BNP-B3830*(ENG)

MAZATROL T PLUS SeriesMAINTENANCE MANUAL (HARDWARE)

AOVANCED AND EVER ADVANCINGMITSUBISHI ELECTRIC

Preface(1) The contents of this manual include the items required to maintenance the entire

MAZATROL T PLUS Series CNC unit, so the system configuration may differaccording to the target model and specified configuration.Use this manual with the Instruction Manual, Instruction Manual issued by themachine maker, and other Instruction Manuals.

(2) This Manual is targeted for the general user and machine maker engineers. If thereare any unclear points, please contact Mitsubishi.

(3) An effort has been made to match the contents of this manual with the NC unit. Weask for your understanding if there are any differences in the contents.

(4) Related materialMAZATROL T PLUS Series Connection Manual

Contents

1. Outline1.1 System Configuration

1.1.1 System configuration1.1.2 Internal system diagram

1.2 Control Unit Configuration1.2.1 Control unit configuration1.2.2 Control section PCB configuration

1.3 Table of Configuration Units

12234456

2. Daily Maintenance and Periodic Inspection and Maintenance ...2.1 Maintenance Instruments2.2 Maintenance Items2.3 Cleaning the Operation Board Escutcheon and CRT2.4 Battery Replacement

8889

10

3. Trouble Diagnosis and Measures3.1 Confirmation of State of Trouble Occurrence3.2 Examples of Troubles and Troubleshooting

3.2.1 Examples of trouble3.2.2 Examples of troubleshooting

3.3 LED Ust of Each PCB (unit)3.4 Presumed Causes for Alarms3.5 Procedure for Inspection of Each Trouble . .3.6 Replacement of Various Units in Control Unit

3.6.1 Replacement of power unit3.6.2 Replacement of cooling fan3.6.3 Replacement of the QX card3.6.4 Replacement of memory cassette card3.6.5 Precautions during replacement

1111121213182029313232323435

364. Installation Adjustment Procedure4.1 Working Conditions4.2 Input Power4.3 External Connections

4.3.1 Connection of input power4.3.2 Connection of motor4.4.3 External connections

363637373737

-i-

4.4 Installation Check List4.5 Turning on the Power

4.5.1 Power on, ready on, emergency stop, ready off flow chart . . .4.6 Setting Capacity (hardware setting)

39404041

5. Explanation of Hardware5.1 Outline

4343

4.4 Installation Check List4.5 Turning on the Power

4.5.1 Power on, ready on, emergency stop, ready off flow chart . . .4.6 Setting Capacity (hardware setting)

39404041

5. Explanation of Hardware5.1 Outline5.2 Flow of Signals5.3 Control Unit Functions and Handling

5.3.1 Power supply5.3.2 PCB functions and handling

5.4 Functions and Handling of the Operation Board5.4.1 CRT5.4.2 PCB functions and handling

5.5 Functions and Handling of Manual Handle (HD60)5.5.1 Functions5.5.2 Replacement and handling

434346494950575759606061

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1. OutlineThe MAZATROL T PLUS Series CNC unit is a product that has thoroughly pursed high productivity andreliability. The following material has been prepared in addition to this Manual. Please refer to thesetogether with this manual.

(1) Connection Manual(2) PLC Interface Manual

Features(1) A high speed and high precision has been realized with the incorporation of a complete 32-bit

microprocessor.(2) A high reliability has been realized with the incorporation of high integrated parts such as the

custom LSI.(3) By fully digitalizing the servo amplifier, a high maintainability, reliability and precision has been

achieved.(4) Systemization has been realized with the modulation and unitization of the product.

This manual commonly explains the maintenance, troubleshooting, installation adjustment and hardwarefor the following CNC units. However, the model name is listed for those units having limits in eachsection.

DisplaySlots Automatic programModel name

Yes 12- CRTM515 3

Yes 14" CRTM535 4

Yes 14- CRTM545 6

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1.1 System Configuration1.1.1 System configuration

The following units are generally used to compose the system using the MAZATROL T PLUS Series.: This unit has the computation processing functions for numerical

control. (This is also called the NC unit.): This unit has the setting and display functions.

(1) Control unit

(2) Operation board(display operation section)

(3) Servo/spindle control unit : This is a servo/spindle amplifier composed of a converter for obtainingDC from AC and an inverter for obtaining AC from DC.

: This drive motor moves the machine.(4) Servo/spindle motor(5) Position/speed detector : This sensor outputs a pulse that corresponds to the machine

movement amount.(6) Other peripheral equipment: Peripheral equipment such as external memory and programming

support.

This manual explains the sections enclosed with a dotted line in Fig. 1.1.

Operation board

Machine operationboardDisplay

L8888 080

O o Manual pulse handleFLD3.5

/Peripheral equipment such as external memoryand programming supportT

Machine powercontrol paneliControl unitas

Rsjnt/ J

Servo/spindle control unit

O loO

Spindle motor

qTf=Position detector lr-*=f] U

Servo motor

Fig. 1.1 General configuration of system using T PLUS Series

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1.1.2 Internal system diagram

NC operation boardNO control unit

0x054NC controlpower supply

Display unit12* CRT14* Color CRT

CPU module rfgxmMain CPU Machine operation boardCPU Ox

1.2 Control Unit Configuration1.2.1 Control unit configuration

The control unit is composed of baskets (3/4/6 slots) and the control power and control modules(integrated control section PCB) that are assembled into the baskets. The back panel into which thecontrol power and control modules are mounted is on the back of the basket, and the cooling fan ismounted on the top. The cooling fan is mounted inside the fan cover as shown in Fig. A, and can bereplaced easily be removing the fan cover from the basket unit. The control power is mounted on the farleft slot of the basket, the CPU module in slot 1, the CRTC model in slot 2, and the number of DIOmodules required from the system are mounted from the far right slot. Optional expansion modules aremounted from the left into the empty slots.

4/6 slot basket

K"'n\ M-OUS RAMFan coverS-BUS connector !JCooling fan

1S-BUS-AVRconnector Iii111 3 < 5 I

ExpansionBUS connector

Back panel t /F-OPT ION\ IN

-

l

p -TO S-BUSconnector 2(Slot 2)

iii BUSFig. A iii

fig. D CRTC module

O IO/A 1 0\-OPT I ON[\ A-BUS

illiirl I!X 1To S-BUS-AVRconnector Batterymm \To S-BUS connectors3 to 6 (Slots 3 to 6)Rg. B

mM- B U S RAMin

Fig. E DIOmodule!il j

* C-BUS\ \c-BUSM-BUSi RAM

!JROMROM C-BUS\ C-BUSXII:To S-BUSconnector 1(Slot 1)

&!!! MCPiii ROMI-T

ROMP-BUS \ Hiii!To S-BUSconnectors3 to 6(Slots 3 to 6)

TOPTION| P-BUSFig. C CPU module

Fig. F Optional expansion module

Fig. 1.2.1 Control unit configuration diagram

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1.2.2 Control section PCB configuration

The control section PCB uses a control module to which various PCBs are mounted horizontally onto a300 x 140mm standard size PCB as shown in Figs. C to E shown in Fig. 1.2.1 Control unit configurationdiagram.A system BUS connector that is connected to the back panel is mounted on the lower back of the controlmodule and an interface connector and LED indicator are mounted on the front. A plastic front panel ismounted over this.Fig. 1.2.2 shows the state from the front and side when the control modules front panel is removed. Fig.1.2.2 shows the CPU module, and the M-BUS PCB, P-BUS PCB are mounted on the 300 x 140mmstandard PCB (S-BUS PCB) so that the part mounting face faces the S-BUS PCB. Cassette memory canbe mounted freely onto the front surface of the S-BUS PCB and M-BUS PCB.This is possible with other control modules if the various add-on PCBs listed above are mounted. In somePCBs, this is not possible due to limits in the configuration, however, the ideology is the same.

Cassette memory S-BUS PC8S-BUS PCB

M-BUS PCBM-BUS PCB /Cassette memory r~l7Fixing screw

Interfaceconnector

L.Cassette memory

P-BUS PCB0SpacerP-BUS PC8 System BUS

IJ

LJFixing screw JSpacer

Fig. 1.2.2 Example of control module (integrated PCB)

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1.3 Table of Configuration Units

(1) Control unit

Model nameFunction RemarksNo. Configura

tion element name

Model name

3-slot control unit

3-slot back panelControl power supply

4MU301A1 Mounting positionS : S-BUSM: M-BUSP : P-BUSA : A-BUSC : C-BUSC: C-BUS

QX031QX084

4-slot control unit4-slot back panelControl power supply

4MU401A2QX041QX084

6-slot control unit

6-slot back panelControl power supply

4MU601A3QX061QX084

2-slot expansion control unitExpansionunit

4

2-slot expansion back panelQX025

(2) Control section printed circuit boards (PCB)

Mounting positionModel name

RemarksFunctionNo. Configuration element name

S IM ! P ! A i C : C1Model name

CPU, memory, servo l/FCPU module1With floating point operator

Refer to Note 1 for

Refer to Note 2 for D

Main CPUQX141 O

SRAM memory

Main memory

User PLC memory

Servo CPU (2ch)

QX42D O

QX81 #1 O

Refer to Note 2 forQX81 #2 O

Skip x 8QX722 O

l/F with display unit, othersCRTCmodule

2

14" color CRT, 10.4" LCD ColorQX524 OFor 9/12" CRT, 9.4" EL

Computer link (RS232)

Computer link (RS422)

MonochromeQX521 O

Added with options

Added with options

0X731 O

QX732 O

Machine input/output l/F

Honda connector type(source output)

Rat connector type(source output)

Rat connector type

Machine input/output l/F

Di/DO:64/64, A!:6, AO:1DIO module3

0X539 O

DI/DO:80/800X535 O

Dl:16QX316 O

Servo CPU addition, othersExpansion l/F

Servo CPU (1ch)

Use with TX-4/6 for MULTIPLEXExpansionmodule

4

Base has no functions0X571 O

Skip x 40X721 O

Note 2) QX812.....256KB (Standard #2)QX813.....512KBQX814.....1MB0X815.....2MB0X816.....4MBQX818.....3MB (Standard #1)Note 1) QX423.....512KB (Standard)0X424.....1MBQX425.....2MBQX429.....1.5MB

- 6 -

- 7 -

2. Daily Maintenance and Periodic Inspection and Maintenance2.1 Maintenance Instruments(1) Measurement instruments

The following instruments are used for measurement to confirm that the power is being properlysupplied to the NC unit and that the wiring to the NC unit is correct, and during simpletroubleshooting.

Table 2.1 Maintenance instruments

Conditions ApplicationInstrumentCheck that the wiring to the NC unit iscorrect before turning on the power.

Tester

The AC power voltage supplied to theNC unit is measured.

AC voltmeter The AC power voltage is measured.The tolerable difference is 2% orless.Maximum scale 10V30V tolerable difference is 2% orless.

The DC power voltage is measured.External supply 24V (I/O interfaceDIO-A)Battery voltageQX084 DC output

DC voltmeter

Check the order of AC 3-phase inputpower connection

Phase rotationmeter

For general measurement and simpletroubleshooting_

Oscilloscope

(Note 1) Currently, a high precision digital multimeter has been generally diffused as a tester,and is most commonly used. This digital multimeter can also be used for the ACvoltmeter and DC voltmeter.

(2) ToolsScrewdriver (large, medium, small)

2.2 Maintenance ItemsMaintenance is divided into daily, periodic inspection and maintenance (items not performed daily but asdesignated), and periodic maintenance replacement (replacement of parts whose life is up).

Table 2.2 List of maintenance items

Inspection/replacement

Life RemarksClass Name

Refer to the section "Cleaning theoperation board escutcheon andCRT".

Cleaning of escutcheonand CRT

Dailymaintenance Daily

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- 9 -

(3) Operation board

Model nameFunctionNo. Remarks

Configurationelement nameModel name

14" color CRT4YZ4xx4YZxx

1

A1QA8DSP40 14" color CRT unit

KS-4MB401 Menu keys

QY221 Board controller

OptionExpansion scanMC251

12" CRT4YZ2xx4YZxx

2

12" CRT unitMDT-1283-02

KS-4MB201 Menu keys

Board controllerQY221

OptionExpansion scanMC251

7

2.4 Battery ReplacementData that must be backed up such as the parameters and machining programs, etc., are saved by thelithium battery mounted in the front panel on the front of the control power supply when the power isturned OFF.

Battery used : BR-CC7P with connector(Matsushita Denchi Kogyo with Mitsubishi specifications)

: 3.0VBattery voltageAlarm voltageBattery capacityBattery back up time : 7 years

2.6V5.000mAH

Battery lifeDischarge current

7 years1OOpA or less

The battery must be replaced before the life is up to ensure proper operation of the system.(If the battery alarm is displayed, the internal data may be destroyed.)

Replacement procedureThe machine (NC) power may be ON or OFF.(1) Remove the battery cover on the front panel of

the control power supply.(2) Disconnect the connector on the battery.(3) Replace the battery and connect the connector.(4) Replace the battery cover.

If the power is turned OFF,complete this procedure within30 minutes.

/

Power supply front panel(left edge of control unit)I

Replace Battery cover

Battery

Battery\

Insert/remove

Power supply PCB

3CPD 0 7

(BAT IN)

State with battery cover removed (enlarged view)

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Inspection/replacement

Class Name Life Remarks

CRT 7,000 hours(Regulated byconductivity time forbrightness to drop below80%.)

Note, that the brightness can beadjusted by the user.Replace when

screen darkens.

Periodicinspectionandmaintenance

Battery (Li battery) Data saving time: 7 years(discharge time 2,000days)The life of the batteryitself is 7 years at 60C(8.5 years at 40C).

The data hold time is calculated bythe discharge time/year Max. 6,840hours (average 240 days x 16 +holidays 125 days x 24)Refer to "Battery replacement" for thereplacement method.

After 7 years

Cooling fan(control unit)

30,000 hours Replace when thetimes on the lefthas passed.

Refer to "3.6.2 Replacement ofcooling fan".

106 punches Replace when thenumbers on theleft has passed.

KeyboardOtherconsumableparts

2.3 Cleaning the Operation Board Escutcheon and CRT

(1) Refer to section 5.4.1 CRT for details on replacing the PCB for the 14-inch color CRT operationboard.

(2) Using a neutral detergent, etc. and soft cloth, wipe the escutcheon and CRT clean.

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3. Trouble Diagnosis and MeasuresIf any trouble occurs during operation, it is necessary to accurately find the cause so that appropriatemeasures can be taken. Perform the following check to find the cause.

3.1 Confirmation of State of Trouble OccurrenceConfirm "when", "what was done" and "what kind of trouble" has occurred.

(1) When did the trouble occur?The time that the trouble occurred.

(2) What was done?What mode was the NC operating in?

During automatic operation: Program No., sequence No., andprogram details of when the troubleoccurred.

During manual operation : What was the manual operation mode?What was the procedure?What were the last and next steps?

What is on the setting and display unit screen?Was data being input or output?What was the machine side state?Were tools being exchanged?Has hunting occurred in the control axis?

(3) What kind of trouble occurred?

What alarm is being displayed on the alarm diagnosis screen in the setting and display unit?Display the alarm diagnosis screen and confirm the displayed details.

What is displayed on the drive amplifiers status display?Look at the display of the drive amplifiers status and confirm the alarm details.

What is displayed for the machine sequence alarm? Is the CRT screen normal?

(4) How frequently does the trouble occur?

When did the trouble occur? How frequently? (During operation of other machines?) If the troubleoccurs infrequently, the power voltage may be incorrect, or noise may be the cause. Check thatthe power voltage is correct (does the power voltage drop instantaneously when other machinesare operated), and confirm that measures against noise have been taken.

Did the trouble occur in a specific mode? Did the trouble occur when the ceiling crane was operated? What is the frequency of occurrence in the same workpiece. Repeat the operation to see if the same trouble occurs during the same step. Confirm whether the same trouble occurs when the conditions are changed.

(Try changing the override, program contents, and operation steps, etc.) What is the ambient temperature?

(Was there a sudden change in temperature? Is the fan on the top of the control unit rotating?) Are there any defective cable contacts or defective insulation?

(Has oil or cutting fluids splattered on the cables?)

- 11 -

3.2 Examples of Troubles and Troubleshooting

3.2.1 Examples of trouble

(1) The NC power does not turn on.

Is the power being supplied to the NC unit? Is the power supply section fuse blown?

(2) The unit does not operate even when started up.

Is the correct mode selected? Is the tape correctly mounted during tape operation? Are the starting conditions correct?

(In some machines, the start up will be locked unless specific conditions are satisfied. Confirm theconditions with the Instruction Manual issued by the machine maker.)

Is the override or manual speed setting 0? Is the reset signal input? Is the feed hold signal input?

Is the machine lock on?

- 12 -

3.2.2 Examples of troubleshooting

Power supply related troubleshooting

The NC power does not turn on.

The NC power does notturn on.

AThe door for the controlis completely closed, ordoor lock is released.

pane*the

' The door to the control 'panel is not completely closedand the door Interlock has

V activated.Open the door and check (Note 1)

AC100V fe not being supplied.AC100V is being supplied.

Check that the power voltageis 100V +10%-15%

I 1 AC200V is being supplied.The power does not turn oneven when the OX064 POWERON switch is turned on.

AC200Vnot being- auppfeu.

Power turns on with theQX064 POWER ON switch.

Turn off the main NEB once.wait approx, two minutes,turn on power. The powerstiQ does not turn on.

Error in the route }om the NC side NF!

to QX064. j(Note 2) ' Check the NC externalPOWER ON switch and wiringsystem, and repair any

v defective areas, >0X064defect

QX064 fuseis blown.

0X084defectThe QX064 CPOOSP.OFF and COM are. short circuited.

The 0X064 CPA02AC OUT is short

circuited (The baseNF turns off). The power turns on for a moment

when the QX064 POWER ON switch'a turned on and then turns off.

The power does not turnon even when QX084 isdisconnected from thecontrol unit

The power turns on whenQX084 is (fiaoonnactad fromthe control unit

The power turns on whenthe power cable PAQ2-C isdisconnected.

The power does not turn oneven when the power cablePAQ2-C is disconnected.

12V short circuit+5V short circuit

Remove the cards from thecontrol unit one by one andfind the defective card.

QX084 powersupply is defective.

Replace.Problem in the

power cable and theoperation board connected

to it

(Note 1) When the NC body door is opened, the door interlock limit switch will turn off. Turn the door interlock switch off with thedoor interlock key and then open the door. Always return the door interlock switch to ON after removing the trouble, andthen close the door.

(Note 2) Refer to section 5.3.1 for details on blown fuses.

- 13 -

Operation board related troubleshooting

The operation keyboard cannot be operated.

The keyboard cannot be operated.

Only a certain keycannot be operated.

All keys cannotbe operated.

GY221cards aredefective.

/ 0X810, \ROM CUT are\ defective, j

f 0X141/QX524/'10X521 cards are\ defective, j

Systemdown

Softwarerelated?

0X810 isdefective.

Board cable isnot connected.

Watch dog error

r\

Keyboard isdefective.

QY221cards aredefective.

- 15 -

CRT and EL display troubleshooting

Screen does not appear.

Screen does not appear.

0X521. 0X524cards aredetective.

CRTAC100V ts notbeing supplied. defect Blank screenCRT cable. SH11.

POOS, PSA02-C arenot connected.

Screen flows.

Screen flows.

7;

0X521.0X524cards aredetective.

CRT defectCRT cabledefect SHI1

(D 'Dots" remain on screen.

*Oots remain on screen.

ft0X521, 0X524

cards aredetective.

CRT defect

- 16 -

CRT screen sways (is distorted).

Screen sways.

There is a magneticfield nearby.

51

The work-piece is

magnetized.There is a

transformer or motornearby.

The CRTstorage case is

magnetized.

There is alarge current flow

ing nearby.

f There is a magnetnearby such as a magnetl stand. j

The fan ismetallic.

(D The screen changes on its own.

The screen changes on its own.

AThe screen changesrandomly.

Occurs after a specificoperation

RQX524

cards aredefective.

Softwarerelated?

Softwarerelated?

The keyboardswitches are. defective. .

- 17 -

3.3 LED List of Each PCB (unit)Fig. 3.3. shows the conventional hardware configuration (max. configuration) of a normal system. Referto section 5.3.2 *PCB functions and handling- for details on PCBs not listed here.

Control powersupply_

Axis expansionCPU module CRTC module module DIO module DIO module DIO module

0X141QX084 QX524/QX521 QX571 QX539 0X539 QX5390X420

Q QLED1 LED2LED3

X X8 81 1O

LED1LED2

QX722 0X7310X732

0X721SDSD

LED1 FBAL1LED2 FBAL2

LED1LED2

Fig. 3.3 Conventional hardware configuration (max. configuration)

Table 3.3 shows a list of LEDs. Some of the PCBs not listed here do have LEDs, so refer to section 5.3.2functions and handling- for details.

Table 3.3 LED list

StateCard name LED name Details of display Measures during errorNormal j Error

LED1(Green)(POWER)LED2 (Red)(AC FAIL)

Control powersupplyQX084

Lit { Not lit Control power ON Refer to '(1) The NCpower does not turn on-.Measure AC input voltage.Not lit j Lit AC input overvoltage,

undervoltageDC24V output OFFBattery alarm (2.6Vand less)_

Is DC24V load too high?Replace batteryimmediately._

ILED3 (Red)(BAT.AL)

Not lit j Lit

Not lie { Red Watch dog alarm One of the PCBs in theCPU module may bedefective.The DRAM in the QX141card or one of the QX42Dcards may be defective.

QX141 LED1(Green, Red) LED

IstableGreen iRedLED ILEDflickers j stable

Memory parity errorLED2(Green, Red)

The PCB may be defective.LED1(Red)LED2(Green)

Not lit I LitGreen j Not lit

Watch dog alarmSoftware monitor

QX721/QX722

LEDflickers j

Lit | Not lit Either the PCB or cablemay be defective.

Same as aboveThe cable may be brokenor the spindle encodermay be defective.Same as above

Indicates that data isbeing transferred between operation board.Same as aboveSpindle encoder nosignal alarm

Same as above

SD (Green)QX524/QX521

RD (Green)FBAL1 (Red)

Lit i Not litNot lit j Lit

FBAL2 (Red) Not lit | Lit

- 18 -

LED on operation board side

QY 2 2 1

]C ] [

[ ] MON RD SDI O O O[ [ ]

Green Green Green

StateDetails of displayLED name Measures during errorCard name

Normal ! Error

Data reception(Indicates thatcommunication datafrom the control unit isbeing received.)

QY221If RD goes out or SD lightswhen MON is flickering,the cable may be brokenor the PCB on the controlunit may be defective.If both RD and SD are out,this PCB may be defective.

RD (Green) Lit i Not lit

Data transmission(Indicates thatcommunication data isbeing transmitted tothe control unit.)

SD (Green) Lit I Not lit

The PCB may bedefective. However, if allLEDs (RD, SD, MON) areout, the DC24V supplyOFF (NC power supply)may be interrupted.

System monitorLit

Not litMON (Green) Flicker

- 19 -

3.4 Presumed Causes for AlarmsThe presumed causes for alarm related to the hardware in the MAZATROL T PLUS Series are explainedin this section.

1. The following system alarms will immediately stop the system operation when a system error occurs.The emergency stop state will be entered, so nothing will display on the screen. All operations willbe invalidated, so turn the power OFF and ON, select the 'HARDWARE ALARM screen' of thediagnosis screens, and note down the register in which the alarm occurred. Then contact the servicecenter.

Possibility ofhardware defect

Alarm generatedsimultaneouslyMessage Details

Great Watch dog errorParity error RAM error

An address that does not exist wasaccessed.Bus error Small Watch dog error

Division of a denominator that is zerowas attempted.Zero divide Very small

Watch dog error The system operation stopped. Medium

An illegal interrupt occurred. SmallIllegal exception

2. The following screen is the 'HARDWARE ALARM screen' that displays the state of when the systemalarm occurred.

[ TEMPfiRfiTlJRE MONITOR![POWER ILLG. MONITOR]t EMERGENCY FFiCTGR!

5S/W 05V 24V1 HC UNITel ILLEGnL COUNTDIO IOP PLC BOD2 OPERATION BOfiHO02 ILLEGnL 71HE

C EXCEPTION INFDRKRi tGNl

04.93.04 13=35 24* DATA REGISTER'17 CR -7-710 pr 43343243 |S1S2C885 938880808 g08088SBft 80080830 E039 SC 8393 RA 50IF7C3C *90003183 33030900 103000000 fiOBSSSSl:

SSW 08008009 ADDRESS REGISTER98968068 S501FF278 flC3658FA8 308996182 8888SS&'L08990088 90064288 S58173EB4 0882BB88 Q0032B854

DFfiInstruction Address

{ HARDWARE RLfiRH 3

- 20 -

Measures for hardware(Small letters are causes otherthan the hardware)

Possibility ofhardware defectMessage Details

011 EEROMerror

This occurs when theparameters were notcorrectly written into theEEROM.

Small Replace QX141

The voltage of the batterymounted to save the data in

008 Batterydrop 100% Replace batterythe NC has dropped.

(Life)

010 Overheat The temperature of QX141or the operation board hasrisen over the specifiedvalue.Specified value

QX141 ON at 705COFF at 555C

Operation boardON at 705COFF at 605C

Fan trouble

However, in most casesthis is caused by theworking environment, soconfirm the heatmeasures taken for thebody as explained in the

Manual".

Small (FAN)

007 DIO 24Verror

The required 24V power isnot being supplied to theI/O interface DIO-A card(DIO card).

Replace DIO card

Small Confirm 24V powersupply connectionCheck for short circuit of24V load on machine side

There are primary alarms (alarms which when occur, another alarm also occurs), and secondaryalarms (alarms that occur even with other cause). Here, the presumed caused of the primary alarmmust be investigated.

Example(1) If both the parity error and watch dog error occur simultaneously, investigate the parity error.(2) If battery drop and another alarm occur simultaneously, investigate the battery drop first.

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(1) Parity error

(a) MeaningA parity bit is added to improve the reliability of the CPU card DRAM and memory card QX42DSRAM.When data is written into the above RAMs, the data is written into the parity bit memory so that thenumber of "1* bits , including the parity bit, becomes an odd number, for each byte. Then, if thememory details change for any reason, the change will be detected when the data is read out, anda parity error will occur.(The changes cannot be detected when two bits are changes simultaneously. However, theprobability that two bits will change in all addresses that the software accesses is very low.)

pi-1-1-1-1-1 i| The number of bit 0 to 7s "1s* are even,10 0 10 11 _1-1-1-1-1-1 1-1 so *1* is written in.7 6 5 4 3 2 1 0

1 1 I 0(b) Cause and measures

Handling of this error will differ according to whether this is a CPU card DRAM parity error or aQX42D SRAM parity error. It is important to determine which parity error has occurred.

How to determine the errorList of presumed causes

Proba-No. Presumed cause Presumed cause (details) Measures bilityThe voltage of the back up battery(Li battery mounted on front ofQX084) has dropped.If the message Z52 Battery drop'appears on the screen after thepower is turned on, and the QX084BAT.AL LED lights, the batteryvoltage has dropped. The detailsregistered in the SRAM may havebeen lost when the power wasturned off.

SRAM Parity error Replace with anew battery.

Great1

Memory card defectIf the battery voltage has notdropped, the card may be defective.

Replace QX42Q Medium

Replace QX141Q MediumThe CPU card DRAM may be defective.DRAM Parity error2 The RAM area has not been initially

cleared, so a SRAM parity error hasoccurred.

Initial clear Great3 Software

Change to thenewest softwareversion, and seehow it works.

Small An illegal address (area wherememory is not mounted) wasaccessed, normally a bus error willoccur.

Replace QX084 Small. AC FAIL and MLOCK are notpossible when the power is turnedoff due to control power QX084defect.

Others4

The error must be canceled with memory all clear after the cause has been eliminated.

-22-

(2) Bus error

(a) MeaningEach PCB (and internal circuit) mounted in the control unit has a characteristic address assignedto it looking from the MPU of the CPU card QX141, etc. (This is called the address MAP or memoryMAP.)When the software runs away or an area other than this designated address is accessed, ananswer will not be returned and a bus error will occur.

(b) Cause and measures

List of presumed causesPresumedcause

ProbabilityPresumed cause (details) MeasuresNo.

Card defectReplace the control modules in theorder of the CPU module, CRTCmodule, DIO module, etc.

When the alarm stops when one ofthe above control modules isreplaced, replace the PCBs on thatcontrol modules. For example, if it isthe CPU module, replace the PCBsone by one in the order of QX141,QX721/QX722, QX42D, QX81D.

Carddefect

Great1Replace with a goodcontrol module.Replace with a goodPCB.

Confirm the 'cable clamptreatment*, 'groundingtreatment', 'surge killertreatment of relays, etc.",according to the

Manual, andtreat if treatment has notbe executed already.

Small NoiseIf measures against noise have notbeen taken, the system may bemalfunctioning due to noise that isentering the NC through the powercable and connection cables.

Noise2

Malfunction during a specificoperation

Change to the newestsoftware version, and seehow it works.

Software3

Confirm the cause of thephenomenon, and thencontact the servicecenter.

The user PLC software accessed anillegal address.

(3) Zero divide

(a) MeaningWhen calculating A-rB, B=0.

(b) Cause and measuresCheck the software list to see if there is any cause for the data corresponding to B being zero.This occurs when there is a cause for the data corresponding to B to be Zero.Confirm the cause of the phenomenon, and then contact the service center.

- 23 -

(4) Watch dog error

(a) MeaningA watch dog error occurs when the system is not running properly to ensure the systems safety.This error has a function to stop the system immediately.In a system that runs in real time such as the NC, a routine that is passed periodically in cyclesis established. Each time this routine is passed, a special counter (watch dog timer) is reset. If thesystem does not run properly for any reason, this routine will not be passed, so this counter willnot be reset. If a set frequency clock is attached to this counters clock terminal, this counter willoverflow. This output will apply an interrupt on the CPU, and will take appropriate measuresimmediately.

Detection positionsThe CPU card (QX141, etc.) and servo CPU cards (QX721/QX722) have watch dog errordetection circuits, and the LED will light when a watch dog error occurs.

(b) Cause and measuresDetermining the cause of these messages is difficult, but the presumed causes are shown below._List of presumed causes_

Probability

No. Presumed cause Presumed cause (details) Measures

CPU moduledefect

CPU module defectThe CPU module in the hardware isdefective.

Replace with agood controlmodule.

Great1

(1a) Servo CPU card defectThis card may be defective if LED1on the QX721/QX722 card is lit.

(1b) CPU card defectIf a watch dog error occurs evenwhen LED1 on the QX721/QX722card is not lit, the CPU card (QX141,etc.) may be defective.

(1c) Main memory card, user PLC carddefect

If a watch dog error occurs evenwhen LED1 on the QX721/QX722card is not lit, the main memory cardor the ROM in the user PLC cardQX81D may be defective._

Replace with agood PCB.

SmallReplace with agood PCB.

Defect in other cardIf a watch dog error occurs evenwhen LED1 on the QX721/QX722card is not lit, QX42D or anothercontrol module may be defective.

Defect in othercard

2

SmallReplace with agood PCB.

QX084 defectThere may be an error in the QX084DC output. Measure the voltage andripple with the QX084 test pinCPD03.

Control powersupply defect

3

MediumRe-insert. Defective insertion of each cardThe control module may be insertedimproperly into the back panel, orthe cassette memory QX81C1insertion may be improper. _

Defectiveinsertion

4

- 24 -

Probability

Presumed cause (details)Presumed cause MeasuresNo.

Confirm the"cable clamptreatment",

treatment", "surgekiller treatment ofrelays, etc.',according to the

Manual", andtreat if treatmenthas not beexecuted already.

Noise NoiseIf measures against noise have notbeen taken, the system may bemalfunctioning due to noise that isentering the NC through the powercable and connection cables.

5 Small

Malfunction during a specificoperation

Software Change to thenewest softwareversion, and seehow it works.

?6

The user PLC software accessed anillegal address.

?

- 25 -

(5) illegal exception

(a) MeaningThis error indicates that an illegal interruption occurred.

(b) Cause and measuresAs with the watch dog error, the cause of this error is very difficult to determine, but the probablecauses are listed below.

List of presumed causesProbabilityNo. Presumed cause Presumed cause (details) Measures

Card defect Card defectReplace the control modules in theorder of the CPU module, CRTCmodule, DIO module, etc.

When the alarm stops when one ofthe above control modules isreplaced, replace the PCBs on thatcontrol modules. For example, if it isthe CPU module, replace the PCBsone by one in the order of QX141,QX721/QX722, QX42HI, QX81H1.

1 GreatReplace with agood controlmodule.Replace with agood PCB.

Control powersupply defect

QX084 defectThere may be an error in the QX084DC output. Measure the voltage andripple with the QX084 test pinCPD03.

2 Replace with agood PCB.

Small

Defectiveinsertion

Defective insertion of each cardThe control module may be insertedimproperly into the back panel, orthe cassette memory QX81insertion may be improper.

3 Re-insert. Medium

Noise NoiseIf measures against noise have notbeen taken, the system may bemalfunctioning due to noise that isentering the NC through the powercable and connection cables.

Confirm thecable clamptreatment*,

treatment, surgekiller treatment ofrelays, etc.,according to theConnectionManual", andtreat if treatmenthas not beexecuted already.

4 Small

?Software Malfunction during a specificoperation

Change to thenewest softwareversion, and seehow it works.

5

? The user PLC software accessed anillegal address.

-26 -

(6) 011 EEROM error

(a) MeaningThis error occurs when the parameters are not correctly written into the EEROM.

(b) Cause and measures

List of presumed causes

ProbabilityPresumed cause (details)No. Presumed cause Measures

EEROM defect The EEROM in QX141 is defective.1 Replace with agood EEROM.

Great

Card defect QX141 defect Replace with agood PCB.

2 Great

3 Control powersupply defect

. QX084 5V output defectThere may be an error in the QX0845V output. Measure the voltage andripple with the QX084 test pinCPD03.Check that the TEST pin has not beset by mistake.

Replace with agood PCB.

Small

Release setting.

(7) 008 Battery drop

(a) MeaningThe voltage of the battery mounted on the front of the control power supply to save the data in theNC has dropped below the specified value (2.6V).

(b) Cause and measuresThe direct cause is that the battery voltage has dropped below the specified value (2.6V) due tothe battery life. However, if the above alarm occurs at a point remarkably sooner than the batterylife (7 years), the discharge current in the control PCB may be excessive. Measure the dischargecurrent before replacing the current.

List of presumed causesProbabilityPresumed cause (details) MeasuresNo. Presumed cause

Great Battery life Replace with anew battery.

Battery life1

Small SRAM memory card QX420 carddefectThe SRAM memory card QX42D isusing too much of the batterycurrent.

Replace with agood PCB.

Card defect2

Other card defectsSome of the PCBs use the batteryfor the CMOS power supply.QX141/QX521/QX524/QX571

Replace with agood PCB.

SmallReplace with agood PCB.

QX084 defectThe QX084 is using the battery forthe CMOS power supply.

Control powersupply defect

3

-27-

(8) 010 Overheat

(a) MeaningThis alarm occurs when the NC control unit (measurement position is QX141) or the operationboard (measurement position is QY221) has risen above the specified value.

NC control unit : Alarm occurs at 7056C, turns off when below 555COperation board : Alarm occurs at 705C, turns off when below 605C

(b) Cause and measuresList of presumed causes

Probability

No. Presumed cause Presumed cause (details) Measures

Workingenvironment

The NC ambient temperature (0 to45C) has been exceeded.

1 Check that theunit is not indirect sunlight,and is not near aheat source(heater, etc.).

Great

2 Workingenvironment

The temperature is within the NCambient temperature (0 to 45C), butthe body temperature has risen 10Cor more.

Refer to the

Manual" andcheck thatmeasures againstheat have beentaken.

Great

Cooling fan troubleFan trouble Replace with agood fan.

3 Medium

(9) 007 DIO 24V error

(a) MeaningA 24V power supply must be connected by the user to the I/O interface DIO-A card (DIO card).This alarm will occur if the 24V power supply is not connected, or if the 24V load (relay, etc.) onthe machine side has short circuited, and the 24V power has dropped.

(b) Cause and measuresList of presumed causes

ProbabilityMeasuresPresumed cause (details)No. Presumed cause

Refer to the

Manual" andconnect a 24Vpower supply.

No 24V power supply connection GreatNo 24V powersupplyconnection

1

GreatReview thewiring.

The DO signal wire has shortcircuited with the GND, and anexcessive load current has flowed.In this case, the output IC on the I/Ointerface DIO-A card may have beendestroyed, so replacement of thecard may be necessary._

I/O interface DIO-A card defect

24V load onmachine sideshort circuited

2

SmallReplace with agood card.

Card defect3

- 28 -

3.5 Procedure for Inspection of Each Trouble

(1) Confirmation of power voltage

Confirmation of input power voltage

The 3-phase input power voltage is connected to the non-fuse breaker terminals R.S.T. on theNC sidevia the non-fuse breaker on the machine side. Confirm that the specified voltage is being output here.

Input side

|| H R S T

ON

QOFF

u V w ll ll --Output sideI To transformer

Fig. 3.5.1

The single-phase input voltage is connected to the DC power QX084 terminal on the control unit, soconfirm that the specified voltage is being output here.

+10%-15%AC100V

Confirmation of DC power voltageThe DC power voltage is output to the DC power QX084 connector on the control unit, so confirmthat the specified voltage is being output here.

Max. total fluctuation rate Max. ripple voltage

~ 50mV-2% ~ +2%+5V~ 60mV+12V -2% ~ +2%~60mV-2% ~ +2%-12V~ 200mV-15% ~ +15%+24V

(Note 1) The QX084 machine input/output power (+24V) capacity will increase according to thesystem, so refer to the corresponding item in the 'Connection Manual*.

(Note 2) A voltage adjustment variable resistor is not mounted on QX084, so settings to slightlyfluctuate the 5V voltage for testing will be required.

1-2 ON 4.75V2-3 ON 5.25V

-29 -

(2) Connection of control power supply

rn

Fig. 3.5.2 Mounting position of control power supply

(Connector name)(Connector maker)

QX084

3.6 Replacement of Various Units in Control UnitThe procedure for replacing the control unit is shown in Fig. 3.6.When replacing the unit, refer to this drawing and the following explanations.

Fan cover

&y /srZ.Fan

P 6(Air flow0 direction)

Fan connector

Card puller

\m_ZILIRIIp A AControl

power unit

H 1VVMemory cassette

C7VBasket

/ rBattery cover

zBattery

\T~T4

Card puller QX card

Fig. 3.6 Control unit replacement procedure drawing

-31 -

3.6.1 Replacement of power unit

Disconnect all connector cables, etc. Rotate the upper and lower card pullers on the power unit, and pull out in the direction of the

arrow. When mounting a new power unit, follow steps and in reverse.

3.6.2 Replacement of cooling fan

Follow procedure 3.6.1 and remove the power unit. Press the notch on the front of the fan cover, and remove the cover. Put your hand in through the front of the basket and pull out the connectors connected from the

fan to the back panel.@ Remove the fan. (It is only held by the fan cover.) When mounting a new fan, follow steps @ to in reverse.

(Insert the fan while sliding it along the guide.)

3.6.3 Replacement of the QX card

If a connector is connected, remove it with the following steps.(1) For the following type of connector, loosen the two screws, and pull out the connector while

holding the fitting.

Screw n-==?&O

B 7Fitting

(2) For the following type of connector, loosen the two screws, and pull out the connector.

I

0o oScrew

- 32 -

(3) For the following type of connector, pull out the connector while pressing it in the direction of thearrows.

0

=

3.6.4 Replacement of memory cassette card

Memory cardCassette case A Cassette case B

X

iOa

-=ldc

%

Memory cassette fixing screw

Loosen the two screws fixing the memory cassettes, and remove the card from the memory cardunit.

Release the claws from cassette case A while pressing down on the notch on the front of cassettecase B.

Remove cassette case B from cassette case A .() After lifting up the front end of the memory card, pull the connector side end from the cassette

case A groove. When mounting a new memory card, follow steps @ to in reverse.

-34-

3.6.5 Precautions during replacement

(1) Take care as parts are mounted on both sides of the QX card. Parts are mounted on the PCB frontsurface (C surface) and back surface (S surface). Take care not to damage the S surface parts when replacing the CPU, ROM or PAL.

(2) The memory cards (QX423, QX424, QX425, QX429) save data with a super capacitor. Always replace the card within 30 minutes. The memory will be damaged if the card is touched with a metal part (ex. screwdriver).

(3) Normally, parts that are suspectable to static electricity are mounted on the PCB. Workers must demagnetize themselves before starting operation. (Especially during the winter.) Do not touch the electronic parts. Carpets, etc., generate a static electricity with a very high voltage. Take special care.

-35-

4. Installation Adjustment ProcedureTake special care to the following points when installing the MAZATROL T PLUS.If these points are not observed, the NC performance may not be satisfactory.

4.1 Working Conditions

The following conditions are to be applied when installing a cabinet or pendant designed andmanufactured by the machine maker. Observe the points listed in section Cabinet and pendant designconditions" in the Connection Manual* to satisfy the following conditions.

(1) Ambient temperatureDuring operation: 0 to 45C (The ambient temperature for the control unit is 0 to 55C)

(2) HumidityNormal relative humidity: 75% or less

The insulation or parts will deteriorate easily if the humidity is high. Special dehumidification measuresare not necessary, but avoid installing the system in areas with extreme humidity.

(3) VibrationDuring operation: 0.5G or less

During transportation: 3.5G or less

(4) AtmosphereAvoid use in environments that have large quantities of dust or high concentrations of organic orcorrosive gas mist.

4.2 Input Power

(D Input voltageControl unit: AC100V +10%-15%

(2) Frequency: 50/60Hz 2%

Power consumption: Refer to section Power consumption' in the Connection Manual" for thecontrol section.Refer to the MELDAS Servo System Specifications for the drive section.

(3)

- 36 -

4.3 External Connections

Follow the procedure given below for connections from the control unit to external sources.

4.3.1 Connection of input power

The 3-phase input power is connected to the amplifier terminal via the non-fuse breaker on the machineside.The NC control units single-phase AC100V is connected to connector CPA01 on NC power QX084.(Refer to the figure in section "3.5 Procedure for inspection of each trouble, (2) Connection of controlpower supply.)

4.3.2 Connection of motor

Follow the "Spindle and Servo Specifications".

4.3.3 External connections

Connect the external connections according to "Machine-to-machine connections" in the "ConnectionManual". All of the cables led into the control unit and operation board must be shielded and clampedaccording to "Lead-in of cables and clamping" in the "Connection Manual".These clamps not only support the cables but also shield the cables, and must be enforced for thesystem to operated properly and not malfunction due to noise, etc.

General system drawings are shown on the following page for explanation purposes.Refer to the "Connection Manual" for actual connections.

- 37 -

Onfiltty o* V'-

With 12 inch CRT display en UDM KXas*a IP-V&P-I

Q CDA-tSS/SS0 M*lf-prfcn ODKXCIorOpwoxm bowl --, AC pof Mpt>y

1-17813-3Jwi Amp

AC po-w wpN

AC pg* xp*y0 0Amp*' CRT patptay ! 2-178128-3J*P*> Amp{gCRT 2sr [gHD6 0 8

ConW PO**f ;~PP*ON ri 31814J3H1Q Y 2 0 1 DCpr upp*yOC powar aupptyo B 0TE 2-178288-3-Ap Amp1-178288-2>P*A Amp

ControlPWsr 5 ;Ci3

SHI 1 3/4 MX aomni vnIOC OPT

OXJJ I

r@CE,s 1 1CSHI I

0 1 0CPUOX t < 1

j AVR0X8 14 ION

orrji ON0P AO 1AClOOV> TIMdM-g IC P ACVM: control txxCSAJ 101 r-6 IP A 0 2 -C :CSHl 2

0pPT:l ON

|MC P0X7 2 10X7 2 2

Tonwlwx

rh>SfCSH 2I

22CP08 5 iPDO 51* o iCPD8S * 1CDPSl4 rf-G IRS232CSAI2- 1 DP2 1CH0| #- (a>($np)

SA2 1 jCNI I ICHI SH2 1 IU.M.U,EncsdarfeftESlVK*

CH2! I

Standard spedfications;Panel Installation type

Refer to theSpindle Servo Spedficatioos*for details oo the drive sectionconnections.

[53 3With color CRT display

----OpmUon tXMrfCooSng un*f Cater CUTMSCRT2

257STri. HD6 OBQY2 0 10w**PO-wr

oCSH1 8CBPt S rf=8+

SHII yianww*:[ AVR

0X8 14C> A 8 l

IOC DI0CPUOXI4I

OPTOXS 2 1 tON.

lOPTilONr6CE,sl 1

CSH t 10ACI00V> :-8 I !CPA 8 2 CSA2 1Hr8 r-6 ICSHI 2DlOPT;iON

)MCP0X7 2 1QX7 22 AM poinr

snM8airfOc H 2 2CP08Sti CSH 2 1Ki ICP08 COPSIm rH3 !* 0P2 t *- Six(SWP)SSH2 ICnooP*' SEASS 1 1 O ipM8*r

Fig. 4.3 General system drawings (for reference)

-38 -

4.4 Installation Check List

Check details Related sectionsCheck itemNo.

Is there any dirt or damage on the NC control unit or operation boardcaused during transportation?

Check of configurationcomponent'sappearance

1

Have the PCBs in the card basket dislocated during transportation.Follow section 3.6 if the PCBs are dislocated, and securely insert theminto the card basket.

Section 3.6

Is the ambient temperature of where the power control box is to beinstalled within 0C to 45C (the internal temperature rise in the powercontrol box must be 10 or less).Even if the external temperature is 45C or less, do not install thesystem in direct sunlight, near a heat source, or outdoors.

Check of installationenvironment (duringmachine installation)

2

In systems where the floppy disk unit 4FD01A is mounted, is theambient temperature of where the power control box is to be installedwithin 10C to 30C (the internal temperature rise in the pendant mustbe 10 or less).

Avoid installation in environments that have large quantities of dust orhigh concentrations of organic or corrosive gas mist.

Confirm the PCB settings.Confirmation ofsettings

3

Confirm that the rotary switches on the PCB are correctly set.

Confirm that the DIP switches on the PCB are correctly set.

Confirm that the PCBs are securely inserted into the card basket.If the PCBs are inserted after installing onto the power control box, theDIN connector match may be loose.

Section 3.6Confirmation of PCBinsertion

4

Section 3.6Are the external cables screwed or locked?Connection of externalcables and groundingwire

5

Have the cables been clamped?Has the cable sheath been peeled, the shield exposed and thatsection contacted against the earth plate with a cable clamp?

Has each earth plate been grounded to one point?

Has the NC control unit been properly grounded?

Has the operation board been properly grounded?

Have the A, B and C signal wire groups been separated?

Section 3.5Has the power cable been properly connected?Connection of powercable

6

Section 4.2NC control unit: AC100 +10% to -15%, 50/60Hz2%Confirmation of inputpower voltage andfrequency

7

Confirm that the output of the I/O interface DIO-A has not been shortcircuited with the grounding.

Confirm that the signalwire has not beenground faulted

8

Confirm that the output of the I/O interface DIO-A has not been shortcircuited with the 24V.

Confirm that the DC24V output of the NC control unit has not beenshort circuited with the 0V.

- 39 -

4.5 Turning on the PowerPrecautions for turning on the power

The power is turned on in the following order.(1) Confirm that the main breaker is ON. If OFF, turn it ON.(2) Press the "POWER ON" switch on the CRT setting and display unit. The "READY" lamp will light

after approximately three seconds, indicating that the control unit is in the operable state.(3) Press the "RESET" switch on the CRT setting and display unit. Now, operation will be ready.

The operable state will be entered even if this "RESET" switch is not pressed, however, make ita habit to press the "RESET" switch after turning on the power for safety and confirmation.

4.5.1 Power on, ready on, emergency stop, ready off flow chart

Ready off(approx. 3 seconds)

Preparation will be completed in approx.3 seconds after turning NC power on.NC power on

Operation ready

(Control of automatic operationand manual operation, etc., possible)

VSPreparation will stop immediatelyif one of the items on the left occurs.

1. Emergency stop B2. Watch dog .3. Memory parity \.4. Battery alarm occurrence)5. MCU error 6. Servo amplifier7. Memory guard

Ready off (one second)

IT 7> Press "RESET".V

Parameter

Emergency stop A,etc. (trouble)

Emergency stop(during trouble)

Emergency ostop hold. 1

The state isheld in the NC.The state after the causeis removed will be set by

the parameters (machine). Emergency stop AEmergency stop

(Remove cause)

-40 -

4.6 Setting Capacity (hardware setting)

OutlineSettings are made to determine the various constants in the NC, characteristic constants on themachine side and specifications, etc. Settings are made with the hardware settings and softwareparameters.If these settings are changed, the machine movement will be obstructed, so take special care whenmaking any changes.The hardware settings will be explained in this section.Hardware settings are made by setting the setting pins, toggle switches and rotary switches mountedon each card in the control unit.These settings have been set at the factory before shipment and thus these do not need to bechanged.This MELDAS-500 Internal setting table' is included with each NC unit. (The one shown on the nextpage is an example.)When replacing the cards or unit, refer to the attached internal setting table and the current card unitto make correct settings.

Set in this direction.

Precaution: DIO card system map setting methodThe emergency stop input setting plug and system map binaryswitch (SW1) setting (SET=) for each DIO card is performed withthe following settings.

SWI(CSI)

T7NL.;

HISET-

DIO #6DIO #4 DIO #5DIO #2 DIO #3DIO #1

Emergency stopinput

OFF OFFOFF OFFOFFON

52 3 410System mapSET=

-41 -

Client Msgr.MELDAS-500 Internal setting table

Machine model name

0X034;a Recording method0) Place a check in the 0 according to the PCS mounted on the NC control unit, operation

board and drive section.Q.

v> TEST 5V adjustment5oQ.

(2) ff there are several PCBs to be filled into the columns, circle the name of the PCSmounted.Note the rotary switch setting value after the Setting value = for the rotary switch.The settings that are shaded are fixed (cannot be changed).

1 2 3I (3)Set to the above setting

regardless of model :5 (4)O QX423/0X424/QX425 O QX721/OX722::QX143/OXl41-t (UOX815/QX816

-]081 js.t**'" SPC Super C SO ICE ;, a 0X721/0X722v.y. .

5. Explanation of Hardware

5.1 OutlineAn outline of the MAZATROL T PLUS Series operation theory will be explained in this section.Please refer to Fig. 1.1 General configuration of system using MAZATROL T PLUS.The MAZATROL T PLUS Series is composed of the control unit that can be called the control computeras a base, and the NC operation board and servo mechanism.The control unit is composed of various control modules (integrated PCBs). The following three modulesare mainly used.The CPU module, is the data processing section that is made up of the main CPU QX141 (composed ofthe latest 32-bit CPU, memory, programmable controller, various gate arrays, and peripheral IC), SRAMmemory QX42D, main cassette memory QX81 user PLC cassette memory QX81 and axis movementcontrol section QX721/QX722.The CRTC module is the display and control section made up of the graphic control PCB QX524(including various functions other than display control) for color CRT correspondence, and graphic controlPCB QX521 for monochrome correspondence.The DIO module is the I/O interface with the machine side.The NC operation board has various display functions such as the CRT display function and the MDIsetting function. The display between the NC operation board and control unit is performed with videosignals, and the data is transferred with high speed serial transmission.The servo mechanism is composed of a full digital servo amplifier, AC servo motor and position detector.Data is transferred between the full digital servo amplifier and control unit with high speed serialtransmission.

To process the data, the CPU reads (fetches) one command at a time of the software (group ofcommands called the control program) that is read into the memory beforehand. The command isanalyzed, executed and processed.This control program is divided into several programs according to the required emergency of the dataprocessing, and is located in the ROM on the memory cassette QX81QThe program that is closely related to the hardware and which waits for controls is called the monitor.Many programs (called tasks) run under the control of the monitor, and include the following:First, the contact input on the machine side, and contact output and command pulse distribution to themachine side must be processed within a set interval. Thus, these have the highest priority. The machinecontrol program that processes these is called motion.Next, the calculation program that reads the tape command, analyzes the NC command to precalculatethe data required for the above process, and that performs interpolation is called the pre-program.The man-machine interface program that displays data on the CRT setting and display unit, andprocesses the data input with the keys is called the operator controlled program.If these programs are processed in order, the request for work with a high degree of emergency cannotbe satisfied, so each task is given an order of priority, and processes are performed according to thisorder.If, during a certain task, a request for processing a task with a higher priority is received, the currentlyexecuted task will be interrupted, and the requested task will be executed. If an even higher task isreceived, that task will be performed first, and when completed, the task interrupted last will be executed.The task interrupted first will be executed last.The operation flow of the MAZATROL T PLUS Series is as shown in Fig. 5.1.As can be seen in the flow chart, the MAZATROL T PLUS Series reads in the data on the machine sidewith the built-in CPU, and makes various judgements according to that data and performs controls.In the automatic mode, when the CYCLE START button is pressed, the machining program is read in fromthe memory. If it is a movement command, the movement data for each axis is calculated and output tothe servo amplifier.If it is machine operation data, the data will be output to the power control sequence.

- 43 -

)( StartMachine data input

Machine data read in

automaticmode?

To manual mode, etc.,processNO

YES

Output machine data topower control sequenceCycle start? NO

YES

Note) The machining program isalso called the partprogram.

Read machiningprogram frommemory

EOB?NO

YES

Check machining program format."

CRT setting and display unit key inputWhen the key switches on the CRT setting and display unit are pressed, the inputs are read into theNC unit with the following route.

SV(Matrix input) iLKey QX141CPUswitch Receiver

circuitl TQX521card(black ancwhite)

QY221 icard

mrLC

QX524card

(color)

Machine operation board inputIn addition to reading in the machine contact inputs of the switches on the machine operation boardas explained above, these can be read into the NC with the following route.

Machine operation boardswitch

QX141 CPU IInput ReceivercircuitQX521 iQY221 card { 1card (black andwhite)

1

tI0X524

card(color)

-S- 24V

Machine operation board lamp outputThe machine operation board lamps (including LEDs) can be lit up with the following route in additionto outputting to the machine side.

Machine operation boardswitch

QX141CPU

QX521 QY221card

card(black andwhite)

0X524card(color)

24VOutputz Protective resistor1

S R or

(External power supplyof 24V is necessary.)

7'7 Open emittercircuit

-45-

5.2 Flow of Signals

Machine contact input

DIO moduleQX539/QX535,etc., machineinput l/F

Machine sidepower controlcircuitMachine controlboard

QX141CPU

Output to machine side

DIO moduleQX539/QX535,etc., machineinput l/F

Machine sidepower controlcircuitMachine controlboard

QX141CPU

(Note) VDE regulations(input circuit: 24V common, output circuit: open emitter (also called source output))

24 VOutput

Input l Protective resistorAReceivercircuit6 a or TLJiI 777- Open emitter circuit-B-24V

Non-VDE regulations(input circuit: GND common, output circuit: open collector (also called sink output))

i24 V --24VOutputInput2.2KI Receiver

circuitA Protective resistorIr ii PLI

k1 I

7777 Open emitter circuit

- 46 -

Screen displayDisplay outputs to a 12 inch CRT screen is performed with the following route.

Settinganddisplay unit

VideoQX141 QX521

cardQY221cardCPU signal

Display outputs to a 14 inch CRT screen is performed with the following route.

Video Settinganddisplay unit

QX524card

QY221card

QX141CPU signal

Manual pulse generator (manual handle)This is used to finely feed the machine table in the manual mode.One pulse is output with each scale on the manual pulse generator, and 25 pulses are output withone dial rotation (100 pulses when multiplied by four).The movement amount per scale can be changed to 0.001mm, 0.01mm or 0.1mm with the externalmagnification selection switch.

QY221Manual handlecontrol circuit

QX524/QX521 QX141 CPU(For board side)

Manual pulsegenerator CPU

The manual handle's internal circuit is as shown below.

Constant voltageConstant current

O Power

Output driver A phase output3Z X\/Luminescentdiode

\/ \Waveformshaping /Photocell O Grounding \\A i

i \ /O B phase output /\ /\ /\"777Slit disk

Handle axis

- 47 -

On the slit disk, the A phase and B phase are deviated, and thus, the A phase output and B phase outputare deviated by a 90 phase. This phase deviation will be either the A phase or B phase first accordingto the direction that the disk is rotated. In the QY221 manual handle control circuit, these arediscriminated by phase and discriminated by rotation direction.

Handle scaleOne pitch

lUIHL Li_LIA phase pulseor

B phase pulse 1 1A phase is first B phase is first

Execution of program and accessing of memoryThe route that the CPU uses to fetch the command from the memory is as follows:

1. System programQX141

QX810#1SystemCassette memory

CPU3- H CPU |Kir JPrograms inthe cassette memory (systemprogram) on the left side of the CPU module that requirehigh speed processing, are transferred to the high speed memory in the main CPU when thesystem power is turned on. Thereafter, the commands are fetched from this high speed memory.(The automatic program may also fetch commands from the cassette memory in the module thathas a special memory added to it.)

2. User PLC programQX141

QX81D#2User PLCCassette memory

CPU0X420SRAM memory CPU |rpufj

Programs in the cassette memory (user PLC) on the right side of the CPU module that require highspeed processing, are transferred to the QX42D SRAM memory when the system power is turnedon. Thereafter, the commands are fetched from this SRAM memory.When the memory is referred to (read,written) during the command, the data flow will be as shownbelow.

QX524 QX42DSRAM memory

QX141Main CPU

QX42DSRAM memory QX521

QX571QX42DSRAM memory

Machining program memory areaIf the tape length is short, the machining program will be written into the QX42D SRAM memory in theCPU module, but if long, the program will be stored in the QX42D SRAM memory in the CRTCmodule.

-48-

5.3 Control Unit Functions and HandlingThe MAZATROL T PLUS Series control unit 4MU301, 4MU401 and 4MU601 is composed of the DC powersupply QX084, back panel QX031, QX041, QX061 and various control modules. These are mounted ona compact and lightweight unit.The configuration of this control unit is shown in the Table of configuration units in section 1.4.The inside of this control unit is as shown in the Internal system diagram in section 1.1.2.The following pages explain the setting of the various configuration elements and adjustment positionsof this control unit.

5.3.1 Power supplySupplementaryexplanationQX084 Appearance and connection connectors

This is the MAZATROL T PLUS Series control unit'sDC power supply. A 5V*12V and 24V DC voltage iscreated.

Usaq1. Mi

e formatAZATROL T PLUS

Series commonpower supply

OXCJ; I: HillctMOTO FCACOUT HACOUT NifOTKiHU- pv rpa**ui POWERONOT AC FAIL fJtxKVe-o,

BAT. AL-O *SYOLC n- - -o|6-fl

I

5.3.2 PCB functions and handling

(1) Back panel

Supplementaryexplanation

QX031/QX041/QXD61 Appearance and connection connectors

QX031, QX041 and QX061 are used tor datacommunication between the control modulesmounted in the control unit.

QX 0 3 I Usage format

QXO 4 1

Maintenance comment

QXO 6 1

(2) Control PCBAs explained in 5.1 Outline, the T PLUS Series PCB uses the control module format.The add-on cards that can be installed onto each control module S-BUS PCB are shown in Table5.3.2 Control module combination table. O indicates a combination that can be mounted on thehardware, A indicates a combination that can be mounted on the hardware but where the softwareis not supported currently, and x indicates a combination that cannot be mounted on the hardware.

Table 5.3.2 Control module combination table

P-BUSModel name A-BUSAll cards

C-BUSAll cards

M-BUSAll cards

C-BUSAll cardsNo. QX721!QX722 j 0X73110X732S-BUSModel name

OO OO ACPU module :QX141/QX141-1 AA1 XOO OCRTC module :QX524/QX521 A xX2 xX

DIO module jQX539IQX535

xX X XXX XX3 O X XXX XXX

Module withspecialmemory

AA AAAAOQX571 x4

- 50 -

CRT setting and display unit key inputWhen the key switches on the CRT setting and display unit are pressed, the inputs are read into theNC unit with the following route.

SV(Matrix input) iLKey QX141CPUswitch Receiver

circuitl TQX521card(black ancwhite)

QY221 icard

mrLC

QX524card

(color)

Machine operation board inputIn addition to reading in the machine contact inputs of the switches on the machine operation boardas explained above, these can be read into the NC with the following route.

Machine operation boardswitch

QX141 CPU IInput ReceivercircuitQX521 iQY221 card { 1card (black andwhite)

1

tI0X524

card(color)

-S- 24V

Machine operation board lamp outputThe machine operation board lamps (including LEDs) can be lit up with the following route in additionto outputting to the machine side.

Machine operation boardswitch

QX141CPU

QX521 QY221card

card(black andwhite)

0X524card(color)

24VOutputz Protective resistor1

S R or

(External power supplyof 24V is necessary.)

7'7 Open emittercircuit

-45-

5.2 Flow of Signals

Machine contact input

DIO moduleQX539/QX535,etc., machineinput l/F

Machine sidepower controlcircuitMachine controlboard

QX141CPU

Output to machine side

DIO moduleQX539/QX535,etc., machineinput l/F

Machine sidepower controlcircuitMachine controlboard

QX141CPU

(Note) VDE regulations(input circuit: 24V common, output circuit: open emitter (also called source output))

24 VOutput

Input l Protective resistorAReceivercircuit6 a or TLJiI 777- Open emitter circuit-B-24V

Non-VDE regulations(input circuit: GND common, output circuit: open collector (also called sink output))

i24 V --24VOutputInput2.2KI Receiver

circuitA Protective resistorIr ii PLI

k1 I

7777 Open emitter circuit

- 46 -

Screen displayDisplay outputs to a 12 inch CRT screen is performed with the following route.

Settinganddisplay unit

VideoQX141 QX521

cardQY221cardCPU signal

Display outputs to a 14 inch CRT screen is performed with the following route.

Video Settinganddisplay unit

QX524card

QY221card

QX141CPU signal

Manual pulse generator (manual handle)This is used to finely feed the machine table in the manual mode.One pulse is output with each scale on the manual pulse generator, and 25 pulses are output withone dial rotation (100 pulses when multiplied by four).The movement amount per scale can be changed to 0.001mm, 0.01mm or 0.1mm with the externalmagnification selection switch.

QY221Manual handlecontrol circuit

QX524/QX521 QX141 CPU(For board side)

Manual pulsegenerator CPU

The manual handle's internal circuit is as shown below.

Constant voltageConstant current

O Power

Output driver A phase output3Z X\/Luminescentdiode

\/ \Waveformshaping /Photocell O Grounding \\A i

i \ /O B phase output /\ /\ /\"777Slit disk

Handle axis

- 47 -

On the slit disk, the A phase and B phase are deviated, and thus, the A phase output and B phase outputare deviated by a 90 phase. This phase deviation will be either the A phase or B phase first accordingto the direction that the disk is rotated. In the QY221 manual handle control circuit, these arediscriminated by phase and discriminated by rotation direction.

Handle scaleOne pitch

lUIHL Li_LIA phase pulseor

B phase pulse 1 1A phase is first B phase is first

Execution of program and accessing of memoryThe route that the CPU uses to fetch the command from the memory is as follows:

1. System programQX141

QX810#1SystemCassette memory

CPU3- H CPU |Kir JPrograms inthe cassette memory (systemprogram) on the left side of the CPU module that requirehigh speed processing, are transferred to the high speed memory in the main CPU when thesystem power is turned on. Thereafter, the commands are fetched from this high speed memory.(The automatic program may also fetch commands from the cassette memory in the module thathas a special memory added to it.)

2. User PLC programQX141

QX81D#2User PLCCassette memory

CPU0X420SRAM memory CPU |rpufj

Programs in the cassette memory (user PLC) on the right side of the CPU module that require highspeed processing, are transferred to the QX42D SRAM memory when the system power is turnedon. Thereafter, the commands are fetched from this SRAM memory.When the memory is referred to (read,written) during the command, the data flow will be as shownbelow.

QX524 QX42DSRAM memory

QX141Main CPU

QX42DSRAM memory QX521

QX571QX42DSRAM memory

Machining program memory areaIf the tape length is short, the machining program will be written into the QX42D SRAM memory in theCPU module, but if long, the program will be stored in the QX42D SRAM memory in the CRTCmodule.

-48-

5.3 Control Unit Functions and HandlingThe MAZATROL T PLUS Series control unit 4MU301, 4MU401 and 4MU601 is composed of the DC powersupply QX084, back panel QX031, QX041, QX061 and various control modules. These are mounted ona compact and lightweight unit.The configuration of this control unit is shown in the Table of configuration units in section 1.4.The inside of this control unit is as shown in the Internal system diagram in section 1.1.2.The following pages explain the setting of the various configuration elements and adjustment positionsof this control unit.

5.3.1 Power supplySupplementaryexplanationQX084 Appearance and connection connectors

This is the MAZATROL T PLUS Series control unit'sDC power supply. A 5V*12V and 24V DC voltage iscreated.

Usaq1. Mi

e formatAZATROL T PLUS

Series commonpower supply

OXCJ; I: HillctMOTO FCACOUT HACOUT NifOTKiHU- pv rpa**ui POWERONOT AC FAIL fJtxKVe-o,

BAT. AL-O *SYOLC n- - -o|6-fl

I

5.3.2 PCB functions and handling

(1) Back panel

Supplementaryexplanation

QX031/QX041/QXD61 Appearance and connection connectors

QX031, QX041 and QX061 are used tor datacommunication between the control modulesmounted in the control unit.

QX 0 3 I Usage format

QXO 4 1

Maintenance comment

QXO 6 1

(2) Control PCBAs explained in 5.1 Outline, the T PLUS Series PCB uses the control module format.The add-on cards that can be installed onto each control module S-BUS PCB are shown in Table5.3.2 Control module combination table. O indicates a combination that can be mounted on thehardware, A indicates a combination that can be mounted on the hardware but where the softwareis not supported currently, and x indicates a combination that cannot be mounted on the hardware.

Table 5.3.2 Control module combination table

P-BUSModel name A-BUSAll cards

C-BUSAll cards

M-BUSAll cards

C-BUSAll cardsNo. QX721!QX722 j 0X73110X732S-BUSModel name

OO OO ACPU module :QX141/QX141-1 AA1 XOO OCRTC module :QX524/QX521 A xX2 xX

DIO module jQX539IQX535

xX X XXX XX3 O X XXX XXX

Module withspecialmemory

AA AAAAOQX571 x4

- 50 -

Supplementaryexplanation0X141 Appearance and connection connector

The differencebetween theQX141 andQX141-1 is thatthe QX141 hasfloating pointprocessingfunctions and theQX141-1 does nothave thisfunction. Theother functionsare the same.

Usage formatUse only for CPUmodule

cAIMI

CPUMu

iDRAiia }--Q iiBI PLC | C BUusS *- D. 8. S. psuais

-| Serial KF pf~s

>A/D IPX [3p sl KM >

[ EPKOIhi

P[QPBI BI uODCT BSW1 sCOW- us Maintenance comment

The machinecharacteristic or NICunit characteristicparameters areregistered in theEEPROM the originalEEPROM (withsocket) must be usedwhen this card isreplaced.

(O? LED!CO?lD2 CSl

Specification Specificationitem

Description of settings and LED32-bit high speed MPU(QX141 has FPP, QX141-1 doesnot have FPP)LSI that executes high speedsequence processingMonitor ROMRegisters machine characteristicor NC characteristic parametersDynamic RAM (with parity)RS-232 2ch.Interrupt control circuitCTC (Counter timer)RTC (Clock mechanism)Cassette memory read/writefunction

CPUSetting StandardDescriptionLED

PLCUsed only for multi-CPU configuration

0CS1EPROMEEPROM Software abort switchPB1

all OFFSW1DRAMSerial I/OOthers

GreenLEDflicker

Watch dog alarmwhen red LED is lit.LED1

GreenLEDflicker

Memory parity errorwhen red LED is lit.LED2

SupplementaryexplanationOX423/QX424/QX425/QX429 Appearance and connection connector

Usage formatCPU module

(Data, stack area,machining program,user PLCs)

CRTC module(Large capacitymemory)

The 0X420 cardis the SRAMmemory card.

tzmIll SFCU CX42D c

[M!li

Is!l-J

3 stJM C

s I

(View from soldered face)Maintenance comment

Always back up thecard beforereplacement as theparameters andprograms are storedwithin.

Specification Specification Description of settings and LEDitemSetting StandardDescriptionQX423 512kB (with parity)

QX424 1MB (with parity)QX425 2MB (with parity)0X429 1.5MB (with parity)With super capacitor

SRAMLED

ON when backing upSRAM with supercapacitor

ONSPCBack up

- 51 -

Supplementaryexplanation

QX812/QX813/QX814/QX815/QX816/QX818 Appearance and connection connector

The QX81 cardis a ROM cardcomposed of theflush ROM.

Usage format1. CPU module on

QX141(System memory)

2. CPU module onQX42D(User PLC memory)

C QXSlO] Ft sou

cIBUs

Description of settings and LJED Maintenance commentsIf a watch dog alarmoccurs on the mainCPU, this PCB maybe defective.ROM-CUT is possibleby this PCB on theactual machine.

Specificationitem

SpecificationSetting StandardDescriptionLEDROM Rush EEPROM

QX812 256KBQX813 512kB0X814 1MBQX815 2MBQX816 4MB0X818 3MB

No settings or LEDs

SupplementaryexplanationQX721/QX722 Appearance and connection connector

Usage format1. CPU module

The QX721 andQX722 cards arePCBs for theservo interfaceusing the CPUinside.

5SC (Normalposition:0X722)

Expansion module(Multiplex:QX721)

CT721/722[~CPU] p 2.

0 I3U20 BP H: CSK212-PORT Serial> uVFm saHigh speed _SRAM Serial CSH22l/F MinLJ| SKIP F-T CDP51DSUB15

amOKI.

(View from soldered face)

Maintenance comments1. This PCB is defective

when LED1 is lit.2. If a watch dog alarm

for this CPU card(QX141) occurs, thisPCB may bedefective.

Description of settings and LEDSpecification Specificationitem Setting StandardDescription

LEDRISC type high speed CPUCode area, data stack area

CPUHigh speedSRAM2-PORT RAMSerial l/F

Watch dog alarm forthis PCB when redLED is lit.

Not litLED1High speed 2-PORT RAMHigh speed serial l/F with servoamplifier

QX721 1ch.QX722 2ch.

Sensor inputQX721 4 pointsQX722 8 points

Software monitorLED2OFFFor testingTP1

Skip input

- 52 -

Supplementary0X521 Appearance and connection connectorexplanation

The QX521 cardis the graphicdisplay PCB forblack and whiteuse.This card alsohas the operationboard l/F, spindleencoder l/F, andRS-232 device l/Ffunctions.

Usage formatUsed only for CRTCmoduleUsed for the 12-inchmonochrome CRTunit.

c?

ors2is Muc I>D i BH ant l u?

-C ioj steni 2S2JDSUB25UIOEO

CSH111/7ism Q[3Xj 5CSH12-| Serial l/F SSUS*0

LED 1 IED2 lD3 lD4

PDSUB15 Maintenance commentWhen the main CPU(QX141) operates,and trouble related tothe operation boardsuch as the keyinputs from theoperation board arenot read or thedisplay does notappear, this PCB maybe defective.

I_ Spindle encoder Vf ICES11 BB U9 ui CSA21 ss

RAM I-1Specification Description of settings and LEDSpecificationitem

Setting Description StandardFor 9 and 12 inch monochrome CRT, 9.4inch ELHigh speed graphic processorFrame memory (two-sides)Font ROM (JIS Class 1 standards)Shift register, expansion characteHigh speed serial l/F with operation board

Display l/Fsection

CRTCVideo RAMVideo l/F

LEDLED1 Communication withoperaii

board when green LED is littion Lit(SD)

r l/F LED2 Communication with operationboard when green LED is lit LitSerial l/FIOP section (RD)

CPU CPU LED3(FBAL1)

Spindle encoder CH1 nosignal when red LED is lit Not litSRAM

Serial l/FSwindle encoder

IOP code and stack areaRS-232 2ch.Spindle encoder (differential) l/F 2ch. LED4

(FBAL2)Spindle encoder CH2 nosignal when red LED is lit Not lit

Supplementaryexplanation0X524 Appearance and connection connector

Usage formatUsed only for CRTCmoduleUsed for the 14-inchcolor CRT

The QX524 cardis the graphicdisplay PCB forcolor use.This card alsohas the operationboard l/F, spindleencoder l/F, andRS-232 device l/Ffunctions.

LS?Q5524 Ucs -* M>0 TS1 In I ImseolLL* m K

i &

2 BPm ut jo_ sKT]E DSUB25UIDS3 I2JCSH11!/7

Serial l/F \ CSH12 8C 5DSUB15 S LED! LED2 LED3 lD4

_ Spindleencoder l/F PCES11 I Maintenance comment

When the main CPU(QX141) operates,and trouble related tothe operation boardsuch as the keyinputs from theoperation board arenot read or thedisplay does notappear, this PCB maybe defective.

I BB UCSA21 U Sl MM I s

Description of settings and LEDSpecification Specificationitem Setting StandardDescription

For 14 inch color CRT, 10.4 inch color LCD

High speed graphic procFrame memory (four-sides)Font ROM (JIS Class 1 standards)Shift register, color oalletHigh speed serial l/F with operation board_IiIOP code and stack areaRS-232 2ch.Spindle encoder (differential) l/F 2ch

Display l/Fsection

CRTCVideo RAMVideo l/F

LEDessor Communication with operation

board when green LED is litLED1 Lit(SD)

Communication with operationboard when green LED is litLED2 LitSerial l/F

IOP sectionCPUSRAM

Serial l/FSwindle encoder

(RD)Spindle encoder CH1 nosignal when red LED is lit

LED3(FBALl)

CPU Not lit

Spindle encoder CH2 nosignal when red LED is lit

LED4 Not lit(FBAL2)

- 53 -

Supplementaryexplanation

0X539 Appearance and connection connector

The QX539 cardsare 1/0 interfaceDIO-A PCBs thatuse Hondaconnectors.The front surfaceis completelyfilled withconnectors so anaddon cardcannot be added.1ch of the analoginput is inputfrom the frontconnector, butwhen 2ch ormore are used, aseparate connection adaptor isrequired, in thiscase, a mountingspace of twoslots is required.

Usage formatUsed only for DIOmodule

0X53S

"T-n-rH PIIDA

[ o CDP3I s o{ DO 64 CDJ31 o

mt Q\ point CDP32Al 35 point

CCDJ32

gCPA21

mg

3is Maintenance commentWhen the contactoutput is shortcircuited, the output1C in the PCB may bedamaged. Alwaysconfirm theconnection with atester, etc., beforeturning on the NCpower.

Specification Specification Description of settings and LEDitemSetting Description StandardContact

inputContactoutputAnalog inputAnalogoutput

64-point(24V common)64-point (VDE)

LEDThis is used forseparation whenseveral DIO modulesare mounted in thecontrol unit.

1st 02nd 23rd 4CS16-point

1-point etc.

Supplementaryexplanation

Appearance and connection connector0X535

The QX535 cardis an I/O interfacePCB that uses aflat cableconnector.The contact inputis 24V commonfor the QX535card.32 points can bechanged over.The VDEregulation for theQX535 card iscontact output.

Usage formatUsed only for DIOmodule

QX535AJX537AS

>0 ADI CDP21R80 B

UH: CDP211 so01 CDJ21R

k80 C0J21Lo

Maintenance commentWhen the contactoutput is shortcircuited, the output1C in the PCB may bedamaged. Always

So !BUS

o

I [ CPP11 confirm theconnection with atester, etc., beforeturning on the NCpower.

Specification Specificationitem

Description of settings and LED80-pointQX535: 24V commonQX537: GND common(32 points can be changed to 24Vcommon or GND common withexternal connection.)

80-pointQX535 VDE (open emitter)

Contactinput Setting StandardDescription

LEDThis is used forseparation whenseveral DIO modulesare mounted in thecontrol unit.

1st 02nd 23rd 4Contact

outputCS1

etc.

- 54 -

Supplementaryexplanation

0X316 Appearance and connection connector

The 0X316 cardis a contact inputinterface add-onPCB that uses aflat cable.

Usage formatUsed only for DIOmodule, and mountedas an option on the0X535 card.

Cu;6

dltS ri A i: i !!B!! u !iJL!

J uu -3 [ rTJfO=3El

Description of settings and LEDSpecificationitem

SpecificationSetting StandardDescriptionLEDContact

input16-point

No settings or LEDs

Supplementaryexplanation0X571 Appearance and connection connector

This PCBfunctions onlyafter the M-BUSPCB, P-BUS PCBand C-BUS PCBsare mounted.(This PCB has nofunctions on itsown.)

Usage format1. Module for axis

expansion, and usedfor the multiplexingmachine as astandard.

2. QX721 is mounted onQX571 for axisexpansion.

Maintenance comment

0X571S uo-t c MI I

BC B-o-c p0cu us s

sIP BI U

8 Sus

SpecificationSpecification itemM-BUS expansion

P-BUS expansion

C-BUS expansionDescription of settings and LED

Setting StandardDescriptionLED

Set to the 2nd PCBwhen using two ofthese PCBs.

1st PCBOFFXIF22nd PCBON

- 55 -

Supplementaryexplanation

QX731 Appearance and connection connector

This PCB is forcomputer linking.

Usage format1. CRTC module2. Mounted as an

option.(Protocol B: RS-232C)

FCPUT CSA32(ich is fordebugging)

r-j! ? !2-PORT SRAM C.'J soRAW | B (U|

LSJ2

-41Serial CSA31l/Fai2[ S35E

Maintenance commentDescription of settings and LEDSpecificationitem

SpecificationSetting Description StandardLEDHigh speed 16-bit CPU

2ch (max. 38, 4KBPS)Code area, data stack areaFor communication with mainCPU

CPUSerial l/FSRAM2-PORT RAM

SO For testing OFF

SupplementaryexplanationAppearance and connection connectorQX732

Usage format1. CRTC module.2. Mounted as an

option.(Protocol B: RS-422)

This PCB is forcomputer linking.

I~CPUT *0 2CSA32(RS232)(Not used) ParcrI2-PORT> SRAM BRAMU

Serial H: sCSA33(RS422)l/F __iCSJso

Maintenance commentDescription of settings and LEDSpecification Specification

item Setting StandardDescriptionLEDHigh speed 16-bit CPU

1ch (max. 38.4KBPS)Code area, data stack areaFor communication with mainCPU

CPUOFFSerial l/F

SRAM2-PORT RAM

For testingSO

- 56 -

5.4 Functions and Handling of the Operation BoardOutline of functions

The operation board is used to input data to the control unit and to display the execution state, etc.

5.4.1 CRT

The MAZATROL T PLUS Series uses a 14 inch color CRT or 12 inch monochrome CRT according to themodel. These CRTs are open frame type CRTs with built-in AFC for data industries that required a highreliability and high resolution play back. These are compact and light weight, and most of the circuits areintegrated on one PCB. The reliability is high, and maintainability is easy so stable operation can beexpected over a long period.

14 inch color CRT12 inch monochrome CRT: MDT-1283-02

: A1QA8DSP40/CD1472D1M2 BKO-NC6542

AdjustmentThere are various positions on the CRT to be adjusted, but these have been adjusted beforeshipment, so readjustment is not required.

Precautions for use

(1) Affect of magnetic fieldsThe CRT displays data by scanning an electronic beam with a magnetic field. Therefore, externalmagnetic fields will affect the display and will cause screen distortion, screen swaying and colordistortion". Take special care to external magnetic fields.For example, if the case in which the CRT is stored is made of steel plates, etc., the case will bemagnetized if a magnetic stand, etc., is installed. Note that this will cause screen distortion. The CRTis also affected by magnetic fields from motors, transformers and magnetized workpieces.

(2) Cathode-ray tube lifeThe life of the cathode-ray tube is said to be approximately 7,000 hours.However, this is the time for the emission efficiency to drop to 70% of the initial value (this will differaccording to the tube maker), and does not mean that the tube cannot be used. The phenomenonwill be a darkening of the screen, and the CRT can be used continuously.

-57-

(3) Replacement of 14 inch color CRT operation board PCB

Data keyboard Escutcheon

ILIE Escutcheon\

K OPb OP jpowervX iON/OFFCJjbuttonQY221

(Conblock)

tact iigg=Q0-='% \NP- % Menu keysScrew (x 6)X

XT

Menu keyboard

(1) Control PCB1) Disconnect the cable connected to the PCB.2) Remove the four screws.

(2) Data keyboard1) Disconnect the two cables connected to the keyboard PCB.2) Remove the four screws. (The control PCB does not need to be removed.)

(3) Menu keyboard (fixed to escutcheon)1) Disconnect the cable.2