Mazatrol Fusion 640M Pro 640MT Pro Connection and Maintenance BNP-B2303engb

MITSUBISHI
MAZATROL FUSION 640M Pro

640MT Pro
CONNECTION AND
MAINTENANCE MANUAL
BNP-B2303B (ENG)
Precautions for Safety
Always read the specifications issued by the machine maker, this manual, related manuals and enclosed documents
before starting installation, operation, programming, maintenance or inspection to ensure correct usage. Thoroughly
understand the basics, safety information and precautions of this numerical controller before using the unit.
This manual ranks the safety precautions into "DANGER", "WARNING" and "CAUTION".
When there is a great risk that the user could be subject to fatalities or serious injuries if
DANGER handling is mistaken.
WARNING When the user could be subject to fatalities or serious injuries if handling is mistaken.
When the user could be subject to injuries or when physical damage could occur if handling is
CAUTION mistaken.
Note that even if the items is ranked as " CAUTION", incorrect handling could lead to serious results. Important
information is described in all cases, so please observe the items.
DANGER
Not applicable in this manual.
WARNING
1. Items related to prevention of electric shocks
Do not operate the switches with wet hands, as this may lead to electric shocks.
Do not damage, apply excessive stress, place heavy things on or sandwich the cables, as this may lead
to electric shocks.
CAUTION
1. Items related to noise
Always treat the shield cables indicated in this manual with grounding measures such as cable clamps.
! Separate the signal wire from the drive line/power line when wiring.
2. Items related to installation
Install the control unit and keyboard unit on noncombustible material. Installation directly on or near
combustible material may lead to fires.
! Always observe the installation direction.
! Do not install or operate a control unit, keyboard unit or display unit that is damaged or that have
missing parts.
CAUTION
! Do not allow conductive foreign matter such as screws or metal chips or combustible foreign matter
such as oil enter the control unit, keyboard unit and display unit.
! The control unit, keyboard unit and display unit are precision devices so do not drop or apply strong
impacts on them.
! Do not install the keyboard unit and display unit where it may be subject to cutting oil.
3. Items related to connection
Do not supply voltages other than those indicated in this manual on the connector. Doing so may lead
to destruction or damage.
Incorrect connections may damage the devices, so connect the cables to the specified connectors.
! When using an inductive load such as relays, always connect a diode in parallel to the load as a noise
measure.
! When using a capacitive load such as a lamp, always connect a protective resistor serially to the load
to suppress rush currents.
Do not connect or disconnect the connection cables between each unit while the power is ON.
Do not connect or disconnect the printed circuit boards.
When using an RS-232-C device as a peripheral devices, caution will be required when connecting and
disconnecting the connector.Always use a double-OFF type AC power supply switch on the device
side, and connect/disconnect the connector with the AC power supply on the device side OFF.
RS232C Switch AC socket

NC unit Device
4. Items related to Hard Disk Drive
! Hard Disk Drive is built in this product. Do not drop and do not give a strong impact to the product
because the hard disk drive is a precise device.
! The hard disk drive has a useful life. Please exchange the hard disk drive before end of the life.
! Please make a backup of the customer's files which is saved in the hard disk drive.At the breakdown of
the hard disk drive, although Mitsubishi provides exchange service of the hard disk drive, Mitsubishi
does not guarantee a customer's files which is saved in the hard disk drive. And Mitsubishi does not
assume the responsibility concerning the damage caused by having damaged the hard disk drive.
5. Items related to Battery
! If the battery low warning is issued, save the machining programs, tool data and parameters in the
input/output device, and then replace the battery.
! Do not short circuit, charge overheat, incinerate or disassemble the battery.
! Dispose of spent batteries according to local laws.

CONTENTS
CHAPTER 1 OUTLINE 1-1
CHAPTER 2 CONFIGURATION 2-1

2.1 System Configuration 2-1
2.2 List of Configuration Units 2-2
2.2.1 Units for M640M Pro 2-2
2.2.2 Units for M640MT Pro 2-3
2.2.3 Common Units for M640M Pro and M640MT Pro 2-4
2.3 Internal System Diagram 2-5
CHAPTER 3 INSTALLATION 3-1

3.1 General Specification 3-1
3.1.1 Environmental Conditions of Operation Box 3-1
3.1.2 Environmental Conditions of Cabinet 3-1
3.2 Designing Conditions of Operation Box 3-3
3.2.1 Installation of Display Unit and Keyboard Unit 3-3
3.2.2 Operation Box Heat Radiation Measures 3-4
3.3 Noise Measures 3-6
3.3.1 Connection of Frame Ground (FG) 3-6
3.3.2 Shield Clamping of Cables 3-8
3.3.3 Connection of Spark Killers 3-9
3.3.4 Protective Measures against Lightning Surge 3-10
CHAPTER 4 SYSTEM CONNECTION 4-1

4.1 General System Diagram 4-1
4.1.1 M640M Pro General System Diagram 4-1
4.1.2 M640MT Pro General System Diagram 4-2
4.2 Connector Layout Drawing 4-3
4.2.1 Connectors, Switches and LEDs Layout Drawing of Control Unit 4-3
4.2.2 Connectors, Switches and LEDs Layout Drawing of Keyboard Unit 4-4
4.3 Connector Pin Assignment 4-5
4.3.1 Control Unit Connector Pin Assignment 4-5
4.3.2 Keyboard Unit Connector Pin Assignment 4-7
4.4 Connection of Various Devices 4-10
4.4.1 Connection of Floppy Disk Unit 4-10
4.4.2 Connection of Hard Disk Unit 4-11
4.4.3 Connection of PC Card (CardBus) 4-13
4.4.4 Connection of PC Card in front of Control Unit 4-14
4.4.5 Connection of PS/2 Mouse 4-16
4.4.6 Connection of PS/2 Keyboard and Parallel Device 4-16
4.4.7 Connection of RX322-1 4-17
4.4.8 Connection of Power Supply 4-18
4.4.9 Connection of Signal Separator Cards 4-20
4.4.10 Connection of Manual Pulse Generator 4-23
4.5 Emergency Stop 4-24
4.5.1 Connection of Emergency Stop 4-24
4.5.2 Compliance with the EN Standard 4-25
CHAPTER 5 CONNECTION OF I/O INTERFACE 5-1

5.1 Outline of I/O Interface 5-1
5.1.1 Types of I/O interface 5-1
5.1.2 Example of DI/DO Connection 5-1
5.2 Connection of Base I/O Unit 5-2
5.2.1 Base I/O Unit Connection System Drawing 5-2
5.2.2 Base I/O Unit Connectors 5-2
5.2.3 Base I/O Unit Connector Layout Drawing 5-2
5.2.4 Base I/O Unit Connector Pin Assignment 5-3
5.2.5 Installation of HR353 Card 5-6
5.2.6 Base I/O Unit Input/Output Specification 5-7
5.2.7 Connection of Power Supply to Base I/O Unit 5-8
5.2.8 Connection of Servo Drive Unit to Base I/O Unit 5-9
5.2.9 Connection of Synchronous Feed Encoder to Base I/O Unit 5-9
5.2.10 Sensor Signal (Skip) Connection 5-10
5.2.11 Outline of Analog I/O Circuit 5-10
5.3 Card-sized I/O Connection 5-11
5.3.1 Example of Card-sized I/O Application 5-11
5.3.2 Card-sized I/O Specification 5-12
5.3.3 Card-sized I/O Connector Pin Assignment 5-13
5.3.4 Notice for Patterning of Connector PCB for Card-sized I/O 5-13
5.3.5 Input/Output Circuit of Card-sized I/O 5-14
5.3.6 Installation of Card-sized I/O 5-15
5.3.7 Cable Connection 5-16
CHAPTER 6 CONNECTION OF REMOTE I/O UNIT 6-1

6.1 Outline of Remote I/O Unit 6-1
6.2 Name of Remote I/O Unit Sections 6-1
6.3 Connection of Remote I/O Power 6-2
6.4 Outline of Digital Signal Input Circuit 6-3
6.5 Outline of Digital Signal Output Circuit 6-4
6.6 Connection of FCUA-DX101 Unit and Machine Control Signal 6-4
6.7 Setting of Channel No. when Using Multiple Remote I/O Unit 6-6
CHAPTER 7 NOTIFICATION OF USING PC PERIPHERAL DEVICE 7-1

7.1 Connection of Parallel I/O, Mouse and Keyboard 7-1
7.2 Recommended Devices List 7-1
7.2.1 Front Access IC Cards 7-1
7.2.2 CardBus PC Cards 7-2
7.2.2 Peripheral Devices 7-2
CHAPTER 8 DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 8-1

8.1 Maintenance Tools 8-1
8.1.1 Measuring Instruments 8-1
8.1.2 Tools 8-1
8.2 Maintenance Items 8-1
8.3 Maintenance of Escutcheon and Keyboard 8-2
8.3.1 Cleaning of Escutcheon and Keyboard 8-2
8.3.2 Replacement of NC Data Key 8-2
8.3.3 Replacement of Menu Key 8-3
8.4 Maintenance of Floppy Disk Drive 8-4
8.4.1 Cleaning of Floppy Disk Drive (Head Cleaning) 8-4
8.4.2 Handling of Floppy Disks 8-4
8.4.3 Other Precautions for Use 8-5
8.4.4 Replacement of Floppy Disk Drive 8-5
8.5 Maintenance of Hard Disk 8-6
8.5.1 Handling of Hard Disk 8-6
8.5.2 Other Precaution for Use 8-6
8.5.3 Replacement of Hard Disk 8-6
8.6 Maintenance of LCD 8-7
8.6.1 Life of LCD Backlight 8-7
8.6.2 LCD Characteristics 8-7
8.6.3 Replacement of LCD Backlight 8-7
8.7 Maintenance of Battery 8-8
8.7.1 Handling of Battery 8-8
8.7.2 Replacement of Battery 8-8
8.8 Maintenance of Cooling Fan 8-9
8.8.1 Life of Cooling Fan 8-9
8.8.2 Replacement of Cooling Fan 8-9
8.9 Cable Replacement Method 8-10
CHAPTER 9 TROUBLESHOOTING 9-1

9.1 List of Unit LEDs and Switches 9-1
9.2 Troubleshooting 9-2
9.2.1 Confirmation of Trouble State 9-2
9.2.2 When in Trouble 9-3
9.2.3 Examples of Troubleshooting 9-4
APPENDIX 1 INSTALLATIONS A1-1
Appendix 1.1 Control Unit Outline Drawing A1-1
Appendix 1.2 Control Unit with Display Unit Outline Drawing A1-2
Appendix 1.3 Keyboard Unit Outline Drawing A1-3
Appendix 1.4 External Power Supply Unit (PD25) Outline Drawing A1-4
Appendix 1.5 Base I/O Unit (HR353) Outline Drawing A1-4
Appendix 1.6 Remote I/O Unit Outline Drawing A1-5
Appendix 1.7 Card-sized I/O Outline Drawing A1-6
Appendix 1.8 Signal Separator Outline Drawing A1-7
Appendix 1.9 Manual Pulse Generator (HD60) Outline Drawing A1-8
Appendix 1.10 "F" Installation Plate Outline Drawing A1-8
Appendix 1.11 Floppy Disk Drive Unit Outline Drawing A1-9
Appendix 1.12 Hard Disk Drive Unit Outline Drawing A1-9
Appendix 1.13 Synchronous Feed Encoder (OSE-1024-3-15-68) Outline Drawing A1-10
Appendix 1.14 Synchronous Feed Encoder (OSE-1024-3-15) Outline Drawing A1-10
Appendix 1.15 Grounding Plate and Clamp Fitting Outline Drawing A1-11
Appendix 1.16 RX322-1 (with Sheet Metal Bracket) Outline Drawing A1-12
APPENDIX 2 CABLE DRAWING A2-1

Appendix 2.1 ENC-SP1 Cable (Spindle Drive Unit) A2-2
Appendix 2.2 ENC-SP2 Cable (FR-TK) A2-2
Appendix 2.3 F012 Cable (I/O Interface, 4th-system) A2-3
Appendix 2.4 F017 Cable (I/O Interface) A2-4
Appendix 2.5 F020/F021/F022 Cable (Manual Pulse Generator, 1ch/2ch/3ch) A2-5
Appendix 2.6 F030/F031 Cable (RS232C, 1ch/2ch) A2-5
Appendix 2.7 F040/F041 Cable (Sync. Feed Encoder, Straight/Right Angle) A2-6
Appendix 2.8 F070 Cable (+24V Input) A2-6
Appendix 2.9 F110 Cable (+24V Input, Power Off Detection) A2-7
Appendix 2.10 F120 Cable (Emergency Stop) A2-7
Appendix 2.11 F132 Cable (Floppy Disk Drive) A2-8
Appendix 2.12 F140 Cable (Hard Disk Drive) A2-8
Appendix 2.13 F171 Cable (ON/OFF Switch) A2-9
Appendix 2.14 F260 Cable (Card-sized I/O Communication) A2-10
Appendix 2.15 F261 Cable (Card-sized I/O Communication) A2-10
Appendix 2.16 F270 Cable (Card-sized I/O +24V Input) A2-11
Appendix 2.17 F271 Cable (Card-sized I/O +24V Input) A2-11
Appendix 2.18 F252 Cable (PC Keyboard Extension) A2-12
Appendix 2.19 F252 Cable (PC Keyboard Extension) A2-12
Appendix 2.20 FCUA-R211 Cable (Remote I/O) A2-13
Appendix 2.21 R301 Cable (DI/DO) A2-13
Appendix 2.22 SH21 Cable (Servo Drive Unit) A2-14
Appendix 2.23 SH41 Cable (Remote I/O) A2-14
Appendix 2.24 F010 Cable (I/O Interface) A2-15
APPENDIX 3 EMC INSTALLATION GUIDELINE A3-1

Appendix 3.1 Introduction A3-1
Appendix 3.2 EMC Instruction A3-1
Appendix 3.3 EMC Measures A3-1
Appendix 3.4 Panel Structure A3-2
Appendix 3.4.1 Measures for Control Panel A3-2
Appendix 3.4.2 Measures for Door A3-2
Appendix 3.4.3 Measures for Power Supply A3-3
Appendix 3.5 Measures for Wiring in Panel A3-3
Appendix 3.5.1 Precautions for Wiring in Panel A3-3
Appendix 3.5.2 Shield Treatment of Cables A3-4
Appendix 3.6 Parts for EMC Measures A3-5
Appendix 3.6.1 Shield Clamp Fitting A3-5
Appendix 3.6.2 Ferrite Core A3-5
Appendix 3.6.3 Surge Absorber A3-6
Appendix 3.6.4 Selection of Stabilized Power Supply A3-8
APPENDIX 4 INSTRUCTION FOR COMPLIANCE WITH UL/c-UL STANDARD A4-1

CHAPTER 1 OUTLINE
This manual, from Chapter 2 to Chapter 7 explains the structure, electrical specifications and connection
methods required when connecting the NC units and a machine tool, and Chapter 8 and Chapter 9 explains
maintenance and troubleshooting for the NC units.
This manual assumes that all functions are added, but the actually delivered device may not all function.
Refer to the following documents for explanations on the function.
M600 Series Specification Manual BNP-B3950

M600 Series PLC Interface Manual BNP-B3950-003
MELDAS AC Servo/Spindle MDS-A/B series Specification Manual BNP-B3759
MELDAS AC Servo/Spindle MDS-C series Specification Manual BNP-C3000
MELDAS AC Servo/Spindle MDS-CH series Specification Manual BNP-C3016
MELDAS AC Servo MDS-B-SVJ2 Series Specification Manual BNP-B3937
MR-J2-CT Series Specification Manual BNP-B3944
Refer to the following document for explanations on the EMC Directives for the European CE Marking.
EMC Installation Guideline BNP-B2230
Refer to the following document for explanations on the UL/c-UL Marking.

UL/c-UL Standard Conformity Unit Manual BNP-A2993-81
Before connecting a peripheral devices of a commercial personal computers to the NC unit, fully comprehend
the structure, electrical specifications and connection method of the peripheral devices.
Model names are written in this manual as follows.

MAZATROL FUSION 640M Pro --> M640M Pro
MAZATROL FUSION 640MT Pro --> M640MT Pro
1-1
CHAPTER 2 CONFIGURATION
2.1 System Configuration
M640M Pro and M640MT Pro system are usually confabulated of following components:
(1) Control unit : This unit has the computation processing function for numerical control.
(2) Display unit : Characters and figures are displayed on this unit.
(3) Keyboard unit : This unit has the setting function.
(4) I/O interface unit : Input and output of machine signals are done through this unit.
(5) Servo/Spindle drive unit : This is a servo/spindle amplifier composed of a conductor for obtaining DC from AC and
an inverter for obtaining AC from DC.
(6) Servo/Spindle motor : This drive motor moves the machine.
(7) Other peripheral device : Peripheral device such as external memory and programming support.
Installed by machine tool manufacturer
PC card
LAN
MODEM
Floppy Disk Drive
NC control unit
Option
Display Unit
Programming Tool
Keyboard unit
Printer
Manual Pulse Generator PC Keyboard

PS/2 Mouse
Servo Amp./Spindle drive unit

Machine operation panel
I/O interface
I/O interface box using by Card-sized I/O
I/O interface boxes are installed by
machine tool manufacturer Servo motor / Spindle motor
<Note>
The noise resistance of most of PCperipheral devices are lower than the CNC system.
If such a low noise resistance devices are used in the CNC system, the noise resistance of the entire NC system
decreases, and noise trouble is caused occasionally. Please follows notes in Chaper 7 when you use PC peripheral
devises.
2-1
2.2 List of Configuration Units
2.2.1 Units for M640M Pro

(1) Control Unit
Type Module description Function
FCU6-MA651-33 HR191 NC base card
HR085 Power supply card
HR073 Battery card
HR161 CPU card
HR481 Main memory card (SRAM/FROM)
HR491 Additional memory card (SRAM)
HR061 #1 Servo/Spindle interface (channel #2)
HR063 #1 Remote-I/O interface (channel #4)
FCU6-EP301 CardBus interface unit (control card HR843)
PC101 Card-PC unit
MMF-06E12DH DC FAN motor
CR2032 Lithium battery
(2) Display unit

FCU6-YZN41 NL8060BC31-20 12.1 inch TFT color LCD unit
121PW111 LCD back light lamp inverter
KS-6MB203A-P Menu key
HR276 LCD signal adapter card
HR253 Front IC-card interface card
F093 cable NC <==> HR276
F089 cable NC <==>LCD
F172 cable Keyboard <==> ON/OFF switch
Escutcheon (plastic bezel) for M640M Pro
(3) Keyboard unit

FCU6-YZ041 HR201 Keyboard control
KS-6YZ211A-P NC data-key
Printed NC data-key sheet for M640M Pro
ATA0000-1002L Tablet pointer
R-TM RIO terminal resister
F051 cable HR021 <==> NC
F400 cable HR021 <==>Keyboard
E-AA1390-001 HR021 <==> Tablet pointer
Escutcheon (plastic bezel)
2-2
2.2.2 Units for M640MT Pro
(1) Control Unit
FCU6-MA651-34 HR191 NC base card
HR085 Power supply card
HR073 Battery card
HR161 CPU card
HR481 Main memory card (SRAM/FROM)
HR491 Additional memory card (SRAM)
HR061 #1 Servo/Spindle interface (channel #2)
FCU6-EP301 CardBus interface unit (control card HR843)
PC102 Card-PC unit
MMF-06E12DH DC FAN motor
CR2032 Lithium battery
(2) Display unit

FCU6-YZN42 NL8060BC31-20 12.1 inch TFT color LCD unit
121PW111 LCD back light lamp inverter
KS-6MB203A-P Menu key
HR276 LCD signal adapter card
HR253 Front IC-card interface card
F089 cable NC <==>LCD
F172 cable Keyboard <==> ON/OFF switch
Escutcheon (plastic bezel) for M640MT Pro
(3) Keyboard unit

FCU6-YZ042 HR201 Keyboard control
KS-6YZ211A-P NC data-key
Printed NC data-key sheet for M640MT Pro
ATA0000-1002L Tablet pointer
R-TM RIO terminal resister
F051 cable HR021 <==> NC
F400 cable HR021 <==>Keyboard
E-AA1390-001 HR021 <==> Tablet pointer
Escutcheon (plastic bezel) for M640MT Pro
2-3
2.2.3 Common Units for M640M Pro and M640MT Pro
(1) NC Control Unit Option

Module discription Function
HR061 #2 Servo interface (channel #4) --- only for M640M Pro
(2) Peripheral
Type Model Module Description Function
FCU6-HD331-1 HDD unit HDD (Hard disk drive)
F140 cable HR191<==> HDD
Sheet metal bracket
Thermistor
Rubber vibration isolator
FCU6-FD221-2 External FDD unit FD235HF FDD (Floppy disk drive)
F132 cable HR191<==> FDD
Sheet metal bracket
FCUA-DX101 Remote I/O unit RX312 card DI:32(Sink)DO:32(Source)
HR353 Base I/O card DI:32(Sink)DO:32(Source)
HR371 Card-sized I/O DI:16(Source) DO:16(Source)
HR021 Servo & I/O Servo1, I/O2
connection card
HR023 Servo Connection Servo1
card
RX322-1 Option I/O card RX322-1 card DI:32DO:16
F332 cable
PD25 External power supply
unit
HD60B Manual pulse
generator
Metal panel D Metal panel D for earth
Metal panel E Metal panel E
Synchronous feed
OSE-1024-3-15-68 encoder with Flange
Synchronous feed
OSE-1024-3-15 encoder without Flange
2-4
2.3 Internal System Diagram
HR161 HR191 HR481 HR49

CPU
FRPM FRPM
CPU bus control
PLC processor
SRAM SRAM
SDRAM
Cassette memory
for maintenance
HR085
AVR HR061
12V/5V/3.3V
Servo
interface
HR073 HR021 Servo Amp.4ch

Battery Connecter card
3V Remote I/O5ch , 6ch
HR063 Synchronous feed

HR353 encoder1ch
Remote I/O
interface Servo Amp.(1ch , 2ch
Base I/O
Servo Amp.(3ch
Remote I/O1ch , 2ch , 4ch
SKIP
Peripheral unit
Card PC
CPU
HR253
IC card IC card
External I/O
CPU bus interface interface
control
HR201 Remote I/O3ch

Manual pulse generator
Memory RS232 NC1ch , 2ch
RS232PC1ch , 2ch
2port RAM Parallel
NC keyboard
Keyboard unit
External I/O
interface
HR276
LCD LCD
interface
Display unit
HR843
CardBus CardBus
interface /PC card
HDD
FDD
Control unit
2-5
CHAPTER 3 INSTALLATION
3.1General Specification
3.1.1 Environmental Conditions of Operation Box

Unit type Control unit Display unit Keyboard unit
Model name FCU6-MA651-33 FCU6-YZN41 FCU6-YZ041
FCU6-MA561-34 FCU6-YZN42 FCU6-YZ042
Ambient Operation 0~55C 0~50C 0~55C
General specification
temperature (*1 System operating 5~55C) (Surface temperature of LCD)

Storage -20~60C
Ambient Operation 45~75%RH (w ithout condensation)
humidity Storage 45~80%RH (w ithout condensation)
Vibration Operation 4.9m/s 2 [0.5G] or less
Shock Operation 29.4m/s 2 [3G]or less
Operation atmosphere No corrosive gas and dust (JEM 1103 grade C)
specification
Supply voltage DC24V5%, Ripple:5%(P-P)

Power
Current (max.) 3A (= Control unit + Display unit + Keyboard unit)

Pow er interruption time 20ms or less (w ith PD25)
Heating value 31W (typ.), 72W (max.) (Control unit + Display unit + Keyboard unit)
Weight 2.2kg 2.8kg 2.4kg
(w ith HDD unit)
Dimension Refer to Appendix 1.1 Refer to Appendix 1.2 Refer to Appendix 1.3
(*1) The lower limits depend on the hard disk drive specification. When the power supply is turned on, the ambient
temperature is detected with the temperature sensor with built-in control unit. The personal computer dose not start
up when the detected temperature is less than 5C.
If the detected temperature is less than 5C, the hard disk drive is warmed with the built-in heater/ When the
temperature rise to 5C, the personal computer is automatically started.
Time until the temperature of the hard disk drive rises from 0C to 5C is about 20minutes.
3.1.2 Environmental Conditions of Cabinet

Unit type External pow er supply unit
Model name PD25
Ambient Operation 0~55C
temperature Storage -20~60C

Ambient Operation 45~75%RH (Without condensation)
humidity Storage 45~80%RH (Without condensation)
Shock Operation 29.4m/s 2 [3G] or less
Operation atmosphere No corrosive gas and dust
Supply voltage AC200V~230V +10% -15%
specification
50/60Hz1Hz
Power
Current (max.) 0.6A

Pow er interruption time 20ms or less
Heating value 35W
Weight 1.5kg
Dimension Refer to Appendix 1.4
3-1
Unit type Base I/O unit Remote I/O unit Card-sized I/O
Model name HR353 FCUA-DX101 HR371

Ambient Operation 45~75%RH (without condensation)
humidity Storage 45~80%RH (without condensation)
Operation atmosphere No corrosive gas and dust
Supply voltage DC24V5%, Ripple5%(P-P) DC5V5%
Power specification
Ripple 50mV(P-P)
DC24V5%
Ripple 240mV(P-P)
Current (max.) 2.6A 0.7A DC5V/0.4A DC24V/1.2A
(All DO turned on) (Control Logic only) (All DO turned on)
Power interruption time Depends on power supply specification. (20ms or more is required)
Heating value 70W (*1) 60W (*1) 30W (*1)
Weight 800g 470g 300g
Dimension Refer to Appendix 1.5 Refer to Appendix 1.6 Refer to Appendix 1.7
(*1) It is the value when all of DI/DO are turned ON and including load heating.
Unit type Connecter card Connecter card

Model name HR021 HR023

Ambient Operation 45~75%RH (without condensation)
humidity Storage 45~80%RH (without condensation)
Operation atmosphere No corrosive gas and dust (JEM 1103 grade C)
Supply voltage DC24V5%, Ripple:5%P-P
specification
Powe r
Current (max.) 400mA 200mA

Power interruption time Depends on power supply specification (20ms or more is required)
Weight 130g 100g

Dimension Refer to Appendix 1.8 Refer to Appendix 1.9
3-2
3.2 Designing Conditions of Operation Box
3.2.1 Installation of Display Unit and Keyboard Unit

The display unit (with control unit) and the keyboard unit are installed in a sealed structure operation box or a
cabinet as a principle. Observe the following points for installation.
(1) Install the keyboard unit with slant the surface 20 15 degrees against vertical. (Refer to the following
figure) The limitation of the inclination is according to the the hard disk specification. The hard disk is
mounted on the back of the keyboard unit with 20 degrees inclination.
Top
Keyboard Unit rear side
HDD unit
2015
Bottom
(2) Do not install the display unit and keyboard unit into the place where the machine vibration is strong.
(3) Secure the space shown below for ventilation in consideration of the control unit's heat dissipation and
wiring for PC-card(CardBus) communication cable.
Wiring allowance
50mm or more
LCD surface Heat dissipation, ventilation and wiring

allowance 15mm or more
3-3
3.2.2 Operation Box Heat Radiation Measures
Refer to the following method for heat radiation measures.
Example of heat radiation measures

<Hypothetical conditions>
Calculate total heat generation (1) Average temperature in cabinet: 55C
of each mounted unit (W) (2) Temperature outside of Cabinet: Ta 0C ~40C
(3) Internal temperature rise value: DT = T - Ta (max) = 15C
Calculate cabinet cooling
capacity (W1) <Supplement>
(1) Refer to "3-1. General Specification" for the heat generated value
WW1 (2) Equation of enclosed cabinet (thin sheet metal) cooling capacity.
Comparison of
W and W1 W1 = UAT
U: 6W/mC---with internal cooling FAN
4W/mC---without internal cooling FAN
Selection of heat exchanger
A: Effective heat radiation area (m)
Area where heat can be radiated from cabinet)
Mounting design T: Internal temperature rise value 15deg
[Note]
When calculating the effective heat radiation area, do not include the
Collection of internal temperature
rise distribution data parts that contact other objects.
(3) Points of caution for heat radiation countermeasures when

T15deg
Evaluation designing mounting state
*Consider convection in cabinet
T15deg
(eliminate heat spots)
Improvements *Collect hot air at suction port in heat
exchanger panel.
Completion (4) Evaluation standards for internal temperature rise distribution data
T15deg
Install a circulation fan in the panel when the following conditions are not satisfied.
Evaluation standards for internal temperature rise distribution data.
T15deg
3-4
An example of operation box heat measure is shown below.
< Example of Operation box >
Heat radiation area (A):

except front, bottom surfa c e
CONTROL

UNIT
A0.6 0.12 + 0.6 0.5 + 0.12 0.5 2 0.49m
Top surface
Rear surface
Both sides surface
500

(COOLING Heat generation W
FAN) Power capacity = 24V 5A = 120 (W)
Power consumption (Typ)= 24V 3A = 72 (W)
Power
consumption Power
PANEL
FRONT Heat generation = - consumption
Power
efficiency
= (72/0.7) - 72
0
12 31 (W)
600
< Examination of cooling FAN necessity >
1. Temperature standard
(1) Temperature standard in cabinet (for each units) T = 0C~ 55C
(2) Cabinet ambient temperature Ta = 0C~ 40C
(3) Internal temperature rise value T = T(max) - Ta(max) = 15deg
2. Cooling capacity of operation box (W1)

W1 = U A T
T = Internal temperature rise value (= 10deg)

U = 6W/ mC < with internal cooling FAN >
4W/mC < without internal cooling FAN >
A = Effective heat radiation area (m)
(1) With internal cooling FA N W1 = 6 0.49 10 = 29.4W 31WT10.5deg

(2) Without internal cooling FA N W1 = 4 0.49 10 = 19.6W < 31WT15.8deg
Decide to use or not to use a cooling FAN in accordance with temperature rise data.
Recommended FAN mounting position: Upper right area of control unit (refer to the figure shown above)
( FANDC24V 92 )
3-5
3.3 Noise measures
3.3.1 Connection of Frame Ground (FG)
The basis of the grounding method is single point ground to prevent common impedance connection between each units.
However, when set up in the place where the control unit and NC keyboard are far from the cabinet like a machine with
the operation part of the pendant box type, connect FG terminal of the control unit and the NC keyboard to the ground
plate in the pendant box with grounding wires, and connect ground plate in the pendant box to the ground plate in the
cabinet with grounding wire.
For the 24Vdc power supply unit which supplies power to the I/O unit, connect GND terminal (Common) and FG terminal
(1) When all of units are installed in a same cabinet, or are installed in the near place.
Control unit Keyboard unit
CF55 (IO Interface) CF21 (RS232C)

DCIN 0V CF50 (IO Interface) EMG CF22 (RS232C)
DC24V CF10 (IO Interface) DC24V
0V HANDLE (Manual pulse generator)
0V ENC2 (Encoder) 0V PARALLEL
FG FG
: Terminal : Terminal
Emergency
stop button
IO Interface
Power supply unit DC24V Power

PD25 supply unit
CF10 (IO Interface)
SV1 (Servo Drive)
DCIN SV2 (Servo Drive)
AC200V AC200V 0V
DC24V DC24V SKIP
0V 0V ENC1 (Encoder)
FG FG FG FG
Terminal
Cabinet Ground Plate
This mark shows that the metal cover of connector is connected with FG terminal block by FG pattern lines in
the printed circuit board.
3-6
(2) Control unit and NC keyboard are installed far from the cabinet
Operation Panel
Control unit Keyboard unit
CF55 (IO Interface) CF21 (RS232C)

DCIN 0V
CF50 (IO Interface) EMG CF22 (RS232C)
DC24V CF10 (IO Interface) DC24V
0V
HANDLE (Manual pulse generator)
0V ENC2 (Encoder) 0V PARALLEL
FG FG
Terminal Terminal
Emergency
stop button
Pendant box
ground plate
IO Interface
Power supply unit DC24V Power

PD25 supply unit
CF10 (IO Interface)
SV1 (Servo Drive)
DCIN SV2 (Servo Drive)
AC200V AC200V 0V
DC24V DC24V SKIP
0V 0V ENC1 (Encoder)
FG FG FG FG
Terminal
Cabinet Ground Plate
Cabinet
This mark shows that the metal cover of connector is connected with FG terminal block by FG pattern lines in
the printed circuit board.
3-7
3.3.2 Shield Clamping of Cables
(1) Method of shield clamping
The shield cable connected to the control unit, servo amplifier and spindle amplifier must be connected to the
grounding plate to stabilize operation while preventing malfunctioning due to noise.
The shield can be connected to the grounding plate with lead wires, with clamp fittings or with the connector
GND plate. Refer to the following drawings to treat the shield cable.
Example of connection with lead wire
soldering
unit
cable
shield cable
lead wire treatment method lead wire
Example of connection with clamp fitting
shield cable
grounding unit
plate cable
clamp fitting
less than
0.8m shield
clamp fitting
(1) Peel part of the cable sheath and expose the shield as shown in the grounding
drawing. plate
Press the exposed part against the grounding plate with the cable
clamp fittings.
(2) If the cable is thin, clamp several together in a bunch.

(3) Use adequate force when tightening the cable so that the wire material is not damaged.
(4) Connect each grounding plate together and ground them at one point.
Refer to APPENDIX 1.15 for the dimension of clamp fittings and grounding plate.
3-8
(2) Cable list that requires the shield clamp
Cables which require shield clamp with a connector cases are following table.
Refer to the 3.3.2 "Shield Clamping of Cables" and each cable drawing of the Appendix 2 "Cable
Manufacturing Drawing" for shield clamp method.
Cable name Connect from Connect to
Unit name Connector Shield clamp Unit name Connector Shield clamp
name necessity name necessity
F017 Control unit CF10/CF50 Required(*1) Base i/o unit CF10/CF50 Required(*1)
F012 Control unit CF50 Required(*1) Base i/o unit CF55 Required(*1)
F040/F041 Control unit ENC2 Required Encoder Not required
Base i/o unit ENC1 Required Encoder Not required
ENC-SP1 Control unit ENC2 Required Spindle amplifier CN8 Not required
Base i/o unit ENC1 Required Spindle amplifier CN8 Not required
ENC-SP2 Control unit ENC2 Required FR-TK Not required
Base i/o unit ENC1 Required FR-TK Not required
F020/F021/F022 NC keyboard HANDLE Required Manual pulse gen. Not required
F030/F031 NC keyboard CF21/CF22 Required RS232Cdevice Not required
SH21 Base i/o unit SV1 Required(*1) Servo/spindle amp. CN1A Required(*1)
Base i/o unit SV2-14 Required(*1) MR-J2-CT CN1A Required(*1)
Base i/o unit SV3 Required(*1) Servo/spindle amp. CN1A Required(*1)
Base i/o unit SV4-14 Required(*1) MR-J2-CT CN1A Required(*1)
Base i/o unit SV-14 Required(*1) MR-J2-CT CN1A Required(*1)
Base i/o unit SKIP Required Not required
FCUA-R211 Base i/o unit RIO1 Required Remote I/O unit RIO1 Required
Base i/o unit RIO2 Required Remote I/O unit RIO1 Required
Base i/o unit RIO4-14 Required Remote I/O unit RIO1 Required
(*1) When using cables witch Mitsubishi supplies, cable clamping with the clamp fitting is not required
because the cable shield connects to ground through the connector case.
3.3.3 Connection of Spark Killers
The generated noise must be removed when the coil or contact operates.
As a measure, connect a spark killer in parallel with the coil or contac t .
The CR compound element is useful for eliminating noise generated by magnetic induction.

Contact
Spark killer C: 0.033~0.1F

SK
R: 10~120

SK
E Coil
3-9
3.3.4 Protective Measures against Lightning Surge
Generally, lightning surge infiltrates the control power supply from the power supply line. Then the internal circuit is
damaged by this control power supply, or via this control power supply.
The Mitsubishi NC unit has a surge absorber on the control power supply for the NC control section and NC control
section. However, this measure is not taken through the control panel, as shown in Fig. 1, so the lightning surface
could flow over the signal line and damage the other devices.
NC control
section
NC drive section Control panel

Power line (Servo, Spindle amplifier) )
(relay
panel, etc.)
Lightning surge path
Power supply
for panel
Fig.1 Path of damage caused by lightning surge
(1) Methods of protective measures

Install the surge absorber on the power supply line for the separately prepared power supply units, etc., as shown in
Fig. 2 and Fig. 3. The following two measures are required as protection against general damage.
Installation of surge absorber
Installation of circuit protector
Power line Other device Control panel

(Power supply (Relay panel,
for panel, etc.) etc.)
Circuit
protector
Surge absorber (1) Surge absorber (2)
Fig.2 Lightning surge measures for 3-phase power supply line
(2) Example of surge absorber

Types of Okaya Denki Sangyo Co., Ltd. Surge absorbers
Surge withstand
Max. tolerable Surge resistance
Circuit voltage Clamp voltage voltage(Electrical-discharge
Surge absorber Part name circuit level
[Vrms] [V]10% start voltage)
voltage[Vrms] 8/20s[A]
1.2/50s[V]
RAV-781BYZ-2 250 300 300 2500 20k
RAV-781BXZ-4 250 500 500 2500 2k
Note Refer to the APPENDIX 3.6.3 for dimention.
Refer to the manufacturer's catalog for details characteristics, outline and connection methods of the surge
absorber.
(3) Surge absorber installation method

Refer to the APPENDIX 3.6.3 .
3-10
CHAPTER 4 SYSTEM CONNECTION
4.1 General System Diagram
4.1.1 M640M Pro General System Diagram
Display Unit
Backlight inverter FCU6-YZN41
Broken lines indicate the machine
RS T builder preparation devices
F089 12.1 inch
INV
IC memory card interface LCD
CNC Unit F093
LCD
Circuit breaker Sync. Encoder FCU6-MA651-33
F040/F041 F132
ENC2 FDD FDD
ON OFF F012
F110 HDD CF55
DCIN F017
MC CF10
CF01 CF50
F140
CF15
MC
F051
ON F172
MC ON/OFF HEATER THM J2 Menu key
CF15
OFF
F070 F020/F021/F022 Pulse generator
24Vdc DCIN HANDLE
HD60
PD25
F171 HDD
DCOUT CF24 F030/F031
Unit CF21
ACIN F030/F031 RS232C Device
CF22
ON/OFF OT release SW
Circuit EMG
F120
CR22 CR21
breaker KEYBOARD PC Keyboard
EMG
24Vdc RX322-1 MOUSE2
Power Supply RA
FG Mouse
DCOUT 24Vdc F252
OPMS Mouse select SW
ACIN
FG CR31 PARALLEL I/O device
J3
Circuit Keyboard Unit
breaker FCU6-YZ041 RIO3 Terminator
J4
FG R-TM
F070
24Vdc
DCIN CF50 CF10

Sync. Encoder R301
F040/F041 CF31
ENC1 R301 Machine I/O
CF33
FCUA-R211 Remote I/O unit FCUA-R211 Remote I/O unit

Sensor signals (SH41) (SH41) To next unit or
SKIP RIO1 RIO1 RIO2 RIO1 RIO2
Max. 8 pints terminator
DX101 DX101
Aio DCIN DCIN
SH21 24Vdc 24Vdc
SV1 Base I/O
Spindle/Servo Machine I/O Machine I/O
Drives Unit
HR353
RIO2
SH21
SV3
SH21 RIO4-1 F260
YMW
HR371
SV2-1 Machine I/O

SH21 RIO4-2 F260 24Vdc I/O board
SV2-2
SH21 RIO4-3 Max. 8 channels
SV2-3
SH21 YMW
HR371
SV2-4 RIO4-4 Machine I/O

Spindle/Servo 24Vdc I/O board
MR-J2-CT max. 7 units
Drives
F070
24Vdc
DC24V CF55
SH21 F260
SV4#1 RIO5#1 YMW
HR371
SH21 F260 Machine I/O

SV4#2 RIO5#2 24Vdc I/O board
SH21 Max. 8 channels
SV4#3 RIO5#3
SH21 YMW
HR371
SV4#4 RIO5#4 Machine I/O

Signal 24Vdc I/O board
separator
24Vdc
F070 SH21 HR021 F260
RIO6#1 YMW
HR371
F260 Machine I/O

RIO6#2 24Vdc I/O board
DC24V SV_IN Max. 8 channels
SH21 RIO6#3
SV#1
Signal YMW
HR371
SH21 RIO6#4 Machine I/O

SV#2
SH21 separator 24Vdc I/O board
SV#3
SH21 HR023
SV#4
Note 1 The noise resistance of most of PS/2 mice and PC keyboards are lower than the CNC system. Please follow
notes in Chapter 7 If using those devices.
Note 2 Use FCUA-R211 cable or equivalent for RIO cable.
SH41 can be used short length between RIO unit in same cabinet inside.
4-1
4.1.2 M640MT Pro General System Diagram
Display Unit
Backlight inverter FCU6-YZN42
Broken lines indicate the machine
RS T builder preparation devices
F089 12.1 inch
INV
IC memory card interface LCD
CNC Unit F093
LCD
Circuit breaker Sync. Encoder FCU6-MA651-34
F040/F041 F132
ENC2 FDD FDD
ON OFF F012
F110 HDD CF55
DCIN F010
MC CF10
CF01 F012
CF50
F140
CF15
MC
F051
ON F172
MC ON/OFF HEATER THM J2 Menu key
CF15
OFF
F070 F020/F021/F022 Pulse generator
24Vdc DCIN HANDLE
HD60
PD25
F171 HDD
DCOUT CF24 F030/F031
Unit CF21
ACIN F030/F031 RS232C Device
CF22
ON/OFF OT release SW
Circuit EMG
F120
CR22 CR21
breaker KEYBOARD PC Keyboard
EMG
24Vdc RX322-1 MOUSE2
Power Supply RA
FG Mouse
DCOUT 24Vdc F252
OPMS Mouse select SW
ACIN
FG CR31 PARALLEL I/O device
J3
Circuit Keyboard Unit
breaker FCU6-YZ042 RIO3 Terminator
J4
FG R-TM
F070
24Vdc
DCIN CF50 CF10

Sync. Encoder R301
F040/F041 CF31
ENC1 R301 Machine I/O
CF33
FCUA-R211 Remote I/O unit FCUA-R211 Remote I/O unit

Sensor signals (SH41) (SH41) To next unit or
SKIP RIO1 RIO1 RIO2 RIO1 RIO2
Max. 8 pints terminator
DX101 DX101
Aio DCIN DCIN
SH21 24Vdc 24Vdc
SV1 Base I/O
Spindle/Servo Machine I/O Machine I/O
Drives Unit
HR353
RIO2
SH21
SV3
SH21 RIO4-1 F260
YMW
HR371
SV2-1 Machine I/O

SH21 RIO4-2 F260 24Vdc I/O board
SV2-2
SH21 RIO4-3 Max. 8 channels
SV2-3
SH21 YMW
HR371
SV2-4 RIO4-4 Machine I/O

Spindle/Servo 24Vdc I/O board
Drives
F070
24Vdc
DC24V CF55
SV4#1 RIO5#1 F260
YMW
HR371
F260 Machine I/O

SV4 is not used SV4#3 RIO5#3 Max. 8 channels
YMW
HR371
SV4#4 RIO5#4 Machine I/O

separator
24Vdc
F070 SH21 HR021 F260
RIO6#1 YMW
HR371
F260 Machine I/O

DC24V SV_IN Max. 8 channels
SH21 RIO6#3
SV#1
Signal YMW
HR371
SH21 RIO6#4 Machine I/O

SV#2
SH21 separator 24Vdc I/O board
SV#3
SH21 HR023
SV#4
Note 1 The noise resistance of most of PS/2 mice and PC keyboards are lower than the CNC system. Please follow
notes in Chapter 7 If using those devices.
Note 2 Use FCUA-R211 cable or equivalent for RIO cable.
SH41 can be used short length between RIO unit in same cabinet inside.
Note 3 Use F010 and F012 cables between CNC unit and Base I/O unit for M640MT Pro. F017 cable can not be
used for M640MT Pro because the servo system allocation is different from M640M Pro.
4-2
4.2 Connector Layout Drawing
4.2.1 Connectors, Switches and LEDs Layout Drawing of Control Unit
FAN1 FAN2
INV
DCIN
DCOUT
CBAT01
DCRST CBUS2
SLOT2
SLOT1
CMEM
CCPU
RTEXT
PSEMG
BATALM
CMAC202#1
CMAC202#2
WDEN
LCD
CMAC302#1
CMAC302#2
CMAC302#3
M50
NCRST NCLD1 NCSYS CF10 ENC2 CF50 CF55 HD FDD HDD CF15 PCRST
Front view
DCIN
CF01
Bottom view
Name indicates connectors.

Name indicates switches (rotary switches, push switches).
Name indicates LEDs.
4-3
4.2.2 Connectors, Switches and LEDs Layout Drawing of keyboard unit
SW1 LED2 LED1 J2 CF25 THM CF15 ON/OFF NCKEY
MOUSE2
KEYBOARD
MOUSE2
KEYBOARD
EMG DCIN CF24 J4 CF21 CF22 HANDLE PARALLEL J3 RIO3 MOUSE2 / KEYBOARD OPMS CR31
Name indicates connectors.

Name indicates switches (rotary switches, push switches).
Name indicates LEDs.
4-4
4.3 Connector Pin Assignment
4.3.1 Control Unit Connector Pin Assignment
IO Interface 1 I/O TXRX1 26 I/O TXRX1* RIO1

25 1 2 I/O TXRX2 27 I/O TXRX2* RIO2
CF10 3 0V 28 0V
4 I SKIP1 29 I SKIP1*
50 26 6 I SKIP3 31 I SKIP3*
7 I SKIP4 32 I SKIP4* SKIP
<Cable side connector type> 9 I SKIP6 34 I SKIP6*
Plug : 10150-6000EL 10 I SKIP7 35 I SKIP7*
Shell : 10350-3210-000 11 I SKIP8 36 I SKIP8*
12 0V 37 0V
Recommended Maker : Sumitomo 3M 13 I ENC1A 38 I ENC1A*
14 I ENC1B 39 I ENC1B* ENC1
15 I ENC1Z 40 I ENC1Z*
16 0V 41 0V
17 O SVTXD2 42 O SVTXD2*
18 I SVALM2 43 I SVALM2*
SV2
19 I SVRXD2 44 I SVRXD2*
20 O SVEMG2 45 O SVEMG2*
21 0V 46 0V
SV1
25 O SVEMG1 50 O SVEMG1*
IO Interface 10 1
1 0V 11 0V
CF50 3 I SVALM3 13 I SVALM3*
20 11 5 0V 15 0V
6 O RTS4 16 O RTS4*
<Cable side connector type> 7 O SVEMG3 17 O SVEMG3*
Plug : 10120-6000EL 8 NC 18 NC
Shell : 10320-3210-000 9 I/O TXRX4 19 I/O TXRX4*
10 NC 20 NC
Recommended Maker : Sumitomo 3M
IO Interface 10 1
1 0V 11 0V
CF55 3 I SVALM4 13 I SVALM4*
20 11 5 0V 15 0V
6 O RTS5 16 O RTS5*
Plug : 10120-6000EL 8 I/O TXRXD5 18 TXRXD5*
Shell : 10320-3210-000 9 O RTS6 19 O RTS6*
10 I/O TXRXD6 20 I/O TXRXD6*
Recommended Maker : Sumitomo 3M
Sync. Feed Encoder 5 1 1 I ENC2A

6 I ENC2A*
2 I ENC2B
7 I ENC2B*
ENC2 3 I ENC2Z
8 I ENC2Z*
4 0V
9 +5V
5 0V
9 6
<Cable side connector type>

Connector : CDE-9PF
Contact : CD-PC-111
Case : HDE-CTH
Recommended Maker : Hirose
4-5
Floppy Disk Drive A B
1 0V 1 0V
FDD 1B 20B 2 +5V 2 +5V
3 +5V 3 +5V
4 NC 4 DENSEL
5 NC 5 NC
1A 20A 6 NC 6 NC
7 0V 7 INDEX
<Cable side connector type> 8 0V 8 DR0
0V
Connector : 7940-6500SC 9 9 DR1
10 0V 10 DR2
Recommended Maker : Sumitomo 3M 11 0V 11 MTON
12 0V 12 DIR*
13 0V 13 STEP*
14 0V 14 WDATA*
15 0V 15 WGATE*
16 0V 16 TRK0*
17 0V 17 WP*
18 0V 18 RDATA*
19 0V 19 HDSEL*
20 0V 20 DSKCHG*
Hard Disk Drive A B

1 O BRSTDRV* 1 0V
HDD 1B 22B 2 I/O DD7 2 I/O DD8
3 I/O DD6 3 I/O DD9
4 I/O DD5 4 I/O DD10
1A 22A 6 I/O DD3 6 I/O DD12
<Cable side connector type> 8 I/O DD1 8 I/O DD14
Connector : FCN-727B044-G/LM-D 9 I/O DD0 9 I/O DD15
10 0V 10 NC
Recommended Maker : Fujitsu 11 I DDRQO 11 0V
12 I/O DIOW* 12 0V
13 I/O DIOR* 13 0V
14 I/O IORDY 14 Pull-up
15 O DDAK0* 15 0V
16 I IRQ14 16 I IOCS16*
17 I/O DA1 17 NC
18 I/O DA0 18 I/O DA2
19 O CS1P* 19 O CS3P*
20 O IDEACTPP* 20 0V
21 +5V(Logic) 21 +5V(Motor)
22 0V 22 NC
LCD Inverter 6 1 <Cable side connector type> 1 0V

Connector : 51030-0630 2 I BLOFF*
INV Contact : 50083-8160 3 O TTL-BLOFF*
4 O OC-BLOFF*
Recommended Maker : MOLEX 5 O BRT
6 +12V
FAN 1 3 <Cable side connector type> 1 +12V

Connector : 51004-0300 2 0V
FAN1/FAN2 Contact : 50011-8000 3 I Sensor
Recommended Maker : MOLEX
DC24V Input 1 3 <Cable side connector type> 1 +24V

Connector : 2-178288-3 2 0V
DCIN Contact : 1-175218-5 3 FG
Recommended Maker : AMP
4-6
Power Off Ditection 2 1 <Cable side connector type> 1 0V
Connector : 51030-0230 2 ACFAIL
CF01 Contact : 50084-8160
CAUTION Do not supply voltages other than those indicated in this manual on the connector.
Doing so may lead to destruction or damage.
Incorrect connections may damage the devices, so connect the cables to the specified
connectors.
4.3.2 Keyboard Unit Connector Pin Assignment
RS232C 13 1 1 NC Signal explanation

14 O SD2
2 O SD1 SD :Send data
15 O ER2
CF21 3 I RD1 RD :Receive data
16 I RD2
4 O RS1 RS :Request to send
17 I CS2
5 I CS1 CS :Clear to send
25 14 18 NC
6 I DR1 DR :Data set ready
19 O RS2
7 0V ER :Data terminal ready
20 O ER1
8 NC
Connector : CDB-25P 9 NC
21 I DR2
22 NC
Contact : CD-PC-111 10 NC
23 NC
Case : HDB-CTH 11 NC
24 0V
12 NC
Recommended Maker : Hirose 13 NC
25 Reserve
RS232C 13 1 1 NC Signal explanation

14 O SD4
2 O SD3 SD :Send data
15 O ER4
CF22 3 I RD3 RD :Receive data
16 I RD4
4 O RS3 RS :Request to send
17 I CS4
5 I CS3 CS :Clear to send
25 14 18 I CD4
6 I DR3 DR :Data set ready
19 O RS4
7 0V ER :Data terminal ready
20 O ER3
8 I CD3
Connector : CDB-25P 9 I RI3
21 I DR4
22 I RI4
Contact : CD-PC-111 10 NC
23 NC
Case : HDB-CTH 11 0V
24 0V
12 Reserve
Recommended Maker : Hirose 13 NC
25 Reserve
Printer 13 1 1 I/O PSTB*

14 I/O PAFD*
2 I/O PD0
15 I PERR*
PARALLEL 3 I/O PD1
16 I/O PINIT*
4 I/O PD2
17 I/O PSLIN*
5 I/O PD3
25 14 18 0V
6 I/O PD4
19 0V
7 I/O PD5
20 0V
8 I/O PD6
Connector : CDB-25P 9 I/O PD7
21 0V
22 0V
Contact : CD-PC-111 10 I PACK*
23 0V
Case : HDB-CTH 11 I PBUSY
24 0V
12 I PEND
Recommended Maker : Hirose 13 I PSLCT
25 0V
DC24V Input 1 3 <Cable side connector type> 1 +24V

Connector : 2-178288-3 2 0V
DCIN Contact : 1-175218-5 3 FG
Recommended Maker : AMP
4-7
Manual pulse 8 1 1 I 1HA
9 0V
Genarator 2 I 1HB
10 O +12V
3 I 2HA
11 0V
4 I 2HB
HANDLE 12 O +12V
5 I 3HA
15 9 13 0V
6 I 3HB
14 O +12V
7 NC
15 NC
8 NC
Connector : CDB-15P
Contact : CD-PC-111
Case : HDA-CTH
Recommended Maker : Hirose
Remote ON/OFF 1 5 <Cable side connector type> 1 NC

Connect to Connector : 3-178127-6 2 P-OFF
PD25 Contact : 1-175218-5 3 I LG-OFF
4 LG-ON
Recommended Maker : AMP 5 I P-ON
CF24
Remote ON/OFF 1 5 <Cable side connector type> 1 NC

Connect to Connector : 3-178127-6 2 P-OFF
switches Contact : 1-175218-5 3 I LG-OFF
4 LG-ON
Recommended Maker : AMP 5 I P-ON
ON/OFF
Emergency Stop 3 1 <Cable side connector type> 1 FG

Connector : 51030-0330 2 I EMG IN
EMG Contact : 50084-8160 3 O COM
HDD Heater 4 1 <Cable side connector type> 1 +24V

Connector : 51030-0430 2 RG
CF25 Contact : 50084-8160 3 FG
4 NC
HD Temperature Sensor 2 1 <Cable side connector type> 1 THM-1

Connector : 51030-0230 2 THM-2
THM Contact : 50084-8160
PC Keyboard 6 5
<Cable side connector type> 1 I/O DATA
Connector : Mini DIN 6P 2 NC
KEYBOARD 3 0V
4 3 4 O +5V
5 I/O CLK
2 1 6 NC
External Mouse 6 5
<Cable side connector type> 1 I/O DATA
Connector : Mini DIN 6P 2 NC
MOUSE2 3 0V
4 3 4 O +5V
5 I/O CLK
2 1 6 NC
4-8
Mouse Selection 5 1 <Cable side connector type> 1 I OPMS*
Connector : 51030-0530 2 0V
OPMS Contact : 50084-8160 3 0V
4 I TPOFF*
Recommended Maker : MOLEX 5 NC
Machine
J3 J4
Operation
Panel B1 B20 B1 B10
A1 A20 A1 A10
<Cable side connector type> <Cable side connector type>

Connector HIF4-40D-3.18R Connector HIF4-20D-3.18R
Recommended Maker Hirose Recommended Maker Hirose
B A B A
20 I X0 20 I X10 10 NC 10 O Y1A
19 I X1 19 I X11 9 NC 9 O Y1B
18 I X2 18 I X12 8 O Y12 8 O Y1C
17 I X3 17 I X13 7 O Y13 7 O Y1D
16 I X4 16 I X14 6 O Y14 6 O Y1E
15 I X5 15 I X15 5 O Y15 5 O Y1F
14 I X6 14 I X16 4 O Y16 4 I +24V
13 I X7 13 I X17 3 O Y17 3 I +24V
12 I X8 12 I X18 2 O Y18 2 0V
11 I X9 11 I X19 1 O Y19 1 0V
10 I XA 10 I X1A
9 I XB 9 I X1B
8 I XC 8 I X1C
7 I XD 7 I X1D
6 I XE 6 I X1E
5 I XF 5 I X1F
4 NC 4 NC
3 +24V/RG 3 +24V/RG
2 I +24V 2 0V
1 I +24V 1 0V
connectors.
4-9
4.4 Connection of Various Devices
4.4.1 Connection of Floppy Disk Unit
(1) Connection of F132 Cable

Connect the F132 cable attached to the floppy disk unit to the connector "FDD" of the control unit. Refer to
"4.2.1 Control Unit Connectors, Switches and LEDs Layout Drawing" for position of connector "FDD".
Connect the F132 cable and floppy disk drive as shown figure below. Place the PCB side downward and face
the connector polarity key upward when inserting.
Control unit
Floppy disk unit
Rear side of floppy disk drive
F132 cable Signals
FDD
PCB side
Power
Polarity key
F132 cable
(2) Installation of Floppy Disk Unit
Install the Floppy Disk unit horizontal or vertical direction as shown in the figure below.
In case of horizontal installation: LED and eject key must be below as shown in the figure below.
Inclination: 25 degree or less as shown in the figure below.
Do not lean the drive face. (Should be 0 degree)
Vertical installation Horizontal installation
Front bezel
25
25
LED Eject key
Incorrect connections may damage the devices, so connect the cables to the
specified connectors.
4-10
4.4.2 Connection of Hard Disk Drive
(1) Connection of F140 cable
Three cables are attached to the hard disk unit. Refer to the Control unit F140 cable Hard disk unit
right figure for the positions of the each cable connection. Flat type
Refer to Chapter 4 for the positions of the HDD connector,
HDD
the HEATER connector and the THM connector.
(Reference item : 4.2.1 Connectors, Switches and LEDs
Layout Drawing of Control Unit, 4.2.2 Connectors, Switches Keyboard unit
and LEDs Layout Drawing of keyboard unit)
HEATER
Use the attached F140 cable that it has the unit
THM
attached. The maximum cable length is 500mm.
Connection of the control unit and F140 cable Connection of the hard disk drive and F140 cable
The connector key

faces downward.
Polarity Key
Red wire
Red wire
(2) Handling of the hard disk unit

Cautions of general handling
Since the hard disk is precision apparatus, be careful of handling.
Do not remove the hard disk unit from the keyboard unit.
Be careful not to give a strong shock or vibration against the keyboard unit.
Cautions of handling exchangefor service person

When the hard disk unit needs to be replaced by the life or failure, please observe the following points.
When you remove the hard disk unit from the keyboard unit, be careful not to make it fall.
Do not use the hard disk unit dropped accidentally.
Do not disassemble the hard disk unit.
Put the hard disk unit removed from the keyboard unit on the stable place.
When you deal with two or more hard disk units, do not stack the unit on another unit or stack them on top of it.
Connect or disconnect the F140 cable straight. And connect the F140 cable as the caution label.
Never touch the connector of the hard disk drive with a finger at the time of the F140 cable connection.
Convey and carry the hard disk in the state of the unit.
Recommendation for data backups

Since the hard disk drive has a limited life, take preventive steps such as backing up data etc. without exception in
order to prevent etc. in cases where data loss may result in loss or damage. Mitsubishi corporation will exchange
the hard disk unit, but make no warranty of damages which may be caused by data loss or errors.
4-11
(3) Cable holder
The cable holder which fixes F140 cable attached with the hard disk unit and F132 cable attached with the
floppy disk unit is prepared on the control unit. After connecting those cables, close the cable holder to
prevent the cables coming off.
Cable holder
CAUTION Do not apply voltages other than those indicated in this manual on the connector.
connectors.
4-12
4.4.3 Connection of PC Card (CardBus)
(1) PC card specifications
Standards PC Card Standard 95/97 compliance (CardBus)
PC Card Standard compliance (PCMCIA_V2.1, JEIDA_4.2compliance)
No. of slots 2 slots Type I/II Up to two cards can be used.
Type III One card can be used.
PC card power (Vcc) DC5V, 1000mA/slot
Program power (Vpp) DC12V, 120mA/slot
(Note 1) PC card thickness Type I (3.3mm), Type II (5.5mm), Type III (10.5mm)
(Note 2) 5V or 5V / 3.3V only can be used.
(2) Handling of PC card

Since the PC card is precision apparatus, be careful of handling.
Precautions for storage
(a) Do not store the PC cards where temperature is extremely
high or change in temperature is sharp.
(c) Do not store the PC cards where they will be subject to PC card
direct sunlight or near heating appliances. Eject button

(d) Do not store the PC cards where a shock
and vibration are added. PC card slot
(e) Do not store the PC cards where appliances
generating strong magnetism and a strong
radio wave is near.
(magnet, display, speaker, radio, radio
machine etc.)
Precautions for handling
(a) Do not remove the PC card during access
to it, since the data on the PC card may be
erased.
(b) The PC card has the maximum number
of times of rewriting. It may not operate,
when rewriting beyond the number.
(3) Insertion and extraction of the PC card

The PC card is inserted in the PC card slot
behind the control unit as the right figure.
Please keep a space of 50mm or more at the
top of the control unit to insert or extract the
PC card.
When connecting the cable to the PC card,
more space for the cable is required. There is direction in the PC card.
Please insert the PC card in the slot without attaching an impossible angle. When extracting the PC card,
push the eject button.
(4) The problem a CardBus type PC card is not detected

There are some CardBus type PC cards which are not detected normally under the condition that other PC
card is used.
Refer to section "7.2.2 CardBus PC Cards" regarding this problem. How to avoid the problem is indicated in
that section.
4-13
4.4.4 Connection of PC Card in front of Control Unit
(1) IC card specifications

Standards PC Card Standard ATA compliance ( Only the memory card can be used. )
No. of slots 1slotType I/II
IC card power (Vcc) DC5V660mA
Program power (Vpp) DC12V100mA
(Note1) IC card thickness Type I (3.3mm), Type II (5.5mm)
Type III (10.5mm) cannot be used.
(Note2) 5V or 5V / 3.3V only can be used.
(2) Handling of the IC card

Since the IC card is precision apparatus, be careful of handling.
Precautions for storage
(a) Do not store the IC cards where temperature is extremely high or change in temperature is sharp.
(c) Do not store the IC cards where they will be subject to direct sunlight or near heating appliances.
(d) Do not store the IC cards where a shock and vibration are added.
(e) Do not store the IC cards where appliances generating strong magnetism and a strong radio wave
is near. (magnet, display, speaker, radio, radio machine etc.)
Precautions for handling

(a) Do not remove the IC card during access to it, since the data on the IC card may be erased.
(b) The IC card has the maximum number of times of rewriting. It may not operate, when rewriting
beyond the number.
IC card
4-14
(3) Insertion of IC card
Be careful in the insertion direction.
Insert the IC card as shown in the following figure.
Open the card slot cover.
In the direction shown on the IC card, insert the IC card into the slot. (Do not give an impossible
angle, and push the IC card in along the slot to the end.)
Flip the eject button to the side.
Note If the cover is closed without the eject button flipped, the eject button will be pushed by
the cover and the IC card will be extracted.
Open the card Flip the eject

slot cover. button to the side.
The state the eject
button stands
Card slot cover
IC card
Insert the IC
card.
Close the card slot cover.
(4) Extraction of IC card

Open the card slot cover.
Pull the eject button.
Push the eject button without an impossible angle.
Extract the IC card which pushes out by hand.
Close the card slot cover.
(NOTE) Keep closing the card slot cover except the time of insertion and extraction of the IC card to
prevent dust getting into the unit.
4-15
4.4.5Connection of PS/2 Mouse
Although the tablet pointer of the front of the keyboard unit
serves as a standard PC pointing device, the external PS/2
mouse is selectable.
The connection between terminals of the OPMS connector
on the back of the keyboard unit performs the change of
the tablet pointer and the external PS/2 mouse. If a switch
is connected between terminals, it can switch easily.
Moreover, double click operation effective / non-effective Tablet pointer
on the pad of a tablet pointer can be set up. Similarly, it
sets up by connection between terminals of the OPMS
connector.
Refer to section "4.2.2 Connectors, Switches and LEDs External PS/2
mouse
Layout Drawing of keyboard unit" for the positions of the
MOUSE2 connector and the OPMS connector.
keyboard unit
MOUSE2 External PS/2 mouse
OPMS Mouse select switch
OPMS
OPMS* 1 OPMS 1-2 open Tablet pointer effective
GND 2 OPMS 1-2 short External PS/2 mouse effective
GND 3 OPMS 3-4 open Double click operation effective (Tablet pointer)
TPOFF* 4 OPMS 3-4 short Double click operation non-effective (Tablet pointer)
N.C. 5
(Note 1) Do not connect or disconnect terminals of the OPMS connector each other, while the power is
ON.
(Note 2) When an external switch performs mouse change and double click effective / non-effect,
please use the switch corresponding to minute current (10uA).
(Note 3) Observe notes of Chapter 7 strictly, when you use the PS/2 mouse, since it is weak in a noise
as compared with NC.
4.4.6Connection of PS/2 Keyboard and Parallel Device
The PS/2 keyboard and parallel device can be used as devices of pc.
keyboard unit
KEYBOARD Keyboard (Note 1) Do not connect or disconnect terminals

of the OPMS connector each other, while
PARALLEL Printer etc. the power is ON.
(Note 2) Observe notes of Chapter 7 strictly, when

Refer to section "4.2.2 Connectors, Switches and LEDs you use the PS/2 mouse, since it is weak
Layout Drawing of keyboard unit" for the positions of the in a noise as compared with NC.
KEYBOARD connector and the PARALLEL connector.
CAUTION Do not apply voltages other than those indicated in this manual on the connector.
connectors.
4-16
4.4.7 Connection of RX322-1
The RX322-1 card is a I/O card which has 32 keyboard unit

inputs and 16 outputs. This card is used in
order to add the I/O signals to the operation
panel. CR31
The following parts are enclesed at the time of
delivery.
RX322-1 card Spacer
Sheet matal bracket
Spacer
Extension cable (F332 cable
Attach to the rear of the NC keyboard unit as
the right figure.
Sheet metal bracket
RX322-1 card
keyboard unit
Cable attached with RX322-1
Extension cable
F332
CR32
Connect the extension cable

CR31 (F322) to the CR31 cnnector RX322-1
on the keyboard unit.
CR21 CR22
RX322-1 Connector Pin Assignment

CR21 (DI) CR22 (DO)
B1 B20 B1 B20
A1 A20 A1 A20
Cable side connector type Cable side connector type

Connector 7940-6500SC Connector 7940-6500SC
Recommended maker Sumitomo 3M Recommended maker Sumitomo 3M
B A B A
20 I X20 20 I X30 20 O Y20 20 NC
19 I X21 19 I X31 19 O Y21 19 NC
18 I X22 18 I X32 18 O Y22 18 NC
17 I X23 17 I X33 17 O Y23 17 NC
16 I X24 16 I X34 16 O Y24 16 NC
15 I X25 15 I X35 15 O Y25 15 NC
14 I X26 14 I X36 14 O Y26 14 NC
13 I X27 13 I X37 13 O Y27 13 NC
12 I X28 12 I X38 12 O Y28 12 NC
11 I X29 11 I X39 11 O Y29 11 NC
10 I X2A 10 I X3A 10 O Y2A 10 NC
9 I X2B 9 I X3B 9 O Y2B 9 NC
8 I X2C 8 I X3C 8 O Y2C 8 NC
7 I X2D 7 I X3D 7 O Y2D 7 NC
6 I X2E 6 I X3E 6 O Y2E 6 NC
5 I X2F 5 I X3F 5 O Y2F 5 NC
4 NC 4 NC 4 NC 4 NC
3 +24V/RG 3 +24V/RG 3 NC 3 NC
2 I +24V 2 0V 2 I +24V 2 0V
1 I +24V 1 0V 1 I +24V 1 0V
4-17
4.4.8 Connection of Power Supply
The PD25 power supply is used to protect the hard disk.

By outputting +24V for 300msec after the 200VAC is turned off, turning off of the power during writing to the
hard disk can be prevented.
(1) Power Supply System Drawing
RST
INV Refer to Appendix 2 for the

Circuit breaker
TFT F110 cable and the F171
ENC2 Control Unit FDD cable.
ON OFF CF55
F110 HDD
DCIN
MC CF10
CF01
F140
CF15 CF50
MC
ON F172
MC ON/OFF CF25 THM J2
CF15
OFF
F070 HANDL
24VDC DCIN E
PD25
DCOU F171 HDD
CF24
T Unit CF21
ACIN CF22
ON/OFF
Circuit
CR22 CR21
breaker KEYBOARD
EMG
RX322-1 MOUSE2
OPMS
J3 CR31 PARALLEL
Keyboard Unit RIO3
J4
(2) Unit specification
Item Specification (Note) The power cannot be turned ON immediately after

Input 200VAC/230VAC (-15%+10%) the PD25 power has been turned OFF.
Output 24VDC 3A Wait approx. two seconds before turnning the power
Size 130mm65mm230mm ON.
Back up time 300ms
(3) Connector layout and pin assignment
ACIN : 200VAC input

1 ACIN N Cable side connector type
2 ACIN H Connetor 2-178128-3
ACIN
3 FG Contact 1-175218-5
Recommended maker AMP
ON/OFF SW : Swich ON (upword) --- 24VDC output

Swich OFF (downword)--- 24VDC output OFF
ON/OFF : Connect to the escutcheon ON/OFF switch
ON/OFF SW 1 NC Cable side connector type
2 P-OFF Connetor 1-178288-5
ON/OFF 3 0V Contact 1-175218-5
POWER
4 0V Recommended maker AMP
5 P-ON
DCOUT
POWER : Green lamp lights during +24V output

DCOUT : Left connector --- 24VDC output
Right connector --- Power off detection signal (ACFAIL) output
A (X) B (Y) Cable side connector type

1 ACFAIL +24V Connetor 3-178128-6
2 0V 0V Contact 1-175218-5
3 FG FG Recommended maker AMP
4-18
(4) Installation direction and spacing
Install the external power supply unit Top
vertically so that the front surface is visible. 100mm
Provide the space around the unit for heat

radiation and ventilation.
20mm 20mm
100mm
Bottom
(5) Connection of ON/OFF Switch
Keyboard unit
ON/OFF
1 NC
2 POWER ON
3 0V
4 POWER CUT
5 +24V
Cable side connector type

Connector 1-178288-5
Contact 1-175218-5
Recommended maker AMP (Note) "A" type contact switches are required for both
the ON switch and OFF switch.
WARNING Do not damage, apply excessive stress, place heavy things on or sandwich the
cables, as this may lead to electric shocks.
CAUTION ! Separate the signal wire from the drive line/power line when wiring.
Do not connect or disconnect the connection cables between each unit while the
power is ON.
connectors.
4-19
4.4.9 Connection of Signal Separator Cards
The following two types of cards are available as the additional star-connection type signal separator for the
auxiliary axis servo drive unit MR-J2-CT and the remote I/O.
Card name Function
HR021 Auxiliary axis servo drive unitStar type separator of SV System-4.4 branches with 1 system
Remote I/OStar type separator of RIO System-5, RIO System-6.4 branches with 1 system
HR023 Separator of auxiliary axis servo lineSeparating 1 line into 4 branches.
(1) Connection Diagram

F012
F070
24Vdc
CF55 SV System-4 DC24V CF55

SH21 F260
SV4#1 RIO5#1 YMW
HR371
SH21 F260 Machine I/O RIO System-5
SH21 Max. 8 channels
SV4#3 RIO5#3
SH21 YMW
HR371
CNC Unit SV4#4 RIO5#4 Machine I/O
separator
FCU6-MA651-33
(Note) The SV System-4 is not used HR021 F260
FCU6-MA651-34 RIO6#1 YMW
HR371
for M640MT Pro. F260 Machine I/O RIO System-6
RIO6#3 Max. 8 channels
YMW
HR371
RIO6#4 Machine I/O
24Vdc I/O board
Auxiliary axis servo line SH21

from SV System-2 or SV System-4
F070
24Vdc
DC24V SV_IN
SH21
SV#1
Signal SH21
SV#2
separator SH21
SV#3
HR023 SH21
SV#4
(2) Addition of Optional card into Control unit

For the expansion of the optional auxiliary axis servo drive unit and Remote I/O by the HR201, the option
cards need to be added to the control unit.
HR063 #1
for RIO System-4
HR061 #1 standard
for SV System-3
standard
HR063 #2
for RIO System-5
option
HR061 #2
for SV System-4 HR063 #3
(option) for RIO System-6
(Only for M640M Pro) option
4-20
(3) HR021 card Connector Layout Drawing and Pin Assignment
DC24V
CF55
RIO5#4 RIO5#3 RIO5#2 RIO5#1
RIO6#4 RIO6#3 RIO6#2 RIO6#1

SV4#1 SV4#2 SV4#3 SV4#4
1 3
DC24V input Cable side connector type 1 +24V
Connector : 2-178288-3 2 0V
DC24V Contact : 1-175218-5 3 FG
Recommended maker : AMP
Remote I/O 1 3 Cable side connector type 1 I/O TXRX1

Connector : 1-178288-3 2 I/O TXRX1*
RIO5#1~4 3 0V
Contact : 1-175218-2
RIO6#1~4
IO interface 10 1
1 0V 11 0V
2 I SVTXD4 12 I SVTXD4*
CF55 3 O SVALM4 13 O SVALM4*
4 O SVRXD4 14 O SVRXD4*
20 11 5 0V 15 0V
6 I RTS5 16 I RTS5*
Cable side connector type 7 I SVEMG4 17 I SVEMG4*
Plug : 10120-6000EL 8 I/O TXRXD5 18 I/O TXRXD5*
Shell : 10320-3210-000 9 I RTS6 19 I RTS6*
10 I/O TXRXD6 20 I/O TXRXD6*
Recommended maker : 3M
Servo drive unit 10 1

1 0V 11 0V
System-4 2 O SVTXD4 12 O SVTXD4*
Dedicated for MR-J2-CT 3 I SVALM4 13 I SVALM4*
20 11 5 0V 15 0V
SV4#1 6 NC 16 NC
SV4#2 Cable side connector type 7 O SVEMG4 17 O SVEMG4*
SV4#3 Plug : 10120-6000EL 8 NC 18 NC
Shell : 10320-3210-000 9 NC 19 NC
SV4#4 10 NC 20 NC
4-21
(4) HR023 card Connector Layout Drawing and Pin Assignment
DC24V
SV_IN
SV#1 SV#2 SV#3 SV#4
1 3
DC24V input Cable side connector type 1 +24V
Connector : 2-178288-3 2 0V
DC24V Contact : 1-175218-5 3 FG

1 0V 11 0V
Signal input 2 I SVTXD 12 I SVTXD*
3 O SVALM 13 O SVALM*
4 O SVRXD 14 O SVRXD*
SV_IN 20 11 5 0V 15 0V
6 NC 16 NC
Cable side connector type 7 I SVEMG 17 I SVEMG*
Plug : 10120-6000EL 8 NC 18 NC
Shell : 10320-3210-000 9 NC 19 NC
10 NC 20 NC

1 0V 11 0V
Star type separation 2 O SVTXD 12 O SVTXD*
Dedicated for MR-J2-CT 3 I SVALM 13 I SVALM*
4 I SVRXD 14 I SVRXD*
20 11 5 0V 15 0V
SV#14 6 NC 16 NC
Cable side connector type 7 O SVEMG 17 O SVEMG*
Plug : 10120-6000EL 8 NC 18 NC
Shell : 10320-3210-000 9 NC 19 NC
10 NC 20 NC
4-22
4.4.10 Connection of Manual Pulse Generator
Up to three manual pulse generators can be connected. Connect the F020/021/022 cable to "HANDLE"
on the keyboard unit.
Refer to the section "4.2.2 Keyboard unit connector,switch and LED layout drawing" for position of
"HANDLE" connector. And refer to "Appendix 2" for the F020/021/022 Cable.
NO.1
Manual pulse generator

12V 0V A B
HD60
When connecting one Rear view
Keyboard unit manual pulse generator
4-M3
F020 cable
HANDLE
NO.2 NO.1
12V 0V A B 12V 0V A B
When connecting two
manual pulse generators
4-M3
F021cable
NO.3 NO.2 NO.1
12V 0V A B 12V 0V A B 12V 0V A B

When connecting three
manual pulse generators
4-M3
F022cable
Input/output conditions Input/output circuit

Input pulse signal type 90 degree phase difference between +5V
A phase and B phase.
Connector
(Refer to waveform (e) below.) pin NO. 470
Input signal voltage H-level 3.5V ~ 5.25V HA1 1 220
L-level 0V ~ 0.5V HA2
HA3
3
5
Max. input pulse frequency 100kHz 4700pF
Power voltage for pulse DC12V10% +5V

0V
Input
generators
Max. output current 300mA 470
No. of pulses per rotation 25pulse/rev HB1 2 220
Control
HB2 4
HB3 6 circuit
4700pF
A(B) phase
0V
+12V 10
B(A) phase +12V 12
+12V 14
a b c d e Output
0V 9
0V 11
0V 13
T
0V
a. b. c. d. e: A phase or B phase rising edge (falling edge)

phase difference = T/4 T/10
T: A or B phase cycle (Minimum 10s)
4-23
4.5 Emergency Stop
4.5.1 Connection of Emergency Stop
The external emergency stop is usable with the "EMG" connector where it is back of Keyboard unit.
Do not use the EMG connector for applications other than emergency stop.
Refer to Appendix 2 (F120 cable) for details on manufacturing the cable.
Keyboard unit
Emergency stop
switch
EMG
F120 cable
ON: Release emergency stop

OFF: Emergency stop
Interconnection the emergency stop and the motor brake
(1) Supply power from NC control unit (2) Supply power from external power supply unit
Power supply unit NC Power supply unit NC
EMG DC24V EMG DC24V
DC24V 3 DC24V 3
2 2k 2 2k
SW Emergency 330 SW Emergency 330

stop switch stop switch
CN20 MDS-B/C1 CN20 MDS-B/C1

1 1
RA RA
Brake 3 Brake 3
Notes
(1) When activate the emergency stop with sequence program not only emergency stop switch, use a
small current type switch. (5mA)
(2) Make the GND of power supply unit which supplies power to the brake and the GND of power
supply unit witch supplies power to the "DCIN" of NC control unit common.
(3) The way of connection to the brake is varied according to type of drive unit. Refer to the
corresponding specification manual.
connectors.
4-24
4.5.2 Compliance with the EN standard
Installation of the external emergency stop switch and the contactor can be met to the EN60204-1 category
1 fundamentally.
Example of the emergency stop circuit

TM1 CNC Unit
Emergency stop is the signal to make a R

EMG SV1/2
External CPU
Emergency RA1 R &
machine tool stop urgently. The emergency Switch NC Emergency ASIC
stop signal is connected to the CNC unit. If 0V
necessary, connect the emergency stop signal MBR* Servo / Spindle Hardware
Power Supply Unit
Drive Unit Emergency
to the power supply unit as well. The servo/ CN23 CN1A/B
CPU
spindle drive units make motors decelerating &
Software
ASIC
0V Emergency
stop by the software control based on the L11 L11 CPU
&
L21 ASIC
decelerating stop instruction from the CNC unit. L21
The right figure is the example of a power line MC

MC1 MC-OFF*
breaking method (EN60204-1 category 0 stop) L1 P CN20

MBR*
L2 N
that is independent of the emergency stop input Motor Brake
L3
to the CNC unit. The off delay timer (TM1) is External
AC Reactor
Contactor
used in it. The component selection and the
circuit design should be given careful
consideration because a higher safety category
may be required by the kind of the machine.
Setting time of the off delay timer (TM1)

TM1 should work after all the motors complete a decelerating stop.
When the setting time of the TM1 is shorter than a decelerating stop time, the spindle
motor gets into a free running.
tm All motors decelerating stop time
Please build a safety circuit that a power line can be cut off even if a CNC system breaks down.
When the power line is cut off forcibly, the servomotor stops with the dynamic brake, and spindle motor gets
into a free running.
Safety category of EN60204-1

- Category 0: stopping by immediate removal of power to the machine actuators.
- Category 1: a controlled stop with power to the machine actuators available to
achieve the stop and then removal of power when the stop is achieved.
Note Refer to the standard book for details.EN60204-1: Safety of machinery

Electrical equipment of machines -Part1 9.2.5.4.2
4-25
CHAPTER 5 CONNECTION OF I/O INTERFACE
5.1Outline of I/O Interface
5.1.1Types of I/O Interface
The following three types of I/O interfaces are available.

1 Base I/O unit The base I/O unit is used for connecting the servo amplifier, encoder, skip and remote I/O
unit. One unit is always required per control unit.
2 Remote I/O unit The remote I/O unit is connected to RIO1, RIO2 and RIO4-#1 to #4 on the base I/O unit.
3 Card-sized I/O The card-sized I/O has 16 points DI and 16 points DO, and size is 55mm x 93mm.
When using the card-sized I/O, the machine builder provides a connector PCB (base board)
for card-sized I/O.
1 Base I/O unit HR353 DI(Sink/Source)/DO(Source) = 32/32 SV1SV2-#1#4ENC1SKIP

RIO1RIO2RIO3-#1#4AI/O
2 Remote I/O unit FCUA-DX101 Refer to Chapter 6
3 Card-sized I/O FCU6-HR371 DI(Source)/DO(Source) = 16/16 Refer to section 5.3
Note: The remote I/O unit and the card-sized I/O cannot be used together in the same machine.
5.1.2Example of DI/DO Connection
There are three types of DI/DO as shown in section 5.1.1 "Types of I/O interface" for the M640M Pro series.
Normally one base I/O unit is used, and the remote I/O unit is connected to RIO1 or RIO2. The number of I/O
points are configured according to the user specifications.
Refer to the Chapter 6 "Connection of Remote I/O unit" for details of the remote I/O unit.
When using the card-sized I/O, the user provides a connector PCB (base board) for the card-sized I/O.
Refer to the section 5.3 "Connection of Card-sized I/O" for details.
(1) Example when using the remote I/O unit
Base I/O unit
HR353
RIO4-1 FCUA-R211
FCUA-R211
RIO4-2 RIO1
(SH41) cable
(SH41) cable
RIO4-3
FCUA-R211(SH41) cable
RIO4-4 RIO2
(2) Example when using the card-sized I/O
Card-sized I/O Card-sized I/O

Card-sized I/O
Base I/O unit
FCUA-R211 Junction box Junction box
Junction box (SH41)cable
FCUA-R211
HR353 RIO1
(SH41)cable
Card-sized I/O RIO4-1
Card-sized I/O Card-sized I/O Card-sized I/O
RIO4-2
Junction box FCUA-R211 RIO4-3 FCUA-R211 Junction box Junction box Junction box
(SH41)cable
RIO4-4 RIO2
(SH41)cable
5-1
5.2 Connection of Base I/O Unit
5.2.1 Base I/O Unit Connection System Drawing
Control unit HR353

F017 cable SH21 cable
CF10 CF10 SV1 Servo drive unit System-1
SH21 cable
CF50 CF50 SV3 Servo drive unit System-3
SH21 cable
SV2-1 Servo drive unit System-2, 1st branch
SH21 cable
SV2-2 Servo drive unit System-2, 2nd branch
FCUA-R211(SH41) cable SH21 cable
Remote I/O System-1 RIO1 SV2-3 Servo drive unit System-2, 3rd branch
FCUA-R211(SH41) cable SH21 cable
Remote I/O System-2 RIO2 SV2-4 Servo drive unit System-2, 4th branch
Remote I/O System-4, 1st branch FCUA-R211(SH41) cable RIO4-1 F040 cable
FCUA-R211(SH41) cable ENC1 Sync. encoder
Remote I/O System-4, 2nd branch RIO4-2
FCUA-R211(SH41) cable SKIP Sensor signals (Skip)
Remote I/O System-4, 3rd branch RIO4-3
FCUA-R211(SH41) cable CF31 DI
Remote I/O System-4, 4th branch RIO4-4
CF32 DO
Analog input/output AIO
DC-IN Power input
5.2.2 Base I/O Unit Connectors

Card nameHR353
SV1 Connect with the servo drive unit system-1.
SV2-1, SV2-2 Connect with the servo drive unit. Dedicated for MR-J2-CT. With the servo drive unit, multiple units can be
SV2-3, SV2-4 used within the range that the total number of occupied unit is seven or less at the SV2-1, SV2-2, SV2-3,
SV2-4.
SV3 Connect with the servo drive unit system-3.
ENC1 Connect with the encoder. When using t w o channels of encoder, connect the second channel to ENC2 of
the control unit
SKIP Connect with the sensor signals (skip). Up to eight points can be used.
RIO1 Connect with the remote I/O unit. There are t w o channels occupied on the base I/O unit, so the remaining six
channels can be used. Refer to section 6.7 Setting of channel No. when Using Multiple Remote I/O Unit for
the occupied channels.
RIO2 Connect with the remote I/O unit. Eight channels can be used. Refer to section 6.7 Setting of channel No.
when Using Multiple Remote I/O Unit for the occupied channels.
RIO4-1, RIO4-2 Connect with the remote I/O unit. Total of the channels connected to the RIO4-1, RIO4-2, RIO4-3 and RIO4-4
RIO4-3, RIO4-4 can be used up to eight channels. Refer to section 6.7 Setting of channel No. when Using Multiple Remote
I/O Unit for the occupied channels.
CF31 DI: 32 (Sink/Source)
CF33 DO: 32 (Source)
AIO Connect with analog input/output signals, Up to t w o analog output signals and four analog input signals can
be used.
DCIN Supply DC24V.
5.2.3 Base I/O Unit Connector Layout Drawing
C F33 CF31
AIO
HR353 C F50
SKIP
RIO4-4 RIO4-3 RIO4-2 RIO4-1
ENC1
RIO2
SV2-4
SV2-3 CF10
DCIN
RIO1
SV2-2 SV1
SV2-1 SV3
5-2
5.2.4 Base I/O Unit Connector Pin Assignment
DC24V Input 1 3
1 +24V
DCIN 2 0V
Connector: : 2-178288-3 3 FG
Contact : 1-175218-5
I/O Interface 1 I/O TXRX1 26 I/O TXRX1* RIO1

25 1 2 I/O TXRX2 27 I/O TXRX2* RIO2
3 0V 28 0V
CF10 4 I SKIP1 29 I SKIP1*
50 26 6 I SKIP3 31 I SKIP3*
7 I SKIP4 32 I SKIP4* SKIP
<Cable side connector type> 9 I SKIP6 34 I SKIP6*
Plug: : 10150-6000EL 10 I SKIP7 35 I SKIP7*
Shell: : 10350-3210-000 11 I SKIP8 36 I SKIP8*
12 0V 37 0V
Recommended maker : 3M 13 I ENC1A 38 I ENC1A*
14 I ENC1B 39 I ENC1B* ENC1
15 I ENC1Z 40 I ENC1Z*
16 0V 41 0V
17 O SVTXD 2 42 O SVTXD 2 *
SV2
20 O SVEMG 2 45 O SVEMG2*
21 0V 46 0V
SV1
25 O SVEMG 1 50 O SVEMG1*
I/O Interface 10 1
1 0V 11 0V
CF50
20 11 5 0V 15 0V
6 O RTS4 16 O RTS4*
<Cable side connector type> 7 O SVEMG 3 17 O SVEMG3*
Plug: : 10120-6000EL 8 0V 18 0V
9 I/O TXRX4 19 I/O TXRX4*
Shell: : 10320-3210-000
10 +5V 20 NC
Servo Drive Unit 10 1

1 0V 11 0V
System-1 4 I SVRXD1 14 I SVRXD1*
20 11 5 0V 15 0V
SV1 6 NC 16 NC
<Cable side connector type> 7 O SVEMG 1 17 O SVEMG1*
Plug: : 10120-6000EL 8 NC 18 NC
9 NC 19 NC
Shell: : 10320-3210-000 10 +5V 20 NC
Recommended maker: 3M
5-3
10 1
Servo Drive Unit 1 0V 11 0V
System-2 4 I SVRXD2 14 I SVRXD2*
(Dedicated for MR-J2-CT) 20 11 5 0V 15 0V
6 NC 16 NC
SV2-1
Plug: : 10120-6000EL 8 NC 18 NC
SV2-2 9 NC 19 NC
Shell: : 10320-3210-000
SV2-3 10 +5V 20 NC
SV2-4
Servo Drive Unit 10 1

1 0V 11 0V
System-3 3 I SVALM3 13 I SVALM3*
20 11 5 0V 15 0V
SV3 6 NC 16 NC
Plug: : 10120-6000EL 8 NC 18 NC
Shell: : 10320-3210-000 9 NC 19 NC
10 +5V 20 NC
Sync. Encoder 5 1 1 I ENC1A

6 I ENC1A*
2 I ENC1B
7 I ENC1B*
ENC1 3 I ENC1Z
8 I ENC1Z*
4 0V
9 +5V
5 0V
9 6

Connector : CDE-9PF
Contact : CD-PC-111
Case : HDE-CTH
Recommended maker : Hirose
Skip 8 1 1 0V
9 0V
2 I SKIP IN1
10 I SKIP IN2
SKIP 3 I SKIP IN3
11 I SKIP IN4
4 NC
12 NC
5 I SKIP IN5
15 9 13 I SKIP IN6
6 I SKIP IN7
14 I SKIP IN8
7 NC
<Cable side connector type> 8 0V
15 0V
Connector: : CDB-15P
Contact : CD-PC-111
Case : HDA-CTH
Recommended maker : Hirose
Remote I/O 1 3 A B
1 I/O TXRX1 1 +24V
RIO1 2 I/O TXRX1* 2 0V
B 3 0V 3 FG
RIO2
RIO4-1 <Cable side connector type>
RIO4-2 A
Connector: : 3-178127-6
RIO4-3 Contact : 1-175218-2
RIO4-4 Recommended maker : AMP
5-4
Analog I/O 10 1
1 0V 11 0V
2 I AI 0 12 I AI 1
3 I AI 2 13 I AI 3
AIO 4 NC 14 NC
20 11 5 0V 15 0V
6 NC 16 NC
<Cable side connector type> 7 O AO 0 17 O AO 1
Plug : 10120-6000EL 8 0V 18 0V
9 NC 19 NC
Shell : 10320-3210-000 10 NC 20 NC
DI/DO
CF31 CF33
B1 B20 B1 B20
A1 A20 A1 A20
<Cable side connector type> <Cable side connector type>

Connector 7940-6500SC Connector 7940-6500SC
Relief : 3448-7940 Relief : 3448-7940
Recommended maker: 3M Recommended maker: 3M
B A B A
20 I X0 20 I X10 20 O Y0 20 O Y10
19 I X1 19 I X11 19 O Y1 19 O Y11
18 I X2 18 I X12 18 O Y2 18 O Y12
17 I X3 17 I X13 17 O Y3 17 O Y13
16 I X4 16 I X14 16 O Y4 16 O Y14
15 I X5 15 I X15 15 O Y5 15 O Y15
14 I X6 14 I X16 14 O Y6 14 O Y16
13 I X7 13 I X17 13 O Y7 13 O Y17
12 I X8 12 I X18 12 O Y8 12 O Y18
11 I X9 11 I X19 11 O Y9 11 O Y19
10 I XA 10 I X1A 10 O YA 10 O Y1A
9 I XB 9 I X1B 9 O YB 9 O Y1B
8 I XC 8 I X1C 8 O YC 8 O Y1C
7 I XD 7 I X1D 7 O YD 7 O Y1D
6 I XE 6 I X1E 6 O YE 6 O Y1E
5 I XF 5 I X1F 5 O YF 5 O Y1F
4 NC 4 NC 4 NC 4 NC
3 I COM 3 I COM 3 NC 3 NC
2 I +24V 2 0V 2 I +24V 2 I 0V
1 I +24V 1 0V 1 I +24V 1 I 0V
The assignment number of I/O signals are changed according to the setting of the channel number select
switch. Refer to a PLC interface manual for detail.
connectors.
5-5
5.2.5 Installation of HR353 card
(1) Do not take out the HR353 card from an anti-static bag until install it in a cabinet. Handle the HR353 card
with an anti-static bag.
(2) When you take out the HR353 card from an anti-static bag and install it in a cabinet, you must put the anti-
static band on your wrist.
(3) Do not touch the electrical components on the HR353 card. Handle the corner of the HR353 card. (See Fig. 1)
(4) To Avoid the twist of HR353 card by screw mounting, fasten screws cross by cross. (See Fog. 2)
(5) The tip of the screw driver must not touch electrical components on the HR353 card.
(6) Connect connectors without mistake, especially be careful CF31 (Dio input) and CF33 (Dio output).
(7) Make sure the connection before power on.
2 4IN
R AL1
24IN
RAL1
5 OUT

5OU T R AL2
RAL 2
L ED LED
R IO4 -4
RI O4 -4 R IO 4 -2 R IO 4-1
R IO 4- 2 RI O4 -1
Fig.1 Handling point of the card Fig.2 Example of the order of fasten screw at the installing
5-6
5.2.6 Base I/O Unit Input/Output Specification
(1) Terminator
Connect a terminator to the final end of the remote I/O unit connected to RIO1RIO2RIO4-1 RIO4-2
RIO4-3 RIO4-4.
Terminator type: R-TM
(2) CF31 input circuit
Sink type Source type
Machine side
Machine side
2.2k +24V 2.2k
0V
2.2k +24V 2.2k
0V
2.2k +24V 2.2k
0V
Input
2.2k +24V 2.2k
circuit
0V
2.2k +24V 2.2k
0V
A3 Control A3 Control
+24V
B3 COM circuit B3 COM circuit
32points 32points
0V
HR353 HR353
Input voltage when external contact is ON 6V or less Input voltage when external contact is ON 18V or more, 25.2V or less
Input current when external contact is ON 9mA or more Input current when external contact is ON 9mA or more
Input voltage when external contact is OFF 20V or more, 25.2V or less Input voltage when external contact is OFF 4V or less
Input Input current when external contact is OFF 2mA or less Input current when external contact is OFF 2mA or less
condition Permissible chattering time 3ms or less (Refer to T1 below) Permissible chattering time 3ms or less (Refer to T1 below)
Input signal hold time 40ms or more (Refer to T2 below) Input signal hold time 40ms or more (Refer to T2 below)
Input circuit operating delay time 3ms T3 T4 20ms Input circuit operating delay time 3ms T3T4 20ms
Machine side contact capacity +30V or more, 16mA or more Machine side contact capacity +30V or more, 16mA or more
T2 T2
T1 T1 T1 T1
External signal External signal

+24V +24V
T3 T4 T3 T4
Internal signal Internal signal
NoteInput signal hold time:"40ms or more" is the guideline, and if not held for longer than the ladder processing
cycle, the input signal will not be recognized.
5-7
(3) CF33 output circuit
Output circuit Output conditions
Machine side Insulation type Non-insulated

+24V
Rated load voltage +24Vdc
RA Maximum output current 60mA
Output delay time 40ms
R
PL The HR353 output circuit is a source type.
RA
(Note 1) When using an inductive load such as a relay, always
connect a diode (withstand voltage 100V or more, 100mA
R or more) in parallel to the load.
PL
Control (Note 2) When using a capacitive load such as a lamp, always
0V circuit connect a protective resistor (R=150) serially to the load
32points HR353 to suppress rush current. (Make sure that the current is
Source type less than the above tolerable current including the
momentary current.)
CAUTION ! When using an inductive load such as relays, always connect a diode in parallel to the
load as a noise measure.
! When using a capacitive load such as a lamp, always connect a protective resistor
serially to the load to suppress rush currents .
5.2.7 Connection of Power Supply to Base I/O Unit
Supply the +24Vdc power to the base I/O unit from the DCIN connector or I/O connectors (CF31, CF33). If
supplying the +24Vdc power from the I/O connectors (CF31, CF33), supply +24Vdc to all +24V pins.
B1 B2 B1 B2
A1 A2 A1 A2
CF33 CF31
Power supply
+24V
Supply from either
0V
HR353
0V
DC-IN
+24V FG
NoteA +24Vdc power supply is necessary for both of the sink type and source type.
5-8
5.2.8 Connection of Servo Drive Unit to Base I/O Unit
Connect the servo drive unit to SV1 (system-1) and SV2 (system-2) of the base I/O unit.
SV2, SV2-1, SV2-2, SV2-3, SV2-4 (system-2) are dedicated for the MR-J2-CT servo drive unit.
MR-J2-CT(System-2)
CN1B
CN1A Servo drive unit (System-1)
CN1A CN1A
CN1B CN1B
CN1B
HR353
CN1A
SH21cable
SV2-4
CN1B SH21cable
CN1A Servo drive unit (System-3)
SV2-3
SH21cable SH21cable
CN1A CN1A
CN1B CN1B
SV2-2 SV1
CN1B SH21cable SH21cable
CN1A
SV2-1 SV3
<Related items>
Cable drawing: Appendix 2 (SH21 cable)
Connector pin assignment: 5.2.3 Base I/O Unit Connector Pin Assignment
5.2.9 Connection of Synchronous Feed Encoder to Base I/O Unit
Connect the synchronous feed encoder to ENC1 on the base I/O unit. When connecting two encoders,
connect the second encoder to ENC2 on the control unit.
Sync. Feed Encoder
ENC1
HR353
<Related items>
Outline drawing: Appendix 2 (F040 cable)
Connector pin assignment: 5.2.4 Base I/O Unit Connector Pin Assignment (ENC1)
4.3.1 Control Unit Connector Pin Assignment (ENC2)
5-9
5.2.10 Sensor Signal (Skip) Connection
Connect the sensor signals (skip) to "SKIP" connector on the base I/O unit. The sensor signals are used to
process high-speed signals. Be sure to shield the cable.
The sensor signals are usable with either +24V common way or 0V common way.
(1) Sensor Signal (Skip) Cable
2 SKIP IN1
2.2k
10 SKIP IN2
2.2k
3 SKIP IN3
2.2k
11 SKIP IN4
2.2k
5 SKIP IN5
2.2k
13 SKIP IN6
2.2k
6
Stabilized Stabilized SKIP IN7
power supp l y power supp l y 2.2k
14
+24V +24V SKIP IN8
2.2k
FG 1,8,9,15 Control
0V 0V HR353 Circuit
In 0V common case In +24V common case
(2) Input conditions

Input voltage with the external contact ON 18V or more, 25.2Vor less Ton
Input current with the external contact ON 9mA or more
+24V
Input voltage with the external contact OFF 4V or less
Input current with the external contact OFF 1mA or less Ton 2ms
Input signal hold time(Ton) 2ms or more
Internal response time 0.08ms or less 0V
Contact capacity on Machine side 30V or more, & 16mA or more t
<Related item>
Connector pin assignment : 5.2.3 Base I/O unit Connector Pin Assignment (SKIP)
5.2.11 Outline of Analog I/O Circuit
Input signal Output signal
R
R
150 DAC 220 DAC
Circuit AI AO
AO
AI*
*
Maximum input rating 15V Output voltage -10V+10V 5%

Resolution 10V/2000 (5mV) Resolution 12bit
04095
Condition
Precision Within 25mV Load condition 10k load resistance
AD input sampling time 14.2ms(AI0)/42.6ms(AI13) Output inpedance 220
5-10
5.3 Card-sized I/O connection
5.3.1 Example of Card-sized I/O Application
The Card-sized I/O can be used as operation board I/O or electric cabinet I/O.
The connector PCB for the card-sized I/O is provided by machine builder.
Operation board I/Os

Electric cabinet I/Os Keyboard unit Connector board for Card-sized I/Os
Connector PCB for Card-sized I/Os
RIO3 DI
DI
CF15 Card-sized I/O
DO
Card-sized I/O
DO
Electric cabinet I/Os CF15
Connector PCB for Card-sized I/Os

Control unit
DI
CF10 CF50
Card-sized I/O
DO
Electric cabinet I/Os Electric cabinet I/Os

Connector PCB for Card-sized I/Os Connector PCB for Card-sized I/Os
CF10 CF50
DI DI
RIO2-1 RIO1
Card-sized I/O RIO2-2 Card-sized I/O

DO Maximum Maximum DO
RIO2-3
8 channel 6 channel
Electric cabinet I/Os RIO2-4 Electric cabinet I/Os

Connector PCB for Card-sized I/Os Connector PCB for Card-sized I/Os
Base I/O unit
DI DI
RIO2
Card-sized I/O Maximum Card-sized I/O

DO 8 channel
DO
HR353
5-11
5.3.2 Card-sized I/O Specification
(1) Outline drawing
+24V power
+5V power
DI HR37
1
DO
Communication signals
(TXRX,TXRX*)
SEL1
SEL2
(2) Basic specifications

Card name HR371 Remarks
Number of input points 16
Number of output points 16
Input/output type Source type
Size of HR361/HR371 PCB 55mm93mm
Connector for the connector PCB 9150-4500SC (50pins) 3M
Connector used in HR361/HR371 7650-5002SC (50pins) 3M
(3) Channel number setting

Card-sized I/O doesn't have rotary switch for setting a channel number. Connect SEL1~SEL3 signal pins of
connector CF30 to +5V or 0V on base PCB as shown below. The card-sized I/O occupies 1 channel.
Refer to section 6.7 "Setting a channel No. for using multiple remote I/O units" for detail of occupied channels.
Channel number Channel Channel Channel Channel Channel Channel Channel Channel
selecting signal 1 2 3 4 5 6 7 8
(Pin number) CF30-1 CF30-2 CF30-3 CF30-4 CF30-5 CF30-6 CF30-7 CF30-8
SEL1(CF30-A3) 0V +5V 0V +5V 0V +5V 0V +5V
SEL2(CF30-B3) 0V 0V +5V +5V 0V 0V +5V +5V
SEL3(CF30-A4) 0V 0V 0V 0V +5V +5V +5V +5V
(4) External power supply specification

The card-sized I/O powers (+24V and +5V) must be supplied from external power supplies. Prepare power
supplies (stabled power supply) under the following condition.
+24V +5V
Output voltage +24V 5% Output voltage +5V 5%
Ripple / noise 240mVp-p Ripple / noise 50mVp-p
Output current(per one card-sized I/O) 1A Output current(per one card-sized I/O) 0.4A
(Note) Output current is calculated as 16 points use 60mA for each.
Use a power supply which can supply the total current of +24V output.
5-12
5.3.3 Card-sized I/O Connector Pin Assignment
CF30
A B <HR371 side connector>
1 0V 1 0V Connector : 7650-5002SC
2 I/O TXRX* 2 I/O TXRX Maker recommended : 3M
3 I SEL1 3 I SEL2
4 I SEL3 4 +24V
5 NC 5 +24V <Connector PCB side connector>
6 0V 6 0V Connector : 9150-4500SC
7 O YF 7 O Y7 Maker recommended : 3M
8 O YE 8 O Y6
9 O YD 9 O Y5
10 O YC 10 O Y4
11 O YB 11 O Y3
12 O YA 12 O Y2
13 O Y9 13 O Y1 The XO and YO assignments are reference value.
14 O Y8 14 O Y0
15 0V 15 0V
When actually making the assignment, add O to
16 I XF 16 I X7 the head address.
17 I XE 17 I X6
18 I XD 18 I X5
19 I XC 19 I X4
20 I XB 20 I X3
21 I XA 21 I X2
22 I X9 22 I X1
23 I X8 23 I X0
24 0V 24 0V
25 +5V 25 +5V
CAUTION Do not supply voltages on the connector other than those indicated in this manual.
Doing so may cause bust or damage.
Incorrect connection may damage the hardware, so connect cables to the specified
connectors.
5.3.4 Notice for Patterning of Connector PCB for Card-sized I/O
(1) Terminator connection

Terminator must be used between communication lines (TXRX, TXRX*) of card-sized I/O. Connect a
terminator as shown below.
Ex.) In case 4 connectors are placed on a connector PCB for card-sized I/Os.
B2
TXRX
NC control unit Recommended resistor
(CF10, CF11 ) 100 1001% 1/4W
A2 RN14C2E101F Koa denko
TXRX*
A connector on a connector PCB for card-sized I/Os(CF30)
(2) Shielding operation on communication lines

Because communication signals of card-sized I/Os are high-speeded, they must be separated from other
signals. Shield both out sides of the signals with GND pattern, and connect the shield with 0V at several
points as shown below.
TXRX
TXRX*
5-13
5.3.5 Input/Output Circuit of Card-sized I/O
(1) Input signal
Input circuit Input condition
Machine side
Input voltage with the external contact ON 18V or more 25.2V or less
+24V
Input current with the external contact ON 9mA or more
2.2k
Input voltage with the external contact OFF 4V or less
Input current with the external contact OFF 2mA or less
2.2k Permissive chattering time 3ms or less (refer to T1 shown below)
Input signal hold time (Ton) 40ms or more (refer to T2 shown below)
Input circuit operating delay time 3msT3T416ms
Control Contact capacity on Machine side 30V or more, 6mA or more
circuit
(NOTE) Input signal hold time : "40ms or more" is a
COM HR371 guideline, and if not held for longer than the ladder
16 points
processing cycle, the input signal will not be
0V
recognized.
T2 T2
T1 T1 T1 T1
External signal External signal

+24V +24V
T3 T4 T3 T4
Internal signal Internal signal
(2) Output signal
Output circuit Output conditions
Machine side
Insulation type noninsulated
+24V Rated load voltage +24V
Saturation voltage +1.6V(Standard)
Maximum output current 60mA/1 point
Output delay time 40s
RA Output of HR371 is source type.
R
Note1Be sure to connect a diode(maximum ratings:100V or
PL more, 100mA or more) in parallel with a load if it is an
Control
inductive load.
0V circuit
Note2To limit the inrush current, be sure to connect a
16 points
HR371 resistor(R=150in series with a load if it is a capacitive
load like a lamp. Design as the current wouldn't be over
the maximum output current shown above even in a
moment.
Caution ! Be sure to connect a diode(maximum ratings:100V or more, 100mA or more)as a

measure against noise in parallel with a load if it is an inductive load.
! To limit the inrush current, be sure to connect a protection resistor in series with a
load if it is a capacitive load like a lamp.
5-14
5.3.6 Installation of Card-sized I/O
(1) Installation direction

The installation direction of the card-sized I/O is shown in the figure below. Install the card-sized I/Os with
Figure 1 way or Figure 2 way.
top
Figure 1
top
Figure 2
bottom
bottom
top
Figure 3
(NOTE)
If the card-sized I/Os are installed
horizontally, the heat will build up, so do
not install the cards as shown on the left.
bottom
(2) Installation spacing

Spacing of the installed card-sized I/Os should be 15mm or more.
Refer to Appendix 1.7 "Card-sized I/O Outline Drawing" for the outline size of a card-sized I/O and a card
holder.
5-15
5.3.7 Cable Connection
The connection between the connector PCBs with the card-sized I/Os and the base I/O unit is explained
below.
F260
RIO 1,2,4-14-4 A Communication
Card-sized I/O
F270
RIO 1,2,4-14-4 B +24V
HR371
(2) Shield
connection
Communication
Base I/O unit Connector
HR353 +24V PCB
24V power supply F261
F271
+24V F070 (3)
DC-IN Communication
Card-sized I/O
0V (1)
FG
FG +24V
HR371
Shield
connection
Communication
Connector
+24V PCB
F261
F271
(3)
Communication
Card-sized I/O
+24V
HR371
See "Note"
Communication
(1) Cable between 24V power supply Connector
+24V PCB
and base I/O unit
The last channel
Connect with F070 cable. Refer to the Appendix
2 for the F070 cable production.
(2) Cable between base I/O unit and connector PCB
Connect with two cables of the F260 cable (communication) and the F270 cable (+24V). Refer to the
Appendix 2.19 and 2.21 for the F260 and the F270 cable production.
For the both cables, a grounding method of the cable shielding is different depending on the number of
the connector PCBs. If only one connector PCB is used, the cable shielding is connected with FG
(chassis). If two or more connector PCBs are used, the cable shielding is connected with the cable
shielding of the next cable but not connected with FG (chassis).
(3) Cable between connector PCBs

Connect with two cables of the F261 cable (communication) and the F271 cable (+24V). Refer to the
Appendix 2.20 and 2.22 for the F261 and the F271 cable production.
If connecting to the last channel of the connector PCB, the cable shielding is connected with FG
(chassis). If connected connector PCB is not last channel, the cable shielding is connected with the cable
shielding of the next cable but not connected with FG (chassis).
(Note) When the last channel connector PCB is Junction box
installed near a noise source such as a motor, Remote I/O

the noise can enter to circuit through the cable +24V +24V
shielding, and the Remote I/O communication Com. Com.
error may increase.
In that case, do not connect the cable shielding
to FG (chassis). Earth plate
The cable shielding is not
connected to FG (chassis). M M
5-16
CHAPTER 6 CONNECTION OF REMOTE I/O UNIT
6.1 Outline of Remote I/O Unit
The machine control signals which remote I/O unit(FCUA-DX101) can handle are as follows.
Number of occupied
Unit type name Machine control signals which can be handled
serial link channel s
Digital input signal : 32(photo coupler insulation)
any of sink/source type
FCUA-DX101 1
Digital output signal : 32(no insulation)
source type
6.2 Name of Remote I/O Unit Sections
Front view
1 DI-L(A connector for machine input signals)
2 DS(A switch to change transfer speed)

1
3 CS(A switch to change the channel)
2
4 DO-L(A connector for machine output signals)
3
5 RIO1(A connector for series connection #1)
4
6 RIO2(A connector for series connection #2)
7 DCIN(A connector for DC24V power supply input)
(Front)
5
DS
Bottom view
6
CS
7
Zoomed figure of DS and CS

(Rear)
6-1
6.3 Connection of Remote I/O Power
+24Vdc power is required for the remote I/O unit. Prepare a power supply that meets the following
specifications.
Output Voltage +24V5%
Ripple 5% (P-P)
Maximum Optput Current 2.4A or more (per one FCUA-DX101)
The +24Vdc power for the control circuit is supplied from the connector DCIN on the bottom of the unit or from
connectors DI-L, DI-R, DO-L or DO-R on the front. When supplying from the front connector, supply to all
corresponding pins.
When manufacturing the R300 cable, use the single-end connector CN300 (optional, with one end), and when
manufacturing the R301 cable, use the connector set CS301 (optional, with two ends).
F ro nt <Connection Outline>
Machine control cabinet,
power distribution panel, etc. Remote I/O unit
DI-L DI-R DI-L
R 30 0 ca b le o r
R 30 1 ca b l e B1
B2
A1
A2
DC24V (+) B1

B2
0V A1
A2
DO-L
DO-L
(Front)
Supply to either method
D C IN
Y
R020 cable Base

DC24V(+)
DC24V(+) 0V
Y
0V FG
FG
Power Supply (Rear)
Prepare separately
CAUTION Do not supply voltages other than those indicated in this manual on the connector. Doing so may lead to
destruction or damage.
Incorrect connections may damage the devices, so connect the cables to the specified connectors.
6-2
6.4 Outline of Digital Signal Input Circuit
The input circuit can be selected from sink type or source type in card uni t s .
Sink Type Source Type
Machine Side
Machine Side
2.2k +24V 2.2k
0V
2.2k +24V 2.2k
0V
2.2k +24V 2.2k
0V
Input
+24V
Circuit 2.2k 2.2k
0V
2.2k +24V 2.2k
0V
Control Control
+24V A3 A3
Circuit Circuit
B3 COM B3 COM
32 inputs 32 inputs
0V
FCUA-DX101 FCUA-DX101
Input voltage when external contact is ON 6V or less Input voltage when external contact is ON 18V or more, 25.2V or l e s s
Input current when external contact is O N 9mA or more Input current when external contact is O N 9mA or more
Input voltage when external contact is OFF 20V or more 25.2V or les s Input voltage when external contact is OFF 4V or less
Input Input current when external contact is OF F 2mA or les s Input current when external contact is OF F 2mA or les s
Conditions Permissible chattering ti m e 3ms or less Refer to T1 below Permissible chattering ti m e 3ms or less (Refer to T1 belo w )
Input signal hold time 40ms or more Refer to T2 below Input signal hold time 40ms or more (Refer to T2 be l o w )
Input circuit operating delay ti m e 3ms T3T416ms Input circuit operating delay ti m e 3ms T3 T416ms
Machine side contact capacity 30V or more 16mA or more Machine side contact capacity 30V or more, 16mA or more
T2 T2
T1 T1 T1 T1
External External
Signal Signal
+24V +24V
T3 T4 T3 T4
Internal Internal
Signal Signal
6-3
6.5 Outline of Digital Signal Output Circuit
The digital signal output circuit of the DX101unit is source type. Use the digital signal output within the range
of the following specification.
Output Circuit Output Conditions
Machine Side Insulation type Non-insulated

+24V
Rated load voltage DC24V
RA Maximum output current 60mA/1 output
Output delay time 40s
R
PL The output type of HR353 is a source.
RA (Note 1) When using an inductive load such as a relay, always connect a diode
(withstand voltage 100V or more, 100mA or more) in parallel to the load.
R
PL (Note 2) When using a capacitive load such as a lamp, always connect a
Control
0V Circuit protective resistor (R=150 ohm) serially to the load to suppress rush
32 current. (Make sure that the current is less than the above tolerable
outputs FCUA-DX101 current including the momentary current.)
Source Type
CAUTION ! When using an inductive load such as relays, always connect a diode in parallel to the load as a
noise measure.
! When using a capacitive load such as a lamp, always connect a protective resistor serially to the
load to suppress rush currents.
6.6 Connection of FCUA-DX101 unit and Machine Control Signal

Connection
Type of machine input/output Input Output
Otline FCUA-DX101
signal and number of pins 32 points 32 points
DI-L
COM
0V
FCUA-DX101
DC24V (+)
2 . 2 k Input circuit
R300 cable/ Source type

R301 cable

DI-L
Machine
Signal
DO-L
R300/
R301 RA
Output circuit
DO-L
PL Source type
Machine
Signal
0V Control
circuit

The signal-end connector CN300 (optional, with on end) Machine
control panel
includes the DI-L connectors. The connector set CS301
RIO1 RIO2 DCIN
(option) includes the DI-L and DO-L connectors, and two
connectors for connection with the terminal block *).
Power supply DC24V(+) 0V FG
*) Izumi Denki I/O terminal BX1f-T40
CAUTION Incorrect connections may damage the devices, so connect the cables to the specified connectors.
Do not connect or disconnect the connection cables between each unit while the power is ON.
6-4
<Signal assignment table>
<Caution> FCUA-DX101
When using two or more remote I/O DI-L
units or when connecting to the
communication terminal, the signal
Machine allocation will differ. Refer to the "PLC 20
19
control panel, interface manual" for details. 18
17
etc. 16
15
+24Vdc DI-L

14
13
12
11
10
9
8
0V 7
6
5
4
COM COM 3
0V 2
0V 1

DO-L

20
19
18
17
16
+24Vdc 15
14
DO-L 13
RA
DO-L 12
11
10
9
PL 8
7
6
0V 5
4
3
0V 2
0V 1

Control un it
RI01
Communication RI02 DC IN
1 2 3 1 2 3 1 2 3
terminal
TXRX TXRX* LG TXRX TXRX* LG +24V 0V FG
+24Vdc
X Y
X AMP
D- 3 A MP
0V
AM P D- 3
R-TM
D- 3
Remote I/O unit
<Adaptive connector>
DCIN (CN220) RIO1/RIO2 (CN211) DI-L/DO-L (CN300) Terminator (R-TM)
Connector: 2-178288-3 Connector: 2-178288-3 Crimp type connector: X
Contact: 1-175218-5 Contact: 1-175218-5 7940-6500SC

AM P
D -3
Maker: AMP Maker: AMP Maker: Sumitomo 3M

Maker: AMP
6-5
6.7 Setting of Channel No. when Using Multiple Remote I/O Units
When the remote I/O unit is connected with serial links (MC link B), multiple units can be used as long as the
total number of occupied channels is within eight channels. Note that a remote I/O unit and card-sized I/O
HR371 can not be used together in the same model.
Maximum number of
System Base module Unit type name
connection units
System 1 FCUA-DX101 3
System 2 HR353 FCUA-DX101 4
System 4 Star connection FCUA-DX101 4
System 3 Keyboard unit
When using multiple remote I/O units, a characteristic channel number should be set for each unit.
The FCUA-DX101 unit has one channel setting switch, and the channel number is set in the M635MNY/LNY
system as shown in the table below.
1st unit 2nd unit 3rd unit 4th unit FCUA-DX101 unit
System 1 Setting: 2 Setting: 4 Setting: 6
System 2 Setting: 0 Setting: 2 Setting: 4 Setting: 6
System 4
Setting: 0 Setting: 2 Setting: 4 Setting: 6
(Star connection)
(Note) The assignment of each unit's input/output signal address will Setting switch
change with the setting of the channel number.
Refer to "PLC Interface Manual" for details
6-6
CHAPTER 7 NOTIFICATION OF USING PC PERIPHERAL DEVICE
This chapter describes the notification of using PC peripheral devices.
7.1 Connection of Parallel I/O, Mouse and Keyboard

Parallel I/O device, enternal mouse, and PC keyboard can be connected to back side of the keyboard unit.
Refer to section "4.4.5 Connection of PS/2 mouse" and "4.4.6 Connection of PS/2 keyboard and parallel
device" for connection example.
The operation of the parallel I/O device, mouse and PC keyboard in the machine operation environment is not
guaranteed. The improvement of noise immunity with the ferrite core like the figure below are required.
Use the "Recommended Devices" which met the Mitsubishi quality standard, or the "Connectable Devices"
which confirmed the operation by Mitsubishi.
Connector installation
Printer cable on the panel
F252 cable or PS/2 extention market, etc.
cable on the market
Accessory cable of PS/2 device
Keyboard Unit
External PS/2 mouse
PS/2 keyboard
Parallel I/O devise, Printer, etc .
Printer cable on the market, etc.

Inatallation
Inatall ferrite core to

cable one turn.
7.2 Recommended Devices List

Introduce the recommended devices that are met the Mitsubishi quality standard and the connectable
devices that are confirmed operation (although not met the Mitsubishi quality standard).
7.2.1 Front Access IC Cards

Supplier Type Specification Class Remarks
SCANDISK SDP3B-48-101 48MB Recommended SDP3B-***-
SDP3B-96-101 96MB Recommended ***: Memory size (MB)
SDP3B-128-101 128MB Recommended : Manufacturer's control number
SDP3B-192-101 192MB Recommended "101" is standard
SDP3B-256-101 256MB Recommended
SDP3B-440-101 440MB Recommended
IO-DATA PCFCA-16M 16MB Recommended PCFCA-***M
PCFCA-32M 32MB Recommended ***: Memory size (MB)
PCFCA-48M 48MB Recommended
7-1
7.2.2 CardBus PC Cards
Device Supplier Type Name Specification Bus Type Class
FLASH Card SANDISK SDP3B series PCMCIA Recommended
IO-DATA PCFCA series PCMCIA Recommended
LAN Card 3Com EtherIII 10 BASE-T Ether PCMCIA Connectable
corega EtherII PCC-T 10 BASE-T Ether PCMCIA Connectable
Fether PCC-TXF 10/100 BASE-T Ether PCMCIA Connectable
Fether CB-TXL 10/100 BASE-T Ether CardBus Connectable
BUFFALO LPC2-T 10 BASE-T Ether PCMCIA Connectable
LPC4-TX 10/100 BASE-T Ether PCMCIA Connectable
Notices in use of CardBus type PC card
(1) Install a driver software under the condition that only the target CardBus type PC card is inserted. Some
trouble may occurs if a driver software is installed under the condition that other PC card is inserted
together.
(2) For using a CardBus type PC card, turn on the power under the condition that the target PC card is
inserted. When the PC card is inserted under the condition that the power is turned on, the PC card is not
sometimes recognized by the combination with other PC cards.
7.2.3 Peripheral Devices

Device Supplier Type Name Specification Class Remark
Keyboard Fujitsu FKB1420 Japanese Connectable No guarantee of noise immunity.
Takamizawa Keyboard
LOGITECH Y-SA2 104 Keyboard Recommended Noise measure is required. Refer to
section 7.1.
Mouse KENSINGTON MOSUI MOUSE IN BOX Connectable Noise measure is required. Refer to
SCROLL section 7.1.
The operating quality in a system can
not be completely guaranteed though
a noise immunity is high.
7-2
CHAPTER 8 DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE
8.1 Maintenance Tools

8.1.1 Measuring Instruments
The following measuring instruments are used to confirm that the voltage is being supplied correctly to the
NC unit, to confirm that the wiring to the NC unit is correct, and to carry out simple troubleshooting.
Tool Condition Application
Tester To check that the wiring to the NC unit is correct before turning the power ON.
AC voltmeter Measure the AC Power voltage. To measures the AC power voltage being supplied to the external 24VDC power supply
The tolerable error is 2% or less. unit.
DC voltmeter Max. scale 30V To measures the DC power voltage.

The tolerable error is 2% or less. External power supply 24V (control section, machine input/output interface)
Battery voltage
HR085DC output
Phase rotation To check the connection order of the AC 3-phase input power supply.
meter
Synchroscope General measurement and simple troubleshooting.
(Note 1) Currently, a high precision digital multi-meter is commonly used as a tester. This digital multi-meter
can be used as both an AC voltmeter and an DC voltmeter.
(Note 2) A logic analyser (200MHz or more) is required for complicated troubleshooting.
8.1.2 Tool s
Screwdriver (Large, Medium, Small
Radio pliers
8.2 Maintenance Items

Maintenance is categorized into daily maintenance items (items to be carried at set intervals) and periodic
maintenance (replacement of parts when life is reached).
Some parts (HDD, FDD, etc.) will not function in a hardware manner when the life is reached, so these
should be replaced before the life is reached.
Class Name Life Inspection/Replacement Remarks
Daily Escutcheon Once/two months
maintenance (Accordingly when dirty)
Cleaning of floppy disk drive (type built Once/two months
in operation bo x )
Periodic Replacement of floppy disk sheet 310 6 passes/track
maintenance (type built in operation box)
Replacement of floppy disk drive (type 12,000 access hours or 5 years of Refer to left
built in operation b o x ) FDD motor rotation, whichever is
sooner
Replacement of hard disk d r i v e 5 years or 20,000 power ON hours, Refer to left
whichever is sooner
Replacement of LCD backlight 40,000 hours (specified with power Replace when display dims
ON time where brightness drops to
less than 50% at 25 )
Replacement of batter (coin shape Cumulative data hold time 50,000 When battery drop caution
lithium battery CR2032 hours alarm occurs
Cooling fan (control section) 50,000 hours (specified with rotation Refer to left
time when rotation speed drops to less
than 20% of initial speed)
Other Keyboard punches Refer to left

consumable
parts
8-1
8.3 Maintenance of Escutcheon and keyboard
8.3.1 Cleaning of Escutcheon and keyboard

Wipe the escutcheon (display unit and plastic frame of keyboard unit) and keyboard surface with a soft dry
clean cloth. If the escutcheon is heavily dirtied, soak the cloth in a neutral detergent, and wipe the display. Do
not use an alcohol or a paint thinner, et c .
The escutcheon and the keyboard are not for waterproofing. Be careful that a liquid doesn't go into inside of it.
8.3.2 Replacement of NC Data Key

The NC data key is the printed circuit board which the switches are mounted on it, and is included into the
keyboard unit. Replace it in accordance with the following procedure.
Check that the machine power is turned OFF. (If the power is not OFF, turn it OFF)
Remove all the cables connected at the back of the NC data key.
Remove the tablet pointer flexible cable and keyboard cable from the PCB (HR201 card). (See Figure 8.1)
Remove six screws, and remove the sheet metal adapter and the HR201 card from the keyboard unit.
(See Figure 8.2)
Remove fourteen screws, and remove the NC data key from the escutcheon (See Figure 8.3)
Install a new NC keyboard with the process which is contrary to ~ .
Tablet pointer
HR201 card flexible cable
keyboard cable
Sheet metal
adapter
Figure 8.1
Figure 8.2
Escutcheon
NC data key
Figure 8.3
8-2
8.3.3 Replacement of Menu Key
The menu key is the printed circuit board which the switches are mounted on it, and is included into the display
unit. Replace it in accordance with the following procedure.
Remove the menu key cable from the keyboard unit. Because the menu key cable is soldered on the
menu key PCB, remove it at the keyboard unit side.
Remove six screws, and remove the menu key from the display unit. (See Figure 8.4)
Install a new menu key with the process which is contrary to ~ .
Figure 8.4
8-3
8.4 Maintenance of Floppy Disk Drive
8.4.1 Cleaning of Floppy Disk Drive (Head Cleaning )

When the floppy disk drive is used for a long time, magnetic particles or dust from the disk may
adhere onto the head surface. This can cause the reading and writing processes to be inhibited.
Clean the head periodically ( once every two months ) with the following procedure.
(1) Recommended cleaning disk

Maker : Japan Morex
Type : Morex cleaning floppy for double-sided 3.5-inch
Method : Dry
(2) Cleaning method

Insert the cleaning disk into the floppy disk drive to be clearned.
Start the cleaning program, and follow the instructions given on the screen.
When the program is completed, eject the cleaning disk.
8.4.2 Handling of Floppy Dis k s

Observe the following items to ensure that the floppy disk can be used for a long time.
(1) Precautions for u s e

Never tough the magnetic surface with hands. Finger prints on the magnetic surface
will inhibit the reading proces s .
Do not touch the floppy disk with hands dirtied with oil or iron chips.
Do not place the floppy disk near cigarette smoke. Do not apply solvents on the
magnetic surface.
Always attach the index label to the correct position so that it will not come off. Do not
layer the index labels.
Fill in the index label before attaching it to the floppy disk. When writing on a label
already attached to the floppy disk, use a felttip pen ,etc .
Carefully insert the floppy disk into the drive with it facing the correct direction. Rough
handling during insertion and ejection could damage the floppy disk.
When bringing the floppy disk inside from outdoors where the temperature and
humidity difference are great from indoors, wait at least 30 minutes before starting use.
(2) Precautions for storage

Store floppy disks that are not in use and the backup floppy disks in plastic cases .
Do not place the floppy disk where it will be subject to direct sunlight or near heating
appliances .
Do not place the floppy disk near magnets or items that generate strong magnetic
fields. Magnetic rings and necklaces could also damage the data on the floppy disk , s o
avoid wearing these items when handling floppy disks.
Do not place heavy items on the floppy di s k .
8-4
8.4.3 Other Precautions for Use
(1) Floppy disk drive life

The durability of the floppy disk drive is guaranteed for five years of the FDD motor rotation or 12,000 access
hours, whichever is sooner. However, if used in a heavily contaminated environment, the reading and writing
processes could be inhibited due to the adherence of dust or foreign matter.
Periodically clean the head to prevent this type of trouble. (Refer to section 3.4.1)
(2) Recommendation for making backups

Make copies of the floppy disks containing important data to be used in case of an accident such as
damaging of the floppy disk or destruction of the data.
(3) Operating conditions

The floppy disk drive and floppy disks are extremely sensitive to changes in the temperature and humidity
and to dust, so always observe the precautions that have been described.
In respect to the temperature, if the working conditions are not satisfied (such as if the system is started at
below freezing), the data track and head positions may deviate and prevent the data from being read
properly .
In this case, wait for the internal temperature to rise.
(4) Writing to floppy disks

The temperature must be 10 to 40C when writing to the floppy disk.
Always observe the temperature conditions when writing data.
8.4.4 Replacement of Floppy Disk Drive
Remove the F132 cable from the floppy disk unit. Refer to section 4.4.1 "Connection of Floppy Disk Unit"
for connection and removal of the F132 cable.
The floppy disk drive is covered with three sheet metals. And three sheet metals are fixed with eight
screws. Remove those sheet metals referring to the figure 8.5.
Install a new floppy disk drive with the process which is contrary to ~ .
Figure 8.5
8-5
8.5 Maintenance of Hard Disk
8.5.1 Handling of Hard Disk

(1) Precaution for Use (2) Precaution for Storage
Correct connection the cable Aboid strong the drive in high temperature, high
Do not touch the connector section with hands or metal. humidity places.
Do not apply excessive force on the connector section. Do not place the drive near magnets or items
Do not drop or apply strong impacts on the drive. thae generate strong magnetic fields.
Do not disassemble the drive.
8.5.2 Other Precaution for Use

(1) Recommendation for making backup
The hard disk is a durable device, so make a backup of the hard disk to save important data.
8.5.3 Replacement of Hard Disk

Do not handle the hard disk without metal case because the hard disk has not much endurance against the vibration and
shock in comparison with other electric devises. Replace the hard disk as the Hard Disk Unit (with the metal case and
the stabilizing rubber).
Remove the F140 cable which is connected between the hard disk unit and the control unit. Remove the HEATER
cable and the THM cable from the keyboard unit. Refer to section 4.4.2 "Connection of Hard Disk Unit" for
connection and removal of cables.
Remove two screws, and remove the hard disk unit from the keyboard unit. (See Figure 8.6)
Install a new hard disk unit with the process which is contrary to ~.
HEATER cable THM cable
Keyboard unit
Figure 8.6
CAUTION ! Hard Disk Drive is built in this product. Do not drop and do not give a strong impact to the product
because the hard disk drive is a precise device.
! The hard disk drive has a useful life. Please exchange the hard disk drive before end of the life.
! Please make a backup of the customer's files which is saved in the hard disk drive.At the
breakdown of the hard disk drive, although Mitsubishi provides exchange service of the hard disk
drive, Mitsubishi does not guarantee a customer's files which is saved in the hard disk drive. And
Mitsubishi does not assume the responsibility concerning the damage caused by having
damaged the hard disk drive.
8-6
8.6 Maintenance of LCD
8.6.1 Life of LCD Backlight

CCFL (Cold Cathode Fluorescent Lamp) is used for the light source (backlight) of the LCD panel. The
estimated life of the backlight is 40,000 hours/25C. (Time for the brightness to drop to 50% of the initial
value).
Life time depends on temperature. When the LCD panel is used under low temperature or high temperature
continuously, the life time has a tendency to become short.
8.6.2 LCD Characteristi c s

(1) Luminan c e
Luminance decreases at a low temperature by the CCFL characteristi c . And, the time until luminance
meets rated value after power-on is about 10-15 minutes.
(2) Uniformity, Luminous Dot, Dark Dot
It is not defect or malfunction though uniformity, a small luminous dot and a small dark dot may appear on
the LCD panel.
8.6.3 Replacement of LCD Backlight
Because the LCD backlight replacement hole is provided at the side of the display unit, replacement of the
LCD backlight is easy.
LCD backlight part number 121LHS16
Remove one screws, and remove the cover from the LCD backlight replacement hole. (See Figure 8.7)
Remove the LCD backlight cable from the LCD backlight inverter PCB.
Pull out the LCD backlight with opening a locking latch. (See Figure 8.8)
Install a new LCD backlight with the process which is contrary to ~ .
Cover
LCD
Backlight
Figure 8.7 Figure 8.8
8-7
8.7 Maintenance of Battery
All data,such as the parameter and machining program that need to be backup when the power is turned OFF, are saved
by a battery installed in the control unit. It is easy to get a battery because a familiar coin type lithium battery is being
used.
Replace the battery as a standard within one week if the Battery Voltage Drop Caution A larm is appeared. If the battery
isn't replaced, the Battery Voltage Drop Warning Alarm is appeared. Then, internal backup data could be damaged.
Battery part number: CR2032
8.7.1 Handling of Battery

Lithium battery contains inflammable material such as lithium, organic solvent. Erroneous handling of lithium battery may
result in such an accident of heat generation, explosion or fire, possibly leading to personnel injuries or machine
malfunction. To prevent such accidents, strict observance of the following precautions is essential.
Do not recharge, disassemble, apply pressure, heat, directly solder or dispose in fire the battery.
Insert the battery (+)(-) correctly.
Do not create short circuit between (+) and (-). And do not carry or store the battery with the metal goods such as a
necklace.
When the battery is stored or disposed, do not stack or jumble up the batteries with other metal goods. Then, put a
insulating tape to the terminals of the batteries to prevent a short circuit.
Do not use the batteries by mixing different types or old batteries together with new ones.
8.7.2 Replacement of Battery

Remove the battery card (HR073) from the control unit.
Replace the three batteries.
Install the battery card (HR073) to the control unit.
Battery Card
Batteries (x3)
Figure 8.9
CAUTION ! If the battery low warning is issued, save the machining programs, tool data and
parameters in the input/output device, and then replace the battery.
! Do not short circuit, charge overheat, incinerate or disassemble the battery.
! Dispose of spent batteries according to local laws.
8-8
8.8 Maintenance of Cooling Fan
Two cooling fans are mounted in the control unit. One cools down the inside of the control unit, and the other
cools down the Card PC.
These two fans are same part.
Type Name of Cooling Fan MMF-06E12DH
8.8.1 Life of Cooling Fan

The life of the cooling fan depends on the grease life of the bearing. The rotation time when 20% of the
rotation speeds decrease more than an initial rotation speed is defined as the life, and the life is 50,000 hours.
8.8.2 Replacement of Cooling Fan

(1) Control unit Cooling Fan
Check that the machine power is turned OFF. (If the power is not OFF, turn it OFF.)
Remove the fan cable from the "FAN1" connector located around the left top of the control unit.
Remove the cooling fan with opening the lock latch.
Install a new cooling fan with the process which is contrary to ~ .
(2) Card PC Cooling Fan

Check that the machine power is turned OFF. (If the power is not OFF, turn it OFF.)
Remove the fan cable from the "FAN2" connector located around the center top of the control unit.
Remove two screws, and remove the bracket and the cooling fan.
Install a new cooling fan with the process which is contrary to ~ .
"FAN1" Connector
"FAN2" Connector
Control Unit Cooling Fan
Wind Direction
Wind Direction
Card PC
Cooling
PCFa n
Bracket
Screw (x2)
Fig. 8.10
8-9
8.9 Cable Replacement Method
If the cable is replaced without turning the power OFF, the normal unit or perirheral devices could be damaged,
and risks could be imposed.
Disconnect each cable with the following procedures.
(1 For the following type of connecter, press the tabs with a thumb and forefinger in the direction of the arrow,
and pull the connecter off.
Press
Press
Pull Pull
Press
View from above
Press
Pull
Pull
CAUTION
Do not connect or disconnect the connection cables between each unit while the power in ON.
Do not connect the cable by pulling on the cable wire.
8-10
(2) For a flat cable type connecter with claws, open the claws in the directions of the arrows, and pull the
connecter off.
Open
Pull
(3) For a flat cable type connecter without claws, hold the connecter with a thumb and forefinger, and pull the
connecter off.
Hold with thumb and forefinger.
Pull
(4) For the screw fixed type connecter, loosen the two fixing screws, and pull the connecter off.
Loosen
Loosen
Pull Pull
CAUTION
Do not connect or disconnect the connection cables between each unit while the power in ON.
Do not connect the cable by pulling on the cable wire.
8-11
CHAPTER 9 TROUBLESHOOTING
9.1 List of Unit LEDs and Switches
DCIN
DCOUT
DCRST
NCRST
NCLD1
NCSYS WDER BATALM PSEMG HD PCRST
Names with underline shows switches.
[ Explanation of LED functions ]

Name Function Color Status Correspondance for error
When normal During error
DCIN During 24VDC supply Green Lit Not lit Refer to section 9.2.3 (1)
DCOUT During internal power output Green Lit Not lit Refer to section 9.2.3 (1)
PSEMG Power supply emergency stop Red Not lit Lit Refer to section 9.2.3 (1)
BATALM Battery drop warning Red Not lit Lit Refer to section 8.7
WDER Watch dog alarm Red Not lit Lit Refer to section 9.2.3 (7)
HD Accessing hard disk Green Flickers during Refer to section 9.2.3 (4)
access
NCLD1 7-segment system status display According to system state
9-1
9.2 Troubleshooting
9.2.1 Confirmation of Trouble S t a t e

Confirm "when", "when doing what", and "what kind of" trouble occurred.
(1) When?
What time did the trouble occur?
(2) When doing what?

What was the NC operation mode?
During automatic operation ---------- Program No. , sequence No. , and program details when the trouble
occurred.
During manual operation ------------- What was the manual operation mode?
What was the operation procedure?
What were the previous and next steps?
What was the setting and unit display unit screen?
Did the trouble occur during input/output operations?
What was the machine side state?
Did the trouble occur while replacing the tools?
Did hunting occur in the control axis ?
(3) What kind of trouble?

What was displayed on the setting and display unit's Alarm Diagnosis screen? Display the Alarm
Diagnosis screen, and check the alarm detail s .
What was displayed for the machine sequence alarm?
Is the LCD screen normal?
(4) How frequent l y ?

When did the trouble occur? What was the frequency? (Does it occur when other machines are
operating?) If the trouble occurs infrequently or if it occurs during the operation of another machine, there
may be an error in the power voltage or the trouble may be caused by noise, etc. Check whether the
power supply is normal (does it drop momentarily when other machines are operating?), and whether
noise measures have been taken.
Does the trouble occur during a specific mode?
Does the trouble occur when the overhead crane is operating?
What is the frequency in the same workpiece?
Check whether the same trouble can be repeated during the same operation.
Check whether the same trouble occurs when the conditions are changed. (Try changing the override,
program details, and operation procedures, e t c . )
What is the ambient temperature? (Was there a sudden change in the temperature? Was the fan at the
top of the control unit rotating?)
Is there any contact defect or insulation defect in the cables? (Has any oil or cutting water splattered onto
the cables?)
9-2
9.2.2 When in Trouble
If the system does not operate as planned or if there is any trouble in the operation, confirm the following points
and then contact the Mitsubishi Service Center.
[ Examples of trouble ]
The power in not ON.
The power turns OFF.
The screen does not appear.
The operation keys do not function.
The HDD does not function.
The FDD does not function.
Machining is not possible.
[ Precautions ]
If the control unit ambient temperature is 5C or less, the NC may not start up. However, warm-up operation
is carried out by warming up the HDD with the heater to protect the HDD from low temperatures.
Check the warm-up operation sign with the LEDs on the operation board.
Approximately 20 minutes will be needed until the HDD temperature become 5C from 0C.
The NC will start up automatically when the warm-up operation is completed.
9-3
9.2.3 Examples of Troubleshooting
(1) Problems related to the power supply
The power does not turn ON.

Cause Remedy
The power cord is disconnected or Check the cable between the NC unit and the external power supply,
loose. and between the external power supply and socket. Make sure that the
cable is inserted securely.
The door interlock is applied. If the control panel door is not completely closed, close it. If the door
interlock is applied even when the door is closed, the door interlock
circuit is damaged. Repair it.
There is a problem in the power If the socket has a switch, turn the switch ON. Make sure that the
socket. specified power voltage and power frequency is being output from the
socket.
The external power supply is faulty. Check that the power can be turned ON with just the external power
supply.
Note) Depending on the external power supply being used, the power
supply may not turn ON in the no-load state, so install a slight load and
check.
The ON/OFF cable is short circuited. Disconnect the ON/OFF cable and check that it is not short circuited. If
short circuited, replace the cable.
The external power supply's input Check that the input voltage is within 200 to 230VAC +10%/-15%.
voltage is not as specified.
The external power turns ON but the NC control power does not turn ON.
Cause Remedy
The external power supply output is Disconnect the cable between the NC unit and the external power
not correct. supply, and check that the
The cable connected from the NC unit Disconnect the cable connected to the peripheral device one at a time
to the peripheral device is short and check that the power turns ON. Check that there are no short-
circuited. circuited cables.
There is a short circuit in the Remove the removable cards one at a time and check that the power
configuration card. turns ON.
Check that there are no short-circuited cards.
The power turns OFF.
Cause Remedy
There is a problem in the power Check whether the voltage fluctuates at certain time zones.
socket. Check whether an instantaneous power failure has occurred.
A problem occurs when the Check whether the voltage drops instantaneously when the peripheral
peripheral device starts operating. device operation starts.
The PSEMG (red) LED on the HR085 cards lights.
Cause Remedy
The emergency stop switch Set the emergency stop switch to the release (B contact) state. Check
connected to the EMG connector is the connection to the EMG connector.
ON (A contact), or the EMG connector
is disconnected.
The BATALM (red) LED on the HR085 cards lights.
Cause Remedy
The LED lights when the voltage of Refer to section 8.7.2 and replace the battery.
the battery mounted on the HR073
has dropped to 2.7V or less.
Do not apply voltages other than those indicated in this manual on the connector.
CAUTION
connectors.
Do not connect or disconnect the connection cables between each unit while the power is
ON.
Do not connect or disconnect the PCBs while the power is ON.
9-4
(2) Problems related to the display section
The LCD screen does not appear.

Cause Remedy
The power is not supplied to the backlight power Check that the F082 cable is connected to the control
for the display section. section's power supply HR085 CF02 connector and
backlight power.
The connection from the LCD display to the Check that the wiring from the LCD display is
backlight power is disconnected. connected to the backlight power.
The F093 cable is not connected to the HR191 card Check that the F093 cable is connected.
LCD connector and HR276 card LCD connector.
The connection from HR276 card and the LCD Check that the wiring from LCD display is connected
display is disconnected. to the HR276 card.
The LCD display, backlight power or card PC is Check the cable connections. If normal, the individual
damaged. module may be damaged. Contact the Mitsubishi
Service Center.
The LCD display is dark and the characters are not visible.
Cause Remedy
LCD looks dark under the influence of sunshine. Shield LCD from the sun.
The life of LCD backlight is over. Replace the backlight.
The LCD screen is disturbed and cannot be synchronized, or the characters are unrecognizable.
Cause Remedy
The card PC or HR191 card is damaged. Contact the Mitsubishi Service Center.
(3) Problems related to the operation section
All key inputs do not function.

Cause Remedy
The F051 cable connected between the operation Check the F051 cable connection.
section key switches and the control section is
disconnected.
The circuit in the HR201 or HR151 card is faulty. Contact the Mitsubishi Service Center.
(4) Problems related to the Hard Disk
The message "Non System Disk Error" appears when the system is started.
Cause Remedy
The HDD connection connector is disconnected. Check the connection state of the HDD cable F140.
When the FDD was connected, a disk other than Remove the disk from the FDD and restart.
the system disk was inserted.
If the heat up lamp on the operation section is lit, Wait for the HDD warm-up operation to be completed.
the warm-up operation to protect against low
temperatures is being carried out.
When none of the above causes apply. Contact the Mitsubishi Service Center.
CAUTION
connectors.
ON.
9-5
(5) Problems related to the Floppy Disk
FDD error occurs.

Cause Remedy
Disk is inserted incorrectly. Insert it correctly.
Disk is faulty. Replace the disk.
Off-truck by using in below freezing point. Retry after waiting for a while. (Refer to section 3.4.3)
Head of FDD is dirty Clean the head. (Refer to section 3.4.1
When none of the above causes apply. Contact the Mitsubishi Service Center.
(6) Problems related to the remote I/O
The communication alarm LED "RAL" is lit.

Cause Remedy
The remote connection cable is not connected. The Check the connection of the remote connection cable
cable has broken wires or the contact is defective. F017 or the cable (SH41, FCUA-R211, F260) between
the remote I/Os.
The HR312 card is defective. Contact the Mitsubishi Service Center.
The power supply system LED is not lit.
Cause Remedy
The input power is not being supplied. (The 24IN Supply a +24V5% voltage to the remote I/O unit.
IED is not lit. )
The input power is not within the tolerable range, or Check that the input voltage is not +20V or less. If it is
the internal power is faulty. (The 50UT LED is not being supplied correctly, contact the Mitsubishi
lit.) Service Center.
(7) Problems when starting the system
The NC does not start up correctly.

Cause Remedy
"8" is displayed on the HR191 card's 7-segment Check that the rotary switch "NCSYS" is set to "0".
LED "NCLD1".
"E" or "F" is displayed on the HR191 card's 7- Contact the Mitsubishi Service Center.
segment LED "NCLD1".
CAUTION
connectors.
ON.
9-6
APPENDIX 1 INSTALLATION DIMENSIONS
Appendix 1.1 Control Unit Outline Drawing
A1-1
Appendix 1.2 Control Unit with Display Unit Outline Drawing
(75)
<Panel cut drawing>
hole
(2-M6 Weld nut)
A1-2
Appendix 1.3 Keyboard Unit Outline Drawing
O( N) GE PQ 7 8 9
XU YV ZW C? 4 5 6
I, JL K @
R 1 2 3
M# S= T A+ 0
F [
D ]
H& BSP
(76)
Panel cut drawing
hole
(2-M6 Weldnut
A1-3
Appendix 1.4 External Power Supply Unit (PD25) Outline Drawing
65
6
AC IN
220
230
230
208
ON/OFF SW
ON/OFF
POWER
DC OUT
R3
2-
6 6
30 130
Appendix 1.5 Base I/O Unit (HR353) Outline Drawing.

200
4-4
5 5
90 90
5 5
5
5
10
5
CF33 CF31
AIO
CF50
SKIP
RIO4-4
160
160
140
RIO2 ENC1
RIO4-3 SV2-4
SV2-3 CF10
RIO4-2
RIO1
SV2-2 SV1
DCIN
RIO4-1 SV2-1 SV3
20
5
5
5 90 90
5
5 5
200
A1-4
Appendix 1.6 Remote I/O Unit Outline Drawing
Top
dissipation
allowance
Heat
100
135
168
40 6
Heat dissipation,
Wiring allowance
70
150
Wiring
allowance
Bottom
Installation
hole
135
2 - M5 - 0.8 screw
6
156
6
34 6
A1-5
Appendix 1.7 Card-sized I/O Outline Drawing
Use the card corner holder for fixing the card-sized I/O.
8
[ Card corner holder ] 10
6.2 15
TypeKGCH-20-0
1.8
Recommended makerKitakawwa Kogyo 6.5 5
20
3.5
1.5
6.5
5.4 7.7
+0.1 7
7.1 -0
+0.1
5.5 -0
+0.1
-0
.8
5.5
R0
93
86 -0.2
+0
5.25
55
15
315=45
A1-6
Appendix 1.8 Signal separator Outline Drawing
HR021 Card
DC24V
CF55
120
110
RIO5#1
RIO6#1
RIO5#2
RIO6#2
SV4#1 SV4#2 SV4#3 SV4#4
55
RIO5#3
RIO6#4 RIO6#3
RIO5#4
4-5
5
5 60
120
130
HR023 Card
DC24V
SV_IN
SV#1 SV#2 SV#3 SV#4

65
55
4-5
5
5 60
120
130
A1-7
Appendix 1.9 Manual Pulse Generator (HD60) Outline Drawing
3-M4 stud bolts L10
3.6 Rubber shield t2.0
600.5
770.5
600.5
801
12V 0V A B
8.89 7.60 M3 x 6 only

16 24 270.5
3 - 4.8
n
tio Uniform
isec
r
T +2

62 -0
120
72 0.2
Panel cut drawing
Appendix 1.10 "F" Installation Plate Outline Drawing
5.5 65 5.5
47.10.2
42.60.2
2.5
2-R Square
120.2
24
5
.75 hole
R1
2-
12
38
76
1.6mm plate thickness
A1-8
Appendix 1.11 Floppy Disk Drive Unit Outline Drawing
Type : FCU6FD2212 <Panel cut> 2-M4 screw
2-5 hole
5.6 143.4
109
120
Square
hole
15.5
108
120
130
31.5
FDD
<F132 cable>
149 (FDD outline)

15
155 1000 (cable length)
30.5
Appendix 1.12 Hard Disk Drive Unit Outline Drawing
Type : FCU6-HD331-1
42
84
2-4.5 hole
(7) 110 7
124
28
The flat cable (F140) is attached to FCU6-HD331-1
A1-9
Appendix 1.13 Synchronous Feed Encoder (OSE-1024-3-15-68) Outline Drawing
68
Caution plate Detector(1024P/rev 56
50 -0.009
-0.025
68
56
68
Encoder side:
20
97F3102E20-29P(DDK) 4 - 5.4 hole
(or equivalent) 2 28
19.5 Cable side:
MS3106A20-29 S 5 3
102 33
135
14.3 -0.11
A 1chA K 0V
0
B -0.012 B 2chZ L
2 5 -0.042 C 3chB M
D N 1chA
-0.006
15 -0.017
-0.009
50 -0.025
16
E Case grounding P 2chZ
3 +0.1
F R 3chB
0
G +5V S
1.15 +0.14
0 1.15 +0.14
0
H T
26 B Cross-section B-B J
The effective depth of
2 key way is 21mm
Enlarge view of key
Appendix 1.14 Synchronous Feed Encoder (OSE-1024-3-15) Outline Drawing
+0.14 +0.14
3 +0.1 2 1.15 0 1.15 0
0 20
B
5 -0.012
-0.042
-0.006
-0.017
-0.11
16
A A
0
Cross-section A-A
14.3
15g6
Cross-section B-B
B
600.1
-0.009
-0.025
680.5
50g6
19.5
28
15g6
4 - M3 screw
depth 6 8
Enclosed four screws(M3 -12):
cross-recessed pan head screw 380.5 971
Key position of
the Connector
Encoder side:
97F3102E20-29P(DDK)
(or equivalent)
A1-10
Appendix 1.15 Grounding Plate and Clamp Fitting Outline Drawing
The shield wire generally only needs to be grounded to the

connector's case frame. However, the effect can be improved Cable
by directly grounding to the grounding plate as shown on the
right. Clamp fitting Grounding
Install the grounding plate near each unit. Peel part of the (Fitting A,B) plate
cable sheath as shown on the right to expose the shield
sheath. Press that section against the grounding plate with
the clamp fitting. Note that if the cable is thin, several can be
40
clamped together.
Install the grounding plate directly onto the cabinet or connect
a grounding wire so that sufficient frame grounding is
achieved.
If the AERSBAN-*SET, containing the grounding plate and
Shield sheath
clamp fitting, is required, please contact Mitsubishi.
Clamp section drawing
Outline drawing
Grounding plate Clamp fitting

17.5
2-5 hole
Installation hole
30
MAX L 10
B0.3
C
A
24 -0.2
+0.3
0
0
24
6
35
3
7
Note 1 M4screw 6 22
35
11
Note 1) Screw hole for wiring to cabinet's grounding plate

Note 2) The grounding plate thickness is 1.6mm
A B C Enclosed fitting L
AERSBAN-D SET 100 86 30 Two clamp fittings A Clamp fitting A 70
AERSBAN-E SET 70 56 One clamp fitting B Clamp fitting B 45
A1-11
Appendix 1.16 RX322-1 (with Sheet Metal Bracket) Outline Drawing
A1-12
APPENDIX 2 CABLE DRAWING
Cable list
Appendix Cable name Usage Maximum Remark
number length
APDX2.1 ENC-SP1 Spindle drive unit 50m
APDX2.2 ENC-SP2 FR-TK 50m
APDX2.3 F012 IO interface (HR021) 20m
APDX2.4 F017 IO interface (HR353) 20m
APDX2.5 F020 Manual pulse generator : 1ch 50m
APDX2.6 F030 RS232C : 1ch 15m
APDX2.6 F031 RS232C : 2ch 15m
APDX2.7 F040 Sync. feed encoder : Strait 50m
APDX2.7 F041 Sync. feed encoder : Right angle 50m
APDX2.8 F070 +24V input 30m
APDX2.9 F110 +24V input, Power off detection 15m
APDX2.10 F120 Emergency stop 30m
APDX2.11 F131 Floppy disk drive 1m
APDX2.12 F140 Hard disk drive 0.5m
APDX2.13 F171 ON/OFF switch 15m
APDX2.14 F260 Remote I/O communication 50m Use for connector PCB of the card-sized I/O
APDX2.15 F261 Remote I/O communication 50m Use for connector PCB of the card-sized I/O
APDX2.16 F270 Remote I/O +24V input #30m Use for connector PCB of the card-sized I/O
APDX2.17 F271 Remote I/O +24V input #30m Use for connector PCB of the card-sized I/O
APDX2.18 F252 PC keyboard extension 1m Use for PC keyboard or PC mouse
APDX2.19 F252 PC keyboard extension 1m Alternative design instead of APDX2.24
APDX2.20 FCUA-R211 Remote I/O 50m
APDX2.21 R301 DI/DO 50m
APDX2.22 SH21 Servo drive unit 30m
APDX2.23 SH41 Remote I/O 1m Use for short length connection between units in a same
cabinet
(Note 1) Cables indicated with (*1) are included with

the keyboard unit supplies by Mitsubishi.
(Note 2) For the cables marked with * in the maximum Maximum cable length
length cable column, the maximum length is L1 L2
the sum (L1+L2) of the cable length (L1) from
the control unit to the base I/O unit and the SH21 Servo
F017 drive unit
Control
cable length (L2) from the base I/O unit to unit FCUA-R211(SH41)
each unit. Remote
Base I/O +24V inut I/O unit
(Note 3) For the cables marked with # in the maximum unit
+24V
length cable column, the maximum length is Powe r F070 L4
supply
the sum (L3+L4) of the cable length (L3) from L3 F040 Sync. feed
the +24V power supply to the base I/O unit encoder
and the cable length (L4) from the base I/O

unit to each unit.
(Note 4) Symbols for wiring cable manufacturing drawing
The following symbols are used in the cable manufacturing drawing.
1. indicates the twisted pair
2. indicates the shield sheath
3. indicates the shield clamping to the ground plate
4. In the cable manufacturing drawings, the partner of the twisted pair cable is given a priority, so the pin numbers
of the connectors at both end are not necessary in number of order.
5. Equivalent parts can be used for the connector, contact and wire material.
A2-1
Cable name ENC-SP1 Cable Usage Spindle drive unit Appendix 2.1
Connector name : ENC1(ENC2) Connector name : CN8
Control unit Spindle drive unit
ENC1(ENC2) CN8
[ENC1] [ENC2] ENC1A (ENC2A) 1 2 [CN8]

ENC1A* (ENC2A*) 6 12
Connector :CDF-9PF Connector :10120-6000EL
ENC1B (ENC2B) 2 3
Contact :CD-PC-111 ENC1B* (ENC2B*) 7 13 Shell :10320-3210-000
Case :HDF-CTH ENC1Z (ENC2Z) 3 4
R/M :3M
R/M :Hirose ENC1Z* (ENC2Z*) 8 14
0V 4 1
0V 5 5
+5V 9
Wire material :DPVVSB 6P0.2SQ

R/M :Bando densen
FG
(Note) Do not connect power (+5V) to pin #9 of ENC1(ENC2).
"R/M" means "Recommended Manufacturer"
Cable name : ENC-SP2 cable Usage : FR-TK Appendix 2.2
Connector name : ENC1(ENC2) Connector name : CONBA
Control unit FR-TK
ENC1(ENC2) CONBA
[ENC1] [ENC2] ENC1A (ENC2A) 1 2 [CONBA]

ENC1A* (ENC2A*) 6 12
Connector :CDF-9PF Connector :MRP-20F01
ENC1B (ENC2B) 2 3
Contact :CD-PC-111 ENC1B* (ENC2B*) 7 13 Contact :MRP-F102
Case :HDF-CTH ENC1Z (ENC2Z) 3 4
Case :MR20L
R/M :Hirose ENC1Z* (ENC2Z*) 8 14 R/M :Honda
0V 4 1
0V 5 5
+5V 9

R/M :Bando densen
FG
(Note) Do not connect power (+5V) to pin #9 of ENC1(ENC2).
A2-2
Cable name : F012 cable Usage : I/O Interface Appendix 2.3
Connector name : CF50 Connector name : CF50
Control unit HR021
CF50 CF50
0V 1 1 0V
0V 11 11 0V
[CF50] SVTXD4 2 2 SVTXD4
[CF50]
Plug :10120-6000EL SVTXD4* 12 12 SVTXD4* Plug :10120-6000EL
Shell :10320-3210-000 SVALM4 3 3 SVALM4 Shell :10320-3210-000
R/M :3M SVALM4* 13 13 SVALM4* R/M :3M
SVRXD4 4 4 SVRXD4
SVRXD4* 14 14 SVRXD4*
0V 5 5 0V
0V 15 15 0V
RTS5 6 6 RTS5
RTS5* 16 16 RTS5*
SVEMG4 7 7 SVEMG4
SVEMG4* 17 17 SVEMG4*
TXRX5 8 8 TXRX5
TXRX5* 18 18 TXRX5*
RTS6 9 9 RTS6
RTS6* 19 19 RTS6*
TXRX6 10 10 TXRX6 (Note)

TXRX6* 20 20 TXRX6*
Fold the wire material shield
over the jacket, and wrap
copper foil tape over it.
Clamp with the connector case
FG FG
GND plate.
Wire material :UL20276 AWG2810P
R/M :Toyokuni Densen
A2-3
Cable name F017 cable Usage I/O Interface Appendix 2.4
CF10 CF10
Connector name : CF10

TXRX1 1 1 TXRX1
TXRX1* 26 26 TXRX1*
HR353 side
TXRX2 2 2 TXRX2
TXRX2* 27 27 TXRX2*
0V 3 3 0V
0V 28 28 0V
SKIP1 4 4 SKIP1
SKIP1* 29 29 SKIP1*
SKIP2 5 5 SKIP2
SKIP2* 30 30 SKIP2*
SKIP3 6 6 SKIP3
SKIP3* 31 31 SKIP3*
SKIP4 7 7 SKIP4
SKIP4* 32 32 SKIP4*
SKIP5 8 8 SKIP5
SKIP5* 33 33 SKIP5*
SKIP6 9 9 SKIP6
SKIP6* 34 34 SKIP6*
SKIP7 10 10 SKIP7
SKIP7* 35 35 SKIP7*
SKIP8 11 11 SKIP8
SKIP8* 36 36 SKIP8*
0V 12 12 0V
0V 37 37 0V
150mm
ENC1A 13 13 ENC1A
ENC1A* 38 38 ENC1A*
ENC1B 14 14 ENC1B
ENC1B* 39 39 ENC1B*
ENC1Z 15 15 ENC1Z
ENC1Z* 40 40 ENC1Z*
0V 16 16 0V
150mm
0V 41 41 0V
0V 21 21 0V
0V 46 46 0V
Control unit side
SVTXD1 22 22 SVTXD1
SVTXD1* 47 47 SVTXD1*
SVALM1 23 23 SVALM1
SVALM1* 48 48 SVALM1*
SVRXD1 24 24 SVRXD1
SVEMG1 25 25 SVEMG1
SVTXD2 17 17 SVTXD3 [CF10]
[CF10] SVTXD2* 42 42 SVTXD3*
Plug :10150-6000EL
Plug :10150-6000EL SVALM2 18 18 SVALM3 Shell :10350-3210-000
Shell :10350-3210-000 SVALM2* 43 43 SVALM3*
R/M :3M
R/M :3M SVRXD2 19 19 SVRXD3
SVEMG2 20 20 SVEMG3
Wire material :UL20276 AWG2825P SVEMG2* 45 45 SVEMG3*
FG FG
CF50 CF50
0V 1 1 0V [CF50]
[CF50] 0V 11 11 0V
Plug :10120-6000EL
Plug :10120-6000EL SVTXD3 2 2 SVTXD2 Shell :10320-3210-000
Shell :10320-3210-000 SVTXD3* 12 12 SVTXD2*
R/M :3M
R/M :3M SVALM3 3 3 SVALM2
SVALM3* 13 13 SVALM2*
SVRXD3 4 4 SVRXD2
Wire material :UL20276 AWG2810P SVRXD3* 14 14 SVRXD2*
R/M :Toyokuni Densen 0V 5 5 0V
0V 15 15 0V
RTS4 6 6 RTS4
RTS4* 16 16 RTS4*
(Note) SVEMG3 7 7 SVEMG2
N.C. 8 8 N.C.
over the jacket, and wrap N.C. 18 18 N.C.
copper foil tape over it. TXRX4 9 9 TXRX4
Clamp with the connector case TXRX4* 19 19 TXRX4*
GND plate. N.C. 10 10 +5V
N.C. 20 20 N.C.
FG FG
A2-4
Cable name : F020/021/022 cable Usage : Manual pulse generator Appendix 2.5
Cable name 1ch 2ch 3ch
F020 cable O
F021 cable O O
F022 cable O O O Connector name

:HANDLE
Note
"O" indicates channels which are used. HANDLE
1HA 1
[HANDLE] 1HB 2
1ch
Connector :CDA-15P +12V 10 Crimp terminal
0V 9
Contact :CD-PC-111 :V1.25-3
Case :HDA-CTH 2HA 3
2HB 4 R/M
R/M :Hirose 2ch :Japan Solderless
+12V 12
0V 11
3HA 5
(Note) 3HB 6
3ch
Fold the wire material shield +12V 14
0V 13
copper foil tape over it.
Clamp with the connector case Wire material :B-22(19)U2SJ-19
GND plate. R/M :Sumitomo Denko
FG
Cable name : F030/031 cable Usage : RS232C Appendix 2.6
Cable name CH1 CH2
F030 cable O Connector name : CF21(CF22) Connector name

:CH1
F031 cable O O
Notes
1. "O" indicates the channel to be used.

Refer to the Appendix 1 Connector name
2. The signal names given in parentheses "F installation plate". :CH2
are equivalent to CF22.
3. The wire material given in parentheses

CF21(CF22) CH1
indicates the F031 cable wire material.
SD1(SD3) 2 2
RD1(RD3) 3 3
RS1(RS3) 4 4
CS1(CS3) 5 5
[CF21] [CF22] DR1(DR3) 6 6

ER1(ER3) 20 20
Connector :CDB-25P
CD3 8 8
Contact :CD-PC-111 RI3 9 9 [CH1] [CH2]
Case :HDB-CTH 0V 7 7 Connector :CDB-25S
R/M :Hirose Contact :CD-SC-111
CH2 Lock nut :HD-LNA
R/M :Hirose
SD2(SD4) 14 2
RD2(RD4) 16 3
RS2(RS4) 19 4
(Note) CS2(CS4) 17 5
Fold the wire material shield DR2(DR4) 21 6

ER2(ER4) 15 20
CD4 18 8
copper foil tape over it. RI4 22 9
Clamp with the connector case 0V 24 7
GND plate.
Wire material :DPVVSB 6P0.2SQ(DPVVSB 12P0.2SQ)

R/M :Bando Densen
FG
A2-5
Cable name : F040/041 cable Usage : Sync. feed encoder Appendix 2.7
Connector name : ENC1(ENC2)
Connector :MS3106B20-29S
F040
Control unit Cable clamp :MS3057-12A
cable
R/M :ITT cannon
Connector :MS3108B20-29S
F04
Cable clamp :MS3057-12A
cable
R/M :ITT cannon
ENC1(ENC2)
ENC1A (ENC2A) 1 A
ENC1A* (ENC2A*) 6 N (Note 1)
ENC1B (ENC2B) 2 C Signal names in the ( ) are for EN2.
ENC1B* (ENC2B*) 7 R
ENC1Z (ENC2Z) 3 B (Note 2)

ENC1Z* (ENC2Z*) 8 P
0V 4 K
Fold the wire material shield over the
jacket, and wrap copper foil tape over it.
[ENC1] [ENC2] 0V 5 Clamp with the connector case GND
Connector :CDF-9PF plate.
Contact :CD-PC-111 +5V 9 H
Case :HDF-CTH
R/M :Hirose
R/M :Bando Densen
FG
Cable name : F070 cable Usage : Base I/O unit, Remote I/O unit +24V power Appendix 2.8
Connector name : DCIN (Base I/O unit, Remote I/O unit, Keyboard unit)
3
2
+24V power
1
Y
[DCIN] DCIN
Connector :2-178288-3 Crimp terminal :V1.25-3
+24V 1 +24V
Contact :1-175218-5 0V 2 0V R/M :Japan Solderless
R/M :AMP FG 3
Wire material :B-18(19)U2J-19

R/M :Sumitomo Denko
A2-6
Cable name : F110 cable Usage : +24V input, Power off ditection Appendix 2.9
Connector name : DCIN
Connector name : DCOUT
Y
1
2
3
DCOUT DCIN [DCIN]

Connector :2-178288-3
[DCOUT] +24V 1B 1 +24V
0V 2B 2 0V Contact :1-175218-5
Connector :3-178127-6 FG 3B AWG16 3 FG R/M :AMP
Contact :1-175218-5 (AWG16)
:1-175217-5 (AWG22) CF01 [CF01]
R/M :AMP AWG22 Connector :51030-0230
ACFAIL 1A 2 ACFAIL
0V 2A 1 0V Contact :50084-8160
3A R/M :Molex
Wire material :UL2464 222AWG+216AWG SS-95138

R/M :Bando Densen
Cable name : F120 cable Usage : Emergency stop Appendix 2.10
Connector name : EMG
[EMG] EMG
Connector :51030-0330 B22-9
FG 1 Crimp terminal :V1.25-3
Contact :50084-8160 EMG IN 2 EMG IN
R/M :Molex COM 3 COM R/M :Japan Solderless
Wire material :B-18(19)U2SJ-19

R/M :Sumitomo Denko
A2-7
Cable name : F132 cable Usage : Floppy disk drive Appendix 2.11
Connector name : FDD Connector name : FD1
Control unit Floppy disk drive
Connector name : FD2

FDD FD1
4A 17B
5A 16B
6A 15B
7A 14B
[FDD] 8A 13B [FD1]
9A 12B
Connector :7940-6500SC 10A 11B Connector :7940-6500SC
11A 10B Strain relief :3448-7934
Strain relief :3448-7940 12A 9B
R/M :3M 13A 8B R/M :3M
14A 7B
15A 6B
16A 5B
17A 4B
18A 3B
19A 2B
20A 1B
4B 17A
5B 16A
6B 15A
7B 14A
8B 13A
Wire material :AWG2820P 9B 12A
R/M :Oki Densen 10B 11A
11B 10A
12B 9A
13B 8A
14B 7A
15B 6A
16B 5A
17B 4A
18B 3A
19B 2A
20B 1A
FD2
2B 1 [FD2]
2A Connector :171822-4
1B 2
1A Contact :170204-1
3
R/M :AMP
4
A2-8
Cable name : F140 cable Usage : HDD Appendix 2.12
Red wire
Connector name : HDD
Insert the protector pin into the pin
assign No.3A.
HDD Control unit
Hard disk
1A
1B
2A
2B
3A HDD
3B
4A 1A
Connector :89361-150 4B 1B
R/M :BERG
5A 2A [HDD]
5B 2B
6A 3A Connector :FCN-727B044-G/LM-D
6B 3B R/M :Fujitsu
7A 4A
7B 4B
8A 5A
8B 5B
9A 6A
9B 6B
10A 7A
10B 7B
11A 8A
11B 8B
12A 9A
12B 9B
13A 10A
13B 10B
14A 11A
14B 11B
15A 12A
15B 12B
16A 13A
16B 13B
17A 14A
17B 14B
18A 15A
18B 15B
19A 16A
19B 16B
20A 17A
20B 17B
21A 18A
21B 18B
22A 19A
22B 19B
23A 20A
23B 20B
24A 21A
24B 21B
25A 22A
25B 22B
Wire material :UL2651 AWG28
Cable name : F171 cable Usage : ON/OFF switch Appendix 2.13
Connector name : ON/OFF Connector name : CF24

5
4
3
2
1
X
ON/OFF CF24
[ON/OFF] NC 1 1 NC
[CF24]
Connector :1-178288-5 Connector :1-178288-5
P-OFF 2 2 P-OFF
Contact :1-175217-5 0V 3 3 0V Contact :1-175217-5
R/M :AMP 0V 4 4 0V
R/M :AMP
P-ON 5 5 P-ON

R/M :Bando Densen
A2-9
Cable name : F260 cable Usage : Remote I/O, Communication Appencix 2.14
Connector name :
3
RIO1, RIO2, RIO4-1~4-4
2
1
X
If connecting two or more connector
PCBs for card-sized I/O.
If connecting one connector PCB for

card-sized I/O.
RIO1, RIO2, RIO4-1~4-4 RIO IN

Connector :5557-04R
Connector :1-178288-3 TxRx1 1A 3 TxRx1 Contact :5556GSL
Contact :1-175218-2 TxRx1* 2A 4 TxRx1*
R/M :Molex
0V 3A 2 0V
R/M :AMP
FG Connector :LR-01F
RIO FG
Contact :SLM-61T-2.0
1 FG
Wire maretial :MVVS 3C0.5SQ (MIC 3C0.5SQ) R/M :Japan Solderless
R/M :Takeuchi Densen FG Crimp terminal :V1.25-3
R/M :Japan Solderless
Cable name : F261 cable Usage : Remote I/O, Communication Appencix 2.15
Connector name : (RIO OUT) Connector name : (RIO IN)
If connected connector PCB for

card-sized I/O is not last channel.
card-sized I/O is last channel.
(RIO OUT) (RIO IN)

Connector :5557-04R
Connector :5557-04R TxRx1 3 3 TxRx1 Contact :5556GSL
Contact :5556GSL TxRx1* 4 4 TxRx1*
R/M :Molex
0V 2 2 0V
R/M :Molex
Connector :LP-01 (RIO FG) (RIO FG) Connector :LR-01F

Contact :SLF-61T-2.0 Contact :SLM-61T-2.0
FG 1 1 FG
R/M :Japan Solderless R/M :Japan Solderless
FG Crimp terminal :V1.25-3
Wire maretial :MVVS 3C0.5SQ (MIC 3C0.5SQ) R/M :Japan Solderless
R/M :Takeuchi Densen
A2-10
Cable name : F270 cable Usage : Remote I/O, +24V power Appencix 2.16
3
Connector name : DCIN
2
1
Y
If connecting two or more connector
PCBs for card-sized I/O.
If connecting one connector PCB for

card-sized I/O.
[DCIN] DCIN DC24V

Connector :2-178288-3 Connector :5557-02R
Contact :1-175218-5
+24V 1 1 +24V Contact :5556GSL
0V 2 2 0V
R/M :AMP FG 3 R/M :Molex
(RIO FG) Connector :LR-01F
Contact :SLM-61T-2.0
Wire maretial :B-18(19)U2SJ-19 1 FG
R/M :Sumitomo Denko
Cable name : F271 cable Usage : Remote I/O, +24V power Appencix 2.17
Connector name : DC24

card-sized I/O is not last channel.
card-sized I/O is last channel.
DC24V DC24V
Connector :5557-02R Connector :5557-02R
Contact :5556GSL +24V 1 1 +24V Contact :5556GSL
0V 2 2 0V
R/M :Molex R/M :Molex
Connector :LP-01 (RIO FG) (RIO FG) Connector :LR-01F
Contact :SLF-61T-2.0 Contact :SLM-61T-2.0
FG 1 1 FG
R/M :Japan Solderless R/M :Japan Solderless
Wire maretial :B-18(19)U2SJ-19 R/M :Japan Solderless
R/M :Sumitomo Denko
A2-11
Cable name: F252 cable Usage: PC keyboard extension Appendix 2.18
PS/2 MIN DIN 6 pin Plug PS/2 MIN DIN 6 pin Receptacle
Plug shell :84165-2 Connector :750131-2

Housing :84167-1 Recommended maker :AMP
Contact: :84141-2 Ferrite core
Recommended maker :AMP Part name :ZCAT3035-1330
(Recommenden maker :TDK) Note
1. Attach the ferrite core.
1 1 Turn the cable on the ferrite core
as figure below.
5 5
4 4
3 3
Part name: ZCAT3035-1330
(Recommenden maker :TDK)
Wire material :DPVVSB 6P x 0.2SQ 2. Cable length should be 1m or less.

Recommended maker :Bando Densen FG
Connect the cable shield to the connector case.
Cable name: F252 cable Usage: PC keyboard extension Appendix 2.19
Produce F252 cable with this design if difficult to get parts of the Appendix 2.18
PS/2 MIN DIN 6 pin Receptacle
Connector :750131-2
Extension cable (with plug and receptacle) Ferrite core Recommended maker :AMP
Part name :ZCAT3035-1330
Part name :6-178528-2
(Recommenden maker :TDK)
Recommended maker :AMP
1. Attach the ferrite core.

1 1
Turn the cable on the ferrite core
5 5 as figure below.
4 4
3 3
Part name :ZCAT3035-1330
(Recemmended maker :TDK)
2. Cable length should be 1m or less.

<Cable modification procedure>
FG
Connect the cable shield to the connector case.
Provide 6-178528-2(AMP).
<Plug> <Receptacle>
Cut the cable at the receptacl side.

<Plug> <Receptacle>
Connect the 750131-2 to the cable.

750131-2
<Plug>
A2-12
Cable name : FCUA-R211 cable Usage : Remote I/O, Communication Appencix 2.20
Connector name : RIO1,RIO2,RIO4(FCUA-R211) Connector name : (FCUA-R211)
X
1
2
3
RIO1,RIO2,RIO4(FCUA-R211) (FCUA-R211)
Connector :1-178288-3 TXRX 1 1 TXRX
Contact :1-175218-2 TXRX* 2 2 TXRX* Contact :1-175218-2
0V 3 3 0V
R/M :AMP R/M :AMP
FG FG
Wire material :MVVS 3C0.5SQ (MIC 3C0.5SQ)

Notes
1. Equivalent of SH41 with shield.
2. Protect both side of cable by an isolated bush.
3. This cable can be used for RIO1, RIO2 and RIO4.
Cable name : R301 cable Usage : DI/DO Appencix 2.21
Connector name : DI-L/DO-L, DI-R/DO-R

CF31, CF32, CF33, CF34
Connector :7940-6500SC Connector :7940-6500SC

R/M :3M Relief :3448-7940
R/M :3M
Wire marerial :B40-S

R/M :Oki Densen
A2-13
Cable name: SH21 cable Usage: Servo Drive Unit Appendix 2.22
Connector name : SV1, SV2, SV3, SV4
Base I/O unit

Servo drive unit
Signal separator
0V 1 1 0V
0V 11 11 0V
SVTXD 2 2 SVTXD
SVTXD* 12 12 SVTXD*
[SV1] [SV2] [SV3] [SV4] Plug :10120-6000EL
Plug :10120-6000EL SVALM 3 3 SVALM Shell :10320-3210-000
SVALM* 13 13 SVALM*
Shell :10320-3210-000 R/M :3M
SVRXD 4 4 SVRXD
R/M :3M SVRXD4 14 14 SVRXD4
0V 5 5 0V
0V 15 15 0V
6 6
16 16
SVEMG 7 7 SVEMG
SVEMG* 17 17 SVEMG*
Wire material : 8 8
UL20276 AWG2810P 18 18
(Note)
R/M :Toyokuni Densen 9 9
19 19
+5V 10 10 +5V
20 20 copper foil tape over it.
Clamp with the connector case
GND plate.
FG FG
Cable name: SH41 cable Usage : Remote I/O, Communication Appendix 2.23
Connector name : RIO1,RIO2,RIO4(CSH41) Connector name : (CSH41)

X
1
2
3
RIO1,RIO2,RIO4(CSH41) (CSH41)
Connector :1-178288-3 TXRX 1 1 TXRX
Contact :1-175218-2 TXRX* 2 2 TXRX* Contact :1-175218-2
0V 3 3 0V
R/M :AMP R/M :AMP
Wire material :MVVS 3C0.5SQ (MIC 3C0.5SQ)

Notes
1. Protect both side of cable by an isolated bush.
2. This cable can be used for RIO1, RIO2 and RIO4.
3. This cable can be used for only short length connection between remote I/O units in the same cabinet, etc.
Use FCUA-R211 normally because high noise immunity.
A2-14
Cable name: F010 cable Usage I/O Interface Appendix 2.24
Connector name : CF10 Connector name : CF10
CF10 CF10
TXRX1 1 1
TXRX1* 26 26
TXRX2 2 2
TXRX2* 27 27
0V 3 3
0V 28 28
SKIP1 4 4
SKIP1* 29 29
SKIP2 5 5
SKIP2* 30 30
SKIP3 6 6
SKIP3* 31 31
SKIP4 7 7
SKIP4* 32 32
SKIP5 8 8
SKIP5* 33 33
SKIP6 9 9
SKIP6* 34 34
SKIP7 10 10
SKIP7* 35 35
SKIP8 11 11
SKIP8* 36 36
0V 12 12
0V 37 37
ENC1A 13 13
Control unit ENC1A* 38 38 HR353
ENC1B 14 14
ENC1B* 39 39
ENC1Z 15 15
ENC1Z* 40 40
0V 16 16
0V 41 41
0V 21 21
0V 46 46
SVTXD1 22 22
SVTXD1* 47 47
SVALM1 23 23
SVALM1* 48 48
[CF10] SVRXD1 24 24 [CF10]
Plug :10150-6000EL SVRXD1* 49 49 Plug :10150-6000EL
Shell :10350-3210-000 SVEMG1 25 25 Shell :10350-3210-000
SVEMG1* 50 50
R/M :3M R/M :3M
SVTXD2 17 17
SVTXD2* 42 42
SVALM2 18 18
SVALM2* 43 43
SVRXD2 19 19
SVRXD2* 44 44
SVEMG2 20 20
SVEMG2* 45 45
FG FG
Wire material :UL20276 AWG2825P

(Note) Fold the wire material shield over the jacket, and wrap copper foil tape over it.
Clamp with the connector case GND plate.
A2-15
APPENDIX 3 EMC INSTALLATION GUIDELINES
This section is an excerpt of the "EMC Installation Guidelines BNP-B2230". Only the pages related to the M640M pro is
given. Refer to the "EMC Installation Guidelines [BNP-B8582-45]" for details on the drive section (servo drive unit/spindle
drive unit).
Appendix 3.1 Introduction

EMC Instructions became mandatory as of January 1, 1996. The subject products must have a CE mark attached
indicating that the product complies with the Instructions.
As the NC unit is a component designed to control machine tools, it is believed that it is not a direct EMC Instruction
subject. However, we would like to introduce the following measure plans to back up EMC Instruction compliance of the
machine tool as the NC unit is a major component of the machine tools.
(1) Methods of installation in control/operation panel

(2) Methods of wiring cables to outside of panel
(3) Introduction of members for measures
Mitsubishi is carrying out tests to confirm the compliance to the EMC Instructions under the environment described in this
manual. However, the level of the noise will differ according to the equipment type and layout, control panel structure
and wiring lead-in, etc. Thus, we ask that the final noise level be confirmed by the machine manufacturer.
Appendix 3.2 EMC Instruction

The EMC Instructions largely regulate the following two items.
- Emission: Capacity to prevent output of obstructive noise that adversely affects external devices.
- Immunity: Capacity to not malfunction due to obstructive noise from external source.
The details of each level are classified table below. It is assumed that the Standards and test details required for a
machine tool are the same as these.
Class Name Details EMC Standard
Restriction of electromagnetic noise radiated through the EN50081-2
Radiated noise
air EN61800-3 EN55011
Emission
Restriction of electromagnetic noise discharged from (Industrial (CLASS: A)
Conductive noise environment)
power supply line
Static electricity Example) Regulation of withstand level of static
IEC61000-4-2
electrical discharge electricity accumulated in human body
Example) Simulation of immunity from digital wireless
Radiation immunity IEC61000-4-3
telephones
Example) Regulation of withstand level of noise from
Burst immunity IEC61000-4-4
relay or live wire being inserted or removed EN50082-2
Example) Regulation of withstand level of noise flowed EN61800-3
Immunity Conductive immunity IEC61000-4-6
from power supply wires, etc. (Industrial
Power supply Example) Regulation of electromagnetic noise of environment)
IEC61000-4-8
frequency field 50/60Hz power supply frequency
Power supply dip Example) Regulation of power voltage drop withs tand
IEC61000-4-11
(fluctuation) level
Example) Regulation of withstand level of noise
Surge IEC61000-4-5
caused by lightning
Appendix 3.3 EMC Measures

The main items relating to EMC measures include the following.
(1) Store the device in an electrically sealed metal panel.
(2) Ground all conductors that are floating electrically. Decrease the impedance.
(3) Increase the distance between the power cable and signal wire.
(4) Shield the cables wired outside of the panel.
(5) Install a noise filter.
Take care to the following items to suppress the noise radiated outside of the panel.
(6) Accurately ground the devices.
(7) Use shielded cables.
(8) Increase the electrical seal of the panel. Reduce the gaps and holes.
A3-1
Appendix 3.4 Panel Structure
The design of the panel is a very important factor for the EMC measures, so take the following measures into
consideration.
Appendix 3.4.1 Measures for Control Panel

(1) Use metal for all members configuring the panel.
(2) When joining the top plate and side plates, etc., treat
the welded or contacting sections so that the
impedance is reduced, and then fix with screws.(Fig. Joining clearance: approx. 20cm
A3-1) Painting mas k

(3) Note that if the plate warps due to the screw fixing,
etc., by that creating a clearance, noise could leak
from that place. <Fig. A3-1>
(4) Plate (nickel, tin) the metal plate surface at the Mesh cover
Control (Conductive sponge)
grounding plate, and connect the connections with a
panel
low impedance.
(5) If there is a large opening, such as ventilation holes,
make sure to close the hole.(Fig. A3-1)
(Note) Using screws to fix the plates that have been

painted is the same as an insulated state. Peel
the paint and fix the screws.
Opening
<Fig. A3-2>
Appendix 3.4.2 Measures for Door
(1) Use metal for all members configuring the door.
(2) When joining the door, use a gasket to lower the impedance of the contacting sections, or use a structure with a
large contact area as shown below. (Fig. A3-3)
(3) The EMI gasket or conductive packing must contact a uniform and correct position of the metal surface.
a) Using gasket b) Enlarge contact area

Control panel
Door
Door
Contact area
Control
panel
Cross section
EMI gasket <Fig. A3-3>
(Note 1) When not using a gasket, ground the control panel grounding with a grounding wire to lower the door's
impedance.
(Note 2) Using screws to fix the plates that have been painted (attachment of packing) is the same as an insulated
state. Peel the paint and fix the screws.
A3-2
Appendix 3.4.3 Measures for Power Supply
(1) Shield the power supply section and insert a filter to prevent the noise from flowing in or out.
Selection of the noise filter capacity will differ according to the drive amplifier and devices being used.
Refer to the "EMC Installation Guidelines" NC Servo Amplifier Section [BNP-B8582-45].
Devices Devices
Radiation noise
Radiation noise Leak
Conductive Shield plate

NF AC input AC input
noise NF
Noise Conductive Noise
filter noise filter
<Fig. A3-4>
(Note 1) The conductive noise can be reduced just by inserting a noise filter, but the radiated noise will leak out.
(Note 2) The conductive and radiated noise can both be reduced by adding a shield plate to the noise filter
Appendix 3.5 Measures for Wiring in Panel

Cables act as antennas to propagate unnecessary noise, and thus must be appropriately shielded and treated.
The following measures must be sufficiently considered for the cables (SH21/F010/FCUA-R211) that carry out high-
speed communication.
Appendix 3.5.1 Precautions for Wiring in Panel

(1) If the cables are led unnecessary in the panel, they will be contaminated by noise. Thus, keep the device layout and
wiring length as short as possible. (Fig. A3-5)
Device Device Device Device Device Device
Noise
<Fig. A3-5>
(2) Always connect the grounding wire to the FG terminal indicated on Devices
the device.
(3) Keep the distance between the power cable and detector cable to
the drive section motor as far apart as possible when wiring.
(4) Do not lead the power wire around the panel without using a filter. Radiation noise
(Fig. A3-6)
Leak
Shield plate
AC input
NF
Conductive
noise Noise
filter
<Fig. A3-6>
A3-3
Appendix 3.5.2 Shield Treatment of Cables
Use shielded cables for the cables wired outside the panel.
Use a shield clamp (refer to section 3.6.1) within 10cm of the lead-out port from the panel.
(1) I/O interface cable [F010 cable]

Shield clamp Always use the shield clamp on
Operation panel Control panel both ends of the connected units.
NC unit Base I/O unit he shield clamp is not required if the

control unit and base I/O unit are
F010 cable
wired in the same panel.
<Fig. A3-7>
(2) DC power supply cable [F110/070/FCUA-R220 cable]

Use a shield clamp within 10cm
Shield clamp
Operation panel Control panel from the panel's inlet/outlet.
Display unit Install a ferrite core on both ends of
Keyboard unit PD25 the connected units.
F110 cable Always install a ferrite core (refer to
section 3.6.2) on the general-
General-purpo s e purpose stabilized power supply.
stabilized power supply
F070 cable or The ferrite core may not be required
FCUA-R220 cable depending on the selected power
supply.
Ferrite core
<Fig. A3-8>
(3) Remote I/O cable [FCUA-R211 cable]

Shield clamp Use a shield clamp within 10cm
Control panel Control panel
from the panel's inlet/outlet.
Base I/O unit Remote I/O unit Install a ferrite core on both ends of
FCUA-R211 cable the connected units.
The shield clamp is not required if
the control unit and base I/O unit
are wired in the same panel.
Ferrite core
<Fig. A3-9>
(4) Servo communication cable [SH21/FCUA-R000 cable]

Shield clamp Use a shield clamp within 10cm
Control panel Control panel
from the panel's inlet/outlet.
Base I/O unit Drive unit Install a ferrite core on both ends of
SH21 cable the connected units.
The shield clamp is not required if
Drive unit the base I/O unit and drive section
unit are wired in the same panel.
FCUA-R000 cable
Ferrite core
<Fig. A3-10>
A3-4
Appendix 3.6 Parts for EMC Measures
Peel the cable sheath
Appendix 3.6.1 Shield Clamp Fitting at the clamp section
The ground can be directly connected to the Cable

grounding plate to increase the effect.
(Fig. A3-11) Grounding plate
Install the grounding plate near the outlet Cable
(within 10cm) of each panel, and press Clamp fitting
against the grounding plate with the clamp (Fitting A, B)
fitting. If the cables are thin, several can be
40
bundled and clamped together.
Shield sheath
To provide sufficient frame grounding, install
the grounding plate directly on the cabinet or
connect with a grounding wire. Clamp section
<Fig. A3-11>
Shape and dimension

Appendix 3.6.2 Ferrite Core
ZCAT type ZCAT-A, ZCAT-AP type ZCAT-B type
The ferrite core is mounted

integrally with the plastic case.
This can be installed with one
touch without cutting the
interface cable or power
supply cable.
ZCAT-C type ZCAT-D type
This ferrite core is effective
against common mode noise,
allowing measures against
noise without affecting the
quality of the signal.
<Fig. A3-12>
Recommended ferrite core : Zseries (Manufacturer : TDK) Unit : mm
Part name A B C D E Applicable cable outer Weightg
diameter
ZCAT1518-0730-M(-BK)*1 221 181 71 151 7max. 6
ZCAT1518-0730(BK)*2 221 181 71 151 7max. 6
ZCAT2017-0930-M(-BK) 211 171 91 201 9max. 11
ZCAT2032-0930-M(-BK)*1 361 321 91 19.51 9max. 22
ZCAT2032-0930(-BK)*2 361 321 91 19.51 9max. 22
ZCAT2132-1130-M(-BK)*1 361 321 111 20.51 11max. 22
ZCAT2132-1130(-BK)*2 361 321 111 20.51 11max. 22
ZCAT3035-1330-M(-BK)*1 391 341 131 301 13max. 63
ZCAT3035-1330(-BK)*2 391 341 131 301 13max. 63
ZCAT1525-0430AP-M(-BK) 251 201 41 151 11.51 2.5 to 4(USB) 7
ZCAT1325-0530A-M(-BK)*1 251 201 51 12.81 11.21 3 to 5(USB) 7
ZCAT1325-0530A(-BK) 251 201 51 12.81 11.21 3 to 5(USB) 7
ZCAT1730-0730A-M(-BK) 301 231 71 16.51 151 4 to 7(USB/IEEE1394) 12
ZCAT2035-0930A-M(-BK)*1 351 281 91 19.51 17.41 6 to 9 22
ZCAT2035-0930A(-BK) 351 281 91 19.51 17.41 6 to 9 22
ZCAT2235-1030A-M(-BK) 351 281 101 21.51 201 8 to 10 27
ZCAT2436-1330A-M(-BK) 361 291 131 23.51 221 10 to 13 29
ZCAT2017-0930B-M(-BK) 211 171 91 201 28.51 9max. 12
ZCAT2749-0430C-M(-BK) 491 271 4.51 19.51 4.5max. 26
ZCAT4625-3430D(-BK) 45.51 24.51 341 121 For 26 wires flat cable 32
ZCAT4625-3430DT(-BK)*3 45.51 24.51 341 131 For 26 wires flat cable 32
ZCAT6819-5230D(-BK) 67.51 18.51 521 161 For 40 wires flat cable 58
ZCAT6819-5230DT(-BK)*3 67.51 18.51 521 171 For 40 wires flat cable 58
*1 The M stamp is attached.

*2 A fixing band is attached at shipment.
*3 Double side tape type. (Double side tape is attached at shipment)
ZCAT-B type: Cabinet fixing type installation hole 4.8 to 4.9mm, plate thickness 0.5 to 2mm.
ZCAT-AP, ZCAT-C type: Structure that prevents easy opening after case is closed.
A3-5
Appendix 3.6.3 Surge Absorber
(1) Surge absorber

Make sure that surge does not directly enter the AC line of the general-purpose stabilized power supply (prepared by
user) supplied to the control unit and DIO. The following product or equivalent is recommended for the surge
absorber. Refer to the manufacturer's catalog for details characteristics, outline and connection methods of the surge
absorber.
Part name: RAV-781BYZ-2

Manufacturer: Okaya Denki Sangyo
Max. Clamp Surge Surge discharge
Circuit voltage Static Operating
tolerable voltage resistance start voltage
50/60Hz Vrms capacity temperature
circuit voltage V10% 8/20s 1.2/50s
250V 3 300V 783V 2500A 20kV 75pF -20 ~ +70C
Outline drawing Circuit drawing

11 1
( 1) Bl ack ( 2) Bl ack (3 ) Bl ack
5.5 1
28.5 1
UL- 101 5 AWG 16

20 030
0
4.5 0.5
28 1
<Fig. A3-13>
4 11
Uni t: mm
Part name: RAV-781BXZ-4

Manufacturer: Okaya Denki Sangyo
Max. Clamp Surge Surge discharge
Circuit voltage Static Operating
tolerable voltage resistance start voltage
50/60Hz Vrms capacity temperature
circuit voltage V10% 8/20s 1.2/50s
250V 3 300V 700V 2500A 2kV 75pF -20 ~ +70C
Outline drawing Circuit drawing

111
( 1) B la ck ( 2) B la ck (3 ) Bl ack G ree n
5.5 1
28 .51
UL -1 015 AWG 16
20 0 30
0
4.5 0.5
281
411 <Fig. A3-14>
Un it: mm
A3-6
(2) Surge absorber installation method
Circuit
Transformer breaker
NC control
section
Other device
(power supply
for panel, etc.)
Control panel
Earth leakage (relay panel,
From power breaker for Circuit etc.)
supply panel breaker MC Reactor
Input
NC control
200/
230VAC section
Other device
(power supply
for panel, etc.)
Circuit
protector
Surge absorber (1) Surge absorber (2)
Grounding <Fig. A3-15>

Grounding plate
Surge absorber installation method
Precautions
(1) Thick wires will enhance the lighting surge absorption effect, so keep the wire as short as possible.
Wire material: Wire diameter 2mm 2 or more
Wire length Connection length (A) to surge absorber (1) is 2m or less.
Connection length (B) to surge absorber (2) is 2m or less.
Connection length (C) to grounding plate (2) is 2m or less.
(2) When carrying out a withstand voltage test, while applying an overvoltage on the power supply line, remove surge
absorbers (2) as the surge absorber will function with the applied voltage.
(3) A short-circuit accident will occur if a surge exceeding the tolerance is applied on the surge absorber. Thus,
always insert a circuit protector to protect the power supply line.
The current does not flow constantly to surge absorbers (1) and (2), so the circuit protector can also be used for
the other devices.
A3-7
Appendix 3.6.4 Selection of Stabilized Power Supply
Consider the following characteristics when selecting the stabilized power supply.
Use a power supply that complies with CE Marking or that follows the safety standards given below.
Stabilized power supply selection items

Item Specification Conditions
Output Voltage fluctuation 5% 5% or less of 24Vdc output
flustuation Ripple noise Maximum 120mV 5% or less of 24Vdc output
Spike noise maximum 500mV
Output current -- Refer to the connection manual
Output holding time Minimum 20ms Instantaneous off time
Standards
Safety Standards : UL1950, CSA C22.2 No. 234 approved, IEC950 compliant
Noise Terminal Voltage : FCC Class A, VCCI-1 Class
High Harmonics Current Restrictions : IEC1000-3-2
A3-8
APPENDIX 4 INSTRUCTIONS FOR COMPLIANCE WITH UL/C-UL STANDARD
To comply with UL/c-UL standard, conform to the following instructions.
(1) External 24Vdc Power Supply

The M600 series CNC meets the UL/c-UL standard on condition that the UL recognized power supply unit is
used for 24Vdc power source.
Please use the UL recognized power supply unit which supplies 24Vdc to each unit.
(2) Ambient temperature of units

The M600 series CNC meets the UL/c-UL standard on condition that the ambient temperature of unit does
not exceed the temperature of this book of 3.1 Chapter 3 descriptions.
Please design so that the maximum ambient temperature of each unit should not exceed the temperature of
this book of 3.1 Chapter 3 descriptions.
A4-1
Revision History
Rev Rev.Date Description of revise
* Jul, 2002 First edition
A 4/17/2003 (1) Added the contents of the M640MT Pro

(2) Added the note to "5.3.7 Cable Connection"
(3) Improved the figures of "Appendix 2 Cable Drawing"
(4) Corrected writing errors
B 2/17/2005 (1) "2.2.3 (1) NC Control Unit Option" : Added the description of "only for M640M Pro" to the HR061#2
section.
(2) Added "4.1.2 M640MT Pro General System Diagram"
(3) "4.4.9 Connection of Signal Separator Cards" : It was Added that the SV System-4 was not applicable to
the M640MT Pro.
(4) "Appendix 2 Cable Drawing" : Added the item of 2.24
(5) Corrected writing errors
Notice
Every effort has been made to keep up with software and hardware revision in the contents
described in this manual. However, please understand that in some unavoidable cases
simultaneous revision is not possible.
Please contact a Mitsubishi business office with any questions or comments regarding the
use of this product .
Mitsubishi Electric Corp. Nagoya Works NC System Section
Duplication Prohibited
This instruction manual may not be reproduced in any form, in part or in whole, without
written permission from Mitsubishi Electric Corporation.
2002 MITSUBISHI ELECTRIC CORPORATION

ALL RIGHTS RESERVE D

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MITSUBISHI

MAZATROL FUSION 640M Pro

Not applicable in this manual.

1. Items related to prevention of electric shocks

1. Items related to noise

2. Items related to installation

! Always observe the installation direction.

3. Items related to connection

Do not connect or disconnect the printed circuit boards.

RS232C Switch AC socket

4. Items related to Hard Disk Drive

5. Items related to Battery

! Do not short circuit, charge overheat, incinerate or disassemble the battery.

! Dispose of spent batteries according to local laws.

CHAPTER 1 OUTLINE 1-1

CHAPTER 2 CONFIGURATION 2-1

CHAPTER 3 INSTALLATION 3-1

CHAPTER 4 SYSTEM CONNECTION 4-1

CHAPTER 5 CONNECTION OF I/O INTERFACE 5-1

CHAPTER 6 CONNECTION OF REMOTE I/O UNIT 6-1

CHAPTER 7 NOTIFICATION OF USING PC PERIPHERAL DEVICE 7-1

CHAPTER 8 DAILY MAINTENANCE AND PERIODIC INSPECTION AND MAINTENANCE 8-1

CHAPTER 9 TROUBLESHOOTING 9-1

APPENDIX 2 CABLE DRAWING A2-1

APPENDIX 3 EMC INSTALLATION GUIDELINE A3-1

APPENDIX 4 INSTRUCTION FOR COMPLIANCE WITH UL/c-UL STANDARD A4-1

Refer to the following documents for explanations on the function.

M600 Series Specification Manual BNP-B3950

Refer to the following document for explanations on the UL/c-UL Marking.

Model names are written in this manual as follows.

Installed by machine tool manufacturer

Installed by machine tool manufacturer

Manual Pulse Generator PC Keyboard

Installed by machine tool manufacturer

Servo Amp./Spindle drive unit

2.2.1 Units for M640M Pro

(2) Display unit

(3) Keyboard unit

(2) Display unit

(3) Keyboard unit

(1) NC Control Unit Option

HR161 HR191 HR481 HR49

HR073 HR021 Servo Amp.4ch

HR063 Synchronous feed

HR201 Remote I/O3ch

3.1.1 Environmental Conditions of Operation Box

temperature (*1 System operating 5~55C) (Surface temperature of LCD)

Supply voltage DC24V5%, Ripple:5%(P-P)

Current (max.) 3A (= Control unit + Display unit + Keyboard unit)

3.1.2 Environmental Conditions of Cabinet

temperature Storage -20~60C

Current (max.) 0.6A

temperature Storage -20~60C

Unit type Connecter card Connecter card

temperature Storage -20~60C

Current (max.) 400mA 200mA

Weight 130g 100g

3.2.1 Installation of Display Unit and Keyboard Unit

Keyboard Unit rear side

LCD surface Heat dissipation, ventilation and wiring

Refer to the following method for heat radiation measures.

Example of heat radiation measures

(3) Points of caution for heat radiation countermeasures when

< Example of Operation box >