Mitsubishi Electric M80 Series Maintenance Manual
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Mitsubishi Electric M80 Series Maintenance Manual

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  • Page 2 Be sure to keep this manual always at hand. The following screens described in this manual are the screens for Mitsubishi Electric's display unit. If the display unit you are using is not manufactured by Mitsubishi, please contact the machine tool builder.
  • Page 3 Manual List Manuals related to M800/M80/E80/C80 Series are listed as follows. These manuals are written on the assumption that all optional functions are added to the targeted model. Some functions or screens may not be available depending on the machine or specifications set by MTB. (Confirm the specifications before use.) The manuals issued by MTB take precedence over these manuals.
  • Page 4 Manuals for MTBs (NC) Manual IB No. Purpose and Contents  Model selection M800/M80/E80/C80 Series IB-1501505 Specifications Manual (Function)  Outline of various functions  Model selection M800/M80/E80/C80 Series IB-1501506 Specifications Manual (Hardware)  Specifications of hardware unit  Detailed specifications of hardware unit M800W/M80W Series IB-1501268 Connection and Setup Manual...
  • Page 5 (Monitor) GOT2000 Series Connection  Outline of connection types and connection method between Manual (Mitsubishi Electric SH-081197 GOT and Mitsubishi Electric connection devices Products) GT Designer3 (GOT2000) Screen  Outline of screen design method using screen creation SH-081220 Design Manual software GT Designer3 ■...
  • Page 6 GX Works3 Operating Manual SH-081215  Outline of functions, programming, etc. Reference Manual for MTBs Manual Purpose and Contents M800/M80 Series Smart safety BNP-C3072-022 observation Specification manual  Explanation for smart safety observation function C80 Series Smart safety observation BNP-C3077-022...
  • Page 8 Precautions for Safety Always read the specifications issued by the MTB, this manual, related manuals and attached documents before installation, operation, programming, maintenance or inspection to ensure correct use. Understand this numerical controller, safety items and cautions before using the unit. This manual ranks the safety precautions into "DANGER", "WARNING"...
  • Page 9 For Safe Use MITSUBISHI CNC is designed and manufactured solely for applications to machine tools to be used for industrial purpos- Do not use this product in any applications other than those specified above, especially those which are substantially in- fluential on the public interest or which are expected to have significant influence on human lives or properties.
  • Page 10 3. Items related to prevention of bodily injury or property damage DANGER When transporting or installing a built-in IPM spindle or linear servomotor, be careful so that your hand or property is not trapped in the motors or other metal objects. Also keep the devices with low magnetic tol- erance away from the product.
  • Page 11 CAUTION Do not transport the controller or drive unit by suspending or holding the connected wires or cables. Do not hold the front cover when transporting the unit, or the front cover could come off, causing the unit to drop. Install on a non-combustible place where the unit's or motor's mass can be withstood according to the in- struction manual.
  • Page 12 CAUTION Following the UN recommendations, battery units and batteries should be transported based on the inter- national regulations such as those determined by International Civil Aviation Organization (ICAO), Interna- tional Air Transport Association (IATA), International Maritime Organization (IMO) and U.S. Department of Transportation (DOT).
  • Page 13 CAUTION When using the RS-232C device as a peripheral device, caution must be paid for connector connection/dis- connection. Always use a double-OFF type AC power supply switch on the device side, and connect/dis- connect the connector with the AC power supply on the device side OFF. Switch Device NC unit...
  • Page 14 (6) Usage CAUTION Install an external emergency stop circuit so that the operation can be stopped and the power turns OFF immediately when unforeseen situation occurs. A contactor, etc., is required in addition to the shutoff func- tion mounted in the controller. Turn OFF the power immediately if any smoke, abnormal noise or odor is generated from the controller, drive unit or motor.
  • Page 15 (7) Troubleshooting CAUTION Use a motor with electromagnetic brakes or establish an external brake mechanism for the Shut off with motor Shut off with CNC brake purpose of holding; this serves as counter- brake control output control PLC output measures for possible hazardous situation caused by power failure or product fault.
  • Page 16 (9) Disposal CAUTION Take the batteries and backlights for LCD, etc., off from the controller, drive unit and motor, and dispose of them as general industrial wastes. Do not alter or disassemble controller, drive unit, or motor. Collect and dispose of the spent batteries and the backlights for LCD according to the local laws. Dispose the spent cooling fan according to local laws.
  • Page 18 Treatment of waste The following two laws will apply when disposing of this product. Considerations must be made to each law. The following laws are in effect in Japan. Thus, when using this product overseas, the local laws will have a priority.
  • Page 20 This symbol mark is according to the directive 2006/66/EC Article 20 Information for end- users and Annex II. Your MITSUBISHI ELECTRIC product is designed and manufactured with high quality materials and components which can be recycled and/or reused. This symbol means that batteries and accumulators, at their end-of-life, should be disposed of separately from your household waste.
  • Page 22 MELDAS, MELSEC, EZSocket, EZMotion, iQ Platform, MELSEC iQ-R, MELSOFT, GOT, CC-Link, CC-Link/LT, CC-Link IE, CC-Link IE/field, EcoMonitorLight and SLMP are either trademarks or registered trademarks of Mitsubishi Electric Corporation in Japan and/or other countries. Ethernet is a registered trademark of Xerox Corporation in the United States and/or other countries.
  • Page 24 本製品の取扱いについて ( 日本語 /Japanese) 本製品は工業用 ( クラス A) 電磁環境適合機器です。販売者あるいは使用者はこの点に注意し、住商業環境以外で の使用をお願いいたします。 Handling of our product (English) This is a class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures. 본...

  • Page 26: Table Of Contents

    Contents 1 System Basic Configuration ........................1 1.1 System Basic Configuration Drawing ........................2 1.2 General Connection Diagram ........................... 4 1.2.1 General Connection Diagram [M800W] ......................4 1.2.2 General Connection Diagram [M80W] ......................7 1.2.3 General Connection Diagram [M800S] ......................10 1.2.4 General Connection Diagram [M80].......................
  • Page 27 4.4.1 I/F Diagnosis Screen............................82 4.4.1.1 Displaying the PLC Device Data ......................84 4.4.1.2 Carrying Out Modal Output ........................85 4.4.1.3 Carrying Out One-shot Output ......................86 4.4.2 List of Devices for PLC Uses ......................... 87 4.5 Diagnosis Based on the Self Diagnosis Screen ..................... 88 4.5.1 Self Diagnosis Screen............................

  • Page 28: System Basic Configuration

    System Basic Configuration IB-1501273-F...

  • Page 29: System Basic Configuration Drawing

    M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration 1System Basic Configuration 1.1 System Basic Configuration Drawing For M800W/M80W Display unit Windows-based display non-Windows-based display Personal Grahpic computer unit control unit Keyboard unit Operation panel Control unit I/O unit Remote I/O unit M800W M80W Manual pulse penerator...
  • Page 30 M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration For M800S/M80/E80 Display unit Keyboard unit (Control unit is added onto back of display unit.) (Operation panel I/O unit is added onto back of keyboard unit.) Control unit Operation panel I/O unit Remote I/O unit Manual pulse penerator Remote I/O unit...

  • Page 31: General Connection Diagram

    M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration 1.2 General Connection Diagram 1.2.1 General Connection Diagram [M800W] Windows-based display (15-type) Dotted lines indicate the sections prepared by the machine tool builder. <> Angle brackets indicates attached cable of unit. Added onto back of Personal computer unit Display unit display unit...
  • Page 32 M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration Windows-based display (19-type) Dotted lines indicate the sections prepared by the machine tool builder. <> Angle brackets indicates attached cable of unit. Display unit Added onto back of Personal computer unit FCU8-DU191-75 display unit FCU8-PC231 FCU8-DU192-75...
  • Page 33 M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration Non-Windows-based display (10.4-type/15-type) Dotted lines indicate the sections prepared by the machine tool builder. <> Angle brackets indicates attached cable of unit. Graphic control unit FCU8-GC211 J170 <J09x> Display unit L1 L2 L3 RS232C <J08x>...

  • Page 34: General Connection Diagram [M80W]

    M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration 1.2.2 General Connection Diagram [M80W] Windows-based display (15-type) Dotted lines indicate the sections prepared by the machine tool builder. <> Angle brackets indicates attached cable of unit. Added onto back of Personal computer unit Display unit display unit FCU8-PC231...
  • Page 35 M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration Windows-based display (19-type) Dotted lines indicate the sections prepared by the machine tool builder. <> Angle brackets indicates attached cable of unit. Display unit Added onto back of Personal computer unit FCU8-DU191-77 display unit FCU8-PC231 FCU8-DU192-77...
  • Page 36 M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration Non-Windows-based display (8.4-type/10.4-type/15-type) Dotted lines indicate the sections prepared by the machine tool builder. <> Angle brackets indicates attached cable of unit. Graphic control unit FCU8-GC211 J170 <J09x> Display unit L1 L2 L3 RS232C <J08x>...

  • Page 37: General Connection Diagram [M800S]

    M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration 1.2.3 General Connection Diagram [M800S] Dotted lines indicate the sections prepared by the machine tool builder. <> Angle brackets indicates attached cable of unit. L1 L2 L3 Control unit No-fuse breaker (NFB) Front memory I/F card FCU8-MU54x/FCU8-MA54x Memory mediums...

  • Page 38: General Connection Diagram [M80]

    M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration 1.2.4 General Connection Diagram [M80] Without smart safety observation Dotted lines indicate the sections prepared by the machine tool builder. <> Angle brackets indicates attached cable of unit. L1 L2 L3 Control unit No-fuse breaker (NFB) Front memory I/F card...
  • Page 39 M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration With smart safety observation Dotted lines indicate the sections prepared by the machine tool builder. <> Angle brackets indicates attached cable of unit. L1 L2 L3 Control unit No-fuse breaker (NFB) Front memory I/F card FCU8-MU511/FCU8-MU512 Memory mediums J120...

  • Page 40: General Connection Diagram [E80]

    M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration 1.2.5 General Connection Diagram [E80] Dotted lines indicate the sections prepared by the machine tool builder. <> Angle brackets indicates attached cable of unit. L1 L2 L3 Control unit No-fuse breaker (NFB) Front memory I/F card FCU8-MU513/FCU8-MU514 Memory mediums...

  • Page 41: How To Check The System Configuration

    M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration 1.3 How to Check the System Configuration 1.3.1 System Configuration Screen Diagn Select the menu [Config] on the diagnosis (Diagn) screen to display the hardware configuration (card name and sub-num- ber), software configuration (software number and sub-number), and PLC program configuration (file name, file label, and execution type).
  • Page 42 M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration PLC program configuration (6) - a    (6) - b  (6) - c  (6) - d    Display items Display items Details Remarks (1) Software list This displays a list of the software being used. keys to change the pages and refer it.
  • Page 43 M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration Display items Details Remarks (4) Hardware list The hardware names are displayed. keys to change the pages and refer it. The following display is an example. :WN111 Main card A single unit of CNC unit is formed with a maxi- :WN891 Back panel card...

  • Page 44: Option Display Screen

    M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration Display items Details Remarks (6) PLC ladder file This displays the file name, file label, execution type for each PLC lad- list der program. keys to change the pages and refer it. (a) Registration No.

  • Page 45: Each Unit Status Display

    M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration 1.4 Each Unit Status Display Each unit status can be confirmed by checking the LED mounted on each unit. 1.4.1 Control Unit FCU8-MU042/FCU8-MA041 (M800W) [LED] Cover opened Name Lamp state Details 24VDCIN Lit (Green) 24V power is being supplied from the external power supply.
  • Page 46 M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration FCU8-MU044 (M80W) [LED] Cover opened Name Lamp state Details 24VDCIN Lit (Green) 24V power is being supplied from the external power supply. The followings may have caused an error: Not lit No 24V-power supply from the external power supply. Disconnection of fuse near DCIN connector.
  • Page 47 M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration FCU8-MU542 / FCU8-MA542 / FCU8-MU541 / FCU8-MA541(M800S) FCU8-MU511 / FCU8-MU512 / FCU8-MU501 / FCU8-MU502(M80) FCU8-MU513 / FCU8-MU514(E80) [LED] Name Lamp state Details 24VIN Lit (Green) 24VDC power is being supplied from the external power supply. Not lit The followings may have caused an error: No 24VDC-power supply from the external power supply.

  • Page 48: Personal Computer Unit

    M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration 1.4.2 Personal Computer Unit FCU8-PC231 (M800W) [LED] Name Function Color State Normal At fault DCIN 24VDC input observation Green Not lit DCOUT DC internal power supply output obser- Green Not lit vation 12VDC output observation Green Not lit...

  • Page 49: Operation Panel I/O Unit

    M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration 1.4.3 Operation Panel I/O Unit FCU8-DX830/FCU8-DX837/FCU8-DX730 (M800W/M80W) [LED] FCU8-DX830/FCU8-DX837 FCU8-DX730 (10) (11) Name Function Color State Supplement Normal At fault FUSE Fuse status Green Not lit Not lit when a fuse has been blown out.
  • Page 50 M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration FCU8-DX731/DX750/FCU8-DX760/FCU8-DX761 (M800S/M80/E80) [LED] FCU8-DX731 FCU8-DX750 FCU8-DX760 FCU8-DX761 (10) (11) Name Function Color State Supplement Normal At fault FUSE Fuse status Green Not lit Not lit when a fuse has been blown out. DOCOM Energization status of DC24V input Green...
  • Page 51 M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration Name Function Color State Supplement Normal At fault ALM4 RIO communication error Not lit Lit when RIO communication error has occurred. (10) FUSE2 Fuse status Green Not lit Not lit when a fuse has been blown out.

  • Page 52: Remote I/O Unit

    M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration 1.4.4 Remote I/O Unit FCU8-DX220/FCU8-DX230/FCU8-DX231/FCU8-DX202/FCU8-DX213/FCU8-DX213-1/FCU8-DX654/FCU8-DX654-1/ FCU8-DX651/FCU8-DX408/FCU8-DX409 [LED: FCU8-DX220/FCU8-DX230/FCU8-DX231/FCU8-DX202/FCU8-DX213/FCU8-DX213-1/FCU8-DX654/ FCU8-DX654-1/FCU8-DX408/FCU8-DX409] FCU8-DX220/FCU8-DX230/FCU8-DX231/ FCU8-DX213/FCU8-DX213-1/ FCU8-DX202 FCU8-DX408 FCU8-DX409 FCU8-DX654/FCU8-DX654-1 Name Function Color State Supplement Normal At fault RIOVER RIO communication status Green Lit during RIO 2.0 communication Not lit during RIO 1.0 communication...
  • Page 53 M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration [LED: FCU8-DX651] Name Function Color State Supplement Normal At fault Safety relay output SYR00 status Green Not lit Not lit when a relay has been blown out. Safety relay output SYR01 status Green Not lit Not lit when a relay has been...

  • Page 54: Communication Expansion Unit

    M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration 1.4.5 Communication Expansion Unit 1.4.5.1 CC-Link Expansion Unit FCU8-EX561 [LED] Name Color State Details Green CC-Link module in the normal state Not lit Watchdog timer error LRUN Green Data link in process of execution Green During data transmission Green...

  • Page 55: Profibus-Dp Expansion Unit

    M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration 1.4.5.2 PROFIBUS-DP Expansion Unit FCU8-EX563 [LED] Name Color State Details RUN (Green) Green Lit when PROFIBUS-DP module is normally operated. RDY (Yellow) Green/yellow Flashing Boot standby (Module status) Yellow Boot error No power supply, module failure STA (Green) Green Lit regularly...

  • Page 56: Cc-Link Ie Field

    M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration 1.4.5.3 CC-Link IE Field FCU8-EX564 [LED] Name Color State Details L ERR Not lit Normal data received and loopback not performed Abnormal data received or loopback being performed SD/RD Green Data being sent or received Not lit Data not sent nor received D LINK...

  • Page 57: Ethernet/Ip

    M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration 1.4.5.4 EtherNet/IP FCU8-EX565 [LED] Name Greed LED Red LED Details MS (Green/Red) Flashing Flashing In self-test (Module status) Flashing Not lit Waiting for initialization Not lit Normal operation Not lit Flashing Recoverable failure Not lit Unrecoverable failure (The hardware needs to be re- placed.)

  • Page 58: 7-Segment Leds On The Control Unit

    M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration 1.4.6 7-segment LEDs on the Control Unit The 7-segment LEDs mounted on the control unit can display NC status. When alarms occur, an alarm with the highest priority within each part system is displayed. 1.4.6.1 Normal State Display In normal state, the 7-segment LEDs display in flashing.

  • Page 59: Display When An Alarm Occurs

    M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration 1.4.6.3 Display when an Alarm Occurs If an alarm occurs, these LEDs show both the occurrence and the meaning of the alarm in two stages. At first, flashes three times. In case of stop code, is shown instead.
  • Page 60 M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration Note (1) When only any of the following alarms occur, LED shows the normal indication. Emergency stop EXIN Emergency stop WAIT M01 Cutting block start interlock 0110 M01 In synchronous correction mode 0120 [Display of the 7-segment LEDs and their meanings] Alarm code for the first time Alarm/warning...
  • Page 61 M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration Example of alarm display (Operation error) Displays of 7-segment LEDs (transition) Alarm/Warning code M01 H/W stroke end axis exists 0006 Operation error Error # (lower 3 digits) Axis bit M01 No operation mode 0101 Operation error Error # (lower 3 digits)
  • Page 62 M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration Example of alarm display (Stop code) Displays of 7-segment LEDs (transition) Alarm/Warning code T01 H/W stroke end axis exists 0105 Stop code Error # (lower 2 digits) No meaning T02 S/W stroke end axis exists 0202 Stop code Error # (lower 2 digits)
  • Page 63 M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration Example of alarm display (System alarm) Displays of 7-segment LED (transition) Alarm/Warning code Z70 Abs posn base set incomplete 0001 Absolute position data er- Error # Axis bit Z71 Abs encoder failure 0002 Encoder failure Error #...
  • Page 64 M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration Example of alarm display (System warning) Displays of 7-segment LED (transition) Alarm/Warning code Z51 E2PROM error 0011 System warning Warning code Type Z52 Battery fault 0001 System warning Warning code No meaning Z53 CNC overheat 0003 System warning...
  • Page 65 M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration Example of alarm display (MCP alarm) Displays of 7-segment LEDs (transition) Alarm/Warning code Y02 SV commu er 0051 0004 System alarm Error # (lower 2 Error code digits) Y03 Drive unit unequipped XYZS Drive unit unequipped Axis bit...
  • Page 66 M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration Example of alarm display (Servo alarm) Displays of 7-segment LED (transition) Alarm/Warning code S01 Servo alarm: PR 0031 Servo alarm: PR Error # (lower 2 Axis bit digits) S02 Initial parameter error 3225 Initial parameter error Error # (lower 2...
  • Page 67 M800/M80/E80 Series Maintenance Manual 1 System Basic Configuration Example of alarm display (Servo warning) Displays of 7-segment LED (transition) Alarm/Warning code S51 Parameter error 2205 Parameter error Error # (lower 2 Axis bit digits) S52 Servo warning Servo warning Error # Axis bit S52 Aux ax servo warning 0092...

  • Page 68: Daily Maintenance And Periodic Maintenance

    Daily Maintenance and Periodic Maintenance IB-1501273-F...
  • Page 69 M800/M80/E80 Series Maintenance Manual 2 Daily Maintenance and Periodic Maintenance 2Daily Maintenance and Periodic Maintenance Maintenance is categorized into daily maintenance items (items to be carried at set intervals) and periodic maintenance items (replacement of parts when life is reached). Some parts may not function in a hardware manner when the life is reached, so these should be replaced before the life is reached.

  • Page 70: Daily Maintenance

    M800/M80/E80 Series Maintenance Manual 2 Daily Maintenance and Periodic Maintenance 2.1 Daily Maintenance 2.1.1 Touchscreen CAUTION Always keep the touchscreen surface clean. When it gets dirty, remove the dirt immediately. Do not perform any operation on the dirty touchscreen. (1) Cleaning the touchscreen When metal powder or sand dust is on the touchscreen, remove it to prevent the scratches.

  • Page 71: Periodic Maintenance

    M800/M80/E80 Series Maintenance Manual 2 Daily Maintenance and Periodic Maintenance 2.2 Periodic Maintenance 2.2.1 List of Durable Parts Durable parts Part type Battery for control unit Q6BAT BKO-C10811H03 Personal computer unit cooling fan 109P0424H3013 (*) Contact the Service Center, Sales Office or dealer for repairs or part replacement. 2.2.2 List of Replacing Parts Replacing parts Part type...

  • Page 72: Durable Parts Replacement

    M800/M80/E80 Series Maintenance Manual 2 Daily Maintenance and Periodic Maintenance 2.2.3 Durable Parts Replacement 2.2.3.1 Control Unit Battery A lithium battery in the control unit battery holder retains parameter settings, machining programs and the like, which re- quires to be backed up at the power OFF. Battery Q6BAT Battery cumulative data holding time...
  • Page 73 M800/M80/E80 Series Maintenance Manual 2 Daily Maintenance and Periodic Maintenance [M800W/M80W] Front cover Battery holder Battery Battery connector BAT connector [M800S] BAT connector Front cover Battery Battery holder [M80/E80] Front cover BAT connector Battery Battery holder IB-1501273-F...

  • Page 74: Personal Computer Unit Cooling Fan

    M800/M80/E80 Series Maintenance Manual 2 Daily Maintenance and Periodic Maintenance 2.2.3.2 Personal Computer Unit Cooling Fan Type 109P0424H3013 Life 60,000 hours (When the rotary speed decreased 30% less than the initial values) Note (1) The life is estimated on the assumption that it is used under 60°C environment. Note that the value above is not a guar- anteed value.

  • Page 75: Replacing Fuse

    M800/M80/E80 Series Maintenance Manual 2 Daily Maintenance and Periodic Maintenance 2.2.4 Replacing Fuse How to check for fuse blowout Operation panel I/O unit When FUSE LED is not lit and DOCOMLED is lit (*1), the fuse is blown out. FCU8-DX750/760/761 FCU8-DX730/830/837 FUSE : Not lit FUSE : Not lit...
  • Page 76 M800/M80/E80 Series Maintenance Manual 2 Daily Maintenance and Periodic Maintenance Remote I/O unit (FCU8-DX220/230/231) When FUSE LED is not lit and 24VDCIN LED is lit (*2), the fuse is blown out. FCU8-DX220/230/231 FUSE : Not lit 24VDCIN : Lit (*2) When 24VDCIN LED is not lit, it is considered that the power is not supplied. Confirm that the power is correctly supplied.
  • Page 77 M800/M80/E80 Series Maintenance Manual 2 Daily Maintenance and Periodic Maintenance Replacement procedures for fuse (1) Turn OFF the machine. (2) Remove the fuse using tweezers, etc. and then replace it with a new fuse. FCU8-DX750/760/761 FCU8-DX730/830/837 LM50 LM50 FCU8-DX731 FCU8-DX220/230/231 FCU8-DX213/213-1/654/654-1 LM50 LM50...

  • Page 78: Maintenance Of The Drive Unit

    Maintenance of the Drive Unit IB-1501273-F...

  • Page 79: Periodic Inspections

    M800/M80/E80 Series Maintenance Manual 3 Maintenance of the Drive Unit 3Maintenance of the Drive Unit WARNING 1. Before starting maintenance or inspections, turn the main circuit power and control power both OFF. Wait at least fifteen minutes until the CHARGE lamp turns OFF, and then confirm that the input and output voltage are zero using a tester, etc.

  • Page 80: Durable Parts

    M800/M80/E80 Series Maintenance Manual 3 Maintenance of the Drive Unit 3.2 Durable Parts A guide to the part replacement cycle is shown below. Note that these will differ according to the working conditions or en- vironmental conditions, so replace the parts if any abnormality is found. Contact Mitsubishi branch or your dealer for repairs or part replacements.

  • Page 81: Adding And Replacing Units And Parts

    M800/M80/E80 Series Maintenance Manual 3 Maintenance of the Drive Unit 3.3 Adding and Replacing Units and Parts CAUTION 1. Correctly transport the product according to its weight. Failure to observe this could result in injury. 2. Do not stack the product above the indicated limit. 3.

  • Page 82: Replacing The Unit Fan

    M800/M80/E80 Series Maintenance Manual 3 Maintenance of the Drive Unit 3.3.1.2 Replacing the Unit Fan Replacing parts <MDS-E Series> Servo drive unit Spindle drive unit Power supply unit Type Fan type Size Type Fan type Size Type Fan type Size MDS-E- [mm] MDS-E-...
  • Page 83 M800/M80/E80 Series Maintenance Manual 3 Maintenance of the Drive Unit POINT When the drive unit of E/EH Series which uses two cooling fans is in an emergency stop or alarm, one of fans (upper one in the case of vertical layout, or either one in the case of horizontal layout) is stopped and power-saving oper- ation is performed.

  • Page 84: Replacing The Battery

    M800/M80/E80 Series Maintenance Manual 3 Maintenance of the Drive Unit 3.3.1.3 Replacing the Battery Replacing parts <Replacing a battery equipped with the spindle/servo drive unit or the battery unit, MDSBTBOX-LR2060> When the battery voltage is low (warning 9F), place an order for the same type of a battery as the one currently equipped with the unit.
  • Page 85 M800/M80/E80 Series Maintenance Manual 3 Maintenance of the Drive Unit Replacement procedure Replace the battery with the following procedures. CAUTION 1. Replace the batteries with new ones immediately after the battery voltage drop alarm (9F) has been output. 2. Replace the batteries while applying the drive unit’s control power. <Replacement procedure for the cell battery MDS-BAT6V1SET>...
  • Page 86 M800/M80/E80 Series Maintenance Manual 3 Maintenance of the Drive Unit <Replacement procedure for the battery unit MDSBTBOX-LR2060> Possible backup period Possible backup period is at most one year. Thus, make sure to exchange the batteries in the one-year cycle. How to replace the battery (1) Remove the battery box cover (four screws).

  • Page 87: Mds-Ej/Ejh Series

    M800/M80/E80 Series Maintenance Manual 3 Maintenance of the Drive Unit 3.3.2 MDS-EJ/EJH Series 3.3.2.1 Replacing the Drive Unit Arrangement of replacing parts Contact Mitsubishi branch or your dealer for an order or a replacement of the drive unit. Place an order for the same type of a drive unit as the one to be replaced. Replacement procedure Replace the drive unit with the following procedures.
  • Page 88 M800/M80/E80 Series Maintenance Manual 3 Maintenance of the Drive Unit Replacement procedure Replace the unit fan with the following procedures. <MDS-EJ-V1-30, MDS-EJ-SP-20> Direction of the fan wind Direction of Disconnect the connection connector the fan wind of the fan mounted Cooling fan on the unit side face.
  • Page 89 M800/M80/E80 Series Maintenance Manual 3 Maintenance of the Drive Unit <MDS-EJ-V1-40/80/100, MDS-EJ-SP-40/80> Direction of the fan wind Direction of Disconnect the connection connector the fan wind of the fan mounted on the unit side face. Cooling fan CON5 Remove the mounting screws. Lead out the cooling fan lead wires from here when installing the fan.
  • Page 90 M800/M80/E80 Series Maintenance Manual 3 Maintenance of the Drive Unit <MDS-EJ-SP-100/120> Cooling fan lead wire Direction of the fan wind Direction of the fan wind Cooling fan Attach the harness to the position described in the figure above. Sleeve Connector Place the fan harness inside the chassis using the positioning boss for the chassis.
  • Page 91 M800/M80/E80 Series Maintenance Manual 3 Maintenance of the Drive Unit <MDS-EJ-SP-160> (1) Remove the mounting screws. (2) Disconnect the connection connector of the fan mounted on the unit side face. Sleeve Direction of the fan wind Direction of the fan wind Insert the connector so that it will reach the end of the stopper...
  • Page 92 M800/M80/E80 Series Maintenance Manual 3 Maintenance of the Drive Unit <MDS-EJ-V2-30, MDS-EJ-SP2-20> Remove the mounting screws. Disconnect the connection connector of the fan mounted on the unit side face. Direction of the fan wind <MDS-EJ-V2-40> Remove the mounting screws. Disconnect the connection connector of the fan mounted Direction of on the unit side face.

  • Page 93: Replacing The Battery

    M800/M80/E80 Series Maintenance Manual 3 Maintenance of the Drive Unit 3.3.2.3 Replacing the Battery Replacing parts <Replacing a battery equipped with the servo drive unit or the battery unit, MDSBTBOX-LR2060> When the battery voltage is low (warning 9F), place an order for the same type of a battery as the one currently equipped with the unit.
  • Page 94 M800/M80/E80 Series Maintenance Manual 3 Maintenance of the Drive Unit (b) Replacing the built-in battery MR-BAT6V1SET that reached the end of the life can be reused by replacing the MR-BAT6V1 battery. Cover Open the cover while pushing the locking part. Locking part Replace the built-in battery with a new battery for MR-BAT6V1.
  • Page 95 M800/M80/E80 Series Maintenance Manual 3 Maintenance of the Drive Unit <Replacement procedure for the battery unit MDSBTBOX-LR2060> Possible backup period Possible backup period is at most one year. Thus, make sure to exchange the batteries in the one-year cycle. How to replace the battery (1) Remove the battery box cover (four screws).

  • Page 96: Mds-Em/Emh Series

    M800/M80/E80 Series Maintenance Manual 3 Maintenance of the Drive Unit 3.3.3 MDS-EM/EMH Series 3.3.3.1 Replacing the Drive Unit Arrangement of replacing parts Contact Mitsubishi branch or your dealer for an order or a replacement of the drive unit. Place an order for the same type of a drive unit as the one to be replaced. Replacement procedure Replace the drive unit with the following procedures.

  • Page 97: Replacing The Fan Unit

    M800/M80/E80 Series Maintenance Manual 3 Maintenance of the Drive Unit 3.3.3.2 Replacing the Fan Unit Replacing parts Drive unit type Fan type MDS-EM-SPV3-16040S EM-FS-18 MDS-EM-SPV3-10040 to 200120 EM-FS-26 MDS-EMH-SPV3-8040 to 10060 MDS-EM-SPV3-320120 EM-FS-30 Replacement procedure Replace the fan unit with the following procedures. (1) Remove the mounting screws from the fan unit cover (2) Remove the fan unit cover.

  • Page 98: Replacing The Battery

    M800/M80/E80 Series Maintenance Manual 3 Maintenance of the Drive Unit (4) When installing the fan unit, insert the sheet metal of the fan unit into the fin rails. Fin rail * Sheet metal * Although MDS-EM-SPV3-16040S and 320120 do not have fin rails, the installation of fan units is not affected. 3.3.3.3 Replacing the Battery Replacing parts <Replacing a battery equipped with the spindle/servo drive unit or the battery unit, MDSBTBOX-LR2060>...
  • Page 99 M800/M80/E80 Series Maintenance Manual 3 Maintenance of the Drive Unit Replacement procedure Replace the battery with the following procedures. CAUTION 1. Replace the batteries with new ones immediately after the battery voltage drop alarm (9F) has been output. 2. Replace the batteries while applying the drive unit’s control power. <Replacement procedure for the cell battery MR-BAT6V1SET>...
  • Page 100 M800/M80/E80 Series Maintenance Manual 3 Maintenance of the Drive Unit <Replacement procedure for the battery unit MDSBTBOX-LR2060> Possible backup period Possible backup period is at most one year. Thus, make sure to exchange the batteries in the one-year cycle. How to replace the battery (1) Remove the battery box cover (four screws).
  • Page 101 M800/M80/E80 Series Maintenance Manual 3 Maintenance of the Drive Unit IB-1501273-F...

  • Page 102: Failure Diagnosis

    Failure Diagnosis IB-1501273-F...

  • Page 103: Introduction

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4Failure Diagnosis 4.1 Introduction If trouble occurs during operation, the accurate cause must be found so that adequate measures can be taken. Confirm "when", "when doing what", "what kind of trouble" and "how frequently" the trouble occurred. Also check how many years the machine has been operated, and how many hours a day it is used.

  • Page 104: Diagnosis Based On The Alarm

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.3 Diagnosis Based on the Alarm Alarm information includes the "NC message", "PLC message", and "Alarm history". 4.3.1 How To Check the Alarm Information Diagn A list of currently occurring alarms or messages can be displayed on this screen. The displayed messages include the NC alarms, stop codes, alarm messages, operator messages, etc.
  • Page 105 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis Display items Display items Details NC message This displays the operation alarms, program errors, MCP alarms, servo alarms, sys- tem alarms, etc. Up to 10 messages are displayed in order of priority. Stop code This displays the automatic operation status or stop status during automatic operation.

  • Page 106: Alarm History

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.3.2 Alarm History When an alarm occurs, the alarm information is recorded. When the NC power is ON, an alarm is automatically recorded in alarm history. Alarm information is recorded from the latest alarm to 512. Alarm information recorded in the history is NC message displayed on "NC message"...
  • Page 107 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis Menus Menus Details This displays the first page of the alarm history. Alarm The history sequentially displays 16 alarms per page from the latest alarm. If there are two or more NC history alarms of same day and time, the alarms are sequentially displayed from the alarm and warning of the 1st part system.

  • Page 108: Alarm Message Details

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.3.3 Alarm Message Details Methods to confirm the alarm message details (Details, Remedy) are as follows: Confirm by "Guidance display" on the NC screen Confirm by "Alarm manual" To confirm by "Guidance display" on the NC screen Confirm details with the alarm guidance (alarm message details) displayed on the NC screen by pressing the [?] key or key.

  • Page 109: Diagnosis Based On The I/F Diagnosis Screen

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.4 Diagnosis Based on the I/F Diagnosis Screen 4.4.1 I/F Diagnosis Screen Diagn The various input/output signals for the PLC (Programmable Logic Controller) control can be displayed and set in this screen. These signals can be used in confirmation of the machine sequence operation during PLC development, and in confirma- tion and forced output, etc., of the input/output data between the NC and PLC.
  • Page 110 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis Display items Details 1-shot output This displays the data and device to carry out one-shot output. The details to be defined are set here when carrying out the one-shot type forced out- put of PLC interface signals. For details, refer to "Carrying Out One-shot Output".

  • Page 111: Displaying The Plc Device Data

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.4.1.1 Displaying the PLC Device Data The various status signals and register data used in the PLC can be monitored and displayed. When this screen is first selected, the respective 16-byte amounts of input/output data are displayed from device "X0000" on the left display area, and from device "Y0000"...

  • Page 112: Carrying Out Modal Output

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.4.1.2 Carrying Out Modal Output Modal type forced output of PLC interface signals is carried out. Once set, this data is held until cancelled, the power is turned ON/OFF, or other data is overwritten. There are four sets of devices that modally output. If this number is exceeded, the previously existing data is overwritten.

  • Page 113: Carrying Out One-Shot Output

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.4.1.3 Carrying Out One-shot Output The one-shot type PLC interface signal forced output is forcibly output only once during the screen operations. Thus, it may not be possible to confirm the PLC interface signals updated with the PLC on the screen. One-shot outputting data "1"...

  • Page 114: List Of Devices For Plc Uses

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.4.2 List of Devices for PLC Uses Devices Device No. No. of points Units Description (Maximum points of project) X (*) X0 to X1FFF 8192 1-bit Input signals to PLC. Machine input, etc. Y (*) Y0 to Y1FFF 8192...

  • Page 115: Diagnosis Based On The Self Diagnosis Screen

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.5 Diagnosis Based on the Self Diagnosis Screen 4.5.1 Self Diagnosis Screen Diagn The hardware state and NC operation state can be confirmed by selecting the menu [Selfdia] on the diagnosis (Diagn) screen. Display items Display items Details...
  • Page 116 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis (*1) As for the NC unit, the contents are as follows depending on the condition: Item Details Battery vol state This displays the current state of the battery voltage as 0 or 1. Condition Class 0 (normal state)
  • Page 117 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis Item Details Power losses Acc This displays the cumulated count of detection frequency of instantaneous power interruption after the power ON. Press the menu [Clear pw loss] to clear the cumulated count to "0". (*2) The following state can be confirmed.
  • Page 118 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis Clearing the cumulated counter to zero (Example) Clearing the cumulated count of the servo communication error Press the menu [Servo clear]. An operation message appears. Press the [Y] or [INPUT] key. The cumulated count of the servo communication error 1 and 2 will be cleared to "0".
  • Page 119 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis Renewing time limit For updating the time limit, users need to ask the MTB to issue a decryption code. The time limit is either updated or can- celed when the decryption code is entered. Decryption code is issued by MTB as decryption code file.

  • Page 120: Diagnosis Based On The Data Sampling Screen

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.6 Diagnosis Based on the Data Sampling Screen Diagn Sampling start/stop, sampling state display, setting the sampling parameters necessary for sampling are performed in the data sampling screen. The NC internal data (speed output from NC to the drive unit, or feedback data from the drive unit, etc.) can be sampled.

  • Page 121: Diagnosis Based On The Drive Monitor Screen

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.7 Diagnosis Based on the Drive Monitor Screen 4.7.1 Drive Monitor Screen (Servo Unit) Diagn The various data related to the servo axis (NC axis, PLC axis) can be monitored by selecting the menus [Drv mon] -> [Servo unit] on the diagnosis (Diagn) screen.
  • Page 122 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis Display items Details Max current 3 (%) This displays the FB value of the motor current in terms of continuous current during stalling. An absolute value of the current FB peak value sampled in most recent 2 seconds is displayed.
  • Page 123 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis Display items Details Superimp errP-P (mm) This displays the synchronous error width between the reference axis and the syn- chronized axis during control axis synchronization between part systems, control axis superimposition, or arbitrary axis superimposition. Motor temp.
  • Page 124 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis Display items Details This indicates the control signal output from servo to NC. (bit0 to bit7) Control output Bit0: Z-phase passed Bit3: In zero speed Bit7: In external emergency stop Control output This indicates the control signal output from servo to NC. (bit8 to bitF) Bit9: In speed monitor BitA: In door closed (controller) BitB: In door closed (self drive unit)
  • Page 125 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis Display items Details Machine end detector This displays the machine end detector type. The type is displayed when the control method is CLOSED or DUAL. * is displayed when the method is SEMI. Mach.

  • Page 126: Drive Monitor Screen (Spindle Unit)

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.7.2 Drive Monitor Screen (Spindle Unit) Diagn The various data related to the spindle can be monitored by selecting the menus [Drv mon] -> [Spindle unit] on the diagnosis (Diagn) screen. Change the display item with Display items Display items Details...
  • Page 127 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis Display items Details Max disturb torq (%) This displays the estimated disturbance torque in terms of stall rated torque when the col- lision detection function is adjusted. An absolute value of the estimated disturbance torque peak value sampled in most recent 2 seconds is displayed.
  • Page 128 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis Display items Details SP sync err +P (deg) This displays the maximum value of the angle at which the synchronized spindle advanc- es beyond the reference spindle during spindle synchronization I, tool spindle synchroni- zation IA/IB, or tool spindle synchronization II.
  • Page 129 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis Display items Details This indicates the control signal input from NC to spindle. (bit8 to bitF) Control input 4H BitC: M coil selection command BitD: L coil selection command BitE: Sub-motor selection command Control input 5L This indicates the control signal input from NC to spindle.
  • Page 130 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis Display items Details Motor end detect No This displays the motor end detector serial No. Mach. end detect No This displays the machine end detector serial No. Motor It displays the motor type which is set for the spindle specification parameter "#3138 mo- tor_type".

  • Page 131: Drive Monitor Screen (Power Supply Unit)

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.7.3 Drive Monitor Screen (Power Supply Unit) Diagn The various data related to the power supply can be monitored by selecting the menus [Drv mon] -> [Power unit] on the diagnosis (Diagn) screen. Change the display item with Display items Display items...
  • Page 132 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis Display items Details Consumed power (kW) The power consumption is calculated and its integrated value is displayed. (0.01 kWh) Pwr. distortion (V) The amount of power distortion (harmonic voltage value) is calculated and displayed. Supplied power (kW) The supplied power is calculated and displayed.

  • Page 133: Drive Monitor Screen (Synchronous Error)

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.7.4 Drive Monitor Screen (Synchronous Error) Diagn The "Synchronous error" appears only when the synchronous control axis specification is valid. The various data related to the synchronous error can be monitored by selecting the menus [Drv mon] -> [Synchro error] on the diagnosis (Diagn) screen.

  • Page 134: Clearing The Alarm History On Drive Monitor Screen

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.7.5 Clearing the Alarm History on Drive Monitor Screen Diagn Operation method Press the menu [Servo unit], [Spindle unit] or [Power unit]. Using the menu [Next axis], tab keys select the axis (device) from which to clear the alarm history.

  • Page 135: Nc Memory Diagnosis Screen

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.8 NC Memory Diagnosis Screen Diagn The NC internal data can be displayed and rewritten on the NC memory diagnosis (Mem dia) screen of the diagnosis (Di- agn) screen. The custom API library's NC data read/write interface is used to display and rewrite the NC's internal data. The contents of the NC data can be displayed by designating the part system No., section No., sub-section No.
  • Page 136 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis Menus Menus Details This erases the information in the line where the cursor is. (One entire line becomes blank.) The cursor Line does not move at this time. clear The contents of the set address data (Part system No, Section/sub-section/axis) for all the lines are con- Data stantly displayed.

  • Page 137: Safety Observation Screen

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.9 Safety Observation Screen Diagn The configuration, signal status, drive status and version in use of the smart safety observation function are displayed on the safety observation screen. 4.9.1 Safety Observation Screen (Configuration Diagnosis) The available/unavailable states of the smart safety observation function are displayed on the configuration diagnosis screen.
  • Page 138 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis Display items Details NC-I/O safety communica- This displays the communication status of the safety I/O communication. tion To perform the safety I/O communication, at least one of remote I/O channels needs to be configured with the safety I/O devices (safety remote I/O unit, opera- tion panel equipped with safety I/Os) and RIO2.0 unit alone.

  • Page 139: Safety Observation Screen (Signal Monitor)

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.9.2 Safety Observation Screen (Signal Monitor) The signal monitor screen displays the safety PLC signal status. The safety PLC signal displays both of the duplex PLC signals to identify the incongruous state. With the initial display, the input/output signal status from the device "X0000" is displayed on the left side and the input/output signals from the device "Y0000"...
  • Page 140 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis Displaying the PLC device input/output signal To refer the arbitrary input/output signal status, enter the target device No. to the input area, and the display will be switched. (Example) For displaying the input/output signal of the arbitrary device No. "X0020" (1) Press the tab key to select the area where the data is displayed.

  • Page 141: Safety Observation Screen (Drive Monitor)

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.9.3 Safety Observation Screen (Drive Monitor) The safety communication state with servo drive (NC axis, PLC axis) and spindle drive can be monitored. Only the safety drive communication parameter enabled axes are displayed on this screen. Display items Display items Details...
  • Page 142 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis Display items Details Safety command 2L This displays the data sent to the drive. Details SBC command (0: No command, 1: With command) SBC command for SBT (1CH side) (0: No command, 1: With command) SBC command for SBT (2CH side) (0: No command, 1: With command)
  • Page 143 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis Display items Details Safety status 2L This displays the data received from the drive. Details SBC status (0: No operation, 1: In operation) SBC status for SBT (1CH side) (0: No operation, 1: In opera- tion) SBC status for SBT (2CH side) (0: No operation, 1: In opera- tion)

  • Page 144: Safety Observation Screen (Version Display)

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.9.4 Safety Observation Screen (Version Display) Software version about smart safety observation is displayed on the version display screen. Display items Display items Details NC Safety This displays the smart safety observation software version of the NC system. This displays the safety parameter changed date and time, comment and CRC.

  • Page 145: Servo Diagnosis Screen

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.10 Servo Diagnosis Screen Mainte You can confirm the following information on the servo diagnosis screen by pressing [Mainte] -> [Servo diagn] on the diag- nosis (Diagn) screen: - The number of alarms of servo/spindle drive unit - DA output information - PLG diagnosis (spindle) - The maintenance diagnosis information of servo/spindle unit such as alarm cause counter...
  • Page 146 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis (2) Display of the spindle PLG diagnosis information Display items Display items Details Alarm times This displays the data for each axis or unit. There are Alarm times 1 to 32, and there are switched with the page up/down keys. The number of times can be cleared for each axis or each column.
  • Page 147 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis Menus Menus Details Displays the servo unit diagnosis information in the data display area. Servo unit Displays the spindle unit diagnosis information in the data display area. Spindle unit <Note> When the parameter "#1039 spinno" is set to "0", this menu is not displayed. Switches the display between the DA output and the spindle PLG diagnosis information.

  • Page 148: Diagnosis Data Collection Setting

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.11 Diagnosis Data Collection Setting Mainte The following operations can be performed on the diagnosis collection setting screen: (1) Setting to perform the diagnosis data collection (2) Confirming the status of the diagnosis data collection (3) Starting/stopping the diagnosis data collection (4) Clearing the diagnosis data.
  • Page 149 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis (1)   (2)   Display items Display items Details State Display the history data and sampling data collection status. Display the history data collection status. History data History collecting: History data collection is in progress. History stop: History data collection is stopped.

  • Page 150: Starting The Data Collection

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis Menus Menus Details This begins collecting sampling data and history data. Start This stops the sampling data and history data collection operation. Stop This stops the sampling data and history data collection operation, and clears the collected data. Data This is not displayed when "#1263 bit1"...

  • Page 151: Clearing The Collected Data

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.11.3 Clearing the Collected Data When the data clear menu is executed, the data collection is stopped and the collected data is cleared. (1) When the menu [Data clear] is pressed, the confirmation message appears. (2) Press the [Y] or [INPUT] key to clear the collected data.
  • Page 152 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis Procedures to output the history data files (1) Select [Mainte]-[I/O]. (2) Set the files of device A as follows: A:Dev: Memory Directory: /LOG (Displayed as "History".) File name: ALLLOG.LOG (all history), KEYLOG.LOG (key history), TOUCHLOG.LOG (touchscreen history) <Note>...
  • Page 153 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis Procedures to output the alarm detailed information history data files (1) Select [Mainte]-[I/O]. (2) Set the files of device A as follows: A:Dev: Memory Directory: /LOGEX File name: ALM-SVn.LOG, ALM-OTRn.LOG (n = 1 to 5) <Note>...

  • Page 154: Display Delay Function For Communication Errors And Servo/Spindle Alarms

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.11.5 Display Delay Function for Communication Errors and Servo/Spindle Alarms When the power is turned OFF, the communication error (Y02 System error 0051) or the servo alarm (S01 Servo alarm 87) may occur depending on the machine configuration. Sometimes these alarms fill up the alarm history display to be obsta- cles for maintenance diagnosis.

  • Page 155: Application Error Detection

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.12 Application Error Detection With the application error detection function, applications using the custom API library are automatically detected from all applications that are operated in the display unit of M800 Series, and the presence and absence of responses are observed at fixed intervals.

  • Page 156: Ip Address Resetting Procedure At Disabled Network Communication [M800W/M80W Series Only]

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.13 IP Address Resetting Procedure at Disabled Network Communication [M800W/M80W Series Only] 4.13.1 Connectable Control Unit IP Address List Screen After NC starts, when the communication between the control unit and the display unit cannot be established even after the time-out time passes, the connectable control unit IP address list screen appears.

  • Page 157: Resetting Procedure

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.13.2 Resetting Procedure Operation method Select the IP address of the connection destination The dialog which notifies the change of the network set- ting is displayed. control unit by using the [↑], [↓], keys To establish the communication between the selected from IP address list, and press the [INPUT] key.

  • Page 158: Message

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis (3) When the display's IP address is automatically searched, it is searched from among up to 254 IP addresses whose up- per 3 bytes coincide with those of the local IP address (#1934 Local IP address). However, depending on the setting of the 4th byte of the PC subnet mask (PC Subnet), the search range may be limited.

  • Page 159: Field Network Diagnostics Function

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.14 Field Network Diagnostics Function This function displays the statistical information of packet transmission and reception (transmission/reception frequency, number of errors, etc.), which is necessary when the communication status of the expansion unit (the field network expan- sion unit) is diagnosed.

  • Page 160: Diagnosis Procedure

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.14.1 Diagnosis Procedure Diagnostic data is displayed on the I/F diagnosis screen. The diagnostic data provides the statistical information of packet transmission and reception, and the specific information of each protocol are provided. Displayed data is refreshed approximately every 3 seconds. However, the displayed data is not refreshed during the process described in the section "4.14.2 Diagnosis Command".
  • Page 161 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis Other than CC-Link IE Field communication: Device Device Details (EXT1/EXT3) (EXT2/EXT4) SD1133 to SD1134 SD1633 to SD1634 The number of times that packet data has been transmitted (4 bytes) (It is cleared by turning the power OFF.) SD1135 to SD1136 SD1635 to SD1636 The number of times that packet data has been transmitted (4 bytes) (The cumulative number until it is cleared) (*1) SD1137 to SD1138 SD1637 to SD1638 The number of times that packet data has been received (4 bytes)

  • Page 162: Protocol-Specific Information

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.14.1.2 Protocol-Specific Information The device ranges SD1164 to SD1182 and SD1664 to SD1682 are opened for each protocol, which are used as indicated below. When multi-project is enabled, use the PLC device for project 1. Device Device CC-Link IE Field...

  • Page 163: Diagnosis Command

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.14.2 Diagnosis Command 4.14.2.1 Clearing Statistical Information of Packet Transmission and Reception The cumulative information of packet transmission and reception can be cleared by using the 1-shot output function on the I/F diagnosis screen. This function is useful when you reset the counter to "0"...

  • Page 164: Error Code List

    M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis 4.14.2.2 Error Code List When an error occurs upon execution of the diagnosis command, the execution result indicates the error code. The display of each error and its meaning are as follows. Value Details E001(HEX) Notification of invalid command input...
  • Page 165 M800/M80/E80 Series Maintenance Manual 4 Failure Diagnosis IB-1501273-F...

  • Page 166: Troubleshooting

    Troubleshooting IB-1501273-F...

  • Page 167: Troubleshooting

    M800/M80/E80 Series Maintenance Manual 5 Troubleshooting 5Troubleshooting If trouble occurs during operation, the accurate cause must be found so that adequate measures can be taken. Perform the following checks for this. 5.1 Troubleshooting Confirm "when", "when doing what", "what kind of trouble" and "how frequently" the trouble occurred. Also check how many years the machine has been operated, and how many hours a day it is used.

  • Page 168: Possible Causes Of Trouble

    M800/M80/E80 Series Maintenance Manual 5 Troubleshooting 5.1.1 Possible Causes of Trouble The most common cause is a cable contact defect and wire breakage defect. Is the connection correct? Are the cables bent or stepped on? Are the joints of the cables and connectors deteriorated? Was a continuity test done on the cables? Is any of the terminal block or connector screws loosen? Is there any oil or cutting oil splattered onto the cables?
  • Page 169 M800/M80/E80 Series Maintenance Manual 5 Troubleshooting IB-1501273-F...

  • Page 170: Replacing Each Unit

    Replacing Each Unit IB-1501273-F...

  • Page 171: Data Backup And Restoration

    M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit 6Replacing Each Unit Carry out a backup of the whole system before replacement as a precautionary measure. 6.1 Data Backup and Restoration The following two functions are available for the data backup and restoration: all backup function for files in batch and input/ output function for separate files.

  • Page 172: All Backup

    M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit 6.1.1 All Backup This section explains the procedures to back up NC data in a memory card in a batch. Note (1) APLC data can be backed up only when the APLC release specification is valid. Operation method Press the menu [Backup].
  • Page 173 M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit The backup is completed without error. The states of backup-complete files turn to "Complete", the date displayed in "Backup list" will be updated. <Note> If the APLC release specification is invalid, the APLC data cannot be backed up and "Unexecute"...

  • Page 174: All Restoration

    M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit 6.1.2 All Restoration The following explains the procedure to restore the various NC data backed up to memory card in a batch. The files which has been automatically backed up can be restored only when the device set by the parameter "#8919 Auto backup device"...
  • Page 175 M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit Move the cursor to select the file. Press the [INPUT] The operation message "OK? (Y/N)" appears. key. <Note> The cursor moves as follows: If there are no files at the position where the cursor [↓] key: Auto1 ->...

  • Page 176: Control Unit

    M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit 6.2 Control Unit Replacement procedures Always replace the control unit with the machine power turned OFF. (1) Check that the machine power is turned OFF. (If the power is not OFF, turn it OFF.) (2) Disconnect all the external cables from the control unit.
  • Page 177 M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit FCU8-MU042/FCU8-MA041 (M800W) FCU8-MU044 (M80W) Mounting screw size: M5 FCU8-MU542/FCU8-MA542/FCU8-MU541/FCU8-MA541(M800S) FCU8-MU511/FCU8-MU512/FCU8-MU501/FCU8-MU502(M80) FCU8-MU513/FCU8-MU514(E80) Mounting screw size: M4 IB-1501273-F...

  • Page 178: Display Unit

    M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit 6.3 Display Unit Replacement procedures Always replace the display unit with the control unit (machine) power turned OFF. (1) Check that the machine power is turned OFF. (If the power is not OFF, turn it OFF.) (2) Open the operation panel door.
  • Page 179 M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit FCU8-DU121 (8.4-type display unit) [Fixed on the front side] Fixing screw: Cheese head screw M3 (4 pcs) (Fixing screws are provided with the unit.) [Fixed on the back side] Fixture: M3 nut (4 pcs) (4 pcs of the screw caps (a) are provided with the unit.) IB-1501273-F...
  • Page 180 M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit FCU8-DU141 (10.4-type display unit) [Fixed on the front side] Fixing screw: Cheese head screw M3 (4 pcs) (Fixing screws are provided with the unit.) [Fixed on the back side] Fixture: M3 nut (4 pcs) (4 pcs of the screw caps (a) are provided with the unit.) IB-1501273-F...
  • Page 181 M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit FCU8-DU181 (15-type display unit) [Fixed on the front side] Fixing screw: Cheese head screw M3 (8 pcs) (Fixing screws are provided with the unit.) [Fixed on the back side] Fixture: M3 nut (8 pcs) (8 pcs of the screw caps (a) are provided with the unit.) IB-1501273-F...
  • Page 182 M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit FCU8-DU191 (19-type display unit) Fixing screw: Use M4×10 with spring washer and plain washer (10 screws). FCU8-DU192 (19-type display unit) Fixing screw: Use M4×10 with spring washer and plain washer (10 screws). IB-1501273-F...

  • Page 183: Personal Computer Unit

    M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit 6.4 Personal Computer Unit Replacement procedures Always replace the personal computer unit with the control unit (machine) power turned OFF. (1) Check that the machine power is turned OFF. (If the power is not OFF, turn it OFF.) (2) Open the operation panel door.

  • Page 184: Keyboard Unit

    M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit 6.5 Keyboard Unit Replacement procedures Always replace the keyboard unit with the control unit (machine) power turned OFF. (1) Check that the machine power is turned OFF. (If the power is not OFF, turn it OFF.) (2) Open the operation panel door.
  • Page 185 M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit FCU8-KB024/KB025/KB026/KB028 [Fixed on the front side] Fixing screw: Cheese head screw M3 (4 pcs) (Fixing screws are provided with the unit.) [Fixed on the back side] Fixture: M3 nut (4 pcs) (4 pcs of the screw caps (a) are provided with the unit.) IB-1501273-F...
  • Page 186 M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit FCU8-KB029 [Fixed on the front side] Fixing screw: Cheese head screw M3 (4 pcs) (Fixing screws are provided with the unit.) [Fixed on the back side] Fixture: M3 nut (4 pcs) (4 pcs of the screw caps (a) are provided with the unit.) IB-1501273-F...
  • Page 187 M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit FCU8-KB041/KB046 [Fixed on the front side] Fixing screw: Cheese head screw M3 (4 pcs) (Fixing screws are provided with the unit.) [Fixed on the back side] Fixture: M3 nut (4 pcs) (4 pcs of the screw caps (a) are provided with the unit.) IB-1501273-F...
  • Page 188 M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit FCU8-KB047 [Fixed on the front side] Fixing screw: Cheese head screw M3 (4 pcs) (Fixing screws are provided with the unit.) [Fixed on the back side] Fixture: M3 nut (4 pcs) (4 pcs of the screw caps are provided with the unit.) IB-1501273-F...
  • Page 189 M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit FCU8-KB048 [Fixed on the front side] Fixing screw: Cheese head screw M3 (4 pcs) (Fixing screws are provided with the unit.) [Fixed on the back side] Fixture: M3 nut (4 pcs) (4 pcs of the screw caps (a) are provided with the unit.) IB-1501273-F...
  • Page 190 M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit FCU8-KB083 [Fixed on the front side] Fixing screw: Cheese head screw M3 (6 pcs) (Fixing screws are provided with the unit.) [Fixed on the back side] Fixture: M3 nut (6 pcs) (6 pcs of the screw caps (a) are provided with the unit.) IB-1501273-F...

  • Page 191: Operation Panel I/O Unit

    M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit 6.6 Operation Panel I/O Unit Replacement procedures (M800W/M80W) Always replace the operation panel I/O unit with the control unit (machine) power turned OFF. (1) Check that the machine power is turned OFF. (If the power is not OFF, turn it OFF.) (2) Open the operation panel door.
  • Page 192 M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit Replacement procedures (M800S/M80/E80) Always replace the operation panel I/O unit with the control unit (machine) power turned OFF. (1) Check that the machine power is turned OFF. (If the power is not OFF, turn it OFF.) (2) Open the operation panel door.

  • Page 193: Remote I/O Unit

    M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit 6.7 Remote I/O Unit Replacement procedures Always replace the remote I/O unit with the machine power turned OFF. (1) Check that the machine power is turned OFF. (If the power is not OFF, turn it OFF.) (2) Open the operation panel door.
  • Page 194 M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit FCU8-DX651 Mounting screw size: M5 IB-1501273-F...

  • Page 195: Function Expansion Unit

    M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit 6.8 Function Expansion Unit 6.8.1 Encoder (Manual Pulse Generator) I/F Expansion Unit [M800W/M80W] CAUTION 1. Incorrect connections could cause devices to damage. Connect the cables to designated connectors. 2. Do not replace the expansion unit/card while the power is ON. 3.

  • Page 196: Functional Safety Expansion Unit [M80]

    M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit 6.8.2 Functional Safety Expansion Unit [M80] CAUTION 1. Incorrect connections could cause devices to damage. Connect the cables to designated connectors. 2. Do not replace the expansion unit/card while the power is ON. 3.

  • Page 197: Communication Expansion Unit

    M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit 6.9 Communication Expansion Unit CAUTION 1. Incorrect connections could cause devices to damage. Connect the cables to designated connectors. 2. Do not replace the operation panel I/O unit while the power is ON. 3.
  • Page 198 M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit Removal procedures (M800S/M80/E80) (1) Check that the machine power is turned OFF. (If the power is not OFF, turn it OFF.) (2) Open the operation panel. (3) Disconnect the LAN cable and SIO cable of control unit to facilitate the removal. (4) Disconnect the cable from the expansion unit.

  • Page 199: Built-In Disk Of The Display Unit

    M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit 6.10 Built-in Disk of the Display Unit CAUTION 1. Incorrect connections could cause devices to damage. Connect the cables to designated connectors. 2. Do not replace the built-in disk of the display unit while the power is ON. 3.

  • Page 200: Sd Card

    M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit 6.11 SD Card Replacement of front-side SD card (1) Open the lower cover on the display unit right end. (2) Insert/eject the SD card. (Insert it so that the top surface faces to the observer's right side.) Replacement of back-side SD card Check that the machine power is turned OFF.

  • Page 201: Usb Memory

    M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit 6.12 USB memory Replacement of front-side USB memory (1) Open the upper cover on the display unit right end. (2) Insert/remove the USB memory. Replacement of back-side USB memory Always replace the back-side USB memory with the machine power turned OFF. (1) Check that the machine power is turned OFF.

  • Page 202: Mitsubishi Cnc Machine Operation Panel

    M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit 6.13 MITSUBISHI CNC Machine Operation Panel Replacement procedures Always replace the MITSUBISHI CNC machine operation panel with the control unit (machine) power turned OFF. (1) Check that the machine power is turned OFF. (If the power is not OFF, turn it OFF.) (2) Open the operation panel door.
  • Page 203 M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit FCU8-KB921/KB922/KB923/KB924/KB925/KB926 [Fixed on the front side] Fixing screw: Cheese head screw M3 (4 pcs) (Fixing screws are provided with the unit.) [Fixed on the back side] Fixture: M3 nut (4 pcs) (4 pcs of the screw caps (a) are provided with the unit.) IB-1501273-F...
  • Page 204 M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit FCU8-KB931/FCU8-KB941 [Fixed on the front side] Fixing screw: Cheese head screw M3 (4 pcs) (Fixing screws are provided with the unit.) [Fixed on the back side] Fixture: M3 nut (4 pcs) (4 pcs of the screw caps (a) are provided with the unit.) IB-1501273-F...
  • Page 205 M800/M80/E80 Series Maintenance Manual 6 Replacing Each Unit IB-1501273-F...
  • Page 206 Revision History Date of revision Manual No. Revision details May. 2015 IB(NA)1501273-A First edition created. Nov. 2016 IB(NA)1501273-B Descriptions corresponding to M80W were added. Added the following chapters: - 1.2 General Connection Diagram - 1.4.5 Communication Expansion Unit - 1.4.5.2 PROFIBUS-DP Expansion Unit - 1.4.6 7-segment LED - 2.2.2 List of Replacing Parts - 2.2.4 Replacing Fuse...
  • Page 207 Also, corrected wrong indications. Nov. 2017 IB(NA)1501273-D The descriptions were revised corresponding to S/W version C7 of Mitsubishi CNC M800/M80 series. Changed the contents in the following chapters: - 1.3.1 System Configuration Screen - 3.3.2.2 Replacing the Unit Fan - 4.5.1 Self Diagnosis Screen - 4.9.2 Signal Monitor Screen...
  • Page 208 Date of revision Manual No. Revision details Feb. 2018 IB(NA)1501273-E The descriptions were revised corresponding to Mitsubishi CNC E80 series. Added the following chapters: - 1.2.5 General Connection Diagram [E80] - 1.4.5.3 CC-Link IE Field Changed the contents in the following chapters: - 1.2.3 General Connection Diagram [M800S] - 1.2.4 General Connection Diagram [M80] - 1.3.1 System Configuration Screen...
  • Page 209 TEL: +420-59-5691-185 / FAX: +420-59-5691-199 BRAZIL Russia Service Center MITSUBISHI ELECTRIC RUSSIA LLC Mitsubishi Electric do Brasil Comércio e Serviços Ltda. LETNIKOVSKAYA STREET 2, BLD.1, 5TH 115114 MOSCOW, RUSSIA Votorantim Office TEL: +7-495-721-2070 / FAX: +7-495-721-2071 AV. GISELE CONSTANTINO,1578， PARQUE BELA VISTA, VOTORANTIM-SP, BRAZIL CEP:18.110-650...
  • Page 210 MITSUBISHI ELECTRIC AUTOMATION (CHINA) LTD. (CHINA FA CENTER) Singapore Service Center China Shanghai Service Center 307 ALEXANDRA ROAD #05-01/02 MITSUBISHI ELECTRIC BUILDING SINGAPORE 159943 1-3,5-10,18-23/F, NO.1386 HONG QIAO ROAD, CHANG NING QU, TEL: +65-6473-2308 / FAX: +65-6476-7439 SHANGHAI 200336, CHINA...
  • Page 211 Every effort has been made to keep up with software and hardware revisions in the contents described in this manual. However, please understand that in some unavoidable cases simultaneous revision is not possible. Please contact your Mitsubishi Electric dealer with any questions or comments regarding the use of this product. Duplication Prohibited This manual may not be reproduced in any form, in part or in whole, without written permission from Mitsubishi Electric Corporation.

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