of this manual may not be reproduced in part or whole. * The contents of this manual are subject to change without notice. * An utmost effort has been made to cover all points of operation in this manual. Contact Mitsubishi if you have any questions regarding the contents. COPYRIGHT(C) 2014 MITSUBISHI ELECTRIC CORPORATION - 2 -

1. For safe use 1-1. For safe use Always observe the following matters to safely use the Mitsubishi industrial electronic sewing machine PLK-G Series (motor and control box). Before starting Before using this control unit, read all of the technical manuals carefully, and correctly use the unit following the manual. Also read the "Mitsubishi Industrial Sewing Machine Technical Manual <Sewing Machine Head>" for details on the general configuration and sewing machine head. Application and purpose This control unit is designed to drive and control the Mitsubishi industrial electronic sewing machine PLK-G Series. Do not use this control unit for other applications or purposes. Do not use this control unit until it has been confirmed that safety measures have been accurately taken for the installed electronic sewing machine head section. Working environment Please use this control unit in the industrial setting only. And do not use this control unit in the following type of environment. (1) Power voltage * Where the voltage fluctuation exceeds ±10% of the rated voltage. * Where the specified power capacity (refer to technical manual [Control unit] page [4]-2 5. Power capacity ) cannot be ensured. (2) Magnetic noise * Where strong fields or magnetic fields are generated, such as near a high-output high frequency oscillating machine or high frequency welder. (3) Temperature and humidity * Where the ambient temperature is 35 C or more and 5 C or less. * Where the unit will be subject to direct sunlight, or outdoors. * Near sources of heat, such as heating appliances. * Where the relative humidity is 45% or less, or 85% or more, and where dew may condense. (4) Atmosphere * In an atmosphere containing dust or corrosive gases, etc. * In a flammable gas or explosive environment. (5) Vibration * If excessive vibration could occur when installed on the sewing machine, separately install the control box. 1-2. Installation Control box Correctly install the control box according to this manual. Accessories Always disconnect the control unit from the main power supply before installing the accessories listed in this manual. (Turn the power switch OFF, and disconnect the plug from the socket (power supply line).) Cable (1) Lay the connection cables so that excessive force will not be applied during operation. Do not excessively bend the cables. (2) Cables laid near operating machine sections (ex., pulley or V-belt) must be separated by at least 25mm. (3) Before connecting the power cable to the control box, confirm that the power voltage matches the specifications given on the control box's rating nameplate and factory shipment voltage nameplate. Connect the cable to the indicated positions, and then supply the power. When using a power unit, connect the cable to the power unit and supply the power. In addition, when using a power unit, confirm that the power voltage matches the specifications given on the power unit's rating nameplate. Turn the power switch OFF before making any connections. Grounding Always ground the power cord's grounding wire. Enclosed units and accessories Connect the electrical enclosed units and accessories only to the positions indicated in the manual. 1

Removal (1) Always turn the power switch OFF and disconnect the plug from the socket (power supply line) before removing the motor or control box. (2) Do not pull out the cord when disconnecting the plug. Always hold the plug receptacle when disconnecting the plug. (3) Note that a high voltage is applied inside the control panel, so always turn the power OFF and wait at least ten minutes before opening the control box cover. 1-3. NOTICE CONCERNING MARKING (1) Electronic sewing machine PLK-G series are applied to CE conformity marking by installing the exclusive device [PLK-G-CE]. When the products are used in the EU region, these devices are necessary to be installed. (2) Electronic sewing machine should be use limited to the industrial areas even though above-mentioned countermeasure is done. [Warning] Use in residential areas may cause interference. 1-4. Maintenance, inspection and repairs (1) Follow this manual when carrying out maintenance or inspections related to this control unit. (2) This unit must be repaired, serviced and inspected only by a worker that has received special training. (3) Do not use this control unit with the ventilation holes on the dust-proof filter of the motor blocked, or clogged with dust, dirt or loose cloth, etc. (This can cause heating.) (4) Always turn the power OFF before replacing the needle or bobbin, etc., on the head. (5) Use genuine replacement parts for repairs and maintenance. 1-5. Other safety measures (1) Keep fingers away from all moving machine parts (especially around the sewing machine needle or V-belt, etc.). (2) Never drop the control unit, or place objects in the clearances. (3) Do not operate the sewing machine without the protective parts such as the cover, or protection devices such as the safety breaker. (4) If any damage is observed in the control unit, if the unit does not operate correctly, or if the operation is suspicious, always suspend operation. Only operate the machine after the supervisor has adjusted, repaired or inspected the machine. (5) The user must not make improvements or changes without instruction from Mitsubishi. 1-6. Caution displays and danger displays (1)In this manual, the dangers and danger levels that arise with incorrect handling are classified using the following displays. Warning The warning display shows that incorrect handling can lead to death or serious injuries. Caution The caution display shows that incorrect handling can lead to injuries or damages to your house, household goods, and others. (2)The meanings of these symbols are as follows. This symbol indicates that the instructions must be followed. This symbol indicates hot temperature requiring caution. This symbol indicates an electrical hazard or caution (electric shock caution). This symbol indicates that ground wire connection is required. This symbol indicates a prohibited action. * Always deliver this manual to the end user. * Store this manual nearby where it can be referred to when necessary. 2

2. Precautions for use Warning 1. Do not place foot on the foot switch when turning the power ON. 2. Always turn the power OFF when leaving the sewing machine. 3. Do not inspect the control circuit with a tester. 4. Always turn the power switch OFF before tilting the sewing machine head, replacing the needle, or passing thread through the needle. Control circuit The tester voltage could be applied on the semiconductor parts, and cause damage. 5. Always ground the grounding wire. Power supply 6. Do not use excessive wiring. Green (Green/yellow) Always ground the provided grounding wire (green(green/yellow)). 7. A high voltage is applied inside creating a hazardous state, so always turn the power OFF and wait ten minutes before opening the cover. 8. Radiation fins and other parts may be hot. Do not touch the parts. High voltage risk 3

9. Never pull out the cable connector of "PLK-G10" control switch panel and do not connect it when the power supply is ON. 10. The sewing machine will coast to a stop when the power is turned OFF or a power failure occurs during sewing machine operation. 11. Always align the connector shape and direction, and securely insert the connector. 12. If the position detector's connector dislocates, the belt dislocates, or the sewing machine is completely locked, the motor will be turned OFF automatically for a set time to prevent burning. (Note that the motor may not turn OFF if there is incomplete locking or an overload.) When the fault has been recovered, turn the power OFF and ON once to resume normal operation. The same type of operation will take place if a detector fault or disconnection occurs. 13.Use the machine away from strong noise sources such as high frequency welders. 14. When connecting the external switch to an optional connector, etc., keep the signal wire as short as possible. A long wire could cause malfunctions. Noise Use a shielded wire for the signal wire when possible. 15. Periodically remove the dust adhered on the motor's dust-proof filter once every two to three weeks. Dust-proof filter If operation is continued with the filter clogged, the motor could heat and adversely affect the motor life. 16. If the fuse blows, remove the cause, and replace the blown fuse with one having the same capacity. PLK-G3-CPU-M XC-G2-2B-PLK05 2.5A fuse(two fuses) XC-G2-2B-PLK05 20A fuse(two fuses) PLK-G2-PMD PLK-G2-PMD 20A fuse(two fuses) (View from the front with cover removed) (View from the front with the cover and CPU removed) 15A fuse(one fuse) Solenoid board located on back of machine head 17. Attention when power supply is turned on again Please make sure that turning on the power supply switch, after the LED of the front panel on the control box is completely turned off. (Please do not turn on the power supply again while displaying the screen of the operation panel.) * Please note that if power supply is turned on again while LED still turns on, clamp outputs (O4, O5 port) may go down. 18. When the value of the sewing area limit is changed or the limit setting is deactivated, note the collision and take care safely. Also when using it outside the range where the mechanism can be operated, it can not assume the responsibility for all problems caused by it. 4

3. Initial settings (Language / Model settings) When you turn on the machine power with the system in an initial state, it is "Language / Model settings" mode. It explains the operation that sets "Language" and "Model". (1) Press key in "Language settings" mode. (2) "Language" is switched by pressing key or Japanese English Spanish Chinese French JPN ENG SPA CHI FRA (3) Select "Language", then press (In this case "ENG") (4) Switch to the "Model settings" mode by pressing key or key (5) Press key in "Model settings" mode. (6) "Model" is switched pressing key or 5

(7) Select "Model", then press (In this case "1306") (8) To exit the settings, press (9) "M-305" code is displayed for confirmation. To execute it, press (When canceling, press ) (10) Turn off the power supply once if "M-300" code is displayed. Initial settings were completed. Please make sure not to turn on the power supply switch until after the LED on the front panel of the control box has completely turned off. 6

4. Operation procedure When power supply is turned on, if there was not sewing data in the internal memory, the following code "M-006" would be displayed. Press key, and then it changes into the display of the normal mode. Please read a sewing data in the reading / writing mode. (Refer to "4-7.Reading / writing mode (Reading a sewing data)) 4-1. Outline of the Control Switch Panel * Example of displaying the normal mode Setting of speed = "9" Number of current sewing data = "800" - Home position - Cancel (To previous mode) - Jog :Forward :Reverse - Switching :Previous :Next Shift to function mode Page 28 - Shift to program mode - Switching item - Increasing value Page 9 [A]key - Shift to speed setting mode - Increasing value Page 13 [B]key - Shift to bobbin winding mode - Increasing value Page 14 [C]key - Shift to counter mode - Switching On/OFF - Increasing value - Speed down Page 15 Enter(Execution) [D]key - Shift to Reading / Writing mode - Switching On/OFF - Switching item - Increasing value - Speed up Page 18 7

* Example of displaying the normal mode. Additionally "Combination mode" is "ON". * Example of displaying the normal mode. Additionally "Up counter mode" is "ON". * Example of displaying the normal mode. Additionally "Down counter mode" is "ON". * Example of displaying the normal mode. Additionally "Combination mode", "Up counter mode" and "Down counter mode" is "ON". 8

4-2. Change in "Program mode" 1 It explains the operation that changes the "WIP" function in the "WIPER" item from "ON" to "OFF". (1) Press key in the state of normal mode. (2) It becomes item selection mode of "Program mode". The item is switched by pressing key or (Refer to Table1) (3) The item is decided, and then press (In this case "WIPER") (4) It becomes function selection mode. The function is switched by pressing key or (5) The function is decided, and then press (In this case "WIP") (6) It becomes value change mode. The value is changed by pressing key or (7) The value is decided, and then press (To return without changing a set value, press ) 9

(8) It becomes function selection mode. Press (9) It becomes item selection mode. Press (10) It returns to the normal mode. The change in the program mode was completed. Table1 The item code (Program mode) and the change order Wiper Slow start Clamp Needle position Thread breaking sensor Home position Halt Counter Brake Bobbin winding Feed method Speed Thread trimming / Thread release Step Jog Feed angle Other Pattern WIPER SLOW CLAMP NEEDL THRDB HP HALT CNTER BRAKE WIND FEEDM SPEED TRIM STEP JOG ANGLE OTHER PTN 10

4-3. Change in "Program mode" 2 It explains the operation that changes the "HIGH" function in the "SPEED" item from "2500" to "2000". (1) Press key in the state of normal mode. (2) It becomes item selection mode of "Program mode". The item is switched by pressing key or (Refer to Table1) (3) The item is decided, and then press (In this case " SPEED ") (4) It becomes function selection mode. The function is switched by pressing key or (5) The function is decided, and then press (In this case " HIGH ") (6) It becomes value change mode. The value is changed by pressing keys. (7) The value is decided, and then press (To return without changing a set value, press ) 11

(8) It becomes function selection mode. Press (9) It becomes item selection mode. Press (10) It returns to the normal mode. The change in the program mode was completed. 12

4-4. Change in "Speed setting mode" It explains the operation of changing the speed setting value from "9" to "8". (1) Press key in the state of normal mode. (2) It becomes speed setting mode. The value is changed by pressing key or key : The value is decreased. key : The value is increased. (3) To return to the normal mode, press (4) It returns to the normal mode. (The display of the speed setting became "8".) The change in the speed setting mode was completed. 13

4-5. Bobbin winding mode It explains the operation that shift to "Bobbin winding mode". (1) Press key in the state of normal mode. (2) It becomes bobbin winding mode. The shift to the bobbin winding mode was completed. (3) To return to the normal mode, press (4) It returns to the normal mode. 14

4-6. Counter mode It explains the operation of changing the setting value in the counter mode (1) Press key in the state of normal mode. (2) It becomes the counter mode. The item is switched by pressing key or (Refer to Table2) (3) The item is decided, and then press (In this case "UPSET") (4) The value is changed by pressing keys. (5) The value is decided, and then press (To return without changing a set value, press ) (6) It becomes item selection mode. The item is switched by pressing key or (Refer to Table2) (7) The item is decided, and then press (In this case "UPCNT") 15

(8) The value is changed by pressing keys. (9) The value is decided, and then press (To return without changing a set value, press ) (10) It becomes item selection mode. The item is switched by pressing key or (Refer to Table2) (11) The item is decided, and then press (In this case "UPC") (12) It becomes value change mode. The value is changed by pressing key or (13) The value is decided, and then press (In this case "ON") (14) To return to the normal mode, press 16

(15) It returns to the normal mode. Table2 The item code (Counter mode) and the change order Current value of DOWN counter Current value of UP counter Setting value of DOWN counter Setting value of UP counter DOWN counter Valid/Invalid UP counter Valid/Invalid DNCNT UPCNT DNSET UPSET DNC UPC 17

4-7. Reading / Writing mode (Reading the sewing data) It explains the operation of reading the sewing data. (1) Press key in the state of normal mode. (2) It becomes reading item of "Reading / Writing mode". Press (3) To read the sewing data from USB memory, press (Every time key is pressed, it alternates the USB memory (F) and the internal memory (I)). (When you use the USB memory, connect the USB memory to the USB port.) * When reading the sewing data from USB memory, the display blinks and reading is prohibited when the same number as data that exists in the internal memory is selected. key is invalid. To read the data, it is necessary to erase the same number data that exists in the internal memory. (4) The sewing data is switched by pressing key or The sewing data is decided, and then press (5) The sewing data was read. 18

4-8. Reading / Writing mode (Writing the sewing data) It explains the operation of writing the sewing data. (1) Press key in the state of normal mode. (2) The item is switched by pressing key or (Refer to Table3) (3) Choose "Writing the sewing data" item, and then press (4) To write the sewing data to USB memory, press (Every time key is pressed, it alternates the USB memory (F) and the internal memory (I)). (When you use the USB memory, connect the USB memory to the USB port.) (5) The number of the sewing data is changed by pressing keys. The number is decided, and then press * The display blinks and writing is prohibited when the same number as data that already exists is set. key is Invalid. Please assign some other number, and write it. To write the data in the number of the demand, it is necessary to erase the same number data that exists in the internal memory or USB memory. 19

(6) The sewing data is written. Table3 The item code (Reading / Writing mode) and the change order Reading the sewing data Writing the sewing data Erasing the sewing data Reading the combination data Erasing the combination data Reading the setting table Reading the step file DATA.R DATA.W DATA.E CONB.R COMB.E TABL.R STEP.R 20

4-9. Reading / Writing mode (Erasing the sewing data) It explains the operation of erasing the sewing data. (1) Press key in the state of normal mode. (2) The item is switched by pressing key or (Refer to Table3) (3) Choose "Erasing the sewing data" item, and then press (4) To erase the sewing data from USB memory, press (Every time key is pressed, it alternates the USB memory (F) and the internal memory (I)). (When you use the USB memory, connect the USB memory to the USB port.) (5) The sewing data is switched by pressing key or The sewing data is decided, and then press 21

(6) The sewing data was erased. * When the key is pressed to erase the sewing data, the message code "M-222" displayed as shown in a right figure means it tried to erase current sewing data. It is not able to erase current sewing data. Please erase it again after reading another sewing data once. 22

4-10. Reading / Writing mode (Reading the combination data) It explains the operation of reading the combination data. (1) Press key in the state of normal mode. (2) The item is switched by pressing key or (Refer to Table3) (3) Choose "Reading the combination data" item, and then press (4) To read the combination data from USB memory, press (Every time key is pressed, it alternates the USB memory (F) and the internal memory (I)). (When you use the USB memory, connect the USB memory to the USB port.) (5) The combination data is switched by pressing key or The combination data is decided, and then press 23

(6) The combination data was read and combination function is "ON". 24

4-11. Reading / Writing mode (Erasing the combination data) It explains the operation of erasing the combination data. (1) Press key in the state of normal mode. (2) The item is switched by pressing key or (Refer to Table3) (3) Choose "Erasing the combination data" item, and then press (4) The combination data is switched by pressing key or The combination data is decided, and then press (5) The message code "M-278" is displayed to confirm the execution. When executing it, press (When canceling, press ) (6) The combination data was erased. 25

4-12. Reading / Writing mode (Reading the setting table) It explains the operation of reading the setting table. (1) Press key in the state of normal mode. (2) The item is switched by pressing key or (Refer to Table3) (3) Choose "Reading the setting table" item, and then press (Please connect USB memory with the USB port before pressing ) (4) The setting table data is switched by pressing key or The setting table data is decided, and then press (5) Please turn off the power supply once if the message code "M-290" is displayed. Please make sure not to turn on the power supply switch until after the LED on the front panel of the control box has completely turned off. 26

4-13. Reading / Writing mode (Reading the step file) It explains the operation of reading the step file. (1) Press key in the state of normal mode. (2) The item is switched by pressing key or (Refer to Table3) (3) Choose "Reading the step file" item, and then press (Please connect USB memory with the USB port before pressing ) (4) The step file data is switched by pressing key or The step file data is decided, and then press (5) Please turn off the power supply once if the message code "M-290" is displayed. Please make sure not to turn on the power supply switch until after the LED on the front panel of the control box has completely turned off. 27

4-14. Tool mode (Switching the pattern of combination) It explains the operation of switching the pattern of combination function. (1) Press key when the combination function is valid. (2) It becomes "Switching the pattern of combination" item. Press (3) The sewing data is switched by pressing key or The sewing data is decided, and then press (4) The pattern of combination function was switched. 28

4-15. Tool mode (Deactivating the combination function) It explains the operation of deactivating the combination function. (1) Press key when the combination function is valid. (2) The item is switched by pressing key or (3) Choose "Deactivating the combination function" item, and then press (4) The message code "M-298" is displayed to confirm the execution. When executing it, press (When canceling, press ) (5) The combination function was deactivated. 29

4-16. Tool mode (Moving the needle up and down) It explains the operation of moving the needle up and down. (1) Press key in the state of normal mode. (2) The item is switched by pressing key or (3) Choose "Moving the needle up and down" item. Movement UP and DOWN changes alternately whenever key is pressed. * Please lower work holder before it operates. *A present needle position is displayed in the control switch panel. (4) Press It returns to normal mode. 30

4-17. Tool mode (Version display) It explains the operation of displaying the system version. (1) Press key in the state of normal mode. (2) The item is switched by pressing key or (3) Choose "Displaying the system version" item, and then press When the version is "S101W16B", it is displayed as "01.16B". (The under line part is displayed.) (4) Press It returns to normal mode. 31

5. Reinstalling the System (1) Save the system data in a USB memory. Copy the [ directory of USB memory. ] folder where the installed system data are included, into the root System data (2) Turn the machine power OFF and insert the USB memory. (3) While holding down the [F] key on the front panel of the control box, turn the machine power ON. (Keep pushing [F] key until red LED on the front panel is turned on.) + (4) Installation is started. Please wait for a while until becoming "Language/ Model settings" mode. At this time, nothing is displayed in the "PLK-G10" control switch panel. (5) Press key in "Language settings" mode. 32

(6) "Language" is switched by pressing key or Japanese English Spanish Chinese French JPN ENG SPA CHI FRA (7) Select "Language", then press (In this case "ENG") (8) Switch to the "Model settings" mode by pressing key or key (9) Press key in "Model settings" mode. (10) "Model" is switched pressing key or (11) Select "Model", then press (In this case "1306") 33

(12) To exit the settings, press (13) "M-305" code is displayed for confirmation. To execute it, press (When canceling, press ) (14) Turn off the power supply once if "M-300" code is displayed. Reinstalling the system was completed. Please make sure not to turn on the power supply switch until after the LED on the front panel of the control box has completely turned off. 34

6. Error / Message (display) list Confirm the error code (E-***) or message code (M-***), and investigate with the following table. Please refer to the technical material "Operation panel" for a detailed explanation of error codes and message codes. CODE ERROR INSPECTION E-001 Main axis overcurrent error - Check the wiring for the main motor. - Check the sewing machine. Main axis lock error - Check the insertion of the connector. - Check the encoder A/B/ phase signal by E-003 using IN/OUT setting mode. - Check the sewing machine. - Check the motor. E-006 X axis a phase adsorption error - Check clamp position. E-007 Y axis a phase adsorption error - Check clamp position. E-009 E-015 SOL substrate solenoid overcurrent error SOL substrate air valve overcurrent error - Check the wiring for the solenoid. - Exchange the solenoid. - Use below rating current value. - Check output wiring from CON-M and remove short-circuited point. - Exchange electromagnetic valve which is connected to CON-M. - Use with below the rating current value. For example, decrease number of output, change to output device with low current value, shift on timing of each output, change setting of the full wave on time to smaller or zero. CODE MESSAGE SUB MESSAGE M-001 NEEDLE IS NOT CORRECT POSITION RETURN NEEDLE TO UP POSITION BY HAND OR NEEDLE UP ICON M-003 CLAMP IS UP TURN ON THE FOOT SWITCH (BLACK FOOT SWITCH) M-004 UP COUNTER SET VALUE UP Please touch Enter key M-005 DOWN COUNTER REACHED SET Please touch Enter key VALUE M-006 PATTERN DATA DOES NOT EXIST READING OR TEACHING INPUT TERMINATION PROCESS COMPLETE SEE YOU AGAIN! * WAIT UNTIL THE LED M-028 OF THE CONTROL BOX IS COMPLETELY OFF, THEN POWER THE SWITCH ON AGAIN M-050 NOT IN THE HOME POSITION PRESS HOME ICON M-161 HALT SWITCH IS ON RELEASE HALT SWITCH. IF MESSAGE IS NOT CLEAR AFTER RELEASE HALT SWITCH, TURN THE POWER OFF AND CHECK HALT SWITCH & CABLE M-188 USB MEDIUM IS NOT CONNECTED PLEASE CONNECT USB MEDIUM M-222 PATTERN DATA CAN NOT BE DELETED CURRENT PATTERN DATA CAN NOT BE ERASED 35

MEMO

[Reference] Table of digital display Numeral 0 1 2 3 4 5 6 7 8 9 Digital display Character A B C D E F G H I J Digital display Character K L M N O P Q R S T Digital display Character U V W X Y Z Digital display

Printed in Japan