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BNP-B3830*(ENG)

USA-E00060-006-*

MAZATROL T PLUS Series


MAINTENANCE MANUAL (HARDWARE)

AOVANCED AND EVER ADVANCING


MITSUBISHI 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 differ
according to the target model and specified configuration.
Use this manual with the Instruction Manual, Instruction Manual issued by the
machine maker, and other Instruction Manuals.
(2) This Manual is targeted for the general user and machine maker engineers. If there
are any unclear points, please contact Mitsubishi.
(3) An effort has been made to match the contents of this manual with the NC unit. We
ask for your understanding if there are any differences in the contents.
(4) Related material
MAZATROL T PLUS Series Connection Manual
Contents

1. Outline 1
1.1 System Configuration 2
1.1.1 System configuration 2
1.1.2 Internal system diagram 3
1.2 Control Unit Configuration 4
1.2.1 Control unit configuration 4
1.2.2 Control section PCB configuration 5
1.3 Table of Configuration Units 6

2. Daily Maintenance and Periodic Inspection and Maintenance .. . 8


2.1 Maintenance Instruments 8
2.2 Maintenance Items 8
2.3 Cleaning the Operation Board Escutcheon and CRT 9
2.4 Battery Replacement 10

3. Trouble Diagnosis and Measures 11


3.1 Confirmation of State of Trouble Occurrence 11
3.2 Examples of Troubles and Troubleshooting 12
3.2.1 Examples of trouble 12
3.2.2 Examples of troubleshooting 13
3.3 LED Ust of Each PCB (unit) 18
3.4 Presumed Causes for Alarms 20
3.5 Procedure for Inspection of Each Trouble . . 29
3.6 Replacement of Various Units in Control Unit 31
3.6.1 Replacement of power unit 32
3.6.2 Replacement of cooling fan 32
3.6.3 Replacement of the QX card 32
3.6.4 Replacement of memory cassette card 34
3.6.5 Precautions during replacement 35

4. Installation Adjustment Procedure 36


4.1 Working Conditions 36
4.2 Input Power 36
4.3 External Connections 37
4.3.1 Connection of input power 37
4.3.2 Connection of motor 37
4.4.3 External connections 37

-i-

4.4 Installation Check List 39


4.5 Turning on the Power 40
4.5.1 Power on, ready on, emergency stop, ready off flow chart . . . 40
4.6 Setting Capacity (hardware setting) 41

5. Explanation of Hardware 43
5.1 Outline 43
4.4 Installation Check List 39
4.5 Turning on the Power 40
4.5.1 Power on, ready on, emergency stop, ready off flow chart . . . 40
4.6 Setting Capacity (hardware setting) 41

5. Explanation of Hardware 43
5.1 Outline 43
5.2 Flow of Signals 46
5.3 Control Unit Functions and Handling 49
5.3.1 Power supply 49
5.3.2 PCB functions and handling 50
5.4 Functions and Handling of the Operation Board 57
5.4.1 CRT 57
5.4.2 PCB functions and handling 59
5.5 Functions and Handling of Manual Handle (HD60) 60
5.5.1 Functions 60
5.5.2 Replacement and handling 61

ii
1. Outline
The MAZATROL T PLUS Series CNC unit is a product that has thoroughly pursed high productivity and
reliability. The following material has been prepared in addition to this Manual. Please refer to these
together 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 hardware
for the following CNC units. However, the model name is listed for those units having limits in each
section.

Model name Slots Automatic program Display

M515 3 Yes 12- CRT

M535 4 Yes 14" CRT

M545 6 Yes 14- CRT

1
1.1 System Configuration
1.1.1 System configuration
The following units are generally used to compose the system using the MAZATROL T PLUS Series.
(1) Control unit : This unit has the computation processing functions for numerical
control. (This is also called the NC unit.)
(2) Operation board : This unit has the setting and display functions.
(display operation section)
(3) Servo/spindle control unit : This is a servo/spindle amplifier composed of a converter for obtaining
DC from AC and an inverter for obtaining AC from DC.
(4) Servo/spindle motor : This drive motor moves the machine.
(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 operation
board
Display
8888 L
080
O o Manual pulse handle

FLD3.5

Peripheral equipment such as external memory


and programming support / T

Machine power
i control panel
Control unit

as
/
Rsjnt
J

Servo/spindle control unit

O O lo
Spindle motor

Position detector
qTf=
lr-*=f] U

Servo motor

Fig. 1.1 General configuration of system using T PLUS Series

2
1.1.2 Internal system diagram

NC operation board
NO control unit
0x054 Display unit
NC control 12* CRT
power supply 14* Color CRT

CPU module rf
gxm
Main CPU Machine operation board
CPU Ox <22 Ox gift]" fOO
M SRAM Cassette ManuaJ
Memory memory (Q)
handle
PLC

C QxeUB
Cassette
memory

S frWrf/ RS-232 device

QX722
smcnj

P
E3
RAM -- h-r Servo
AMP motor

- input/
D
f
Servo
AMP
Servo
motor

CRTC module
Display controller for *1
,Qx 524 cokx
0x<2D
'Qx 521 bteckMuto M Large capacity memory
Spindle L_
S
Qx 731/1} x732
[AMP>1motor
Computer
Host computer
link To next system
P Memory-
*1

- hfxAS

Encoder
ic [
y fl
Spindle encoder
i/r
RS-232 device x 2 units
-V Host computer
Memory

DIO module
QX539 x 535 QX316 *1

Machine I/O interlace A *0


*2
Di Machine

Do <J Machine contact input


Machine contact output
D> power panel

1: Mounted as an option
I *2: Can be added only for QX535
I 3: Mounted for T PLUS-4/6
9x571 Expansion module
3 S : S-BUS (Syslea BUS)
M
M : M BUS (Memory BUS)
S (Ptrlferil BUS)
P : P-BUS
C : C-BUS (Casselt BUS)
C (Additional BUS)
A : A- BUS

QX721 *3
Servo CPI
ii

P Serial Servo Servo


RAM input/ 3
OUtpUT AMP> motor

(Note) The above diagram shows the most general configuration, and the actually mounted hardware
configuration may differ according to hardware flexibility and specifications.

- 3
1.2 Control Unit Configuration
1.2.1 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 the
control power and control modules are mounted is on the back of the basket, and the cooling fan is
mounted on the top. The cooling fan is mounted inside the fan cover as shown in Fig. A, and can be
replaced easily be removing the fan cover from the basket unit. The control power is mounted on the far
left slot of the basket, the CPU module in slot 1, the CRTC model in slot 2, and the number of DIO
modules required from the system are mounted from the far right slot. Optional expansion modules are
mounted from the left into the empty slots.

4/6 slot basket

S-BUS connector
Fan cover K"'
n\
M-OUS
RAM

1 !
S-BUS-AVR I
connector
11 1 3 < 5 I J Cooling fan ii
Back panel BUS
Expansion
connector
t /F -
\ IN p- OPT I ON

Fig. A
TO S-BUS
connector 2 iii -
BUS

(Slot 2) iii l

fig. D CRTC module


O I O/A 1 0
[\ A- BUS \-OPT I ON
ill
ii
X
rl I!
To S-BUS-AVR
connector
m
m
Battery
1
To S-BUS connectors \
Rg. B 3 to 6 (Slots 3 to 6)

in
M - BUS RAM m
Fig. E DIO module
l
!i
j M-BUS
i RAM

* C-BUS\ \c-BUS
!
ROM
ROM J
C-BUS

To
\
S-BUS
II: X C-BUS

connector 1 !!! & MCP


(Slot 1) iii I P-BUS ROM ROM

-T \ Hi
To S-BUS ii! T
OPTION
Fig. C CPU module
connectors
3 to 6
(Slots 3 to 6)
| P-BUS

Fig. F Optional expansion module

Fig. 1.2.1 Control unit configuration diagram

4
1.2.2 Control section PCB configuration
The control section PCB uses a control module to which various PCBs are mounted horizontally onto a
300 x 140mm standard size PCB as shown in Figs. C to E shown in Fig. 1.2.1 Control unit configuration
diagram.
A system BUS connector that is connected to the back panel is mounted on the lower back of the control
module and an interface connector and LED indicator are mounted on the front. A plastic front panel is
mounted 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 140mm
standard PCB (S-BUS PCB) so that the part mounting face faces the S-BUS PCB. Cassette memory can
be 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 some
PCBs, this is not possible due to limits in the configuration, however, the ideology is the same.

S-BUS PCB Cassette memory S-BUS PC8

M-BUS PCB M-BUS PCB


Cassette memory r~l
/
7

Fixing screw
L. Interface
Cassette memory connector
P-BUS PCB
Spacer

P-BUS PC8
0
System BUS
I
J
Fixing screw LJ

J
Spacer

Fig. 1.2.2 Example of control module (integrated PCB)

-5-
1.3 Table of Configuration Units

(1) Control unit


Model name
No. Function Remarks
Configura
Model name tion ele
ment name

1 4MU301A 3-slot control unit Mounting position


QX031 3-slot back panel S : S-BUS
QX084 Control power supply M : M-BUS
2 4MU401A 4-slot control unit P : P-BUS
A : A-BUS
QX041 4-slot back panel
C : C-BUS
QX084 Control power supply C: C-BUS
3 4MU601A 6-slot control unit
QX061 6-slot back panel
QX084 Control power supply
4 Expansion 2-slot expansion control unit
unit
QX025 2-slot expansion back panel

(2) Control section printed circuit boards (PCB)

Model name Mounting position

No. Configura Function Remarks


Model name tion ele S IM! P ! A i C : C1
ment name

1 CPU module CPU, memory, servo l/F

QX141 O Main CPU With floating point operator


QX42D O SRAM memory Refer to Note 1 for
QX81 #1 O Main memory Refer to Note 2 for D

QX81 #2 O User PLC memory Refer to Note 2 for

QX722 O Servo CPU (2ch) Skip x 8

2 CRTC l/F with display unit, others


module
QX524 O 14" color CRT, 10.4" LCD Color
QX521 O For 9/12" CRT, 9.4" EL Monochrome

0X731 O Computer link (RS232) Added with options


QX732 O Computer link (RS422) Added with options
3 DIO module Machine input/output l/F Machine input/output l/F

0X539 Honda connector type Di/DO:64/64, A!:6, AO:1


O
(source output)
0X535 Rat connector type DI/DO:80/80
O
(source output)
QX316 O Rat connector type Dl:16
4 Expansion Servo CPU addition, others Use with TX-4/6 for MULTIPLEX
module

..... .....
0X571 O Expansion l/F Base has no functions

.....
0X721 O Servo CPU (1ch) Skip x 4

Note 1) QX423

.....
512KB (Standard) Note 2) QX812 256KB (Standard #2)

....... .
0X424 1MB QX813 512KB
QX425 2MB QX814 1MB
QX429 1.5MB 0X815 2MB
0X816 4MB
QX818 3MB (Standard #1)

-6 -

7
2. Daily Maintenance and Periodic Inspection and Maintenance
2.1 Maintenance Instruments
(1) Measurement instruments
The following instruments are used for measurement to confirm that the power is being properly
supplied to the NC unit and that the wiring to the NC unit is correct, and during simple
troubleshooting.
Table 2.1 Maintenance instruments

Instrument Conditions Application


Tester Check that the wiring to the NC unit is
correct before turning on the power.
AC voltmeter The AC power voltage is measured. The AC power voltage supplied to the
The tolerable difference is 2% or NC unit is measured.
less.
DC voltmeter Maximum scale 10V The DC power voltage is measured.
30V tolerable difference is 2% or External supply 24V (I/O interface
less. DIO-A)
Battery voltage
QX084 DC output
Phase rotation Check the order of AC 3-phase input
meter power connection
Oscilloscope For general measurement and simple
troubleshooting _
(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 AC
voltmeter and DC voltmeter.

(2) Tools
Screwdriver (large, medium, small)

2.2 Maintenance Items


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

Table 2.2 List of maintenance items

Inspection/
Class Name Life Remarks
replacement

Refer to the section "Cleaning the


Daily Cleaning of escutcheon
Daily operation board escutcheon and
maintenance and CRT
CRT".

-8-

9
(3) Operation board

Model name
No. Function Remarks
Configuration
Model name
element name

1 4YZ4xx 14" color CRT


4YZxx
A1QA8DSP40 14" color CRT unit

KS-4MB401 Menu keys

QY221 Board controller

MC251 Expansion scan Option

2 4YZ2xx 12" CRT


4YZxx
MDT-1283-02 12" CRT unit

KS-4MB201 Menu keys

QY221 Board controller

MC251 Expansion scan Option

7
2.4 Battery Replacement
Data that must be backed up such as the parameters and machining programs, etc., are saved by the
lithium battery mounted in the front panel on the front of the control power supply when the power is
turned OFF.
Battery used : BR-CC7P with connector
(Matsushita Denchi Kogyo with Mitsubishi specifications)
Battery voltage : 3.0V
Alarm voltage 2.6V
Battery capacity 5.000mAH
Battery back up time : 7 years
Battery life 7 years
Discharge current 1OOpA 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 procedure
The machine (NC) power may be ON or OFF.
(1) Remove the battery cover on the front panel of
the control power supply. If the power is turned OFF,
(2) Disconnect the connector on the battery. complete this procedure within
(3) Replace the battery and connect the connector. 30 minutes.
(4) Replace the battery cover.

Power supply front panel

I (left edge of control unit)

Replace Battery cover

Battery

Battery
\

Insert/
remove
Power supply PCB

3
CPD 0 7
(BAT IN)

State with battery cover removed (enlarged view)

10
Name Inspection/
Class Life Remarks
replacement

CRT 7,000 hours Note, that the brightness can be


(Regulated by Replace when adjusted by the user.
conductivity time for screen darkens.
brightness to drop below
80%.)

Periodic Battery (Li battery) Data saving time: 7 years The data hold time is calculated by
inspection (discharge time 2,000 the discharge time/year Max. 6,840
and days) After 7 years hours (average 240 days x 16 +
maintenance The life of the battery holidays 125 days x 24)
itself is 7 years at 60C Refer to "Battery replacement" for the
(8.5 years at 40C). replacement method.

Cooling fan 30,000 hours Replace when the Refer to "3.6.2 Replacement of
(control unit) times on the left cooling fan".
has passed.

Other Keyboard 106 punches Replace when the


consumable numbers on the
parts left has passed.

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

9
3. Trouble Diagnosis and Measures
If any trouble occurs during operation, it is necessary to accurately find the cause so that appropriate
measures can be taken. Perform the following check to find the cause.

3.1 Confirmation of State of Trouble Occurrence


Confirm "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., and program details of when the trouble
occurred.
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 trouble
occurs infrequently, the power voltage may be incorrect, or noise may be the cause. Check that
the power voltage is correct (does the power voltage drop instantaneously when other machines
are 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 the
conditions 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 not


turn on.

The door for the control pane*


A
is completely closed, or the
door lock is released. The door to the control '
'panel
is not completely closed
and the door Interlock has
Open the door and check (Note 1) V activated.

AC100V fe not being supplied.


AC100V is being supplied.

Check that the power voltage


is 100V +10%
-15%

I 1 AC200V is being supplied.


The power does not turn on AC200V
Turn off the main NEB once. even when the OX064 POWER Power turns on with the not being
wait approx, two minutes, ON switch is turned on. QX064 POWER ON switch. - auppfeu.
turn on power. The power
stiQ does not turn on.

Error in the route }


om the NC side NF!
(Note 2) to QX064. j
'POWER
Check the NC external
ON switch and wiring
system, and repair any
v defective areas, >
0X064 QX064 fuse The QX064 CPOOS 0X084
defect is blown. P.OFF and COM are defect
. short circuited.

The 0X064 CPA02


AC OUT is short
circuited (The base
NF 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 turn The power turns on when


on even when QX084 is QX084 is (fiaoonnactad from
disconnected from the the control unit
control unit

The power does not turn on The power turns on when


even when the power cable the power cable PAQ2-C is +5V short circuit 12V short circuit
PAQ2-C is disconnected. disconnected.

Remove the cards from the


QX084 power control unit one by one and
supply is defective. Problem in the find the defective card.
Replace. power cable and the
operation 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 the
door interlock key and then open the door. Always return the door interlock switch to ON after removing the trouble, and
then close the door.
(Note 2) Refer to section 5.3.1 for details on blown fuses.

- 13 -
<2) AC FAIL (red) on QX084 lights.

AC FAIL lights.

The power
voltage is not +24V short
100V + 10%
-15%
circuit

(Note) When the QX084 24V output is being used for the I/O interface DIO-A, the machine output
signal may be short circuited due to mis-wiring, etc.
In the above case, the IC in the I/O interface DIO-A card may be destroyed.

Troubleshooting in operation preparation stage

Operation preparation (READY) cannot be entered.

READY does not light

s 1
No alarm is displayed on
Alarm is displayed on CRT
setting and display unit the CRT setting and display unit

Refer to the Alarm Lists provided


for each model, confirm the alarm
details, and inspect accordingly.

'The parameters QX141 card EMG state


i are not input is defective.

- 14-
Operation board related troubleshooting

The operation keyboard cannot be operated.

The keyboard cannot be operated.

Only a certain key All keys cannot


cannot be operated. be operated.

/ 0X810, \ GY221
0X810 is ROM CUT are Software System f 0X141/QX524/'
10X521 cards are
Board cable is cards are
defective. related? down not connected.
\ defective, j
\ defective, j defective.

Watch dog error

r\
Keyboard is QY221
defective. cards are
defective.

- 15
CRT and EL display troubleshooting

Screen does not appear.

Screen does not appear.

AC100V ts not CRT 0X521. 0X524


being supplied. cards are
CRT cable. SH11. defect detective . Blank screen
POOS, PSA02-C are
not connected.

Screen flows.

Screen flows.

7;

0X521.0X524
cards are CRT defect
detective.
CRT cable
defect SHI1

(D 'Dots" remain on screen.

*Oots remain on screen.

ft
0X521, 0X524
cards are
CRT defect
detective.

16 -
CRT screen sways (is distorted).

Screen sways.

There is a magnetic
field nearby.

5 1

The work- There is a


piece is The CRT There is a f There is a magnet transformer or motor
magnetized. storage case is large current flow nearby such as a magnet The fan is nearby.
magnetized. ing nearby. l stand. j metallic.

(D The screen changes on its own.

The screen changes on its own.

A
Occurs after a specific The screen changes
operation randomly.

R
QX524
The keyboard Software Software
cards are
.switches are
defective. .
related?
defective.
related?

- 17
3.3 LED List of Each PCB (unit)
Fig. 3.3. shows the conventional hardware configuration (max. configuration) of a normal system. Refer
to section 5.3.2 *PCB functions and handling- for details on PCBs not listed here.

Control power Axis expansion


supply _ CPU module CRTC module module DIO module DIO module DIO module
QX084 0X141 QX524/QX521 QX571 QX539 0X539 QX539
0X420

Q Q
LED1 X X
LED2 8 8
LED3 1 1
O

LED1 QX722SD 0X731 0X721


LED2 SD 0X732
LED1 FBAL1 LED1
LED2 FBAL2 LED2

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 5.3.2
functions and handling- for details.
Table 3.3 LED list

State
Card name LED name Details of display Measures during error
Normal j Error
Control power LED1 (Green) Lit { Not lit Control power ON Refer to '(1) The NC
supply (POWER) power does not turn on-.
QX084 LED2 (Red) Not lit j Lit AC input overvoltage, Measure AC input voltage.
(AC FAIL) undervoltage
I DC24V output OFF Is DC24V load too high?
Not lit Lit Battery alarm (2.6V Replace battery
LED3 (Red)
(BAT.AL)
j
and less) _ immediately. _
QX141 LED1 Not lie
Red { Watch dog alarm One of the PCBs in the
(Green, Red) LED CPU module may be
I stable defective.
LED2 Green i Red Memory parity error The DRAM in the QX141
(Green, Red) LED I LED card or one of the QX42D
flickers j stable cards may be defective.
QX721/QX722 LED1 (Red) Not lit I Lit Watch dog alarm The PCB may be defective.
LED2(Green) Green j Not lit Software monitor
LED
flickers j
QX524/QX521 SD (Green) Lit | Not lit Indicates that data is Either the PCB or cable
being transferred bet may be defective.
ween operation board.
RD (Green) Lit i Not lit Same as above Same as above
FBAL1 (Red) Not lit j Lit Spindle encoder no The cable may be broken
signal alarm or the spindle encoder
may be defective.
FBAL2 (Red) Not lit | Lit Same as above Same as above

18 -
LED on operation board side

QY 2 2 1

C ] [ ]

[ ]
MON RD SD
[ I O O O [ ]
Green Green Green

State
Card name LED name Details of display Measures during error
Normal ! Error
QY221 Data reception
(Indicates that If RD goes out or SD lights
RD (Green) Lit i Not lit communication data when MON is flickering,
from the control unit is the cable may be broken
being received.) or the PCB on the control
Data transmission unit may be defective.
(Indicates that If both RD and SD are out,
I Not lit this PCB may be defective.
SD (Green) Lit communication data is
being transmitted to
the control unit.)
System monitor The PCB may be
Lit defective. However, if all
Not lit LEDs (RD, SD, MON) are
MON (Green) Flicker
out, the DC24V supply
OFF (NC power supply)
may be interrupted.

- 19 -
3.4 Presumed Causes for Alarms
The presumed causes for alarm related to the hardware in the MAZATROL T PLUS Series are explained
in 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 will
be invalidated, so turn the power OFF and ON, select the 'HARDWARE ALARM screen' of the
diagnosis screens, and note down the register in which the alarm occurred. Then contact the service
center.

Possibility of Alarm generated


Message Details
hardware defect simultaneously
Parity error RAM error Great Watch dog error
An address that does not exist was
Bus error Small Watch dog error
accessed.
Division of a denominator that is zero Very small
Zero divide
was attempted.
Watch dog error The system operation stopped. Medium
Illegal exception An illegal interrupt occurred. Small

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

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

S/W 05V 24V 5


DIO IOP PLC BOD l ILLEGnL COUNT e 1 HC UNIT

2 ILLEGnL 71HE 0 2 OPERATION BOfiHO

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 REGISTER
DFfi 98968068 S501FF278 flC3658FA8 308996182 8888SS&'L
Instruction Address 08990088 90064288 S58173EB4 0882BB88 Q0032B854

{ HARDWARE RLfiRH 3

- 20 -
Measures for hardware
Possibility of
Message Details (Small letters are causes other
hardware defect than the hardware)

011 EEROM This occurs when the


error parameters were not
Small Replace QX141
correctly written into the
EEROM.
008 Battery The voltage of the battery
drop mounted to save the data in
100% Replace battery
the NC has dropped.
(Life)
010 Overheat The temperature of QX141 Fan trouble
or the operation board has
risen over the specified However, in most cases
value. this is caused by the
Specified value Small (FAN) working environment, so
QX141 ON at 705C confirm the heat
OFF at 555C measures taken for the
Operation board body as explained in the
ON at 705C Manual".
OFF at 605C
007 DIO 24V The required 24V power is Replace DIO card
error not being supplied to the
I/O interface DIO-A card Small Confirm 24V power
(DIO card). supply connection
Check for short circuit of
24V load on machine side

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

21
(1) Parity error
(a) Meaning
A parity bit is added to improve the reliability of the CPU card DRAM and memory card QX42D
SRAM.
When data is written into the above RAMs, the data is written into the parity bit memory so that the
number of "1* bits , including the parity bit, becomes an odd number, for each byte. Then, if the
memory details change for any reason, the change will be detected when the data is read out, and
a parity error will occur.
(The changes cannot be detected when two bits are changes simultaneously. However, the
probability that two bits will change in all addresses that the software accesses is very low.)

5 4 3 2 1 0 p
7
1 I
1
6
0
-
i
10
-
1
0
-
1 1
10
-
1
11
-
1 i _
| The number of bit 0 to 7s "1s* are even,

-
1 -
1 -
1 -
1 -
1 1 -
1 1 so *1* is written in.

(b) Cause and measures


Handling of this error will differ according to whether this is a CPU card DRAM parity error or a
QX42D SRAM parity error. It is important to determine which parity error has occurred.

How to determine the error


List of presumed causes
Proba-
No. Presumed cause Presumed cause (details) Measures
bility
1 SRAM Parity error The voltage of the back up battery Replace with a Great
(Li battery mounted on front of new battery.
QX084) has dropped.
If the message Z52 Battery drop'
appears on the screen after the
power is turned on, and the QX084
BAT.AL LED lights, the battery
voltage has dropped. The details
registered in the SRAM may have
been lost when the power was
turned off.

Memory card defect Replace QX42Q Medium


If the battery voltage has not
dropped, the card may be defective.
2 DRAM Parity error The CPU card DRAM may be defective. Replace QX141Q Medium
3 Software The RAM area has not been initially Initial clear Great
cleared, so a SRAM parity error has
occurred.

An illegal address (area where Change to the Small


memory is not mounted) was newest software
accessed, normally a bus error will version, and see
occur. how it works.
4 Others . AC FAIL and MLOCK are not
possible when the power is turned
Replace QX084 Small

off due to control power QX084


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

-22-
(2) Bus error
(a) Meaning
Each PCB (and internal circuit) mounted in the control unit has a characteristic address assigned
to it looking from the MPU of the CPU card QX141, etc. (This is called the address MAP or memory
MAP.)
When the software runs away or an area other than this designated address is accessed, an
answer will not be returned and a bus error will occur.

(b) Cause and measures


List of presumed causes
Presumed Proba
No. Presumed cause (details) Measures
cause bility
1 Card Card defect Great
defect Replace the control modules in the Replace with a good
order of the CPU module, CRTC control module.
module, DIO module, etc.
Replace with a good
When the alarm stops when one of PCB.
the above control modules is
replaced, replace the PCBs on that
control modules. For example, if it is
the CPU module, replace the PCBs
one by one in the order of QX141,
QX721/QX722, QX42D, QX81D.
2 Noise Noise Confirm the 'cable clamp Small
If measures against noise have not treatment*, 'grounding
been taken, the system may be treatment', 'surge killer
malfunctioning due to noise that is treatment of relays, etc.",
entering the NC through the power according to the
cable and connection cables. Manual, and
treat if treatment has not
be executed already.
3 Software Malfunction during a specific Change to the newest
operation software version, and see
how it works.

Confirm the cause of the


The user PLC software accessed an phenomenon, and then
illegal address. contact the service
center.

(3) Zero divide


(a) Meaning
When calculating A-rB, B=0.
(b) Cause and measures
Check 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) Meaning
A 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 cycles
is established. Each time this routine is passed, a special counter (watch dog timer) is reset. If the
system does not run properly for any reason, this routine will not be passed, so this counter will
not be reset. If a set frequency clock is attached to this counters clock terminal, this counter will
overflow. This output will apply an interrupt on the CPU, and will take appropriate measures
immediately.

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

(b) Cause and measures


Determining the cause of these messages is difficult, but the presumed causes are shown below.
_ List of presumed causes _
No. Presumed cause Presumed cause (details) Measures Proba
bility
1 CPU module CPU module defect Replace with a Great
defect The CPU module in the hardware is good control
defective. module.

(1a) Servo CPU card defect Replace with a


This card may be defective if LED1 good PCB.
on the QX721/QX722 card is lit.
(1b) CPU card defect
If a watch dog error occurs even
when LED1 on the QX721/QX722
card is not lit, the CPU card (QX141,
etc.) may be defective.
(1c) Main memory card, user PLC card
defect
If a watch dog error occurs even
when LED1 on the QX721/QX722
card is not lit, the main memory card
or the ROM in the user PLC card
QX81D may be defective. _
2 Defect in other Defect in other card Replace with a Small
card If a watch dog error occurs even good PCB.
when LED1 on the QX721/QX722
card is not lit, QX42D or another
control module may be defective.
3 Control power QX084 defect Replace with a Small
supply defect There may be an error in the QX084 good PCB.
DC output. Measure the voltage and
ripple with the QX084 test pin
CPD03.
4 Defective Defective insertion of each card Re-insert. Medium
insertion The control module may be inserted
improperly into the back panel, or
the cassette memory QX81C1
insertion may be improper. _

- 24 -
No. Presumed cause Presumed cause (details) Measures Proba
bility
5 Noise Noise Confirm the Small
If measures against noise have not "cable clamp
been taken, the system may be treatment",
malfunctioning due to noise that is
entering the NC through the power treatment", "surge
cable and connection cables. killer treatment of
relays, etc.',
according to the

Manual", and
treat if treatment
has not be
executed already.
6 Software Malfunction during a specific Change to the ?
operation newest software
version, and see
how it works.

The user PLC software accessed an ?


illegal address.

- 25 -
(5) illegal exception
(a) Meaning
This error indicates that an illegal interruption occurred.

(b) Cause and measures


As with the watch dog error, the cause of this error is very difficult to determine, but the probable
causes are listed below.

List of presumed causes


Proba
No. Presumed cause Presumed cause (details) Measures
bility
1 Card defect Card defect Great
Replace the control modules in the Replace with a
order of the CPU module, CRTC good control
module, DIO module, etc. module.
When the alarm stops when one of Replace with a
the above control modules is good PCB.
replaced, replace the PCBs on that
control modules. For example, if it is
the CPU module, replace the PCBs
one by one in the order of QX141,
QX721/QX722, QX42HI, QX81H1.
2 Control power QX084 defect Replace with a Small
supply defect There may be an error in the QX084 good PCB.
DC output. Measure the voltage and
ripple with the QX084 test pin
CPD03.
3 Defective Defective insertion of each card Re-insert. Medium
insertion The control module may be inserted
improperly into the back panel, or
the cassette memory QX81
insertion may be improper.
4 Noise Noise Confirm the Small
If measures against noise have not cable clamp
been taken, the system may be treatment*,
malfunctioning due to noise that is
entering the NC through the power treatment, surge
cable and connection cables. killer treatment of
relays, etc.,
according to the
Connection
Manual", and
treat if treatment
has not be
executed already.
5 Software Malfunction during a specific Change to the ?
operation newest software
version, and see
how it works.

The user PLC software accessed an ?


illegal address.

-26 -
(6) 011 EEROM error
(a) Meaning
This error occurs when the parameters are not correctly written into the EEROM.

(b) Cause and measures


List of presumed causes
Proba
No. Presumed cause Presumed cause (details) Measures
bility
1 EEROM defect The EEROM in QX141 is defective. Replace with a Great
good EEROM.
2 Card defect QX141 defect Replace with a Great
good PCB.
3 Control power
supply defect
. QX084 5V output defect
There may be an error in the QX084
Replace with a
good PCB.
Small

5V output. Measure the voltage and


ripple with the QX084 test pin
CPD03.
Check that the TEST pin has not be Release setting.
set by mistake.

(7) 008 Battery drop


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

(b) Cause and measures


The direct cause is that the battery voltage has dropped below the specified value (2.6V) due to
the battery life. However, if the above alarm occurs at a point remarkably sooner than the battery
life (7 years), the discharge current in the control PCB may be excessive. Measure the discharge
current before replacing the current.
List of presumed causes
Proba
No. Presumed cause Presumed cause (details) Measures
bility
1 Battery life Battery life Replace with a Great
new battery.
2 Card defect SRAM memory card QX420 card Replace with a Small
defect good PCB.
The SRAM memory card QX42D is
using too much of the battery
current.

Other card defects Replace with a


Some of the PCBs use the battery good PCB.
for the CMOS power supply.
QX141/QX521/QX524/QX571

3 Control power QX084 defect Replace with a Small


supply defect The QX084 is using the battery for good PCB.
the CMOS power supply.

-27-
(8) 010 Overheat
(a) Meaning
This alarm occurs when the NC control unit (measurement position is QX141) or the operation
board (measurement position is QY221) has risen above the specified value.
NC control unit : Alarm occurs at 7056C, turns off when below 555C
Operation board : Alarm occurs at 705C, turns off when below 605C
(b) Cause and measures
List of presumed causes

No. Presumed cause Presumed cause (details) Proba


Measures
bility
1 Working The NC ambient temperature (0 to Check that the Great
environment 45C) has been exceeded. unit is not in
direct sunlight,
and is not near a
heat source
(heater, etc.).
2 Working The temperature is within the NC Refer to the Great
environment ambient temperature (0 to 45C), but
the body temperature has risen 10C Manual" and
or more. check that
measures against
heat have been
taken.
3 Fan trouble Cooling fan trouble Replace with a Medium
good fan.

(9) 007 DIO 24V error


(a) Meaning
A 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.) on
the machine side has short circuited, and the 24V power has dropped.

(b) Cause and measures


List of presumed causes
Proba
No. Presumed cause Presumed cause (details) Measures
bility
1 No 24V power No 24V power supply connection Refer to the Great
supply
connection Manual" and
connect a 24V
power supply.
2 24V load on The DO signal wire has short Review the Great
machine side circuited with the GND, and an wiring.
short circuited excessive load current has flowed.
In this case, the output IC on the I/O
interface DIO-A card may have been

_
destroyed, so replacement of the
card may be necessary.
3 Card defect I/O interface DIO-A card defect Replace with a Small
good card.

- 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 the NC side
via the non-fuse breaker on the machine side. Confirm that the specified voltage is being output here.

Input side

||
R S
H
T
ON

Q
OFF

I--
u V w
ll ll

Output side

To transformer

Fig. 3.5.1

The single-phase input voltage is connected to the DC power QX084 terminal on the control unit, so
confirm that the specified voltage is being output here.
+10%
AC100V
-15%

Confirmation of DC power voltage


The DC power voltage is output to the DC power QX084 connector on the control unit, so confirm
that the specified voltage is being output here.

Max. total fluctuation rate Max. ripple voltage


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

(Note 1) The QX084 machine input/output power (+24V) capacity will increase according to the
system, 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 slightly
fluctuate the 5V voltage for testing will be required.
1-2 ON 4.75V
2-3 ON 5.25V

-29 -
(2) Connection of control power supply

rn

Fig. 3.5.2 Mounting position of control power supply

QX084 (Connector name)


<2-178128-5(Y
(Japan AMP)' (Connector maker)
CPA 0 1 O FG 3
<2-178138-5> O AC I N H 2 AC100V input
(Japan AMP) o AC t N N 1
FUSE
oo
<1-1781285(X)>
(Japan AMP)
CPA 0 2 O O FG 3
<l-178139-5> o o ACOUT H 2 AC100V output
(Japan AMP) o o ACOUT N 1

POWER (Green) Lit when power supply is normal


AC FA 1 L (Red) DC24V error

BAT. AL (Red) Battery error

n
Battery for
data storage
S W l Power ON/OFF switch

PB 1 System reset

O LG (AG)
o LG (AG)
O -12V
CPD 0 3 o >12 v Test pin
o
&-
o +5 V
ILoJ +5 V
a
CD SW 2 Battery check switch 3 Si
CPD 0 4
m +B V
-BV
Battery check pin
CPD 0 7
(BAT
Battery connector
IN)
2
1
OFF
-o

- <1-178288-5(X)>
CPD 0 5 fo] Jo P-ON 3(Japan AMP)
Power ON/OFF external signal
<l-178137-5> O O COM 2
(Japan AMP) [O] |Q P-OFF 1
<2-178288-5(Y)>
CPDO 6 (Olio FG 3 (Japan AMP)
DC24V output
<2-178137-5> O O +2 < V 2
(Japan AMP) O O RG 1 (0. 7 A max)

Fig. 3.5.3 Control power supply QX084 connector layout

(Note 1) Use a twisted pair shield cable that is 2mm2 or longer for AC100V
wiring.
a shield cable for the wiring to the AC ON/OFF switch, and connect the shield to the common terminal.
(Note 2) Use

- 30 -
3.6 Replacement of Various Units in Control Unit
The 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

sr
y & /
Z.
Fan

P 6
(Air flow
0 direction)
Fan connector

Card puller

Control
I
\m
_ZILI R
Ip A A
power unit

H 1
Memory cassette V V

V
C7
Basket
/ r
Battery cover

z
Battery

\
4 T~T

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
7
Fitting

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

o o
Screw

0

32 -
(3) For the following type of connector, pull out the connector while pressing it in the direction of the
arrows.

=
<= t=
fc=

dT
ft
(4) For the following type of connector, open the claws in the direction of the arrows and pull out
the connector.

Claw

0
JOB 3fO|

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

0 When the upper and lower card pullers are opened into the direction of the arrow shown in Fig.
3.6, the QX card will protrude slightly, and can be pulled out.

0 When mounting a new QX card, slide the card into the back along the guide groove on the basket.
The card name is indicated on the basket, so make sure that the card is inserted into the correct
slot.

@ Close the card lock.

-33-
3.6.4 Replacement of memory cassette card

Cassette case A Memory card Cassette case B

iO
a

-=l
c d
%

Memory cassette fixing screw

Loosen the two screws fixing the memory cassettes, and remove the card from the memory card
unit.
Release the claws from cassette case A while pressing down on the notch on the front of cassette
case 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 front
surface (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 Procedure
Take 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 and
manufactured by the machine maker. Observe the points listed in section Cabinet and pendant design
conditions" in the Connection Manual* to satisfy the following conditions.

(1) Ambient temperature


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

(2) Humidity
Normal relative humidity: 75% or less
The insulation or parts will deteriorate easily if the humidity is high. Special dehumidification measures
are not necessary, but avoid installing the system in areas with extreme humidity.

(3) Vibration
During operation: 0.5G or less
During transportation: 3.5G or less

(4) Atmosphere
Avoid use in environments that have large quantities of dust or high concentrations of organic or
corrosive gas mist.

4.2 Input Power

(D Input voltage
Control unit: AC100V +
10%
-15%

(2) Frequency: 50/60Hz 2%

(3) Power consumption: Refer to section Power consumption' in the Connection Manual" for the
control section.
Refer to the MELDAS Servo System Specifications for the drive section.

- 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 machine
side.
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 control
power 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 "Connection
Manual". All of the cables led into the control unit and operation board must be shielded and clamped
according 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 the
system 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 KX


as*a IP-V&P-I

Q CDA-tSS/SS
Opwoxm bowl

Amp*' CRT patptay
-- !
,

0
0 M*lf-prfcn ODKXCIor

AC pof Mpt>y
1-17813-3
Jwi Amp 0
AC pg*
2-178128-3
J*P*> Amp
xp*y

{gCRT AC po-w wpN


ConW PO**f ; 2sr [g 31814J3H1
~PP*ON ri Q Y 2 0 1 HD6 0 8
TE o B OC powar auppty
1-178288-2
>P*A Amp
0
DC pr
2-178288-3
-Ap Amp
upp*y

PW sr
Control
5
;Ci3
SHI 1 3/4 MX aomni vn

j AVR CPU IOC OPT 010


0X8 14 OX t < 1 OXJJ I ION
orr
r@CE,s 1 1 ji ON
AClOOV>
P AO 1
0
C P A
CSHII
-g I
TIMdM
control txx

CVM: CSAJ 1
P A 0 2 -C 01 r-6
CSH
I l2
:

0
|M C P pPT
0X7 2 1 :l ON To nwlwx
0X7 2 2

PDO 5
CP08 5 rh>Sf 22
i

1* o
* i
CPD8S
CSH 2 I

CDPSl
1

RS232C 4 rf-G I
SA I 2- 1 DP2 1
CH0| #- (a>($np)
SA2 1 jCNI I I
CHI SH2 1
Encsdarfeft IU.M.U,
CH2!
ESlV<>
K*

I

[53
Standard spedfications;
Panel Installation type 3

Refer to the
Spindle Servo Spedficatioos*
for details oo the drive section
connections.

With color CRT display

---- OpmUon tXMrf

CooSng un*

MS CRT2
f Cater CUT

257STri. QY2 0 1
HD6 OB
o
CSH1 8
CBPt S
0w**PO-wr rf=
SHI I
8+
yianww*:

[ AVR CPU IOC OPT DI0


0X8 14 OXI4I OXS 2 1 tON.
C> A 8 l lOPT
r6CE,sl
0 il ON
1
ACI00V> CSH t 1 :
CPA 8 2 -8 I
CSA2 1
!

Hr8 r-6 I2
CSH I

D
)MCP lOPT
0X7 2 1 ;i ON
QX7 22 AM po inr

CP08S rfOc H22


snM8ai

ti
CSH 2 1
Ki I
m
CP08 COPSI

rH3 !

*
0P2 t
*- Six(SWP)

SS 1 1
SH2 I
CnooP*' SEA

O
S ipM8*r

Fig. 4.3 General system drawings (for reference)

-38
4.4 Installation Check List
No. Check item Check details Related sections

1 Check of configuration Is there any dirt or damage on the NC control unit or operation board
component's caused during transportation?
appearance
Have the PCBs in the card basket dislocated during transportation. Section 3.6
Follow section 3.6 if the PCBs are dislocated, and securely insert them
into the card basket.

2 Check of installation Is the ambient temperature of where the power control box is to be
environment (during installed within 0C to 45C (the internal temperature rise in the power
machine installation) control box must be 10 or less).
Even if the external temperature is 45C or less, do not install the
system in direct sunlight, near a heat source, or outdoors.

In systems where the floppy disk unit 4FD01A is mounted, is the


ambient temperature of where the power control box is to be installed
within 10C to 30C (the internal temperature rise in the pendant must
be 10 or less).

Avoid installation in environments that have large quantities of dust or


high concentrations of organic or corrosive gas mist.

3 Confirmation of Confirm the PCB settings.


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

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

4 Confirmation of PCB Confirm that the PCBs are securely inserted into the card basket. Section 3.6
insertion If the PCBs are inserted after installing onto the power control box, the
DIN connector match may be loose.

5 Connection of external Are the external cables screwed or locked? Section 3.6
cables and grounding
wire Have the cables been clamped?
Has the cable sheath been peeled, the shield exposed and that
section 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?

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

7 Confirmation of input NC control unit: AC100 +10% to -15%, 50/60Hz2% Section 4.2
power voltage and
frequency

8 Confirm that the signal Confirm that the output of the I/O interface DIO-A has not been short
wire has not been circuited with the grounding.
ground faulted
Confirm that the output of the I/O interface DIO-A has not been short
circuited with the 24V.

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

39
4.5 Turning on the Power
Precautions 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 it
a 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 Preparation will be completed in approx.


NC power on (approx. 3 seconds) 3 seconds after turning NC power on.

Operation ready

(Control of automatic operation


and manual operation, etc., possible)

VS
Preparation will stop immediately
if one of the items on the left occurs.
1. Emergency stop B
2. Watch dog . Ready off (one second)
3. Memory parity \.
4. Battery alarm occurrence)
5. MCU error 7>
6. Servo amplifier
7. Memory guard
IT Press "RESET".

V
Parameter

Emergency stop Emergency o Emergency stop A,


(during trouble) stop hold. etc. (trouble)
1

The state after the cause The state is


is removed will be set by held in the NC.
Emergency stop the parameters (machine). Emergency stop A

(Remove cause)

-40 -
4.6 Setting Capacity (hardware setting)

Outline
Settings are made to determine the various constants in the NC, characteristic constants on the
machine side and specifications, etc. Settings are made with the hardware settings and software
parameters.
If these settings are changed, the machine movement will be obstructed, so take special care when
making 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 mounted
on each card in the control unit.
These settings have been set at the factory before shipment and thus these do not need to be
changed.
This MELDAS-500 Internal setting table' is included with each NC unit. (The one shown on the next
page is an example.)
When replacing the cards or unit, refer to the attached internal setting table and the current card unit
to make correct settings.

Set in this direction.

Precaution: DIO card system map setting method


SWI(CSI)
The emergency stop input setting plug and system map binary
T7N
switch (SW1) setting (SET=) for each DIO card is performed with L.;
the following settings.
HI
SET-

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


Emergency stop ON OFF OFF OFF OFF OFF
input
System map 0 1 2 3 4 5
SET=

-41 -
Client Msgr.
MELDAS-500 Internal setting table
Machine model name
a 0X034; Recording method
Q. 0) Place a check in the 0 according to the PCS mounted on the NC control unit, operation
v>

5
TEST 5V adjustment (2)
board and drive section.
ff there are several PCBs to be filled into the columns, circle the name of the PCS
o
Q. 1 2 3 mounted.
I
5 Set to the above setting (3) Note the rotary switch setting value after the Setting value = for the rotary switch.
regardless of model : (4) The settings that are shaded are fixed (cannot be changed).

: QX143/OXl41-t O QX423/0X424/QX425 O QX721/OX722: (UOX815/QX816



-]081 js.t**'" SPC Super C SO ICE <R)QXaj3/QXe<4/Qxaivais

E
o
E

S*l
amii
-
Set to the above
rgard>ecs model .
1 2
Set to the above setting
regardless of model
1
Set to the above setting
regardless of modeTH:h
2

:
No settings j.

D OXS24/OX521:i OX423/OX424/QX425 0X731 O 0X738 O OX '

2

Nc settings SPC
1 2
Super C SO
12
ICE: S1
1 2
Final end **':'* *. :i
A

o
tr
o Set to the above setting ; > Set to the above setting Set to the above setting
regardless of model : regardless of model regardless of tnodel
OX531/QX533/QX535/ QX531/QX533/GX535/ 0X531/0X533/0X535/ OX531/QX533/QX535/ The upper level is the
QX537/QX539 #1 0X537/0X539 #2 OX537/QX539 #3 QX537/QX539 #4 base card, the lower level
CS1 CS1 CS1 C$1 is the add-on card.

Setting*' Setting Setting' Setting'


E value value value value
Q =0 =2 6
Q

a QX311/QX3124;v m 0X311/0X312 a 0X311/0X313 O 0X311/0X312 The add-on card has no


0X314/0X317 0X3.14/0X317 . ::> : 'I:/: 0X314/0X317 _ % settings.

QX571 i o 0X771 :
i
M
- v:

1 XIF2
2nd card Super C t SO ICE :
. SO n sp)cotaQxai4/ ,
|
C
1 2 Mi mm
1': : ;'
My 1
. 1.-:2 iliil :8l 0X815/0X816 vl
Set to the above setting Set to the above setting No setting* , affiSn Bi

.......
a regardless of model regardless of model
><

m ' . . . D (L)QX813/QXBW
s

0X571 O 0X423,0X424/0X425 :0- OX77T?i|... a 0X721/0X722


JB
O ' ;, <s'> v.y. .<
.0X615/0X816 .
*8
E X1F2
1 2
2nd card ;SFC $uper,C;::f'; SO
t:2
ICE: SO i t tCEy- "z D <8*0X813/0X814/
QX81S/QX816
C jlMf
l Set to the above setting Set to the above setting Set to the above setting No settings
regardless of model regardless of model regardless of model
D QY201 O QY221 MC231 #1 MC231 #2
CS1 Setting CS1 S1 GND common S1 GNO common Nosetfirjgs
value Setting'1 S2 GND common S2 GND common
o
5 value
5 S3
24V common S3
24V 24V common
8
1
CS2 Setting
value
CS2
Setting'
S4
ss
24V common

OFF -
Always ;&y-v
S4
S5
Always OFF i
common

8 value
ft v cm S6 2nd card.,;: r - -; S6 *?;! v m
1: r EL
1 2 1 2

MDS-ArCV(ch.1) O axis O axis axis axis O axis 0| O axis

SW1 SW1 SW1 SW1 SW1 SW1 SW1


Setting Setting Setting Setting Setting Setting Setting
value value value value value value value
*0 =i =2 *= 3 -4 -5
\c
Contactor : 0 A-V1, V2 A-V1. V2 A-V1, V2 A-V1. V2 A-V1.V2 A-V1, V2
I
z No contactor: 1 A-SP A-SP A-SP A-SP A-SP A-SP
axis O axis axis O axis axis D axis
O MDS-A-CV(ch) O
SW1 SW1 SW1 SW1 SW1 SW1 SW1
Setting Setting Setting Setting Setting Setting Setting
value
kz. . value
=0
value
=1
A-V1, V2
value
=2
A-V1, V2
value
3
ArV1. V2
value

A-V1, V2
value
*5

Contactor :0 A-V1, V2 A-V1. V2


No contactor: 1 A-SP A-SP A-SP A-SP A-SP A-SP
Main unit order BW-

8
Option order BW-

5
I
Z
Do not connect Order list No. SSO-
& Manufacture No. S/N
Connect S8W-

-42-
5. Explanation of Hardware
5.1 Outline
An 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 computer
as a base, and the NC operation board and servo mechanism.
The control unit is composed of various control modules (integrated PCBs). The following three modules
are mainly used.
The CPU module, is the data processing section that is made up of the main CPU QX141 (composed of
the latest 32-bit CPU, memory, programmable controller, various gate arrays, and peripheral IC), SRAM
memory QX42D, main cassette memory QX81 user PLC cassette memory QX81 and axis movement
control 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 control
PCB 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 MDI
setting function. The display between the NC operation board and control unit is performed with video
signals, 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 serial
transmission.
To process the data, the CPU reads (fetches) one command at a time of the software (group of
commands called the control program) that is read into the memory beforehand. The command is
analyzed, executed and processed.
This control program is divided into several programs according to the required emergency of the data
processing, and is located in the ROM on the memory cassette QX81Q
The 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 the
machine side must be processed within a set interval. Thus, these have the highest priority. The machine
control program that processes these is called motion.
Next, the calculation program that reads the tape command, analyzes the NC command to precalculate
the 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, and
processes 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 cannot
be satisfied, so each task is given an order of priority, and processes are performed according to this
order.
If, during a certain task, a request for processing a task with a higher priority is received, the currently
executed task will be interrupted, and the requested task will be executed. If an even higher task is
received, 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 side
with 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 from
the memory. If it is a movement command, the movement data for each axis is calculated and output to
the servo amplifier.
If it is machine operation data, the data will be output to the power control sequence.

- 43 -
( Start )
Machine data input
Machine data read in

automatic To manual mode, etc.,


mode? NO process

YES

Output machine data to


Cycle start?
NO power control sequence

YES

Read machining Note) The machining program is


program from also called the part
memory program.

EOB?
NO
YES

Check machin
ing program format. To program error
"<''OK? NO
YES

"Movement Output machine data to


command? NO power control sequence

YES

Calculate each axis


movement data

I
To axis movement
control

Note) This is an example of the flow of operation when executing


an EIA/ISO program.

Fig.5.1 MAZATROL T PLUS Series Operation Flow Chart

-44-
CRT setting and display unit key input
When the key switches on the CRT setting and display unit are pressed, the inputs are read into the
NC unit with the following route.

SV
(Matrix input)

iL
Key QX141
switch CPU
Receiver

l
T circuit
QX521
QY221
card i
card (black anc
white) mr
LC
QX524
card
(color)

Machine operation board input


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

Machine opera QX141


tion board CPU
switch
Input I
Receiver
QX521 circuit
QY221 card i 1
card (black and
white)
{ 1

t
I
0X524
card -S- 24V
(color)

Machine operation board lamp output


The machine operation board lamps (including LEDs) can be lit up with the following route in addition
to outputting to the machine side.

Machine opera
QX141 tion board
CPU switch

QX521 QY221
card
(black and card
white)

0X524
card
(color)

Output

z 24V

1
R or
Protective resistor

7'7 Open emitter (External power supply


circuit of 24V is necessary.)

-45-
5.2 Flow of Signals

Machine contact input

Machine side DIO module


power control QX539/QX535, QX141
circuit etc., machine CPU
Machine control input l/F
board

Output to machine side

DIO module Machine side


QX141 QX539/QX535, power control
CPU etc., machine circuit
input l/F Machine control
board

(Note) VDE regulations


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

24 V
Output

Input

6
i
Receiver
circuit
a
l
A
or
Protective resistor

TLJ

I 777-
-B-24V Open emitter circuit

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

24 V i
Input Output --24V
I 2.2K
A Receiver

r I
i
i
circuit Protective resistor

PL
I
k
1 I
7777 Open emitter circuit

- 46 -
Screen display
Display outputs to a 12 inch CRT screen is performed with the following route.

Video Setting
QX141 QX521 QY221
and
CPU card card signal display unit

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

Video Setting
QX141 QX524 QY221
and
CPU card card signal display unit

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 with
one 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 external
magnification selection switch.

QY221
Manual pulse QX524/QX521 QX141 CPU
Manual handle
generator CPU (For board side)
control circuit

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

Constant voltage
Constant current
O Power

Output driver A phase output

diode
3Z
Luminescent
Waveform
/
/
X \
\
\
Photocell shaping O Grounding / \
\A i
i O B phase output \
\
\ /
/
/

"777 \ /

Slit 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 output
are deviated by a 90 phase. This phase deviation will be either the A phase or B phase first according
to the direction that the disk is rotated. In the QY221 manual handle control circuit, these are
discriminated by phase and discriminated by rotation direction.

Handle scale
One pitch

A phase pulse lUIHL Li_LI


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

Execution of program and accessing of memory


The route that the CPU uses to fetch the command from the memory is as follows:

1. System program

QX141
QX810#1 CPU
System
Cassette memory
Kir
3- J H CPU |

Programs in the cassette memory (system program) on the left side of the CPU module that require
high speed processing, are transferred to the high speed memory in the main CPU when the
system 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 that
has a special memory added to it.)

2. User PLC program


QX141
QX81D#2 0X420 CPU
User PLC SRAM memory rpufj CPU |
Cassette memory

Programs in the cassette memory (user PLC) on the right side of the CPU module that require high
speed processing, are transferred to the QX42D SRAM memory when the system power is turned
on. 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 shown
below.

QX42D QX524 QX141 QX42D


SRAM memory Main CPU SRAM memory
QX521

QX42D QX571
SRAM memory

Machining program memory area


If the tape length is short, the machining program will be written into the QX42D SRAM memory in the
CPU module, but if long, the program will be stored in the QX42D SRAM memory in the CRTC
module.

-48-
5.3 Control Unit Functions and Handling
The MAZATROL T PLUS Series control unit 4MU301, 4MU401 and 4MU601 is composed of the DC power
supply QX084, back panel QX031, QX041, QX061 and various control modules. These are mounted on
a 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 positions
of this control unit.

5.3.1 Power supply


QX084 Appearance and connection connectors Supplementary
explanation
This is the MAZATROL T PLUS Series control unit's Usaqe format
DC power supply. A 5V* 12V and 24V DC voltage is 1. MiAZATROL T PLUS
created. Series common
power supply
Input side OXCJ<
CPAO I FC
a AC I N H
WO AC 1 N K

OFT O

: I
; z>
FUSE

m
Hill
ctMOTO

-
v
p
rpa**u
ifOTK
i HU
FC
ACOUT H
ACOUT N

ONOT
i POWER
AC FAIL fJtxKVe-o,

n
-O *SY BAT. AL
OLC
fl - - -o|6-

AC IK
I
I
J
O AC
<12V
-0-I2Y u PB I
LG
AC lJY SO/WRi
HO
CP 0 3 o
LG
-I2V
+ KV
: -O<?<Y
-otc
o + JV
+ $v
FC O- Maintenance comment
ijr ire SW2 ry th.OeHtt

__
R
-OK
=51 +8V
-BV
Battery Causes of input fuse
blowing
*
H
Ol
AC an P-ON
AC WCV SA SO/SOK* COM A protection fuse is
P-OFF
mounted on the AC
re v input line in the power
Output
2 < supply QX084. The
RG following causes can be
The following values are a guideline for the output considered when the
perform a fuse blows.
Rated output voltage + 5V + 12V -12V 4- 24V
Description of settings and LED 1. Power capacity for AC
Rated output current 15A 1A Q.5A 2A OUT output
Total fluctuation rate 2% 2% -2% 15% exceeded.
or toss or less or less or lass (including AC OUT
Ripple voltage 50mV 60mV 60mV 200mV output short circuit)
or less or less or less or less
Setting
2. Short circuit of
LED
Description Standard varistor inserted
between AC lines.
AC100 OUT
POWER Indicates
when green LED is lit. _
normal power supply Lit 3. Short circuit of
rectifying diode stack
5A Indicates that a DC 24V error, AC
or AC input in power supply.
AC FAIL input overvoltage, Not lit
undervoltage has occurred when 4. Short circuit between
The power supply QX084 detects undervoltage or red LED is lit C and E of the
temporary stoppage of input voltage and Indicates that battetry voltage is switching transistor in
overvoltage, undervoltage and under currents of the BAT-AL
2.6V or less when red LED is lit.
Not lit
the power supply.
output voltage. When detected, the power is Top: Power ON 5. Short circuit of
automatically turned off. SW1
Bottom: Power OFF rectifying diode stack
However, for +24V, the output droops during an System reset switch (Do not in auxiliary power
overcurrent operation and the power is not turned PB1 touch) supply
off. In this case, the power supply LED lamp (red) 6. Short circuit between
will light. This LED lamp lights when the input C and E of the
voltage is detected as 85V or less or 130V or higher. switching transistor in
Once lit, it will remain lit until the power is turned the auxiliary power
on. supply.
tf the power supply is turned off due to a detection
an overvoltage in the output voltage, an error signal
will be output in the power supply section and will
be held. Thus, the power will not turn on even if the
Power ON switch is turned on. (Turn off the main
NFB (approx. 2 minutes), and turn on again. The
error signal will be released, and the power can be
turned on.)

-49-
5.3.2 PCB functions and handling

(1) Back panel

QX031/QX041/QXD61 Appearance and connection connectors Supplementary


explanation
QX031, QX041 and QX061 are used tor data QX 0 3 I Usage format
communication between the control modules
mounted in the control unit.

QXO 4 1

Maintenance comment

QXO 6 1

(2) Control PCB


As 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 Table
5.3.2 Control module combination table. O indicates a combination that can be mounted on the
hardware, A indicates a combination that can be mounted on the hardware but where the software
is not supported currently, and x indicates a combination that cannot be mounted on the hardware.

Table 5.3.2 Control module combination table


Model name P-BUS A-BUS M-BUS C-BUS C-BUS
No.
Model name S-BUS QX721! QX722 j 0X7311 0X732 All cards All cards All cards All cards

1 CPU module :QX141/QX141-1 A O A A X O O O

2 CRTC module :QX524/QX521 A X O O x O X x

DIO module jQX539 X X X X X X X x


3
IQX535 X X X X O X X X

Module with
4 special QX571 O A A A x A A A
memory

- 50 -
CRT setting and display unit key input
When the key switches on the CRT setting and display unit are pressed, the inputs are read into the
NC unit with the following route.

SV
(Matrix input)

iL
Key QX141
switch CPU
Receiver

l
T circuit
QX521
QY221
card i
card (black anc
white) mr
LC
QX524
card
(color)

Machine operation board input


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

Machine opera QX141


tion board CPU
switch
Input I
Receiver
QX521 circuit
QY221 card i 1
card (black and
white)
{ 1

t
I
0X524
card -S- 24V
(color)

Machine operation board lamp output


The machine operation board lamps (including LEDs) can be lit up with the following route in addition
to outputting to the machine side.

Machine opera
QX141 tion board
CPU switch

QX521 QY221
card
(black and card
white)

0X524
card
(color)

Output

z 24V

1
R or
Protective resistor

7'7 Open emitter (External power supply


circuit of 24V is necessary.)

-45-
5.2 Flow of Signals

Machine contact input

Machine side DIO module


power control QX539/QX535, QX141
circuit etc., machine CPU
Machine control input l/F
board

Output to machine side

DIO module Machine side


QX141 QX539/QX535, power control
CPU etc., machine circuit
input l/F Machine control
board

(Note) VDE regulations


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

24 V
Output

Input

6
i
Receiver
circuit
a
l
A
or
Protective resistor

TLJ

I 777-
-B-24V Open emitter circuit

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

24 V i
Input Output --24V
I 2.2K
A Receiver

r I
i
i
circuit Protective resistor

PL
I
k
1 I
7777 Open emitter circuit

- 46 -
Screen display
Display outputs to a 12 inch CRT screen is performed with the following route.

Video Setting
QX141 QX521 QY221
and
CPU card card signal display unit

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

Video Setting
QX141 QX524 QY221
and
CPU card card signal display unit

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 with
one 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 external
magnification selection switch.

QY221
Manual pulse QX524/QX521 QX141 CPU
Manual handle
generator CPU (For board side)
control circuit

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

Constant voltage
Constant current
O Power

Output driver A phase output

diode
3Z
Luminescent
Waveform
/
/
X \
\
\
Photocell shaping O Grounding / \
\A i
i O B phase output \
\
\ /
/
/

"777 \ /

Slit 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 output
are deviated by a 90 phase. This phase deviation will be either the A phase or B phase first according
to the direction that the disk is rotated. In the QY221 manual handle control circuit, these are
discriminated by phase and discriminated by rotation direction.

Handle scale
One pitch

A phase pulse lUIHL Li_LI


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

Execution of program and accessing of memory


The route that the CPU uses to fetch the command from the memory is as follows:

1. System program

QX141
QX810#1 CPU
System
Cassette memory
Kir
3- J H CPU |

Programs in the cassette memory (system program) on the left side of the CPU module that require
high speed processing, are transferred to the high speed memory in the main CPU when the
system 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 that
has a special memory added to it.)

2. User PLC program


QX141
QX81D#2 0X420 CPU
User PLC SRAM memory rpufj CPU |
Cassette memory

Programs in the cassette memory (user PLC) on the right side of the CPU module that require high
speed processing, are transferred to the QX42D SRAM memory when the system power is turned
on. 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 shown
below.

QX42D QX524 QX141 QX42D


SRAM memory Main CPU SRAM memory
QX521

QX42D QX571
SRAM memory

Machining program memory area


If the tape length is short, the machining program will be written into the QX42D SRAM memory in the
CPU module, but if long, the program will be stored in the QX42D SRAM memory in the CRTC
module.

-48-
5.3 Control Unit Functions and Handling
The MAZATROL T PLUS Series control unit 4MU301, 4MU401 and 4MU601 is composed of the DC power
supply QX084, back panel QX031, QX041, QX061 and various control modules. These are mounted on
a 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 positions
of this control unit.

5.3.1 Power supply


QX084 Appearance and connection connectors Supplementary
explanation
This is the MAZATROL T PLUS Series control unit's Usaqe format
DC power supply. A 5V* 12V and 24V DC voltage is 1. MiAZATROL T PLUS
created. Series common
power supply
Input side OXCJ<
CPAO I FC
a AC I N H
WO AC 1 N K

OFT O

: I
; z>
FUSE

m
Hill
ctMOTO

-
v
p
rpa**u
ifOTK
i HU
FC
ACOUT H
ACOUT N

ONOT
i POWER
AC FAIL fJtxKVe-o,

n
-O *SY BAT. AL
OLC
fl - - -o|6-

AC IK
I
I
J
O AC
<12V
-0-I2Y u PB I
LG
AC lJY SO/WRi
HO
CP 0 3 o
LG
-I2V
+ KV
: -O<?<Y
-otc
o + JV
+ $v
FC O- Maintenance comment
ijr ire SW2 ry th.OeHtt

__
R
-OK
=51 +8V
-BV
Battery Causes of input fuse
blowing
*
H
Ol
AC an P-ON
AC WCV SA SO/SOK* COM A protection fuse is
P-OFF
mounted on the AC
re v input line in the power
Output
2 < supply QX084. The
RG following causes can be
The following values are a guideline for the output considered when the
perform a fuse blows.
Rated output voltage + 5V + 12V -12V 4- 24V
Description of settings and LED 1. Power capacity for AC
Rated output current 15A 1A Q.5A 2A OUT output
Total fluctuation rate 2% 2% -2% 15% exceeded.
or toss or less or less or lass (including AC OUT
Ripple voltage 50mV 60mV 60mV 200mV output short circuit)
or less or less or less or less
Setting
2. Short circuit of
LED
Description Standard varistor inserted
between AC lines.
AC100 OUT
POWER Indicates
when green LED is lit. _
normal power supply Lit 3. Short circuit of
rectifying diode stack
5A Indicates that a DC 24V error, AC
or AC input in power supply.
AC FAIL input overvoltage, Not lit
undervoltage has occurred when 4. Short circuit between
The power supply QX084 detects undervoltage or red LED is lit C and E of the
temporary stoppage of input voltage and Indicates that battetry voltage is switching transistor in
overvoltage, undervoltage and under currents of the BAT-AL
2.6V or less when red LED is lit.
Not lit
the power supply.
output voltage. When detected, the power is Top: Power ON 5. Short circuit of
automatically turned off. SW1
Bottom: Power OFF rectifying diode stack
However, for +24V, the output droops during an System reset switch (Do not in auxiliary power
overcurrent operation and the power is not turned PB1 touch) supply
off. In this case, the power supply LED lamp (red) 6. Short circuit between
will light. This LED lamp lights when the input C and E of the
voltage is detected as 85V or less or 130V or higher. switching transistor in
Once lit, it will remain lit until the power is turned the auxiliary power
on. supply.
tf the power supply is turned off due to a detection
an overvoltage in the output voltage, an error signal
will be output in the power supply section and will
be held. Thus, the power will not turn on even if the
Power ON switch is turned on. (Turn off the main
NFB (approx. 2 minutes), and turn on again. The
error signal will be released, and the power can be
turned on.)

-49-
5.3.2 PCB functions and handling

(1) Back panel

QX031/QX041/QXD61 Appearance and connection connectors Supplementary


explanation
QX031, QX041 and QX061 are used tor data QX 0 3 I Usage format
communication between the control modules
mounted in the control unit.

QXO 4 1

Maintenance comment

QXO 6 1

(2) Control PCB


As 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 Table
5.3.2 Control module combination table. O indicates a combination that can be mounted on the
hardware, A indicates a combination that can be mounted on the hardware but where the software
is not supported currently, and x indicates a combination that cannot be mounted on the hardware.

Table 5.3.2 Control module combination table


Model name P-BUS A-BUS M-BUS C-BUS C-BUS
No.
Model name S-BUS QX721! QX722 j 0X7311 0X732 All cards All cards All cards All cards

1 CPU module :QX141/QX141-1 A O A A X O O O

2 CRTC module :QX524/QX521 A X O O x O X x

DIO module jQX539 X X X X X X X x


3
IQX535 X X X X O X X X

Module with
4 special QX571 O A A A x A A A
memory

- 50 -
Supplementary
0X141 Appearance and connection connector
explanation
The difference Usage format
between the Use only for CPU
AIMI QX141 and module
CPU QX141-1 is that
u the QX141 has c M
iDRAiia }--Q i i
floating point
I PLC | C B B
processing
functions and the u U
S *- D. 8. S. psuais
QX141-1 does not s s
> -| Serial KF pf~
have this
A/D IPX

l KM
[ EPKOI h
>
p function. The
other functions
are the same.
[3 P
s
i
[QPBI I
B
ODCT B
u
SW1 s
COW- u
s Maintenance comment
(O? LED!
The machine
CO?lD2 CSl
characteristic or NIC
Specification Specification unit characteristic
item parameters are
CPU 32-bit high speed MPU Description of settings and LED registered in the
(QX141 has FPP, QX141-1 does Setting EEPROM the original
Description Standard EEPROM (with
not have FPP) LED
PLC LSI that executes high speed socket) must be used
sequence processing CS1 Used only for multi- 0 when this card is
EPROM Monitor ROM CPU configuration replaced.
EEPROM Registers machine characteristic PB1 Software abort switch
or NC characteristic parameters all OFF
SW1
DRAM Dynamic RAM (with parity)
Serial I/O RS-232 2ch. Watch dog alarm Green
Others Interrupt control circuit LED1 when red LED is lit. LED
CTC (Counter timer) flicker
RTC (Clock mechanism) Memory parity error Green
Cassette memory read/write LED2 when red LED is lit. LED
function flicker

Supplementary
OX423/QX424/QX425/QX429 Appearance and connection connector explanation
The 0X420 card Usage format
is the SRAM tzm CPU module
U
Ill
CX42D c
memory card. SFC (Data, stack area,
machining program,
3 stJM C [M! user PLCs)
li CRTC module

Is!I
s
(Large capacity
memory)

l-J

(View from soldered face)


Maintenance comment
Always back up the
card before
Specification Specification Description of settings and LED replacement as the
item
parameters and
SRAM QX423 512kB (with parity) Setting Description Standard programs are stored
QX424 1MB (with parity) LED
within.
QX425 2MB (with parity) ON when backing up
0X429 1.5MB (with parity) SPC SRAM with super ON
Back up With super capacitor capacitor

- 51 -
QX812/QX813/QX814/QX815/QX816/QX818 Appearance and connection connector
Supplementary
explanation
The QX81 card Usage format
is a ROM card 1. CPU module on
C QXSlO
composed of the QX141
] Ft sou
flush ROM. (System memory)
c 2. CPU module on
I QX42D
B (User PLC memory)
U
s

Specification Description of settings and LJED Maintenance comments


Specification
item Setting
If a watch dog alarm
Description Standard occurs on the main
ROM Rush EEPROM LED
CPU, this PCB may
QX812 256KB No settings or LEDs be defective.
QX813 512kB
ROM-CUT is possible
0X814 1MB by this PCB on the
QX815 2MB
actual machine.
QX816 4MB
0X818 3MB

Supplementary
QX721/QX722 Appearance and connection connector
explanation
The QX721 and Usage format
QX722 cards are 5S 1. CPU module

CT721/722
PCBs for the
servo interface
C (Normalposition:
0X722)
[~CPU] using the CPU p 2. Expansion module

P
> 2-PORT
m
Serial
VF
3U20
H: CSK21
inside.
0 I
B
u
s
(Multiplex:QX721)

High speed
SRAM

am
OKI.
_ Serial
l/F

| SKIP F-T CDP51


DSUB15
CSH22
a Min
LJ

(View from soldered face)

Description of settings and LED Maintenance comments


Specification Specification 1. This PCB is defective
item Setting Description Standard when LED1 is lit.
CPU RISC type high speed CPU LED 2. If a watch dog alarm
High speed Code area, data stack area Watch dog alarm for for this CPU card
SRAM LED1 this PCB when red Not lit (QX141) occurs, this
2-PORT RAM High speed 2-PORT RAM LED is lit. PCB may be
Serial l/F High speed serial l/F with servo defective.
amplifier LED2 Software monitor
QX721 1ch. TP1 For testing OFF
QX722 2ch.
Skip input Sensor input
QX721 4 points
QX722 8 points

- 52 -
0X521 Appearance and connection connector Supplementary
explanation
The QX521 card Usage format
<r~>
is the graphic c? Used only for CRTC
display PCB for module


ors2i
s
>D
H ant l
c
u

?
black and white
use.
This card also
has the operation

i
M
I
B
u
Used for the 12-inch
monochrome CRT
unit.

-C board l/F, spindle


ioj s
encoder l/F, and ten

UIOEO
1/7
DSUB25
RS-232 device l/F
functions.
CSH11
i S2J
2

ism Q
-| Serial l/F 3Xj CSH12 [ 5
S
SUS*0 P
_ Spindle
encoder Vf
DSUB15
CES11 LED 1 I
I Maintenance comment
When the main CPU
B
IED2 B (QX141) operates,
U
u
i
9 CSA21 lD3
s s and trouble related to

RAM I -1 lD4 the operation board


such as the key
inputs from the
Specification Specification Description of settings and LED operation board are
item not read or the
Setting Description Standard
Display l/F For 9 and 12 inch monochrome CRT, 9.4 display does not
section inch EL LED
CRTC High speed graphic processor appear, this PCB may
Video RAM Frame memory (two-sides) LED1 tion
Communication withoperaii Lit be defective.
Video l/F Font ROM (JIS Class 1 standards) (SD) board when green LED is lit
Shift register, expansion character l/F LED2 Communication with operation
Serial l/F High speed serial l/F with operation board (RD) board when green LED is lit Lit
IOP section
CPU CPU LED3 Spindle encoder CH1 no
SRAM IOP code and stack area (FBAL1) signal when red LED is lit Not lit
Serial l/F RS-232 2ch.
encoder Spindle encoder (differential) l/F 2ch. LED4 Spindle encoder CH2 no
Swindle (FBAL2) signal when red LED is lit Not lit

Supplementary
0X524 Appearance and connection connector
explanation
The QX524 card Usage format

Q5524
s -* U
is the graphic
display PCB for
color use.
L S? Used only for CRTC
module
Used for the 14-inch
>0 c This card also TS1
M
I color CRT
P has the operation 2 B
n I ImseolL
L* mK
m board l/F, spindle
encoder l/F, and t jo_
u
s
i & RS-232 device l/F KT]

UIDS3
!/7
DSUB25
functions.
CSH11 E I2J

Serial l/F \ CSH12 8


_ Spindle
DSUB15
CES11
C 5
P
S
encoder l/F I
LED! I Maintenance comment
B
LED2 B When the main CPU
CSA21 U
LED3 U (QX141) operates,
S
l MM I lD4 s and trouble related to
the operation board
such as the key
Specification Description of settings and LED inputs from the
Specification
item operation board are
Setting Description Standard not read or the
Display l/F For 14 inch color CRT, 10.4 inch color LCD LED
section display does not
CRTC High speed graphic proc essor
Video RAM Frame memory (four-sides) LED1 Communication with operation Lit appear, this PCB may
Video l/F Font ROM (JIS Class 1 standards) (SD) board when green LED is lit
Shift register, color oallet
be defective.
LED2 Communication with operation Lit
Serial l/F High speed serial l/F with operation board (RD) board when green LED is lit
IOP section
CPU _Ii
CPU LED3 Spindle encoder CH1 no Not lit
SRAM IOP code and stack area (FBALl) signal when red LED is lit
Serial l/F RS-232 2ch. LED4 Spindle encoder CH2 no
Spindle encoder (differential) l/F 2ch Not lit
Swindle encoder (FBAL2) signal when red LED is lit

- 53 -
0X539 Appearance and connection connector Supplementary
explanation
The QX539 cards Usage format
0X53S are 1/0 interface Used only for DIO
A DIO-A PCBs that o module
CDP3I use Honda
[ s

"T-n-rH PI ID connectors. o

The front surface


{ DO 64 CDJ31 is completely o
filled with mQ
Al
\ point

5 point
connectors so an
CDP32 addon card
cannot be added.
t 3

1ch of the analog


CDJ32 input is input
C
from the front g
connector, but
CPA21 when 2ch or
more are used, a
separate connec
tion adaptor is
required, in this m
case, a mounting g
space of two
slots is required.
3 is Maintenance comment
When the contact
Specification Specification output is short
item Description of settings and LED
circuited, the output
Setting Description Standard 1C in the PCB may be
Contact 64-point
input (24V common) LED damaged. Always
Contact 64-point (VDE) This is used for 1st 0 confirm the
output separation when 2nd 2 connection with a
CS1 several DIO modules 3rd 4 tester, etc., before
Analog input 6-point
Analog 1-point are mounted in the etc. turning on the NC
output control unit. power.

Supplementary
0X535 Appearance and connection connector
explanation
The QX535 card Usage format
QX535AJX537 is an I/O interface Used only for DIO
S A PCB that uses a module
flat cable
>0 connector. A
DI The contact input
CDP21R
80 is 24V common B
for the QX535 U
H: CDP211 card.
o
s
01 32 points can be
CDJ21R changed over.
80

k C0J21L
The VDE
regulation for the
QX535 card is o
contact output.
Maintenance comment
S When the contact
o
! output is short
B circuited, the output
U 1C in the PCB may be
S damaged. Always
o

Specification
I [ CPP11 confirm the
Specification connection with a
item tester, etc., before
Description of settings and LED
Contact 80-point turning on the NC
input QX535: 24V common Setting Description Standard power.
QX537: GND common LED
(32 points can be changed to 24V 1st 0
This is used for
common or GND common with
separation when 2nd 2
external connection.)
Contact CS1 several DIO modules 3rd 4
80-point
output are mounted in the etc.
QX535 VDE (open emitter)
control unit.

- 54 -
0X316 Appearance and connection connector Supplementary
explanation

Cu;6
The 0X316 card Usage format
is a contact input Used only for DIO

A
interface add-on module, and mounted
dltS r
J
uu [=3 El
r
-3 PCB that uses a
flat cable.
TJ
fO
i
:i!
! B!
i as an option on the
0X535 card.

! u!
iJL!

Specification Specification Description of settings and LED


item Setting Description Standard
Contact 16-point LED
input No settings or LEDs

Supplementary
0X571 Appearance and connection connector
explanation
This PCB Usage format
functions only 1. Module for axis
0X571
S

o-t
u after the M-BUS
PCB, P-BUS PCB
and C-BUS PCBs
c
I
M
I
expansion, and used
for the multiplexing
machine as a
C are mounted. B B standard.
-o-c (This PCB has no
u u 2. QX721 is mounted on

c
0
p functions on its
own.)
s s QX571 for axis
expansion.
Maintenance comment
s
I
P
B
I
U
8
S
u
s

Specification item Specification


M-BUS expansion
P-BUS expansion
C-BUS expansion
Description of settings and LED
Setting Description Standard
LED
Set to the 2nd PCB 1st PCB
XIF2 when using two of OFF
these PCBs. 2nd PCB
ON

- 55 -
QX731 Appearance and connection connector Supplementary
explanation
This PCB is for Usage format
computer linking. 1. CRTC module

FCPUT CSA32
(ich is for r-j
2. Mounted as an
option.
2- PORT
SRAM
debugging)
! ?! (Protocol B: RS-232C)
RAW C.'J so
2 |B (
U|
Serial
-41 CSA31
l/F
ai
[ 2S3
LSJ
5E

Maintenance comment
Specification Specification Description of settings and LED
item Setting Description Standard
CPU High speed 16-bit CPU LED
Serial l/F 2ch (max. 38, 4KBPS) SO For testing OFF
SRAM Code area, data stack area
2-PORT RAM For communication with main
CPU

Supplementary
QX732 Appearance and connection connector
explanation
This PCB is for Usage format
computer linking. 1. CRTC module.
2. Mounted as an
I~CPUT CSA32(RS232)
(Not used)
*
0 rcr 2a P
option.
(Protocol B: RS-422)

__
I
> 2-PORT
RAM
SRAM B
U
Serial
l/F H: CSA33(RS422) s
i

CSJso

Maintenance comment
Specification Description of settings and LED
Specification
item Setting Description Standard
CPU High speed 16-bit CPU LED
Serial l/F 1ch (max. 38.4KBPS) SO For testing OFF
SRAM Code area, data stack area
2-PORT RAM For communication with main
CPU

- 56 -
5.4 Functions and Handling of the Operation Board
Outline 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 the
model. These CRTs are open frame type CRTs with built-in AFC for data industries that required a high
reliability and high resolution play back. These are compact and light weight, and most of the circuits are
integrated on one PCB. The reliability is high, and maintainability is easy so stable operation can be
expected over a long period.
14 inch color CRT : A1QA8DSP40/CD1472D1M2 BKO-NC6542
12 inch monochrome CRT : MDT-1283-02

Adjustment
There are various positions on the CRT to be adjusted, but these have been adjusted before
shipment, so readjustment is not required.

Precautions for use


(1) Affect of magnetic fields
The CRT displays data by scanning an electronic beam with a magnetic field. Therefore, external
magnetic fields will affect the display and will cause screen distortion, screen swaying and color
distortion". 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 be
magnetized if a magnetic stand, etc., is installed. Note that this will cause screen distortion. The CRT
is also affected by magnetic fields from motors, transformers and magnetized workpieces.
(2) Cathode-ray tube life
The 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 differ
according to the tube maker), and does not mean that the tube cannot be used. The phenomenon
will 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 O
Pb jpower O

QY221
P vX iON/OFF
CJ jbutton
(Contact
Q block) iigg=
N
P-
%
0-='
%
\
Menu keys
Screw (x 6)
X
XT

Menu keyboard

(1) Control PCB


1) Disconnect the cable connected to the PCB.
2) Remove the four screws.
(2) Data keyboard
1) 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) Remove the Power ON/OFF button contact block (wiring side).
3) Remove the four screws and remove the escutcheon.
4) Remove the six screws fixing the menu keyboard.

-58-
5.4.2 PCB functions and handling

QY221 Appearance and connection connector Supplementary


explanation
This PCB is used for the NC operation board and Usage format
SCAN type machine operation board control. 1. SCAN type operation
~ board
OY221

> Display l/F


{ C8CU
j C8H1S

0
I |CSell I
0
NC main unit
CRT/EUookx
LCO DDn Maintenance comments

csa3
VIDEO
cams
CPU
l
424V
CBS 15
Full keyboard

10P ?SO
KXC
Serial
l/F
NC Opera-
[ 0682
NC operation
board 2
pO
?
Q2064
Power
RCV t{ C5EI1
Manual pulse
generator
tupp|y
412V

board V*

412V
0682
Scan board

H 0684
Scan board
B
B
0685
424V MCS1 tpaor*
Description of settings and LED
(12V
[12V
Setting
Description Standard
fSV LED
CBP1S
Setting
CS1 For testing
table
Specification item Specification
For judgement of Setting
CPU 8bit CPU CS2 operation board table
ROM Program area type
SRAM Data stack area
PB1 QY221 reset switch
Serial l/F Transmission/reception with
control unit Indicates reception
NC operation from control unit is Ut
RD
board l/F normal when green
Machine SCAN type machine LED is lit.
operation board operation board l/F Indicates
l/F transmission to
Manual handle l/F 2ch. SD control unit is Ut
FLD IF Floppy disk Max. 2 units normal when green
Control power Conversion from 24V to 5V, LED is lit.
supply 12V
Indicates QY221
software operation is Ricker
MON
normal when green
LED is lit.

- 59 -
5.5 Functions and Handling of Manual Handle (HD60)

rfa
mK
% s

G- >
5

Fig. 5.5 Appearance of manual handle (HD60)

5.5.1 Functions

(1) Outline
The manual handle is rotated by hand, and when rotated, two types of pulse signals are generated
in proportion to the rotated angle.

(2) Electrical characteristics


Input/output terminals
Terminal block No. Signals
+12V +12V
0V OV
A A phase signal output
B B phase signal output

Power
A 12V voltage is required.

Signal output
The A phase output and B phase output signals are output, and the following outputs are made
according to the handles rotated angle.
Output waveform and phase relation (When handle is rotated in positive (+) direction)

T
A phase output V

B phase output V
4-
V, : 5 V10% a b

a : 30% P
2

a : 40%
4
Maximum output frequency
100Hz or more

- 60 -
5.5.2 Replacement and handling

If DC12V is impressed, the signals will be automatically output from the A phase and B phase. If the
signals are no longer output, the handle must be replaced. (The LEDs on the back will alternately flicker
when the handle is rotated.)
Take special care not to mistaken the wiring when replacing the handle. The handle will be damaged if
the wiring is mistaken.

- 61 -
-?

NOTICE: These products/technologies are subject to U.S.


regulations and/or COCOM strategic restrictions:
diversion contrary thereto is prohibited.

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