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CONTENTS

Page
OUTLINE i

1. MAZAK POSITIONING SEQUENCER 1-1

1-1 Specification (MPS-510/520/530) ...... 1-4
1-2 Detailed Explanation for MAZAK MPS-500
Positioning Sequencer 1-11
1-3 Magazine Index Table (MT) ROM Versions 1-17
1-4 Parameters . 1-19
1-5 Alarms 1-24
1-6 0° Search Switch ... 1-28
1-7 INDEX TABLE 0° Pushbutton Switch 1-29
1-8 Monitor Function 1-29

2. MAZAK SERVO DRIVER 2-1

2-1 Specifications of MAZAK. Servo Driver 2-1
2-2 Operation Description . 2-2
2-3 Setting Details 2-6
2-4 LED Condition 2-10
2-5 Alarm 2-12
2-6 Trouble Shooting 2-15
!
2-7 DC Motor Maintenance 2-21
2-8 DC Motor External View 2-32

z
3. MAGAZINE ADJUSTMENT 3-1
3-1 Type 1 3-1
3-1-1 Adjusting the chain tension 3-1
3-1-2 Adjusting the timing belt . 3-3 i
i

3-2 Type 2 3-5

3-2-1 Adjusting the chain tension 3-5
i
3-2-2 Adjusting the timing belt . 3-6

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 1

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11
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3-3 Type 3 3-7 i

3-3-1 Adjusting the chain tension 3-7 I

3-3-2 Adjusting the timing belt 3-8
3-4 Adjusting the magazine position detect encoder 3-9
3-4-1 Outline 3-9
3-4-2 Adjustment step 3-9 l
3-4-3 Measures for improper conditions 3-12

4. INDEX TABLE ADJUSTMENT 4-1

4-1 Type 1 . * 4-1
4-1-1 Checking and adjusting the gear backlash 4-1
4-1-2 Adjusting the optocoder . 4-2
4-2 Type 2 . 4-3
4-2-1 Checking and adjusting the gear backlash 4-3
4-2-2 Belt tension . 4-5
4-2-3 Adjusting the optocoder 4-6

5. POSITION DETECTOR SPECIFICATIONS 5-1

6. MAZAK POSITIONING SEQUENCER CIRCUIT DIAGRAM & PARTS LIST ... 6-1
(1) MPS-510 .. 6-2
(2) MPS-530 .. 6-3
(3) MPS-520 .. 6-5
(4) Parts List 6-7

7. MAZAK SERVO DRIVER CIRCUIT DRAWING AND PARTS LIST 7-1

7-1 Servo Driver Circuit Drawing 7-2
7-2 Parts List 7-19

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OUTLINE

This system has been developed to control YAMAZAKI's MAZAK's magazine,

index table by>' the positioning control method.

The typical features of the positioning control are:

(1) Stop position after deceleration from the high speed is the target
since three is no high or low speed classification in the speed
control; thus high performance can be attained.

(2) A fixed speed turning because of no turning speed fluctuation due to

load status variation, etc.

(3) No shock when accelerating or decelerating.

This system is composed of the "MPS-500" MAZAK positioning sequencer

and the "MV-4/ 30" MAZAK servo driver.

This system features that it can apply to whatever system by the

sequencer software because the software counter within the sequencer is to
be used instead of the hardware counter to be provided separately.

Moreover, the zero return operation after switching the power on at

the beginning of the day's work is not required; which produces an excellent
operability.

The maintenance instructions of the MAZAK positioning sequencer and the

MAZAK servo driver are described below for the repair of troubles and the
maintenance work.

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1. MAZAK POSITIONING SEQUENCER

The features of the MAZAK "MPS-500" positioning sequencer:

(1) A high speed sequencer with an extremely short processing time of

0.5 Msec per step.

(2) All memory areas are hold type memories.

4 x 256 x 2 = 2048 bits

(3) Capable of 4-channel analog output (0 ± 10V) because of built-

in D/A converter.

(4) Available 7-segment, 6-digit display.

The features of the MAZAK "MV-4/30" servo driver:

(1) Power transformer is not required since the power voltage is

3<J> 200V VAC.
(2) Protection circuit is completed.

(3) Speed loop gain is high.

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mm
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mm mm

==
mm mm

Configuration for rough positioning

(For magazine, index table)

,
;
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MAZAK. positioning sequencer

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Short cover changeover
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MAZAK positioning sequencer MPS-500
±15V D/A converter, amplifier power
outlet changeover

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V
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Not used

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—--
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1

Servo Servo i
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200 V
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200 V AC
Servo driver for table Servo driver for magazine I
\ t. -- MV-4 MV-30
Q
- Z'A 7— I ! /_-* V

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Relay power for
c7
— <>• A t :••• or he.A 705 A 3 CM OV
CV

[Vi 4 :$t ‘-Or—-.0- 0—0

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Thermal Thermal
LI sensor •!>££, sensor f
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-V/ DC motor ;
200 W
or 400W
(y) DC motor
1.1 kw:
White 5V 1.8 kw
Black 0V 2.6 kw
L
Red phase A Tachogenerator Tachogenerator
Green
Yellow
phase B
phase Z
iv.re, )7 V/1000 rpm T
7 V/1000 rpm

I
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Encoder -r C J Encoder )
I
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Wliite +5V
Black 0V
Red phase A )
Creen phase B
Yellow phase Z I

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1-2
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 ——
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1 1 1040IV
Eÿr

Rough positioning block diagram

(For MAZAK "MPS-500" positioning sequencer)

Movement Pulse Error D/A

disperse counter con- VCMD
Command computa¬
verter +.
tion Output to
BCD code
Present Acceleration/ servo
value deceleration- driver
pattern
-Command
value

Direction Phase A
Phase B
Present position . discrimination
counter 4-Multiplication Input from
per IP encoder

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1-3
 1

i 1
11i===s===iiÿ

1-1 Specification (MPS-510/520/530)

(1) MPS-510

1) Program memory
I
EPROM 2764 TYPE (standard)
27128 TYPE (optional)
Maximum steps: 8192

2) Data memory
I
C-MOS. RAM is used I
Contains four "A. A'. B. B I »! pages; 4 bits x 256 memory I
area as 1 page
t
Battery backup function is provided
(NiCd battery, 3 months at the maximum)

3) Instruction
2 byte: 1 instruction
Process time for 1 instruction: approximately 0.5 us

4) Parameter set

A maximum of 128 parameters can be set using 8 DIP switches

5) Hardware fixed address on the memory map

(A page only)
)
8 points for 7-segment, 6-digit display
i
12 points for 4 analog output circuit
1 point for RAM page change
1 point for display light on the circuit board I
)
6) Monitor
i
l
By the data-memory-content check function, self-diagnosis,
\
LED relating to bit and two rotary switches.
i
Input/Output (I/O)
\)
1-4
I
 iYIdictk

7) Number of I/O points

MPS-520, 530 each 1 sheet is used

Input 64 points
Output 32 points

8) I/O extension

Up to 320 points at the maximum.

9) Digital/analog (D/A) output

Deviation counter capacity: ±125 pulses

D/A output: 80 mV/1 pulse
±9.96V, four outputs at the maximum

10) Power supply

+5V (between +5 and OV) I.5A

+5V (between PG and OV) 0.5A
±15V (CN-507, 508) 0.05A

Shown above is at I/O maximum extension.

11) Usable temperature range

0°C +55°C

12) Ambient humidity range

30 90%RH (without dewfall)

13) Atmosphere

Without corrosive gases

14) Construction

Printed circuit board assembly only or cased with the

open flame. i

1-5
 i =ÿ

niu&pR

15) Noise resistivity

Assembled with multilayer print boards and pattern parts

which passed the product evaluation test, the sequencer
should not cause erroneous operation with the pulse
width of ±2000V.l ps noise component fed to 100 VAC at
the primary power source.

(2) MPS-520

1) Number of output points/method

)
32 points
Linkage common 0V by one-point ground

2) Power output

"H" level below 22V/100mA

"L" level 0V

3) Open collector

Negative logic below 30V/100mA

* Construction of 2) and 3) should be designated by

the customer.

MAZATROL (M) Specification

FANUC (F) Specification
MAZATROL T-l (T) Specification

4) Responce time
Within 50 ps or approximate after computation.

5) Ambient, noise conditions

Same as MPS-510
i

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1-6 )
 lYloidk

6) Power supply

In addition to 5V/0.05A supplied by the MPS-510 connector,

+24V from the CN-503 or 504 pin which varies depending on
the load.

(3) MPS-530

1) Number of input points/method

64 points
The photo coupler connection common 0V is in common with
the system 0V by one-point ground.

2) Power voltage input level

"H" level 16V t 28V

"L" level below 7V

Input impedance approximately 2.4 K$

3) Contact point/PG input

"H" level 4.3V or more
"L" level 2.5V or less
Sink current approximately 12mA

* Construction of 2) or 3) depends on the designation by the

customer.

MAZATROL (M) Specification

FANUC (F) Specification
MAZATROL T-l (T) Specification

4) Responce time *
Power voltage.contact point input part 5 10 mS
i
PG input part Approximately 100 pS

(
1-7 \
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—==
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5) Ambient, noise conditions

Same as MPS-510

6) Power supply

In addition to 5V/0.05A supplied by the MPS-510 connector,

+24V/0.06A max. from the CN-500 or 501 pin.

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1 2 )( 3 5 14 (15
220 (8.67) -=> /
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+ L£ a / .

4 o /
o I
nv= 5
O LJL. .41 J
/
o / /

11
15 /
/
/
...r / Note: This drawing shows the
external form of KPS-500
with UPS-530, MPS-520 each
1 / 1 being added to
r- /
O vD
9 /
Ch CO /
o o /
CO -csa /
CO CO G
/
/ /

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/
lO
L j
/ No. tlaoe Remarks
, l KPS-510
/ 2 MPS-S30 P.H.T

<> <5
/
/
m 4
b
HPS-520
Power terminal bo*
CircuiC board
F.H.T

CW506(H)
connection CN
/ 6
'7
Servo
Servo
CH50B
CNgj7
/ 18 Display conncc-
15 / ) 13 _
cion CN CN505
9 ROM

VL X a / -jzr\ 10 MouncinR support P-11-16H

-
11 Backup battery i CB150-3
-O- G- 12
12
13
Setscrew
Part height below 12h
U Input connector I CH500,
/ i CH501
/ IT Output connector CN503,

* 12) 10 CHS04
/
6 7 8
L /
/
/ 1 10h
(4.33)
"<1.
T IIIIIII
Unit; mm(inch)
HP Mi i
MAZAK SEQUENCER llll
EXTERNAL DIMENSION,
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/// 7ÿ77 ASSEMBLY DRAWING
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ITICIMUX

Magazine index table controller associated parts list

No. Name Model Part number Machine Remarks

5-digit display
1
unit iPM-100 D808IC000210 Entire
machines

2 6-digit display 120 Tools,

unit iPM-106 D80SK000960
Tool Hive

3 CPU board MPS-510 D80SK001960

4 MPS-520F D80SK001970 F6MB, F6TB
5 Output board MPS-520M D80SK001980 MAZATR0L-T2/
T3,M2,M2R
FS11M, FS10T
6 MPS-520T D80SK001990 MAZATR0L-T1

7 MPS-530F D80SK002000 F6MB, F6TB

8 Input board MPS-530M D80SK002010 MAZATROL,
FS11M, FS10T
9 MPS-530T D80SK002020 MAZATR0L-T1

10 H-15MA/MB MPS-510+MPS-
Controller MPS-500M D80SK002030
H-25Q, H-30 520M+MPS-530M
H-20N, H-25N
11 Controller MPS-500F D80SK002040 H-15MA/MB MPS-510+MPS-
H-25Q, H-30 520F+MPS-530F
H-20N, H-25N

12 Controller MPS-500MA D80SK002050 H-12N MAZATROL) MPS-500M+MPS-

:ONLY) 530F ;•

13 Controller MPS-500FB D80SK002060

: H-12N F6MB)
ONLY)
MPS-500F+MPS-
530F

14 Controller MPS-500MC D80SK002070 AJC MPS-500M-MPS-

520M+MPS-530M

15 Controller MPS-500MD D80SIC002080 H-25Q SLIDE MPS-500M+MPS-

INDEX 520M+MPS-530M
x 2

1-10
 1
ITId£0!v

1-2 Detailed Explanation for MAZAK "MPS-500" Positioning Sequencer

(1) Setting on the CPU board (short bar) (MFS-510)

J1 CN507 As shown in the figure,

A
o o 1 J1 short bar is provided.
o
oo B
oo
o O
oo A
oo o
oo
8 B
CN508

Details
*
J1 Supply ±15V for D/A converter from
CN507 (index table driver)
o o 1
o o 2
o o 3 Supply ±15V for D/A converter from
o o 4 CN508 (magazine driver)

o o 5 Limit memory area to A, A' pages (standard

setting)
o o 6
Use all pages for memory area
o o 7
o o 8 Spare

I
Standard setting

J1 (a) When the object machine is the following:

o o 1 H-15MA, H-15MB
YP/PA"/ÿMagazine H-20N, H-25N > Supply ±15V from
O O y the magazine
rpwr H-12N(120 Tools) servo driver
FP75] i
o o
o o 8
i

1
1-11
 1
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(b) When the object machine is the following:

H-12 (NOT 120 TOOLS)

H-15MA, H-15MB (TOOL HIVE)
H-400

J1
IM 1
O o r-
Index table Supply ±15V from index
wm table servo driver
_6.
_o 8
(2) Setting on digital input/digital output (DI/DO) card

1) Setting on input card (MPS-530)

Set 1 location only, malfunction will occur if 2 or more
are set at the same time.

o o OUT 1
o o IN 1
I/O o o 3
I/O o o 2
I/O o o 1

(a) OUT 1: This is not used normally. Leave it open.

I
(b) IN 1 : Basic input card setting
Input address is EO 'v EF
IN 1 is short-circuited with standard input 1

setting.
(c) I/O 3: Setting for extension input card
Input address DO 'V' DF o o 0UT1
o o INI
(d) I/O 2: Setting for extension input card I/O o o 3
I/O o <j 2
Input address Cif) CF o_o
I/O 1 (
(e) I/O 1: Setting for extension input card
Input address B<J> •v BF

\
1-12
)
*
 __
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E~ :

2) Setting on output card (MPS-520)

Set 2 locations at the same time, malfunction occurs if more
than 2 are set.

o o DO (DOWN)
o o UP (UP)
o o I/O 1
o o I/O 2
o o I/O 3
o o IN 1
o o OUT 1

(a) DO/UP
Setting for determining the output address since the
output card has 32 output points.
Standard output card has been set to "DO"; that is,
when FO F7 (FO.O F7.3) extension output card is
used, the output addresses are as follows:

At DO I/O 3 DO D7 At UP I/O 3 D8 DF
I/O 2 CO C7 I/O 2 C8 CF
I/O 1 BO n- B7 I/O 1 B8 BF

(b) I/O 1: Setting for extension output card

Besides, output address is determined by UP/DO
setting in (a).
DO: output address BO 'v B7
UP: output address B8 BF
K
(c) I/O 2: Setting for extension output card i

Besides, output address is determined by UP/DO

i
setting in (a).
DO: output address CO C7
UP: output address C8 CF

1-13
 1
.1
I 1

iTIcfidK

(d) I/O 3: Setting for extension output card

Besides, output address is determined by UP/DO

setting in (a). DO: output address D0-uD7
UP: output address D8v DF
(e) IN 1: This is not used normally. Leave it open.

(f) OUT 1: Setting for basic output card

Besides, standard output address is determined by
UP/DO setting in (a).

DO: FO 'u F7 for display and analog output, etc.

UP: F8 FF This address cannot be set since it is

used for other than I/O card.
Malfunction will occur on display or
analog output, etc., if it should be
set.

DO and 00T 1 are short-circuited with standard output

setting.

wm DO (DOWN)
o o UP UP cannot be used with standard
output setting. I
o o I/O 1
\
o o I/O 2 I
o o I/O 3 )
o o IN 1 )
f

MTFl1 00T 1
)

(Note) Since I/O 1, I/O 2 and I/O 3 are used both for input and
7 1
output, I/O 1 cannot be used as the output address if
I/O 1 is used as the input. Therefore, select additional J
output address from I/O 2 or I/O 3. I

J
1-14 I
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 -S'
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(3) Analog output zero setting

Four analog output points are provided as shown below.

LSI"5
“
2 |7406 [ o

°OilI* 2.6ifg.§
3
Output change N 62
2
Hi 3 15
10
«
cM-l
istor •
i 15V
ovj-
Jc ircuicj - 15V O ',', 1 J g
+15V
1
10V
LSI 75
12
ia| Trimmer
U
\0 1 11 2 W wIK Adjustment
!_iu 10 10K is required
cro-j 1 Analog
X H>
4
•VA
IV 3 15 58
10K -
-T oil * i-

Data
- LS175
N60
8 IS
DAC
2
VM

5.1 K
£
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cro I
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I'D 3
2 15
7 32
s 64
6
15

(?0-XT D>
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U.O 1/r rÿ°ii 5 s
-15V I
00 22/i
IMC08C Max. output
current 1mA
1) Output timing chart

Data signal
u u
min: take time for each
LJ
1 // 1//100ÿ
1
Trimmer
1 scan*ÿ"
Adjustment
2
Output is required
change L
3

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1-15
=--=
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1 I l===4i=ii\

A single D/A converter converts the output to four analog

signals through the sampling-and-hold circuit and transfers
them to the output data area, FC, FD addresses and sets the
output area change signal at the FB address. Thus, one
analog data has been transferred. Next, turn the change
signal OFF once, renew the data area and set the change
signal at other than previous address. Then, next analog
data has been transferred. As described, it is required to
take timing in data transfer. When the analog signal is
used, supply power from CN507 or 508 since there is no ±15V
power within M/T controller.

2) Trimmer adjustment

A single 1 Kfi volume control is provided to adjust offset.

Adjust the volume control so that the D/A-converter-2-pin
output becomes 0V when FC address is 0, FD address is 8;
that is, the condition when the power only is thrown to the
MAZAK positioning sequencer.

3) Data and output voltage

Enter data to FC,
Address FD,FC data FD addresses and
Output voltage
FD data FC data
F F +9,920V check voltage with
Increase by the D/A converter
+80mV step 2 pin.

8 3 +240mV
8 2 +16OmV
8 1 +8OmV
8 0 OmV
7 F -8OmV
7 E -160mV
7 D -240mV
7 C -320mV

Decrease by
-80mV step

0 0 -10,000V
1
1-16
J
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 11

1-3 Magazine Index Table (MT) ROM Versions

(1) MT ROM Version List (MAZATROL M1/M2)

V-series: MAZATROL
H-series: MAZATROL, FS11M

ROM for IMP-500, ROM for MPS-500, Remarks

No. Machine MV-20 MV-30

1. SV-20/25 without pallet P41096M P155B

changer

2. SV-20 with 2PC P41098P P157B

3. SV-25 with 2PC ditto ditto

4. H-12N 30,60,80 tools P47881M P159A hydraulical¬

ly driven
magazine

5. H-20N/25N 40,60,80 P47970(M) P161B DL-SEZ-

tools driven
magazine

6. H-25Q/30Q 40,80 tools ditto ditto ditto

7. H-12N 120 tools P47984N P161B

8. H—20N/25N 120 tools ditto ditto

9. H-15MA/MB P48379M P163B L

10. H-500/630 P168A

11.

12. ST-40N ATC M/C P117D P117D

30 tools

13. ST-40N ATC M/C P153A P153C DL-SEZ- i

i
60,80 tools driven
magazine
14. 1

(Note) In H-series machines, the FANUC 11M uses the same MT ROM to be
used on MAZATROL.
,v

1
1-17
 1

---= — —
=-
= I IC140IV

(2) MT ROM Version List (FANUC)

ST-40N:
V-series: F6MB, FS11M
H-series: F6MB only

No. ROM for iPM-500, ROM for MPS-500,

Machine Remarks
MV-20 MV-30
1. SV-20/25 without pallet P41092N P154B
changer

2. SV-20 with 2PC ditto ditto

3. SV-25 with 2PC P102M P156B

4. H-12N 30,60,80 tools P47883M P162A hydraulical-

ly-driver
magazine
5. H-20N/25N 40,60,80 tools P47968M P158A DL-SEZ-
driver
magazine
6. H-25Q 40,80 tools ditto ditto ditto

7. H-12N 120 tools P47991M P158A

8. H-20N/25N 120 tools ditto ditto

9. ST-40N ATC M/C P117D P117D

30 tools

10. ST-40N ATC M/C P153A P153C

60,80 tools
r
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1-18 )
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 I
IVi
== =ÿ==ÿ
==

1-4 Parameters

The eight dip switches (SWI thru SW8) on the MAZAK Positioning Sequencer
are used to obtain an area of 16 x 8 (=128) parameters on the MAZAK
Positioning Sequencer memory space. *

Setting Procedure:

1) Make certain that the SET switch (SWI) is at the OFF position.
2) Use the SW2 thru 4 to set the addresses.
3) Use the SW5 thru 8 to set the desired data.
4) First, turn the SET switch (SWI) on then turn it off.
Data will be entered into the memory at the leading edge of pulse
formed when the switch is turned ON (_l !_).
5* Using the monitor function, check that the data are set correctly
into the memory.

7E T
=¥//
• LD6
LD5 MPS-500
iJ Monitor LED
LDO LD4

HW 1 2 3 4 5 o 7 8 ON
aO a I a2 dO d1 d2 d3 OFF
!«l

z Data area
Address area
i
SET switch
1

MPS-500 I
Parameter Diagram
1-19
 1

i= 1
I1 klÿLIIX
0 ... 1.2 sec. 1 ... 1.8 sec. 2 ... 0.6 sec.

Address Standard Setting

SW RAM Comment 8 4 2 1
2 3 4 Address b3 b2 b 1 bO
0 0 0 10 Setting the number of tools in the
magazine.
0 ... 40 pcs. 1 ... 60 pcs.
2 ... 80 pcs. 3 ... 120 pcs.
4 ... 30 pcs(H-12N)
1 0 0 11 Setting the magazine acceleration/
deceleration time constant.
0 ... 1.2 sec. 1 ... 1.8 sec.
.2 ... 0.6 sec.
0 1 0 12 Setting the maximum table rotating
speed.
0 ... 6.7 rpm 1 ... 10 rpm
' NC-Rotary table 13-2 Table Auto
1 1 0 13 13-0 & SEARCH
*1 13-3
13-1 1° Index Table
I
Table 0° LS Magazine con¬
0 0 1 14 14-0
available
14-2 troller
DL-SE8
14-1 14-3
1 0 1 15

0 1 1 16

1 1 1 17 Setting the absolute position counter

in a simplified manner.

)
*1 ROM No. P478830 /P162 and
RAM Data
P47991D /P158n only. I

I
J

MPS-500
PARAMETER DIAGRAM
I
1-20
J
 i
lYciÿCiix OP

* Monitor function ... The MPS-500 printed circuit board has monitor switches
and LEDs for checking the contents of all MPS-500
memory.

Monitor switch, lower

column _
Monitor switch,
nppo r col nnin
\
I/O unit Q
Monitor LEDs
Setting the monitor T
memory area DO o /
D1 o
TTTT, \s) LD6 D? o
M O D3 o * While checking the
i ON
Page A 0 I 0 I OFF LD4 o parameters, check

Page A' 1 ON
0 I 0 I 0 I OFF o LD5
o
MPS-500
the contents of
memory areas 10 thru
17 on page A.

Parameter setting switch

Address
lower digit © SW1
Set the address to "V".

Address
The figure shows the address "10".
upper digit SW2

f
r

MPS-500
D u r ii m ii I. ii r l)i II g !’ il III i
1-21
 "5
1
Ms
1 1 1040IV
E
1

High Quality Magazine/Table M/T Controller (MPS-500)

Parameter Setting Procedure 1
(Machine Specification)

Procedure
No. Contents Operation Switch: 0-0N, X-OFF
Dip switch Lamp : 0-0N, O-OFF
1 initial 12345678
Procedure
setting fxfaxbdxbdxbcl No. Contents Operation

2
Monitor
address set-
ting at "10"
fji|
SW2
ft
SW1
12
Monitor address
setting at area
"12"
0
SW2 SW1
Address and Setting the
3 data setting 12345678 13
12345678
address and
I xbdxlxj I I |x| data Ixlxldxl ffl
Check in the Check in the
4 data at area 12345678 14 data at area 12345678
"10" loIxUsd ! I 1x1 "12" |cjx|olxl Ixffl
Check out Check out the
12345678 15 12345678
5 the data data )
Verification
Ixbehdxl i ! Ixl
Verification
EE dxj Ixlxlxl
0 0 0
of the data 16 of the data
6 1 0 Monitor 1 , Monitor
2 Of lamp 2 lamp
3 0J 3
Monitor Monitor address
* <
7
address set¬
ting at area 0 0
SW1
SW2
17
setting at area
"13" II S
SW2 SW1
J
"11"
Address and Setting the
8 12345678 12345678
data setting 18 address and
1 xjo|xjxix|x|x|xl data MW 1 MK|
Check in the Check in the
12345678 12345678
9 data at area 19 data of area
"11" 1 C|o[x[xjx|x|x|xl "13" Idow 1 Mx|
Check out the Check out the
10 data
12345678 20 data
12345678
e
[RoMx|xWx| Ixtofrl I W
Verification Verification
of the data
00
All the of the data
0 ol J
1 0 > monitor 1 0 ’Monitor
11 2 0 lamp 21 20
lamp
•*
3 0 OFF 3 Oj

\
1-22

i
 I
ITldidR

High Quality Magazine/Table M/T Controller (MPS-500)

_Parameter Setting Procedure 2 _
(Machine Specification)

Procedure Switch: 0-0N, X-OFF

Contents Operation
No. Lamp : O-ON, O-OFF
Dip switch
12345678
22 initial Procedure
Contents Operation
setting IxlxbdxMxtxlx] No.

23
Monitor
address set¬
ting at area
"14"
ESI
SW2
6 SW1
33
Monitor address
setting at area
"16" SIS
SW2 SW1
Setting the Setting of the 12345678
12345678 address and
24 address and 34
data IxHxIOm lx| data fxlxlobl jxMxl
Check in the Check in the 12345678
12345678 data at area
25 data at area 35
"14" itUdaiiixi "16" 1 oMojol Ixjxjxl
Check out the Check out the
26 data 12345678 36 data 12345678
IxlxM I I H [xlxldol bdxbcl
Verification 0 O' Verification 00
of the data 1 0 Monitor of the data 1 0 Monitor
27 2 0 lamp 37 2 0 lamp
3 Oj 3 Oj
Monitor Monitor address i
28
address set¬
ting at area
"15"
66SW2 SW1
38
setting at area
"17" SW2 SW1
Setting the Setting of the
12345678 address and
12345678
29 address and 39 i
data |x|o|x|o|x|x)x|x| data |x|o|o|o|otx|o[x| £

Check in the Check in the

30 data at area 12345678 40 data at area 12345678 f
"15" 10|0|x|0|xjxHx| "17" ES5SS5S3 r
Check out the Check out the
31 data 12345678 41 data
12345678
1 4>x|0|xjx|x|xl
Verification 00 Verification 0 •'I t
i
32
of the data 1 0 [Monitor 42 of the data 1 0[Monitor
20 lamp 2 9[ lamp
3 OJ 30
i

il
1-23

I
 1
.1
== 1
11

1-5 Alarms

(1) A/B PHASE REVERSED CONNECTION ALARM (MAL-A ... 222AAA

TAL-A ... 333AAA
If A/B phases are connected backwards by mistake, the positional servo
system will enter into the RUNAWAY mode. However, reversed connection
is detected by this controller before the RUNAWAY condition can occur.

MT controller
Speed amplifier
VCMD
+
C(M)I
'
i
This should be a negative
feedback. Actually, how¬ o T/C
ever, a positive feedback
occurs, producing a runaway. 6 A/B phase signal
I
i
O P/C

VCMD after alarm detec t i on

VCMD
sec Servo off

0 t
— Alarm detection
After the alarm has been detected, ***AAA is displayed. Turn off the
power supply once and turn on again to correct the A/B phase directions
automatically and to reset the display. It is, thei-efore, unnecessary to
reconnect the A/B phase leads.

(2) A/B PHASE SIGNAL DISCONNECT ALARM (MAL 1 ... 222 111)
4
TAL 1 ... 333 111
If either or both A or B phase signals are disconnected, the system
e
will go into the RUNAWAY mode because the positional servo system feed¬
back is interrupted and does not allow the remaining quantity to
decrease. The present controller, detects a signal disconnection before
the system x_uns away. Thus, a runaway is prevented.
i
Once the alarm has been detected, the ***111 display will flash. After
gradually decreasing the VCDM, and locking it at 0 V., turn off the
I
servo amplifier. Then, turn it on again to cancel the alarm,

J
MPS-500
I
Alarm List
1-24 J
l
 iflrittiS
(3) A/B Phase Pulser Replacement (Set the Z-phase of the pulser to zero
point.)
After failure, replace the A/B phase pulser by the following method:
(1) After replacing, tempeorarily set the pulser and clamp the magazine
or table to any position. .
(2) After turning on the power supply, check that 0 SEARCH switch is
OFF. Then, control the magazine and the table are positioned
mechanically to the No. 1 tool and 0° position, respectively.
770) After positioning the magazine and the table to No./tool and 0°,
' loosen the pulser and locate it so that the dot point# appear on
the display.
(4) Turn the 0° SEARCH switch on, give any desired command the indica¬
tion will be automatically corrected. Then the positioning is
, completed. . .
3) D& foe */i1~k the! yna.(Lh J
Tcol pC6if/0*\
Magazine Table

rmn
Dot point# come on, when the pulser
Z-phase is on.

* 0° SEARCH:
This function automatically locates to the desired position
after correctly setting the position which existed while
seeking the Z-phase signal of A/B phases by 1 turn of the
pulser, which was first made, after the 0 SEARCH switch was
set.
The setting is made at 0° for the table and
at the center of No. I tool for the magazine.

<i

MPS 500
Alarm List.

1-25
 1

i
1 1 Iÿi4ÿ==\

(4) Alarm Display

Alarm No. 0 < 9

Alarm Code
b ... Miss Operation
1
2 ... Magazine
3 ... Table
4 'i- 9 ... Not Used

Display Alarm No. Description Comment

000 000 MOP 0 Tool Select Interlock Tool Set Switch ON!! -> OFF

111 MOP 1 Manual Tool-Select With the 0 SEARCH swith positioned

Interlock at ON the manual tool selected is
prevented when the 0 SEARCH opera¬
tion not ended.

222 MOP 2 Inhibit T-Code OUT OF RANGE command, other than

1ÿ40, 60, 80, and 120

333 MOP 3 Inhibit B-Code OUT OF RANGE command, other than

0ÿ359.

(Note) The alarm may come out upon restarting the table swing t
after depressing the reset button during the table
swinging. This does not mean the trouble, so perform y
0° search.

MPS 500
A I u r in l . i rt I.
i
1-26 J
i
 —
I 1 l==§s=i=liÿ,
=

Display Alann No. Description Comment

222 000 MAL 0 Magazine Servo Alarm Magazine servo amplifier alarm

111 1 Magazine A/B Pulser Magazine A/B phase pulser position

Cut Alarm feedback signal alarm interrupted

222 2 Pin Extend PRS EXT PRS does not turn off more
ON Alarm than 10 seconds after giving PIN
RET command.
333 3 Pin Extend PRS EXT PRS does not turn on more than
OFF Alarm 10 seconds after giving PIN EXT
command.

444 4 Pin Retract PRS RET PRS does not turn off more than
ON Alarm 10 seconds after giving PIN EXT
command.

555 5 Pin Retract PRS RET PRS does not turn on more than
OFF Alarm 10 seconds after giving PIN RET
command

AAA MAL A A/B Pulser Magazine A/B phases are reverse-

Connected Inversly connected. They will be automati¬
cally reset, with the power supply
turned on again.

333 000 TAL 0 Table Servo Alarm Table servo alarm; Tachogenerator
signal is interrupted, etc.
»
111 1 Table A/B Pulser Table A/B phase position feedback c
Cut Alarm signal interrupted.

222 2 Table Clamp PRS CLAMP PRS does not turn off more
ON Alarm than 10 seconds after giving TABLE
UNCLAMP command.
i

333 3 Table Clamp PRS CLAMP PRS does not turn on more
OFF Alarm than 10 seconds after giving TABLE
CLAMP command. i
444 4 Table position Memory Changed
Register Alarm Please do "SEARCH "
AAA TAL A A/B Pulser Table A/B phases are connected
Connected Inversly backwards. They will be automati¬
cally reset , with the power supply
turned on again. i
1-27 MPS 500 ALARM LIST
 '!

= 1
lYId ==ii\

1-6 0° Search Switch

(1) Availability

Since this system (magazine and index table) provides rough

positioning using the incremental encoder, the machine position
and the reading of the absolute counter in' the MAZAK positioning
sequencer must be the same.

Since the MAZAK positioning sequencer stores the machine position

in the hold type memory. It is not necessary to return to the
X-, Y-, or Z-axis zero points before initiating the testrun.
However, equalize always perform the 0° search to the machine
position and the absolute counter after doing the following:

1. Replacing the MAZAK positioning sequencer,

2. optocoder ,
3. Adjusting the mechanical system,
4. Adjusting the optocoder, and
5. Adjusting or repairing any part of the system which
requires it.

(2) 0° Search steps

1) (l) Switch the machine power ON.

(2) Return all (X, Y, Z) axes to their zero points.

(Note) Required for MAZATROL, although FANUC will operate
in the MDI mode even if this is not done.
(3) Turn the 0° SEARCH switch ON.
(T) In the MDI mode, command the proper position when the
magazine is in the tool select mode and the index table
in the B-code mode.
Each tool will be positioned at the command position
)
after the magazine passes the No. 1 pocket and the index
table, the 0° position.

)
i
1-28
)
»
 __I
1 1 r==iÿ===i\

(5) After the operation is completed turn the 0° SEARCH switch

OFF. To complete the 0° search.

1-7 INDEX TABLE 0° Pushbutton Switch

If the index table is stopped by an emergency stop or a machine power

interruption while the table is being turned; that is, the index table
is not clamped, the machine status cannot be. (The Index command cannot
be given in the MDI mode because the X- and X-axes were interlocked and
could not return to the zero. This means that the X-, Y- and Z-axes
cannot be returned to zero manually, which is the first step in restor¬
ing the machine status. This cannot be done because the index table
was not clamped.)

Therefore, the index table must be clamped at 0° with the INDEX TABLE 0°
pushbutton switch, then the X-, Y- and Z-axes returned to their
respective zero points, to restore the machine operating status.

1-8 Monitor Function

The monitor function allows all data the MAZAK "MPS-500" positioning
sequencer to be checked.

Checking the I/O signal is described in detail in the next section

"Using the Monitor". :
UPS 510
SW3 *'
2 3. 4 o Switch for designating
Lower
SW1 column the address
-0FF-
*1 Address position
Not T *' is just above the
to use '00ÿ\ Upper SW1, SW2.
column
t*
;

Memory
\ area A A’ B B’
Switch B, B' pages are i
not used in the
SW3 -1 0 0 X X standard software.
2 0 X 0 X
0; ON X: OFF I
1-29
 1

=~~= —= -=~
1 1 1040i\ — 1

Monitor light MPS-500

battery check
Memory LD5
~\ÿrea A page A' page 0 When on,
0 LDO Light indicates
that the
0 LD1 LDO 0 bit 4 bits battery
> LD1 1 bit 5 bits voltage is
0 LD2 correct.
LD2 2 bits 6 bits
OLD6
0 LD3 LD3 3 bits 7 bits When on,
indicates
that the 5V
0 LD4 Indicates that the M/T operates DC voltage
is correct.
normally and blinks every 0.5-
LD5,LD6 are
second. normally on.
If the LD4 stays ON or OFF, this
indicates that the M/T is not
operating properly and must be
repaired.
This function is effective only
after the sequence ROM has been
modified as described elsewhere.
P154A
version and after
P163A

\
1-30
 11l==ii===il\

Using the Monitor:

1) Since the M/T controller input/output is executed on Page A, turn

both "SW3-1" and "-2" to ON to select Page A.

2) Then, enter the I/O address to be checked, by turning the digital

switch. i

Oddralues are indicated by the dots between the even values.

Only the even values, however, are printed on the digital switch
panel.

o. 1
Indicates "1".
Indicates "F"

3) Check the operating status with the LDO LD3: bit status display
lights on.

ex. Checking the ED.3 index table clamp check sensor signal

(a) SW3-1
ON
SW3
SW3-2
12 3 4
I
-OFF-
I
(b) Put the address switch to the object address using a small
screwdriver.
1
SWly
D(F) i
\
\
SW2y . Set ED
•3 •->
E(L)
X t
1-31
 1
1
-I-
I 1 1ÿ=4===iiÿ

(c) Check the monitor light

o LDO

o LD1

o LD2 Light ON = Index table clamp sensor

operating
LD3
Light OFF = Index table clamp sensor
does not operating

o LD4 <= Not related to the monitor.

J
J
j

I
i
J
)
J
I
J
1-32 )
J
I
 PAGE A

3 2 1 0 3 2 1 0 3 2 1 0 3 2 1 0
00 MSVAL TSVAL iR BTTAL 20 40 60
0 1 s w4 s w3 sw2 6W1 2 1 41 6 1
0 2 sw8 s w7 s w6 s w5 22 42 6 2
0 3 04 03 02 RCO 1 23 43 6 3
04 06 05 24 44 64
0 5 Display - Counter 25 45 6 5
06 // (fir LED) 26 46 6 6
07 4= 0 3=0 2=0 1=0 27 47 67
08 6=0 5=0 28 48 68
09 Display Data re[ 1 29 49 69
0A // 2 2A 4A 6A
0B // 3 2B 4B 6B
0C // 4 2C 4C 6C
0D // 5 2D 4D 6D
0E // 6 2E 4E 6E
0F Alarm Friaker TMR 2F 4F 6F
10 Par am< ter Area 0 30 50 70
1 1 // 1 3 1 5 1 71
1 2 // 2 3 2 52 72
1 3 // 3 3 3 53 73
14 // 4 34 54 74
1 5 // 5 3 5 55 75
1 6 // 6 36 56 76
1 7 // 7 37 57 77
1 8 38 58 78 t

19 39 59 79
1A 3A 5A 7A i*

1B 3B 5B 7B
i*
1C 3C 5C 7C i
1D 3D 5D 7D
1E SETT r SET ON SET 3E 5F 7E I
1F Chattaring - TMR 3F 5F 7F

L
PAGE A

3 2 1 0 3 2 1 0 3 2 1 0 3 2 1 0

80 A0 C0 E0 i TB i TA MG B MG A
8 1 A1 C 1 E1 MPRLS MPELS QUDLS MiLS
82 A2 C2 E2
83 A3 C3 E3
84 A4 C4 E4
8 5 A5 C5 E5
ci
86 A6 C6 E6 a
bL
87 A7 C7 E7 cn
88 A8 C8 E8 B18 B14 B12 B1 1 s
a.
89 A9 C9 E9 B 28 B 24 B 22 B 21 c
8A AA CA EA iTREV T3 1 B 32 B3 1
8B AB CB EB T18 T1 4 T1 2 Til
8C AC CC EC T28 T2 4 T22 T2 1
8D AD CD ED i TOLLS TF BF TS iNTSS
8E AE <t>
CE EE * EMG SCH iTZ MGZ
8F AF CF EF TSPB i TÿPB MNL
* RST
9 0 B0 D0 F0 TBC MGC MG iNT
9 1 B1 F1 MGAL
D1 MG </> * MG RUN MGFN
92 B2 D2 F2 i TFN
iTAL iT (/>
* iTRUN
93 B3 D3 F3 i TUC MCB MPRET MPEXT
94 B4 D4 F4 DEC STP TF
a
95 B5 D5 F5
9 6 B6 D6 F6 C/D

97 B7 D7 F7
c*
9 8 B8 D8 F8 D i B p ay Data
O
99 B9 D9 F9 // C o mm( n
9A BA DA FA MS VON TS VON LED B-PAGE
9B BB DB FB ANALOG Common
9C BC DC FC An a 1 o £ ; Da t a i

9D BD DD FD
9E BE DE FE I
0 A 1 wa y e
9F BF DF FF 0 0 0
PAGE A'

7 6 5 4 7 6 5 4 7 6 5 4 7 6 5 4

00 20 TB TA MB MA 40 Error Cou n ter Au x. (MG .) 60

0 1 2 1 TB' TA' MB' MA' 4 1 16 0 6 1 Pulse Distribution

02 22 TM TP MM MP 42 Er r o Count e r 16 6 2 Up—Da on Co u n t c r

03 10 mn 6 ipn Nu SET 23 43 16 2 6 3

04 120 T 80 T 60 T 40 T 24 TBL. M -j- 44 64 POO

OUTP UTP
0 5 Ana 1 og Ou t pu t Count er 25 ON ON ON 45 Abs o u t e Cou n( er 6 5 PI 3 PI 2 PI 1 PI 0
06 26 STP STT STP STT 46 66 17 16 15 14
07 Maga z ne 27 BCFN BFM 'CFN TFM 47 67 19 18

08 Comand Pc sit ion 28 BFFN ACC FFN ACC 48 68 23 22 21 P20

09 29 TUCE TCLE M-RETE MPEXE 49 69 27 26 25 24
0A 2A i TSTP M'STPX MGSTP 4A Di s t • i bwt i on Co u nt e r 6A 29 28

0B 2B 0* CD BFX INTS TFX 4B 6 B

0C Tabl e 2C 0 FN CAL 0 FN CAL 0 4C 6C for Short Cu t J ugme n t

0D Command Po s i t i on 2D iP.T iP.M 1 FN 1 4D 6D (for MG )

0E 2E d ON 2 FN 2 4E 6E

0F 2F OF 0T OF 2 Of 1 OF 0 4F DEC Point reg. 6F

10 3 0 TB OV 1IG 0V DWN TYP 1 5 0 70

1 1 Alarm Herch Coimter 3 1 R-Trg tCRST R-Trg ECRST 5 1 7 1
1 2 MG. Tin EXT. TMR 3 2 BFMON 3ATA TFMON DATA 52 72
1 3 3 3 BFMON 3UONT TFM—Tr SUONT 53 73 Di s t a nee Cal cu 1 a t ion

14 MG .P n RET TMR 34 i TUCT i TCT MPRETT MPEXTT 5 4 Er r o '

Cou n t e Memo r g 74 reg.

15 3 5 MAL3 MAL2 MAL 1 MAL 0 55 75

1 6 TBL. Servo ON TMR 36 TAL3 MAL 5 MAL4 56 Error Counte • Output — Da ta 76

17 37 SALON TAL2 TALI TAL0 57 77

1 8
1 9
MG . Servo ON TMR 38
39
DEC X DEC
ACC Z TDECZ
FL-Tr
MDECZ
ALM
MSTP
58
59
Ou e r
TF
— Run
Dount er
Counter 78
79

1A TBL . U • d amp TM * 3A POSFN rZSCH POSFN MGS OH 5A 7A Car r y reg.

1B TBL. C amp TMR 3B ACC-M OF IT Z-ON Z-ON 5B Drift Data Memory 7B 3 2 1 FN 0

1C MG. Ac o r d i e nc e TMR 3C DWN TYP 1 CAL 1 FN CAL 1 5C De erase Spe e 1 Count e ]ÿ 7C FG3M FG 3MFN 4 ?

1D TBL. // 3D ZT OF ZT-ON 5D 7D 3 2 1 FG 0
ZM OF ZM ON
1E TBL. BF TM* 3 E CMD-ON BS-CMD 5E 7E SHT ON SPIT
CMD-ON TSCMD
1F MG. TF TM* 3F 5F 1 =0 0=F 0=0 7F 4FN 3FN 2FN 1 FN
W Z Y X 1 =F

L
PAGE A'

7 6 5 4 7 6 5 4 7 6 5 4 7 6 5 4
80 Shift r eg A0 Error Counter Aux C0 E0 SHTON SHT
8 1 A 1 O 1 Pu 1 s o Distribution E 1 4FN 3FN 2FN 1 FN
8 2 answear reg A2 Error Count e r C2 UP - Do *vn Count >r E2 Tob 1 e C 1 amp A 1 a rm TMR
83 A3 C3 E3
84
85
x/2 Ca luau [at i on A4
A5
V Distribution Counter
C4
C5 P13 P12
POO E4 // Unci amp //

P1 1 P10 E5
86 Carry reg A6 C6 17 16 15 14 E6
87 A7 i C7 19 18 E7
88 A8 C8 23 22 P20 E8
\ 21
89 A9 C9 27 26 25 24 E9
8A AA CA 29 28 EA
8B DEC. Pc int Judgement AB 7 CB EB
8C AC CC EC
8D AD Er r o r Count e r Memo ry CD Distance Ca luculation reg. ED
8E Er ror (bunt e r o TMR (Mg) AE CE EE
8F // (TBL) A F Er ror Count e r Ou t pu t Data CF EF
90 T M T M B0 D0 F0
SVOF SVOF ECOD EC 0
9 1 Error Counter Down Couctor (Mg) B 1 D1 F1
9 2 // (TBL) B 2 BF Count er D2 F2
93 MAL 1 Count e r B3 D3 Car ry reg. F3
94 TMR B4 Drift Da t a M«mo ry D4 3 2 1 FNO F4
9 5 Z Pu 1 e Co u n t e r (Mg) B5 Ouer~? en Counter D5 FG3M 3MFN F5
9 6 // (TBL) B6 D6 3 2 1 FGO F6
9 7 TAL 1 Count e r B7 DEC . Point reg D7 Shiff reg . F7
98 // TMR B8 D8 F8
99 Mg.AyB Pu 1 s e r De r c F.F B9 D9 An s wee r veg F9
5
9A TBL // // BA DA FA
9B MAL 1 Alarm C>unter BB Dec. Point. Jud gment Data DB CE luau lat ion F B
f
9C TAL 1 // BC DC \ Carry reg. FC
i,
9D TAL-ON TAL-A MAL-ON MAL-A BD DD FD
i
9E BE DE FE )
MOP-3 MOP-2 MOP-1 MOP— 0
9F BF 1 =F 1 =0 0=F 0=0 DF FF
ad-by 08
P/W
ces >
Stand-by
_
J2
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9
A yi-iÿ2iaÿ<A6>
B <J4 I
.Condition Juap (A6). %?“1
Aux. input
C
0 Ac
20 8 Input
TSj-J SMK5N-S-300)t5T E .Li Juap 3
Coil

-P5V > av- 1 2_

P Aff Mutation raault
5ÿ-24. '

4 bit tranafer _
liner
L0IOO i
F(4F
ovO
I 0
SP/I.' ST
Q O|-2 vi
v2
V

V 5g>i

--
d
__
UP counter
«-+5TTi
5N:I <MA> r DO counter

pÿ-O I *• 15YFT CRTF Figure aectlng

OTQ
i JO?
2nd and 3rd layer floating portion
Note) Pass condenser is used each one to memory, counter, latch
- Menory lead ‘

rf8&
(P) <HA> and FF, and one to general gate IC (3 units). (Sub-Con.-)
100 /10V chemical condenser Is used one to 5-6 units of IC. (C025-035)
 =
11
DC Motor Specification for MAZAK Positioning System
( DC motor - Daito Seisakusho )
Type DTMT DTMT DTMT DTMT DTMT DTMT
Spec. 7080 8560 85120 120110 120190 120280
(unit)
Rated output 0.4 1.1 1.8 2.6
( Kw ) 0.2 0.8

Rated torque 176 255

( Kg/cm Vl33.05) (22.47)
19.5 39 107
(44.94) (123.29) (202.79) (293.81)
Rated rotati- 1000 1000
on (rpm) 1750 2000 2000 1000

Rated voltage 200 200 200 200

( V) 200 200

Rated
currency( A )
1.4 2.5 4.7 6.6 10.5 15

Instant Max. gg 48.75 97.5 215 352 513

'
torque (32.07) (56.17) (112.34) (247.72) (405.53) (591.08)
Instant Max.
currency(A) 3.5 6.25 11.75 13 21 30

Mechanical
time constant 8.53 14.43 17.6 16 14.4
( msec )
Electrical
time constant 3.05 2.88
( msec )
Rotor inertia
0.01167 0.0244 0.046 0.175 0.303 0.386
(Kgcms/)(tn_lbs_s 2;(0.Q134)(0.0281)(0.053) (0.202) (0.349) (0.448)
Rate of
use (%ED)
Conte- II If
nuous 70 70 70
Speed
detection DTG3307
( ~ ) 7V-l0%/1 OOOrpm
Weight
(kg)(lb) 10.5 15 29 39 53
(23.14) |(33.07) (63.93) (85.98) (116.84)

<
i

i
1-37
 I
1
YictidK
Tachogenerator

Type
Spec. DTG3307

Output Voltage 7V±10% V/lOOOrpra

Linearity 0.3% belov
Ripple 5% below (lOOOrpm)
Difference of
rotative direction 0.5% below
Thermal
Coefficient 0.02%/°C I

Speed range 5 - 4000 rpm

Rotor inertia ? 0.065gcms2(0.000075) )
.(in-lbs-S )
i
Circumferance
temperature
0 - 100 °C

Measuring Circuit )
)
10Kfi
)
o I
> )
Oscillating
0.1 pF
TG
5= 10KO graph
.

O
i

)
t

)
)

1-38E >
J
 —
iildidk
2. MAZAK SERVO DRIVER

2-1 MAZAK SERVO DRIVER Specifications

Parts No. D80AD002090 D80AD0021 00 D80AD0021 10 D80AD D80AD D80AD

002120 002130 002140
MV-4(0.2kw) MV-4(0.4kw) MV30(1.Ikw) MV30 MV30 MV30
Type (MV-2) (MV-4) (MV-20) ( 1 .81cw)(2.6kw)(0.8kw)
Spec. (MV-20)
Type DTMT DTMT DTMT DTMT- DTMT- DTMT-
Appl i- -7080 -8560 -1201 10 120190 120280 85120
ed
Capaci¬ 1 .8 2.6 0.8
Motor 0.2 0.4 1.1
ty KW
O)
Rated output 1 .4 2.5 6.6 10.5 15 4.7
u currency A
id

u Max. output 2.8 6.25 13 21 30 12

aQ. currency A
U
a Rated
1750 2000 1000 1000 1000 2000
rotation rpm
Power 1 .0 2.5 2.8 3.2 2.0
capacity(KVA) 0.5

o Voltage 30 AC 200V 50/60Hz

c Frequency
H
Voltage
3
allowance
30 Ac 180V - 242V 50/60Hz
Frequency
allowance
+5% below
Feed back DC Tachogenerator 7V/1000 rpm
Control
system
Transistor PWM
Speed comm¬
a 1 : 1000
c and range
•H
Speed comm¬
o
CJ
u-i
and input DC 0 - +10V
o Power for
command
DC +15V 10mA
D,
:>
Load
u
u
id change Within 0.1%
4J l
C
o Voltage
u c change
“3
j
id
£3 (+10% of
WithinO.05%
•J
the rate)
w (U
o Temperat-
w ure +0.2% below
Over currency block
Regeneration over voltage block
TG abnormal block
I
2-1
 •1

1 1 l=.==L-=_=S'

(Note 2)
2-2 operation Description
C3: MV-4=0.047pF
MV-30=1000PF
Control Circuit 1000PF'(Note 2) P.W.M modulation circuit
I S8
1
Command voltage -1AV
10K
—-|—n—VW—-j,L
O.lp 100ft
K5 220K 10K R4 5
(VCMD)
(Note 1) 10K
R37

10K
4 7K
12
0—10V
Speed
error
M

voltage
3
I
10K 13ÿ

I - (o

Tachometer generator
voltage (TCA)
22K
w,
1143 Mil
F> Direction I
signal
__
--
(GAIN)
10K
(Note 1) (fTV A/VW
R43: MV-4=22K
MV-30=10K
W (OFF
v
— SET)
Chopped wave
generating circuit
1156

13
Overcurrent detection
signal
12
11

4
I
> Tr4 signal

-ijri
Bill
V
l
!~rr7t 1
3
5

12
8
> Tr2 signal

o. 1
B VP

i A
Continuous overcurrent
(over O.lrasec.) detection
11
13
8
> Trl signal
t-
III 1 2

1BVN B
DC motor
Servo ready signal
8 8
2
(shows H-level when the servo ON command is
sent and no alarm occurs.)
> Tr3 signal '
BUN -<Tr2

LPM2
N
h
Tr4

PM 1

Command voltage \
(VCMD)

Tachometer generator +
voltage (TGA)

P.W.M. circuit +
IC6 -
l pin -y

Tr 1 L
T r4 nnrLTLii JTTL I
)
Tr2 nn__rLrin_rLU

Tr3 /•
IJJ
4 j
2-2 J
 §
1 I l===ÿ:==ilX

Protection Circuit

(!) When the control power source (+15V) does not operate normally,
the current dr'iving transistor is turned OFF to prevent damaging
the unit (Detection of control power source abnormal).

+ 1 5V
H78
560 S.I
AYr
ZD1 R79
—
— 1 5V-2t>f-4V—2.2K
Q2
2S A.495

l R80
Signal power source for current
driving transistor Ignition
f 47K
7f7s

(2) When the motor has overheated (over 75°C) for whatever reason, the
overheat circuit will operate to turn the current driving
transistor OFF (Overheat detection).

(3) When the input power source (3<$, 200V) experiences any overcurrent
condition, the fuse will blow to protect the circuit. As a result,
the tachometer loss alarm will be triggered and remain on even
after the fuse is replaced if the previous malfunctions are not
corrected. (The power supply must be turned off at once).

(4) If, due to any malfunction, the motor-normal and

tachometer-generator-voltage-normal signals are not detected within
l sec. after the control voltage (VCMD) is applied, the system will
stores the condition electronically as a tachometer loss alarm and
will turn off the current driving transistor. To release the
alarm, turn off the input power (3jS, 200V) at once. <r4

I
2-3
 y
1

srid = i!\

The tachometer loss alarm is triggered when:

1. The +15V control voltage is not normal.
2 The motor has an abnormally heavy load, and cannot run.
3. The motor power circuit is disconnected or shorted.
4. The tachometer generator malfunctions or the tachometer
generator cable is disconnected.
5. The 24V DC power is OFF.

Ignition Circuit

Transformer

8V oJ
AC C
Ti
+15V 47011
4WV
16V
2200// F
+
P
IK 560 (Note)

__
7 1011 or 3011
Motor current
j>—WV
10K £

1
> 6
drive circuit

+±L47p
flC9 35V
lo
M 57903
(Note)
MV-4 Insert 0.47y condenser
only into Tr2 & Tr4.
MV-30 .. Insert 3.3y condenser &
56011 resister into all Trs.
Overcurrent Detection Circuit I
PCI
CUR.LIMIT
VR3 ) TLP521-1 * »
CN2 10K
JSl 2 $ Overcurrent
detection signal
)

9 2 J
RH2 3 8 3
1 3 i
I
0. 1 11
I A2
10 -r
—3

O Detected voltage
rectification circuit )
MV-4=0.1SU0W I
Motor current
MV-30=0.ini0Wx3=0.1/3010W
=0.033f210W
2-4
I
(

ITididk
Regenerative Brake Circuit

The regenerative brake circuit is provided to stop the motor- If the

inverse command is issued when the motor is running, the motor will be
stopped. The kinetic energy of the motor is transformed into electric
power when the circuit is activated. This residual power returns to the
supply through a load resistor which converts it to heat energy and
dissipates it to the air.

RH(Regeneration resister)

Normally 300V DC 0
! JU 360V Zener
(DC 350 |t
- 400V time) diode I zfc <M>
t± 53
at regeneration
!i Motor

Regenerative brake board

2-5
 §
1 1 1===ÿ=====ÿ.

2-3 Setting Details

No setting short bar is provided for the MAZAK servo driver, instead,
the following 3 kinds of VRs only are.

(1) Offset (VR2)

Reference triangle wave offset and the triangle wave described

below are compared through the comparator and the output voltage
obtained by amplifying the difference between the command voltage
and the tachometer voltage will be set as the PWM pulse width
command.

Reference triangle waveform without command

Check terminal TP3-GND Allowance can be adjusted

at the bottom.
OV
250mV

-7V

Since the offset volume regulator (VR2) in MV-4, MV-30 series has
been preset to 250 mV as shown above, it need not be adjusted by
the customer.
I
In MV-2/MV-20, however, adjust the VR2 referring to the above
figure if something is wrong. J

(2) Gain adjustment volume regulator (VR1)

The VR1 determines the command followability of the machine.
Preset to 3.5 division before shipment.

!
i
2-fS i

J
 =
ITldZdtC

Reading the variable resistor division

The left figure shows the example

of 3.5 division.

0 10

(3) Current limit volume regulator (VR3)

Set according to the motor used.

Adjust the VR3 by measuring the voltage between TP4 and TP5 check
pins with a digital voltmeter.

During adjustment, turn the VR3 a little excessively to the CW

direction, then adjust it in the CCW direction.

Motor used Voltage between

(kW) Servo driver TP4-TP5 (V)

0.2 kW MV-4 0.4 V

0.4 kW MV-4 0.63V
0.8 kW MV-30 0.43V
1.1 kW MV-30 0.43V
1.8 kW MV-30 0.69V
2.6 kW MV-30 1.0 V

.*

1
l

i
2-7
 E =
1 1 i==is=i:==\

Thermal relay position in the MAZAK servo driver

1. MV-30

A thermal relay is incorporated, therefore, use the driver conformed to

the motor to be used.

Thermal relay
Currency setting dial

ololo
i

000033 olololol&f510 ooo

Reset button
lololololoTo' (Can be set by pushing it)
oo o oo o

n n
2. MV-4
A thermal relay is provided beside the MAZAK servo driver.

MAZAK SERVO Driver

U "MV-4"
j
I
II 11
Thermal relay
J
Reset button
(Can be set by pushing it)
To motor
Currency setting dial
I

2-8
 nA =
s= =•==ÿ=ÿ E= "V

3. Thermal relay setting value

Thermal
Thermal setting Thermal model
Motor value

0.2 kW 1.4A TH-K20-1.3 A (1 1.6A)

0.4 kW 2.5A -2.5 A (2 3A)
0.8 kW 4.7A -5 A (4 6A)
1.1 kW 6.6A -6.6 A (5.2 8A)
1.8 kW 10.5A -11 A (9 * 13A)
2.6 kW 15 A -15 A (12 * 18A)

YAMAZAKI servoamplif ier purchased part list

No. Model Part No.

1 MV-4 (0.2 kW) D80AD002090

2 MV-4 (0.4 kW) D80AD002100
3 MV-30 (1.1 kW) D80AD002110
4 MV-30 (1.8 kW) D80AD002120
5 MV-30 (2.6 kW) D80AD002130
6 MV-30 (0.8 kW) D80AD002280

<
•»

•f
*

2-9
 I=
lYlei i=\

2-4 LED Conditions

Servo ON When the LED is ON, the servo power

Green LED source is connected. When the LED is
OFF, the servo power source is OFF.

F.A Fuse Alarm When the LED is ON, the fuse has
Red LED blown and the servo power source is
OFF, Whenever the fuse is replaced,
the T.L Alarm LED is ON. The
tachometer loss alarm is output
because, although the fuse is burned
out, the power source to control
board is still ON and the signal of
tachometer generator shows no output.
Turn off the power source at once.

XX T.L Tachometer Loss Alarm When a power circuit such as the

Red LED motor or tachometer generator circuit
is disconnected although the control
system is ON, the T.L alarm is given.
Once triggered, it will continue
until the power source is turned OFF.

££ Normal and Inverse This normally-OFF LED shows that the

XX Acceleration final power transistor has been
Red LED triggered. The brighter the LED, the
larger the current being sent to the
motor by the power transistor.

V
Usually this LED is ON only during acceleration or deceleration.
Under a heavy load condition, the LED will be ON longer. If it
stays ON for more than 1 sec, the system suspects an i
abnormality and triggers the tachometer loss alarm.

)
)
I
2-10 )
i
I
 I=
1I l==lÿ:l=II\

Overcurrent When the motor current exceeds the

Red LED design value (RV3 volume), the
current limitater circuit will
operate to prevent damage to the
power transistor. This light shows
when current limitater is working.
The larger the current, the brighter
the light. Normally, it is fairly
dim (Servo ON time), but brightens
during motor acceleration or
deceleration time.

OHO Fa n Overheat Alarm When the motor has overheated

ova 3
- I
Motor
LEDRed (surface temperature over 90°C), the
power source is turned OFF and this
The thermal sensor
is always working. alarm is given. Usually, this is due
to lengthy overloading. Check the
motor load.

N*

2-11
 *

=
== ====ÿ :
==

2-5 Alarm

Protection/abnormality detect function

No. Kind Display Contents

Displayunit (T) Motor current exceeds the thermal
relay operating current
222-000
1 Overload 333-000 (2) Thermostat inside the servo motor
is operated.
LED OH is lit
Once alarm was triggered, it has
been saved and cannot be cleared
until the power is shut off.
LED T.L is lit (T) Speed feedback (tachogenerator
Speed feed¬ Display unit
signal) is off.
{ 2
back
222-000 (2) Motor power cable is disconnected.
disconnec¬
tion 333-000 Once alarm was triggered, it has
detected been saved and cannot be cleared
until the power is shut off.
Display unit When the current exceeding the value
Overcurrent set the current limit volume regulator
3 222-000 (VR3) continues to flow more than a
alarm
333-000 fixed time (about 1 sec.), T.L will be
LED T.L is lit lit and the operation stops.
When the abnormal current exceeding the
Display unit amperage of the fuse inside the MAZAK
222-000 servo driver flows, this alarm will be
333-000 triggered, F.A is lit and the operation
Melting
4 stops.
fuse
F.A. is lit If the fuse is replaced for a new one j
in this condition, the T.L must be lit,
however, this can be cleared by switch¬
ing the power off once.
J
Display unit
(T) Regenerative discharge circuit is I
abnormal.
222-000
333-000 (2) Too high acceleration/deceleration s’
Circuit frequency F.A is lit and the opera¬
5
abnormal tion stops.
F.A is lit
detection Once alarm was triggered, it has
been saved and cannot be cleared
until the power is shut off.
Iff

I J
2-12
 I
1 1 iu£uiv

Trouble and its remedy

Check methods and remedies for troubles are listed below. Pinpoint the
cause of troubles and perform appropriate measures referring to this
manual.

The following 3 types of alarm indication light are provided for the
MAZAK servo driver.

Check LEDs on the servo driver if the blink alarm "222-000" or "333-000"
is triggered.

Trouble Cause and check of trouble Remedy

1. Overheat (T) When the thermal relay is operated; Change the setting
Check the setting value and re-set value. Check the
it by turning the current set dial mechanical load.
if the value is not proper.
Thermal relay is
If the setting is proper, check if reset by pressing
the motor current value while the Reset button
operating is larger than the about 10 minutes
thermal setting value by connect¬ after start of
ing the ammeter to the motor power operation.
cable.

(2) When the motor thermostat is Replace motor.

operated; Check the
Remove wires connected to the mechanical load.
servo driver terminals 0H+, 0H-
and measure the resistance
between wires. Normal when less
than several ohms, the the motor
thermostat is operating if it is
open (more than several hundred
Kohms),
In the latter case; check the v
motor current while operating if t
the motor surface temperature is
from 80 90°C; the motor is
defective if the temperature is
below 50°C.

2-13
 t-

I
ITfo&otY

Trouble Cause and check of trouble Remedy

2. Fuse is (T) Fuse inside the servo driver was Replace fuse after
flown melted. switching the
F.A is power OFF.
lit
(2) Although the remedy in 1 was done, Replace "RCF"
the fuse was melted immediately diode module or
after the power was switched ON. servo driver.

"RCF" diode module or other part

inside the servo driver is
defective.
(5) Regenerative discharge continued Replace RH5
for over 30 msec. resistor or servo
1. Regenerative discharge resistor
driver.
RH5 (30ft,50W) was disconnected.
Change the trans¬
2. Primary power voltage is former tap.
abnormally high; 300V DC
turned to 360V DC or more.

(4) The alarm is triggered when the Replace print

power is switched on although the board or servo
fuse is not melted. driver.
Wrong connector contact
Wrong print board

3. Tacho- (T) Motor power cable is not connected Connect the

generator to the servo driver terminals A,B. cable.
loss
alarm (2) Speed feedback voltage is not Check cable. I
T.L is gained or sometimes interrupted. Replace I
lit tachogenerator.
Observe the condition between TSA I
and TSB using the oscilloscope to
check the speed feedback voltage.

(3) Wrong print board setting Correct the < I

variable resistor
Check if the setting of the motor setting. I
current limit volume VR3 is
correct.

2-14
 1Y—1===ÿ===!ÿ
§

2-6 Trouble shooting

2-6-1 Fuse is blown out as soon as Power is turned on.

i*
t

i
Note: Cause of damage of transistors
1) Defective control PC board (current limit or trigger circuit)
2) Discontinuity in current detecting circuit
3) Faulty transistor

2-15
1
 —I
="=== = =====
= = §ÿ==ÿ====1ÿ

-
2-6 2 Motor r. ates at High-Speed or it hunts as soon as Power is
turned on even though no Command is given.

Motor rotates
Motor hunts.
at high-speed.

Check tachogenerator voltage. caused by

(Check voltage between TGA and reversed A- and B- YES
TGB with multimeter set at connec- /
10 V DC range.)

NO
Normal Reversed connection
NO voltage (±7 V/ YES of A- and B-phase.
'\1000 rpm)?ÿ-

Faulty tacho¬ Check polarity for

generator or wiring wiring connection. Once turn power off.

(Only for models for which

such feature is supported
by software in MAZAK
Positioning Sequencer)

' 1

Disconnect the connector CN1

and power on.

Check motor rotating condition.

Does
NO motor rotate at YES
high-speed?
*

Defective control Faulty transistor in

PC board main circuit

Change servo driver Refer to: I

7-5. How to Check Faulty Transistor * J

l
J

2-16
!
 I
IYla«ii

2-6-3 Motor does not start even when a Command is given.

Motor does not start even when

a command is given.

YES Fuse NO
blown?
' i
Servo ON LED: LED! (green) on PC board
Replace Is
fuse. NO servo ON LED YES
\lamp on?
<' Tacho-loss alarm LED:
LED\ÿ LED4 (red)
Check signal circuit NO
for "servo on" . for tacho-loss
on?/

Is YES
velocity N.
NO command voltage' Check
l .
-present?/ÿ
( 6 V max ) between' NO
R, S and T-phase.
Check VCMD signal Is it
circuit. 200 Vis'
YES
Check power
YES circuit.
Faulty
PC board s' Are
motor power NO
lines correctly
/ 1
Connect motor
YES power lines
correctly.
Does
voltage
(50 to 300 V DC)\
NO develop across terminals
A and B for approx. 1
v second after command/
\is given again?

YES DC 24V supplied

to DC 24V terminal for YES
relay DR1 & DR2?

NO
V
Defective motor
l
Mechanically
or faulty wiring overloaded

Defective main
circuit Supply DC 24V

Change servodriver
l

2-17
 1
1
—= =
ST?S
S' :s*
I~
= =:
1

2-6-4 Other Pi-oblems

a) When a command is given, the motor hunts and positioning is not
completed.

Disconnection or reversed connection for a tachogenerator.

b) When a command is given, the motor rotates slightly and A/B-phase

discontinuity alarm is indicated.

Defective A/B-phase encoder or wiring disconnection.

c) When a command is tiven, the motor rotates at a high-speed for a

second and A/B-phase reversed connection alarm is indicated.

Reversed connection of A- and B-phase each other.

Once turn power off and turn power on again without changing
present connection, and the motor will rotate normally according
with the command,

The above description is for the control of tables and magazines of

Yamazaki's standard machining centers. In other cases there would be
some differences because the software in MT controller is different.

I
I

t
2-18
/
 a
Silo = ilv

2-6-5 How to Check the Faulty Transistor

Discormect the motor side wires from the terminals A and B.

Check the continuity between the terminals A and B, and the lead SV7 and
SV8 (SV8 and SV9 for 2 kW) of 220 pF capacitor (470 pF capacitor for 2 kW).

Check continuity between

terminals and capacitor.
s
. SV8 SV7 i \
/ MS //
Capacitor SV8 SV9
\

/
Terminal
220p /
/

C140 . /
/
&
Capacitor
Terminal block
\
\

block.
/ M*/" / L %

MV-200 (200 W) MV-20 (2 KW)

Transistor Normal Resistance:

to be
Infinite (at "xlO range") Reference
(+) Collector (C)
checked Emitter (E) (-)

Trl SV7 (SV8) A Apply the black probe to

Tr2 A SV8 (SV9)

measurement .
] Rea
Tr3 SV7 (SV8) B
©
Tr4 B SV8 (SV9) ©
Black

-f
!
Note: The procedure for checking transistors Tr5 to Tr8 is similar
to that of Trl and Tr4; resistance between (+) collector (C)
and (-) emitter (E) should be infinite (°°). In the case of i

200 W motor, if the transistors Trl to Tr4 are faulty, the

transistors Tr5 to Tr8 in the front stage would also be faulty.

2-19
 n
1
i=
1 1 i==is=OIV
2-6-6 How to Check the Faulty Capacitor

/
/
/

r© ©i •
Multimeter

Bump
$2

'7> - + 4

eg
'

©
y
—
i 500
0.25 2c
DCraA
r\

e>
3
a) Small bumps on a capacitor, outward expansion similar in shape to a
convex optical lens, or rupture on the surface of capacitor.

If a voltage of more than 240 V AC (370 V between the capacitor

leads) is applied to the capacitor with a misconfiguration of taps,
the capacitor will be damaged.

b) Measure the capacitor resistance between the leads with a multimeter

ranged in "k-ohm" ; in non-charged state, the pointer will first go to 1
zero and then turn to indicate gradually higher resistance. Finally, l
it should indicate infinite (“) reading. If the pointer remains at I
zero-ohm position or if it cannot indicate infinite reading, the
capacitor is faulty. In addition, the capacitor is faulty if the * *
multimeter set in the 0.25 mA DC range shows even a slight current )
flow even in cases where the resistance check showed an approximate )
i
infinite reading. >
' I
I
)
2-20
I
J
 .!
ITIef
2-7 DC Motor Maintenance

2—7—1 Maintenance
(1) Winding

1) The temperature during operation must not be excessively higher

than the temperature under which the test has been conducted.

If an abnoimal condition is found, immediately stop the operation and

check the winding and find out the defective cause according to the
instructions described in section 2, "Troubleshooting".

(2) Commutator and Brush

I) There must not be much of spark, comparing with a spark in usual
operation, which is liable to fail the operation.

2) Be sure that there is no generation of abnormal sliding sound or

excessive chattering of brushes.

3) There must be little rough wearing on the surface of the.

commutator.

4) Be sure that the slide between brush and its holder is smooth
without binding in the sliding stroke. Also make sure that the
brush holder spring correctly presses the brush without excessive
deterioration of spring pressure. If there is any trouble about
the commutator or brush, immediately stop the operation and check
and find out the defective cause according to the instructions
described in section 5, "Troubleshooting".

(3) Bearings
V
1) Vibration and sound <

There must be no abnormal vibration and/or sound in comparison

with normal motor operation state.

I
2-21
 — u
==
2) Temperature rise

Temperature rise must be normal compared with temperature rise

during normal operation condition.

If there is any trouble with bearings, immediately stop the operation

and check and find out the defective cause according to the instruc¬
tions described in section 2, "Troubleshooting".

(4) Excessive Current

If the current flowing into the DC servo motor or brake is too much
in comparison with the factory test data or normal state even when
the input power voltage meets the rated value, immediately stop the
operation and check and find out the cause of such failure, and make
corrections according to the instructions described in section 5,
"Troubleshooting".

(5) Periodically Measure the Insulation Resistance

Refer to 7—2—(2).

I
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2-22
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2-7-2 Troubleshooting

(1) General
1) The DC servo-motor happen to stop during operation or it cannot
be started.

2) The input current has excessively increased in comparison with

the factory test data or normal state.

Since the above problems are closely related to the following problems,
refer to the following items.

(2) Winding
1) The cause of burning smell and smoke emission will be the follow¬
ing:
a) Excessive current
b) Faulty winding
c) Loosened conductor connections

For a) and c), check and repair them. For b), further carry out
checkups below:

Insulation resistance measurement:

Measure the insulation resistance between the winding and yoke
(housing) under with a 500 V-insulation tester after disconnect¬
ing external wirings. The tester should indicate at least 1.0
Megohms. If the measured value is lower than 1.0 Megohms,
measure again each section of winding to find out the cause of
low insulation resistance. Then, portions of lower insulation
resistance or whole assembly of servo-motor should be dried by
infrared or electric heater until the insulation resistance
reaches a sufficient saturated level.

Determination of disconnection:
If the motor cannot start and no specific reasons are found out,
the disconnection of winding would be the cause of this problem.
Measure the resistance between the terminals of the winding

2-23
 n
is 1
ITtaiciiv
with an insulation tester. When the resistance, which must he
zero, is infinite, the cause is determined as a disconnection
of the winding. In this case, contact your local Yamazaki
representative.

Determination of layer-short or burning:

Under no-load operation if the motor input current is excessive¬
ly higher than the factory test data, burning or layer-short of
the windings or on the commutators will be the possible cause.
If this is the case, contact your local Yamazaki representative.

In addition, since the motor is equipped with a non-excitation

braking system brake, a defective brake will also cause the
problem above. Energize only the brake and rotate the motor by
hand. If it is heavy or cannot be rotated, the brake would be
defective. In this case, contact your local Yamazaki
representat ive.

(3) Commutator, Brush or Related Parts

Probable cause of faulty commutators are indicated below:

Check and find out causes of faulty and repair them.

1) Brush seizure J

2) Inadequate run-in; pressure for pressing brush against commutator

too low due to weak spring force; excessively work brush exceed¬
ing allowable wear limit; lead discontinuity or loose connection I
J
3) Mixed use of different types of brushes
J
4) Rough surface of commutator and chattering
5) After the replacement of brushes, observe the commutating condi¬
v
tion for a while.
I
Do not apply used brushes into a brush-holder in opposite direc¬ I
i
tion, because arc and sliding sound will be generated. I

6) Make sure that an abnormal sliding sound is not produced.

I

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 lYIrt .=!
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For the items 1), 2), 3) and 5), check and correct them.
For the items 4) and 6), the following check and work are necessary:

Clean and repair on the commutator finish surfaces:

In cases where commutator surface shows only slight damage which

can be visually checked from glossiness, color change, color shade,
or surface roughness is slightly damaged, the surface of the
commutator with a piece of dried cotton cloth. For harsher surface,
finish the surface with sand paper or oil stone. If the surface is
excessively damaged, a finishing by a lathe is necessary.

(4) Bearings
When excessive vibration or sound, or temperature rise in comparison
with normal operation occurs, following points should be checked.

1) Incompletion of installation or coupling

2) Belt subject to excessive tension (in case of belt-drive system)

3) Excessive external vibration

4) Too much grease applied (except ZZ type bearings)
5) Deterioration or lack of grease
6) Excessive thrust load on the motor
7) Faulty bearings
For the items 1), 2), 3), 4) and 6), check and repair them.
For 5) and 7), bearings have to be replaced. Contact your local
Yamazaki representative.

2-25
 1
'1
.=
ITlCKcnv
2-7-3 Brush, Spring and Bearing

(l) Brush types

Following types of brushes are used in each of the three different
types of motors. Approx. 10 mm is allowable brush worn limit, which
(0.4 inch)_
corresponds to the brush worn quantity after a 2000- to 3000-hour
operation.
(Brush)

Brush
Motor Type Brush Brush size Shape
Material
DTMT-7080 Morganite PM-803 BR58-1
(England)

DTMT-120110
-120190
-120280
Ditto PM-803 BR616-1
O ||r"3fB:
DTG-3307 Area
(Tacho-
generator)
Ditto x Length
3x2.3x9.5 mm
(0.12x0.09x0.37 inch)
—
DTMT8560
85120 Ditto PM-803 BR516-1
o
(2) Brush Spring

The brush and brush spring are supplied in one piece except ones used
with Model DTG 3307 (Tachogenerator). The following illustration
shows the shape of the brush spring for Model DTG 3307. The brush
spring is not often damaged but if the spring is subject to excessive
force when brushes and changed, the spring, may be damaged.
' i
1 (0.04)
Wire diameter : 40.3 mm J
(0.04) (0.01)
Number of turns: 6 (0.24) J
1 i
)
10 (0.4)
/ I
(0.20) 30° I
)
3 6 (0.24) Unit: mm(inch) \I
(0.12)
2-26
I
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(3) Brush Holder

Two types of brush holders are available - rocker - ring type

(Fig. 1) and cylinder type (Fig. 2).

Fig. 1 Rocker-ring type brush holder (for tachogenerator)

( Brush holding
\
C Brush \spring

c Brush leads
4 units of
brush holders

o ( Brush spring
fixtue
B

-o- -o-

-0- -€)-

Rocker-ring
(made of resin)

Fig. 2 Cylinder type brush holder

( Cap )
C
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Motor housing
1
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\ spring

Brush ;
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(4) Bearings
T}rpe ZZ (W) ball bearings lubricated with packed grease are used.
The model of the bearing for each motor is as follows:

A 10,000-hour continuous operation is available without addition of

grease *

(Bearings)

Motor Model Front

Manufacturer (Output Axis) Rear Used Grease

6203ZZ(NT11) Esso Beacon

DTMT-7080 6201ZZ No. 325

DTMT-120110 6207ZZ 6305VV

DTMT-120190 6207ZZ

DTMT-120280 6207ZZ

Note: DDU type: dust-proof type lubricated with packed

grease.

2-7-4 Tachogenerator
(1) Motor Assembly
Tachogenerator is incorporated on the shaft of the DC servo-motor.
The arrangement from the opposite side of the output shaft is: DC
servo-motor (indicated as DTM), and tachogenerator (indicated as T
after DTM).

(2) Tachogenerator is free from any trouble. But, the brush may be worn
out after 10,000 hours use. In this case, change the brush detaching
the fixing screw of tachogenerator cover.

2-28 to 2-29
I
l
 1
IYICM™
How to Assemble General Type Tachogenerator

No. Working Remarks

1 Mount (18) magnet by (17) two screws.

2 Place (16) armature.

3 Tighten (15) two armature mounting screws. Fixed by screwlock.

Mount (14) locking ring by (13) two screws. Use smaller holes and
4 clamp by screwlock.

5 Remove (20) holder brush clamping screws.

6 Put back (11) carbon-holding springs.

7 Tap (10) bearing into place.

8 Put in (9) wave washer.

Pass lead wire through (6) leadboss of Do not clip lead wire
9 (8) cover and pull lead wire. by cover edge.

10 Set (8) cover by (7) screws.

11 Fix lead wire at the leadboss. By silicone adhesive

Pass lead wire through (4) leadboss of

12 (19) encoder cover.
13 Solder lead wires to (3) connector pins. Red = A, Black = B
14 Adhere lead wire at (4). By silicone adhesive

15 Mount (2) connector to (19) encoder

cover by (1) four screws.

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Brush (R°l/1) 4 - (z$9 drilled holes

Brush: PM-803
SJ Material: Carbon
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Maker: Seiyo-sha
N3 / /Four-core cabtyre cable
/ Motor wiring: red/white 0.75 mm2 Length: 1800 mm (70.87 inches)
£_ Thermal protection wire: black/gray 0.75 mm2 Length: 1800 mm (70.87 inches)
TG wire: Two-core cabtyre cable, 0.3 mm2, Length: 1800 mm (70.87 inches)

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Specifications
Type Fully protected
State Continuous operation
Output powder 200 W
Rated voltage 200V AC

Rated current 1.4 A

Rated speed 1,750 rpm
Torque constant 10 kg-cm/A (11.52 in-lbs/A)
Induced voltage constant 102 V/1000 rpm

Insulation class F

Insulation resistance 10 Megaohms or more with 500V DC

insulation measuring device
Continuous-operation voltage test 1500V AC for one minute

TG-generated voltage 7 V at 1000 rpm

TG ripple voltage 5% p-p or less at 1000 rpm
Oil seal gasket Model SC 4>17 x 935 x 6 ({50.67x36.81
xQ.24)
Triggers at 75°C (contact opens at
Thermal protection a temperature which exceeds the I
above value)
J
Note: Apply a silicone-base Waterproofing compound to
the front console screws and on the output terminal
J
of the wiring before securing these parts.

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Unit: mm(inch)
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130 \ 4-09
(5.12) (<50.35)
Section A-A

Connections

DTMT-8560 (0.4 kW) ""'"ill1

iiiiiii
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IIIIIII

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Wire Specifications

Model Maker
Cable Color Screw Head Specification
Sleeve

Red A A © , B @ when
turning clockwise
Motor Wire 2.0 ram" Teflon 2-5 round viewed from the
output end of the
White B
shaft

TGB TGB © , TGA ©

White
when turning
TG Wire 0.75mm- Teflon 1.25-4 round clockwise viewed
from the output
Black TGA
end of the shaft

Green OH Thermal relay

Thermal Wire 0.75mm- Teflon functioning temp.
Black OV temperature: 75°C

Connections
Type: DTMT-8560 (0.4 kW)

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2-35
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Unit; mm(inch) Section A-A

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Wire Specifications

Model Cable Maker

Color Sleeve Screw Head Specification

Red A A © , B © when
turning clockwise
Motor Wire 2.0 mmÿ Teflon 2-5 round viewed from the
White B output end of the
shaft

White TGB TGB © , TGA ©.

when turning
TG Wire 0.75mmÿ Teflon 1.25-4 round clockwise viewed
TGA from the output
Black
end of the shaft

Green OH Thermal relay

Thermal Wire 0.75mmÿ Teflon functioning temp.
Black 0V temperature: 75°C

Connections
Type: DTMT-85120 (0.8 lew)

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($0.53)
Unit: mm(inch)

Connections
Tachometer Motor
generator """Sill*
mu.;;
White ® o o ® Red limn III
mini

Black © o o © White "'<1

n
1i

Rotation direction: clockwise viewed mi i

till mu
from the output end of the shaft (I**

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Wire Specifications

Maker
Color Screw Head
Sleeve
Red A
Motor Wire 3.5 mm2 Teflon
White B
>3.5 - 5 round
White TGB
TG Wire 0.75 inmÿ Teflon
Black TGA
, 1.25-4 round
Green OH
Thermal Wire 0.75 mmÿ Teflon
Black OV

Wire length: 130 mm (5.12 inches) from the outlet terminal

Protection: Built-in thermal relay (set to 75°C)

Case finish: Matte black

Note: The wires are marked with maker sleeves and connected
to the terminal board.

Type: DTMT120110 (1.1Kw)

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(40.53)
Connections
Tachometer Motor
generator
White ® o o ® Red
Black © o o © White mini III
Rotation direction: clockwise viewed IIIIIII
from the output end of the shaft \
ii
mi
l!I! IIIII

DTMT120190 (1.8 kW)

iii' ii,

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Wire Specifications
Unit: mm

Color Maker
Sleeve
Screw Head

Red A
Motor Wire 3.5 mmÿ Teflon •3.5 - 5 round
White B

White TGB
TG Wire 0.75 inmÿ Teflon
Black TGA

Green OH i

2 Teflon
Thermal Wire 0.75 mm" 1.25 -4 round
Black OV

Wire length: 130 mm (5.12 inches) from the outlet tei'minal

Protection: Built-in thermal relay (set to 75°C)

Case finish: Matte black

Note: The wires are marked with maker sleeves and connected
to the terminal board.

Type: DTMT120190 (1.8Kw)

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Unit: mm(inch)

White

Black
Tachometer
generator
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Connections
Motor
o

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© Red

© White
...
""•'i
mum II
inilli
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Rotation direction: clockwise viewed from \

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the output end of the shaft llll
me mu
DTMT- 1 20280 ,ii( <ii

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Wire Specifications

Maker
Color Screw Head
Sleeve
Red A
Motor Wire 3.5 mm2 Teflon •3,5 - 5 round
White B
White TGB
TG Wire 0.75 mmÿ Teflon
Black TGA

Green OH
Thermal Wire 0.75 mmÿ Teflon - 4 round
Black OV

Wire length: 130 mm (5.12 inches) from the outlet terminals

Protection: Build-in thermal relay (set to 75°C)
Case finish: Matter black

Note: The wires are marked with marker sleeves and connected
to the terminal board.

Type: DTMT - 120280 (2 kW, with brake)

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3. MAGAZINE ADJUSTMENT

3-1 Type I

H-15MA, H-15MB, SV-20, SV-25

3-1-1 Adjusting the chain tension

The chain tension must be adjusted so that the following 3 items are
satisfied at the same time. In this manual, only the scope of
adjustment is described, therefore, refer to the maintenance manual
attached to the machine for actual adjustment procedure.

Adjust the chain tension at the position shown by the arrow in the
following figure.

40 tools magazine 80 tools magazine

+± ~h $1
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f
: $ -+-J-
+

120 tools magazine

fT\ v

ftf
KS \t7 '
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3-1
 m =
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(1) DC motor armature current

If the chain is not tensed properly, the load becomes unusually

heavy and the excessive current flows to the motor. Adjust the
tension, therefore, so that the current does not exceed the
value range shown in the figure below.

DC motor armature current value (high speed operation).

(Unit A)

Tool
40 80 120
Magazine Motor
.type DTMT-120110 DTMT-120190 DTMT-120280
condition (1.1 kW) (1.8 kW) (2.6 kW)

Without tool 3ÿ4 3ÿ4 4ÿ5

Not balanced 4ÿ5 4ÿ7 6ÿ7

(20 kg tool x 6)

Maximum load (Note) 5ÿ6 4v8 6ÿ8

(Note) Maximum load varies with the number of tools.

40 tools 600 kg (1322.76 lb)

80 tools 800 kg (1763.68 lb)
120 tools 1,200 kg (2645.52 lb)

(2) Gap between the liner (rail) and the link plate

within 0.5 mm
(0.02 inch) J
Link plate
/
/ |

(o onto
V///7/A y////M
o) i

\ Liner (rail)
Within 0.5 mm
(0.02 inch)
J
3-2

I
 Mefÿcfk

(3) Tool declination

To adjust the decline of the tool, it is required to adjust the

allocation between the ATC-chain linkplate and the liner (rail)
as well as the chain tension.

Y////
I
Declination
a

m
2=300 //S A V///
(11.81)
oS5 mm
ATC-chain
(0.2 inch)

3-1-2 Adjusting the timing belt

Adjust the timing belt so that it is tensed to give proper elasticity

to the thumb finger when pushed. Excessive tension will prevent the
optocoder from moving smoothly and be the cause of unusual movement
such as hunting, etc.
Sprocket

Quadrant Wormwheel
sensor

C Cam
O
o Inposition sensor

X.
A
x Worm
fro
¥ Stop pin
B
Motor ifo)j
Optocoder

3-3
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Ci
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4J
a
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Thrust "F" —
i

4-4
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+•
•+•
Timing belt tension

No. Location to be used Thrust "F" Deflection "a" mm Belt type

Kg.
A Motor Worm shaft 4.0 3.36 300H200

B Sprocket Optocoder 0.25 6.0 376XL037

C Optocoder
0.3 10.0 600L050
Quadrant dog

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3-2 Type 2

H-20N, H-25N (60, 80, 120 tools)

3-2-1 Adjusting the chain tension

Similar to the type 1 described above, the chain tension must be

adjusted so that the following 3 items are satisfied at the same
time. For actual adjustment steps, refer to the maintenance manual
attached to the machine.

(1) DC motor armature current

If the chain is not tensed properly, the load becomes unusually

heavy and the excessive current flows to the motor. Adjust the
tension, therefore, so that the current does not exceed the
value range shown in the figure below.

DC motor armature current value

(Unit: A)
Tool
60 80 120
Magazine' Moto
type DTMT-120280
condition HD-100 HD-200
(2.6 kW)
Without tool 2ÿ3 3ÿ4 4ÿ5

Not balanced 4ÿ5 5ÿ6

(20 kg tool x 6) 6*7

Maximum load 5ÿ6 5ÿ6 6 n. 7

(Note) Maximum load varies with the number of tools.

60 tools 600 kg (1322.76 lb)
80 tools 800 kg (1763.68 lb)
l
120 tools 1,200 kg (2645.52 lb)

3-5
 n
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(2) Gap between the liner (rail) and the link plate.

Refer to the Type 1 (2) (P3-2).

(3) Tool declination

Refer to the Type 1 (2) (P3-3).

3-2-2 Adjusting the timing belt

Adjust the timing belt so that it is tensed to give proper elasticity

to the thumb when pushed. Excessive tension will prevent the
optocoder from moving smoothly and be the cause of unusual movement
such as hunting, underrun, etc.

Wormwheel

v
Motor

on D
\ r

-4- \ Worm
Quadrant
sensor f
C
\
Cam
Inposition Optocoder
sensor Stop pin

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Timing belt tension

Thrust "F" Deflection "a"

No. Location to be used Belt type
kg(lb) mm
60 225H200
A Motor— shaft 6.3 2.7
80
(13.89) (0.11) 270H200
120
B Worm shaft—-Shot pin 60 360H200
6.3 3.5 80
(13.89) (0.14) 120 370H200
C Sprocket
—Optocoder 0.2
(0.44)
6.4
(0.25)
60 600L050
80 581L050
120 619L050
D Optocoder
— Quadrant dog
(0.44)
0.2
(0.22)
5.6
80
120 510L050

3-3 Type 3

H-12N (120 tools)

3-3-1 Adjusting the chain tension

Similar to the Type 1 and 2 above

(1) DC motor armature current

If the chain is not tensed properly, the load becomes unusually

heavy and the excessive current flows to the motor. Adjust the
tension, therefore, so that the current does not exceed the
value range shown in the figure below.

V
!

3-7
 n
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DC motor armature current value

(Unit: A)

Tool
120
Magazine Motor
type DTMT-120190
condition (1.8 kW)

Without tool 3ÿ4

Not balanced 5ÿ6

(8 kg tool x 10)
(17.64 lb) -
Maximum load (600kg) 5%6
_(1322.76 lb)

3-3-2 Adjusting the timing belt

Refer to the Type 2 (2) (P3-6).

( H-12 120 tools use )
Thrust "F" Deflection ”an Belt type
No. Location to be used
kg (lb) mm(inch)

A Motor Worm 6.3(13.89) 2.7 (0.11) 270H200

B Worm Shot pin 6.3(13.89) 3.5 (0.14) 370H200
C Sprocket Optocoder 0.2 ro.44) 6.4 (0.25) 619L050

D Optocoder
—
Quadrant dog
0.2
(0.44)
5.6 (0.22) 510L050
* )
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3-4 Adjusting the magazine position detect encoder

3-4-1 Outline

Read this adjustment manual (1) when the magazine is to be operated

initially after assembled, (2) when the defective encoder is replaced
and (3) when the deflection in the encoder is to be readjusted

3-4-2 Adjustment step

(1) Position the No. 1 pocket at the ATC position.

ATC position

o /
ATC arm

X 3®C
o
Q

a) Move the No. 1 pocket to the ATC position by the MANUAL TOOL
SELECT and stop the machine by the emergency stop, etc.
before the stop pin extends.

b) Shut the power OFF, move the timing belt between the motor
and the gear box manually and match the No. 1 pocket at the
ATC position.
<
c) Switch the power ON, remove leads to the solenoid associated
with the magazine stop pin, forcibly operate the solenoid
manually to extend the stop pin, and the magazine is fixed.

3-9
 <1
n
IiidiClix
i

(2) Adjusting the timing belt tension driving the encoder

Encoder side Driving side

Thrust
Deflection !,a"

e •ÿ0-

Timing belt

Machine _
Thrust "F" kg Deflection "a" mm
Clbl - (inchl
H-12N 0.2 (0.44) 0.4(0.25)

H-15MA 0-25(0.55) 6*°(0.24)

H-15MB 0-25(0.55) 6*°(0.24)
H-20N 0-2 (0.44) 6-4(0.25)
H-25N 0-2 (0.44) 6-4(0.25)
SV-20 0.25(0.55) °(0.24) J
SV-25 0* 25(o.55) 6 -°(0.24)

Refer to the Adjustment Procedures for the magazine mechanical

system for other timing belt tension. * J

I
i

3-10

1
 M =
= ;r*
==
:

(3) Adjusting the encoder

Loosen the encodes fixtures, move the encoder in the CW or CCW

direction so that the dot pointer on the display unit is lit
and fix the encoder.
Dot pointer is OFF
Dot pointer is ON
Tool number Center

V
i Dot pointer
2-digit for up to
M5 bolt

Loosen the bolt

Encoder
80 tools
Using this
V pulley
3-digit for 120 or
more tools Move the encoder

Fix the encoder so that it positions at the center of the dot-

point-ON width after moved.

(A) Synchronize

Synchronize the actual mechanical position with the electrical

position using the 0° search function.

(5) Repetitive test

Operate the magazine repetitively by the program which moves
the magazine reciprocally to the reverse direction.
Check the magazine movement, particularly that when striking
the stop pin. -f
<

3-11
 1
1
5~=~ ~
i i ====4=====ÿ%

Stop pin

A
Check that the magazine stopped
moving and the stop pin is
located at the center of the cam.

If an excessive underrun condi¬

tion occurs, refer to the next
\ Worm shaft item "Measures for improper
condition" and make readjustment.
Cam
3-4-3 Measures for improper conditions

If the improper condition canot be corrected after adjusting the

encoder in accordance with the adjustment steps in item (2), refer
to this item.

No. Condition Measures

Relation between cam and stop pin
1. CW direction
—
CCW direction-
» center
center
Optimum condition

Relation between cam and stop pin (T) Adjust the analog voltage
output from the M/T
—
—
2. CW direction center
controller to OV without
CCW direction — underrun giving the command and
check the condition.
Relation between cam and stop pin
© Magazine load is eccentric. I
3. CW direction
CCW direction
— underrun
center
Reallocate tools so that the
load is balanced properly.

Relation between cam and stop pin © Excessive backlash in the

mechanical system
i
CW direction underrun I
(2) Excessive load in the
CCW direction —
»- underrun mechanical system
4. Readjust the load referring *t i
to the Adjustment manual for
i
the machine.
© Replace the servo amplifier J
i
If the MV-20 servo amplifier I
is used, replace it for the
MV-30. I
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1

4. INDEX TABLE ADJUSTMENT

4-1 Type 1
Object machine: H-15MA, H-15MB, H-400

4-1-1 Checking and adjusting the gear backlash

(1) Push the single solenoid valve
by the hand to clamp the table.

(H-400) 100'
-200(7.87)
(3.94)

Dial
d500 (19.69)
( a630)(24.80) F
(2) Apply the dial gauge and turn the pallet.

below 0.1 (tooth 0.08 'v* 0.12)

n630 below 0.1 (tooth 0.08 0.12)
below 0.055 (tooth 0.06 'u 0.1)

(3) If the backlash exceeds the above values, turn the eccentric
ring holding the wormwheel. The left and right housings must
be matched since the eccentric position is printed on them
by the numeral.

(0.2) (0.2) fi

__
Eccentric housing

l
jr
F=TO
Eccentric housing

Or
4-1
 <1
1
I
i I 1===ÿ====IX

4-1-2 Adjusting the optocoder

Performed with the table being clamped at 0°.

(1) Loosen the M4 bolt fixing the optocoder.

]_r r=4
r H--r

M4 bolt
(2) Turn the optocoder and check that the
dot goes ON.

Dot
(3) Find out the dot-ON width and fix the optocoder so that it
positions at the center.
I
(4) Turn ON the 0° SEARCH switch on the electrical control panel
after turn the power OFF and back ON again.

(5) Designate the BO in the MDI mode from the control panel
positioning is made at the command value after once passes
through the 0° position.

(6) Automatically clamped at 0°.

(7) Turn the 0° SEARCH switch OFF, run in the machine and check
? J
the result of the adjustment. t

OK Adjustment is completed.
i
NG Readjust the optocoder from the step 1). )

4-2
i
)
 I 1 klÿi=\

When the table is clamped/unclamped , the pallet goes up and down

being jammed, however, it does not matter as described below.

Advancing angle 3.8226°

Cylinder stroke 4 mm (0.16)

Gear diameter <ji 489(ÿ19.25)

4 x tan 3.8226° 360° 0.0626° ±0.0313°)

489 x v x =

Difference 0.0954°
/////////.

7///
(p.283 - 0.125 = O.lIP
0.283° 0.283°
T7777T77TI //////

///////.
Electrical positioning error ±0.125°

Backlash and the coupling (upper, lower) eccentricity are

considered the factor of index error.

4-2 Type’ 2
Object machine: H-12, H-20N, H-25N

4-2-1 Checking and adjusting the gear backlash

(1)
(5)
VWWWWWN/

I (4)

y
(2)
(3)
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1
4-3
 '1
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i= 1
= S S' =' is:

(1) Coupling and pinion gear backlash

Target value (0.03 0.08)

Retainer

Eccentric housing o o y
(0.5)

o o
Pinion gear /

Coupling gear/

Loosen the retainer and turn the eccentric housing to adjust

the backlash. In this case, a small tester is useful.

(2) Gear backlash

Target value (0.03 0.05)

Grind the liner between the index base and the gear box to
adjust its thickness.
I
For example, to lessen the backlash by 0.01 mm, grind the
liner by 0.03 mm.

(3) Worm and wormwheel backlash

Target value (0.03 'v 0.06)

Turn the upper and lower eccentric housings holding the

wormwheel to adjust the backlash.

4-4
A
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i== :=ÿ
Li
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(4) Gear backlash

Target value (0)

Eliminate the backlash using the gap because the gear box hole
is larger than the housing.

For adjusting the For adjusting the

housing (4) housing (3)

\Jfe / r
Rd
1 4.

J S Adjustment liner
T n nUi Kl (2)

For adjusting the

housing (3)

4-2-2 Belt tension

3 5 mm
(0.12x 0.2 inch)

t
0.2 a, 0.5 kg (0.44-vl.lO lb)
1
4-5
 'I
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4-2-3 Adjusting the optocoder

Performed with the table being clamped at 0°.

(l) Loosen the M5 bolt fixing the smaller

pulley.

Dot
(2) Turn the larger pulley and check that
M5 bolt
the dot goes ON.

P
Smaller
5 pulley
(3) Find out the dot-ON width and fix the smallei pulley so that
it positions at the center.

(4) Turn ON the 0° SEARCH switch on the electrical control panel.

(5) Instruct the BO in the MDI mode from the pendant control panel.

(6) Automatically clamped at 0°.

(7) Turn the 0° SEARCH switch OFF, run in the machine and check
I
the result of the adjustment.
I
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 lYidzok

5. POSITION DETECTOR SPECIFICATIONS

The following two types of position detector (optocoder) are available

for the machines.

Position detector for the magazine

LEC-72BM-S38

Position detector for the index table

1. H-15MA, H-15MB, H-400

LEC-0.6 BM-S44

2. H-12, H-20N, H-25N

LEC-72 BM-S38

5-1
 'y

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—
(1) Name Optocoder
(2) Model
LEC 0.6 BM - S44
Line of the model\ \Special article
1/10 the number of output Two 90°-phase-diff erence
pulses signals + zero point
(3) Outline drawing 2-254029
(A) Output
1) Output waveform T
X1 X2 X3 X4
H(OFF)
fA phase (SI) L(0N) Output waveform when the
turning direction is CW toward
the input shaft is shown in
2 signals with the figure.
90 phase difference
B phase (S2)

Z phase (M)
'
—
T = 360°
N
Zero point
signal Y1 Y2 Y3|Y4
TM N: Number of output
pulses per revolution
i) Two 90°-phase-diff erence signals
° Waveform ratio xp + X2 = 0.5T ± 0.1T
X2 + X3 = 0.5T ± 0.1T
° C phase difference xn S0.125T (n=l, 2, 3, 4)
ii) Zero point signal 0.25T < TM < 0.75T
iii) Relation of the phase between the two 90°-phase-diff erence
signals and the zero point signal
yi > 0 > y9 > 0 (CW turning)

y3 > 0 , > 0 (CCW turning)

i
2) Signal position precision
i) Pitch error between adjacent signals: t0.05T
1
)
ii) Cumulative error from the zero point signal: ±0.1T )

1
5-2
 1 I I==Iÿs=== =ÿ%.

(5) Name Optocoder

(6) Model
LEC - '72 BM - S 38
Line of the model' |Special article
1/10 the number of output Two 90°-phase-difference
pulses signals + zero point
(7) Outline drawing 2-254029
(8) Output
1) Output waveform T
X1 X2 X3 X4
H(OFF)
s' A phase (SI) L(ON) Output waveform when the
turning direction is CW toward
the input shaft is shown in
2 signals with the figure.
90 phase
B phase (S2)
difference

—
T = 360°
N
Zero point Z phase (M)
signal
N: Number of output
TM pulses per revolution
i) Two 90°-phase-difference signals
XI + X£ = 0.5T
0
Waveform ratio ± 0.IT

x2 + x3 = 0.5T ± 0.IT
0
C phase difference xn SO.125T (n=l, 2, 3, 4)
ii) Zero point signal TM = IT ± 0.5T
iii) Phase relation between the two 90°-phase-difference signals
V
and the zero point signal is not prescribed.

2) Signal position precision

i
i) Pitch error between adjacent signals: ±0.05T
ii) Cumulative error from the zero point signal: ±0.1T

5-3
 0

itib UK
&

(9) Electrical specification (05E)

1) Input voltage DC 5V ± 0.25V

(Ripple content must be less than 1%)

2) Current consumption 150raA max. (10 K0 load)

3) Output i) Output method Emitter ground

ii) Output circuit
g +5V
s 510
2SC372 OUT
0V
O

iii) Output voltage (at 10 Kfi load, ± 0.25V input voltageÿ

"H" 2 3.5V

"L" S 0.5V

iv) Rise, lowering time

1 ps max. (with lm shield cable, 10 KO load

at the terminal)

4) Frequency response 0 'v 30 KHz

5) Insulation resistance 100 M0 min.

£ )
(Between total output + power source and body/ )
by 500 VDC Megger (insulation tester)). I
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(10) Connection Cable output (wired with the cabtyre cable specified
by YAMAZAKI)

1) Wiring table
Wire color Mark Signal

White +5V DC + 5V

Black 0V 0V common

Red SI A phase Two 90°-phase-

diff erence
Green S2 B phase signals

Yellow •
M Z phase Zero point
signal

2) Cabtyre cable used (by SHINAGAWADENSEN)

SP-1139

Nominal cross-sectional area 0.3 mm2 (0.0047 in2)

Wire element diameter x pcs. 4>0.18 x 12 pcs.
Sheath material ESFLEX (oil resistant)
Outer diameter <J>6 (<i0.24 inch)
Cable length 5 m (16.04 ft)

3) Shield inside the encoder

Shields are not connected to the body.

4) Body coupling capacitor <

0.01 pF between 0V and the body.

5-5
 *n
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1 1 h=i£====w%.

(11) Mechanical specifications

1) Allowable input rpm 1200 rpm - LEC-0.6BM - S44

2) Start torque
3) Allowable input angle
acceleration
4) Inertia moment
5) Allowable shaft load
6) Play in the input shaft
thrust direction
7) Shaft eccentricity
1000 rpm - LEC-72BM-S38
approx. 300 g.cm max. (at 25°C)
(0.345 in-lbs)
104 rod/S2
approx. 3.6 x 10-5 kg'em- S2
(approx. 35*g‘cm")
2 *g: mass
radial direction 2 kg (dynamic load)(4,4 lb)
thrust direction 1 kg (dynamic load)
(2.2 lb)
0.05 mm max. (0.002 in max)
(when the input shaft loaded with 1 kg
is moved to and fro)
0.01 mm max.(0.0004 in max)

8) Eccentricity between the

shaft and inside low 0.01 mm max.(0.0004 in max)
9) Decline of shaft end
toward the mounting
surface 0.01 mm max.(0.0004 in max)

(12) Environmental specifications

1) Operable temperature range -10°C -v +60°C
(All mechanical specifications except (2) start torque are
satisfied in this condition.)
J
2) Temperature range when stored -30°C a, +70°C

3) Dewfall prevention
)
Conformed to the NDS standard Clause 3-10-1 in CO-110 dewfall )
prevention test, No. 1 test method.
i

5-6
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=
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=5

- NDS standard Clause 3-10-1 in CO-110 dewfall prevention test,

No. 1 test method

This test method is applied to room equipment. Incline the equip-

ment to be tested 15 degrees below the level, drop waterdrops
naturally at the ratio of lcc per minute for more than 3 hours
from approximately 30 cm above to a proper position of Che equip-
(11.81 in)
ment. Difference between room and water temperatures should be
within 10°C.

(13) Weight approx. 450g (0.99 lb)

(14) Guarantee

Troubles due to designing or manufacturing which have happened within

1 year after delivery to the customer shlall be repaired gratis.

Those after 1-year guarantee period or caused due to manner in which

it is handled or used shall be charged actual expense.

(15) Optocoder External View

5-7
 4.5 fitting hole Cable outlet 23(0.91) 54 Cabtyre cable 4>6,(0.26)
5-cores, L. 5000
.
""Villi'
(nun

IIIIIII

illll"
1111 Hill
jfr **1
ll

(0.18) (0.24) (2.13)

6„ 1(0.16) (196.85)
(0.55) \
14 2 (0.08)
I\

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\ Set bolt M4 x 15 I
Fitting hole pitch dia. 96 (3.78)
Servo mount fixture
Metal fixture Max. 0D. 112
(4.41)

Unit: mm(inch)

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6. MAZAK POSITIONING SEQUENCER CIRCUIT DIAGRAM & PARTS LIST

MAZAK Positioning Sequencer is composed of the following three kinds of

printed circuit board:

(1) MPS-510 (Control print board)

(2) MPS-530 (Input print board)
(3) MPS-520 (Output print board)

Circuit diagrams and parts lists are described in the following pages:

6-1
 41
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(4) Parts List

(Electrical Parts List for MPS-510)

Draw. Standard
No. Parts Name Maker Q'ty Remark
Type

1 Circuit diagram 1-353046

2 Print board 1-829037 1
3
4
5
6 SN coil SN-5-300 Tohoku Kinzolcu 1 SN-1
7 SN coil SN-5-200 ditto 1 SN-2
8
9 Terminal block S-02-(B)-4P Kowa 1 TB-1
10
11 Dip switch DSS-104 Fujisoku 1 DIP SW3
12 Dip switch DSS-108 ditto 1 DIP SW4
13
14 Dip code switch KDS 16-322 ICEL 2 SW1, 2
15
16 Connector FCN3649 024AG Fujitsu 2 CN505
CN506
17 Connector FCN364P016AG ditto 2 CN507
CN508
18 Metal fixture FCN364A1 ditto 8
19
20 Test terminal P-99-8P Kowa 7 TPO 6
21 28P-IC socket IC26-2806 Yamaichi 1 N18R0M
22 DIC terminal board DIC-152-20P Honda Tsushin 1 N40
23 DIC terminal board DIC-152-16P ditto 1 J1
24 DIC short bar DIC-128 ditto 3
25
26 Battery GB150-3S Nihon Denchi 1 BATT
27
28 Crystal oscillator CX046-10MHZ Kinsekisha 1
29
30 IED lamp SEL2110R Sanken 7 LD, 0,1,2,
3,4,5,6
31 Diode 1S1587 2 Dl, D2
32 Diode F14E NEC 1 D100
33 Zener diode RD2R2EB NEC 1 (R25)ZD2
34 Zener diode RD14EB NEC 1 ZD1 <
I
35 CP amplifier MPC451C NEC 2 0P1 0P2
36 Transistor 2SA495(G)TM-Y Toshiba 2 Q1 Q2
37
38 Transistor 2SA495(G)TM-Y Toshiba 4 N40-a,b,c,d
39
40 D/A Converter DAC48EQ PM1 1 N39 DAC

1
6-7
 *1

mcfiriK

No. Parts Name Draw. Standard

Type Maker Q'ty Remark

41 CMOS-RAM HM6148HLP-55 Hitachi 1 N17 RAM

42
43 EPROM M5L2764K Fujitsu 1 N18 ROM
44
45 CMOS-IC HD14011B Hitachi 1 N27
46 CMOS-IC TC5068 Toshiba 1 N71
47 CMOS-IC TC4016BP Toshiba 1 N41
48 HC-MOS-IC SN74HC00 TI 1 N66
49 HC-MOS-IC SN74H138 TI 1 N72
50 HC-MOS-IC SN74H175 TI 6 N37,38,49 ,
50,61,62
51 HC-MOS-IC SN74H367 TI 2 N7, 8
52 HC-MOS-IC TC74HC154 Toshiba 2 N19, 20
53 HC-MOS-IC TC74HC174 Toshiba 1 N67
54
55
56 Transistor alley TD62304 Toshiba 1 N73 I
57 ditto TD62504 Toshiba 1 N51
58 ditto TD62505 Toshiba 1 N70
59 i
60
61 TTL-LS1C SN74LS00 TI 3 N28,53 ,57
62 i’TL-LSIC SN74LS02 TI 3 N32,47,54
63 TTL-LS1C SN74LS04 TI 4 N48,65,30,55
64 TTL-LS1C SN74LS08 TI 4 N10,21,33,34 J
65 TTL-LS1C SN74LS10 TI 2 N29 , 31 t
66 TTL-LS1C SN74LS27 TI 2 N42, 59
67 TTL-LS1C SN74LS32 TI 2 N56 , 58
68 TTL-LS1C SN74LS51 TI 2 N44, 64
69 TTL-LS1C SN74LS54 TI 3 N43,45,46
70 TTL-LS1C SN74LS86 TI 1 N22
71 TTL-LS1C SN74LS75 TI 3 Nil,12,68
72 TTL-LS1C SN74LS85 TI 3 N5,15 ,16
73 TTL-LS1C SN74LS126 TI 2 N13, 60
74 TTL-LS1C SN74LS139 TI 1 N9
75 TTL-LS1C SN74LS157 TI 2 N3 , 14
76 TTL-LS1C SN74LS257 TI 1 N4
77 TTL-LS1C SN74LS153 TI 1 N23
78 TTL-LS1C SN74LS109 TI 2 N52, 63
79 TTL-LS1C SN74LS191 TI 4 N6,24,25,26
80 TTL-LS1C SN74LS138 TI 2 N35, 69

6—8
J
 ==
liloÿn a

Draw. Standard Maker Q'ty Remark

No Parts Name Type

81 TTL-LSIC 74LS393 TI 1 N36

82 TTL-LSIC 74LS74 TI 2 Nl, 2
83
84
85
86 Painted insulation RD25UI0J Kowa Ohme 2 R22, 23
resistance
87 ditto RD25U560J Kowa Ohme 1 R17
88 ditto RD25U680J Kowa Ohme 2 R20, 21
89 ditto RD25U100J Kowa Ohme 1 R9
90 ditto RD25U1KJ kowa Ohme 2 R6, 25
91 ditto RD25U1R5KJ Kowa Ohme 1 R16
92 ditto RD25U2R4KJ Kowa Ohme 1 R4
93 ditto RD25U4R7KJ Kowa Ohme 6 R12,13,14,
15,30,35
94 ditto RD25U5R1KJ Kowa Ohme 1 R38
95 ditto RD25U6R8KJ Kowa Ohme 1 R3
96 ditto RD25U10KJ Kowa Ohme 10 Rl,2,5,10,
11,51,36
97 ditto RD25U10KJ Kowa Ohme R37,50,27
98 ditto RD25U22KJ Kowa Ohme 3 R17,18,19
99 ditto RD25U27KJ Kowa Ohme 1 R39
100 ditto RD25U15KJ Kowa Ohme 1 R26
101 ditto RD25U47KJ Kowa Ohme 9 R31ÿ34,40ÿ44
102 ditto RD25U330KJ Kowa Ohme 1 R8
103 ditto RD25U560KJ Kowa Ohme 1 R28
104 ditto RD2501MJ Kowa Ohme 2 R7, 70
105 ditto
106 Resistance network
RKC1/8B7-10KJ Kowa Ohme 3 RA5,7,11
107 ditto RKC1/8B5-10KJ Kowa Ohme 1 RA8
108 ditto RKC1/8B6-10KJ Kowa Ohme 1 RA10
109 ditto RKC1/8B8-10KJ Kowa Ohme 3 RA2, 3, 6
110
111 Resistance network RKC1/8B5-22KJ Kowa Ohme 2 RA1, 9
112 ditto RKC1/8B8-22KJ Kowa Ohme 2 RA4, 12
113 ditto RKC1/8B8-1R2KJ Kowa Ohme 1 RA14
114 ditto RKC1/8B4-3R6KJ Kowa Ohme 2 RA13, 15
115
116 Tantalum film PN822H102H NEC 1 VR1
variable resistor v
4
117
118 Photo coupler TLP521-4-GB Toshiba 2 PCI, 2
119
120 I

6-9
 1
1

IYId«fk

No. Parts Name Draw. Standard

Type Maker Q'ty Remark

121 Ceramic condenser CK451H101M KCK 1 C6

122 ditto CK451H221M KCK 2 C5, 7
123 ditto CK451H331M KCK 1 C3
124 ditto CK451H471M KCK 2 C14, 15
125
126 Mica condenser CQ921H102M 1 C21
127 ditto CQ921H103M 5 CIO,11,12,
13,24
128 ditto CQ921H223M 4 C27,28,29,30
129
130 Tantalum condenser CS15E1A100MIS NEC (D series) 1 C26
131
132 Chemical condenser SMC-CE441E10 Nihon Chemi-Con 7 C2,16,17,18,
19
133
134 Chemical condenser SMC-CE041A47 Nihon Chemi-Con 1 Cl
135 ditto SMC-CE041A200 Nihon Chemi-Con 11 CO25 035
136
137 Laminated ceramic B37988-J5104-Z Siemens 65 C22,C01a,O24
condenser (Z5 u type)
138 ditto B37988-J5104-Z ditto C036a,075
139
140 Support P-11-16M Kowa (M3xl6mm) 7

i
/
t

< I

6-10
 lYIdidk
(Electrical Parts List for MPS-520)

No. Parts Name

Draw. Standard Q'ty
Type Maker Remark

1 Circuit diagram 1-353051 o

2 Print board 1-829 038 1 (MPS-520)
3
4
5
6 DIC terminal block DIC-152-14P Honda Tsushin 1 DIC
7 Short bar DIC-128 2 DIC
8
9 Connector FCN364P024AG Fujitsu 1 CN506N
10 Connector FCN364J024AG Fujitsu 1 CN506N
11 Connector FCN365P024AG Fujitsu 1 CN303N
12 Connector FCN365P016AG Fujitsu 1 CN504N
13
14 Metal fixture FCN360A2 Fujitsu 4 CN503N,304N
15 FCN360A Fujitsu 2 CN506N
16
17 Support P-11-16M Kowa (M3xl6mm) 2
18
19
20
21 TTL-LSIC 74LS04 TI 1 Nil
22 TTL-LSIC 74LS138 TI 1 N12
23 TTL-LSIC 74LS175 TI 8 N13 20
24
25 Photo coupler TLP521-4-GB Toshiba 8 PCI 8
26 Transistor ally TD62503 Toshiba 5 N6 10
27 ditto TD62503 A N1
28 Toshiba AA
ditto TD62505 Toshiba N1 5
29
30
31 Painted insulation RD25U684J Kowa Ohm 32 R1 32
resis tance
32 ditto RD25U4R7KJ Kowa Ohme 32 R33 't 64
33 Resistance network RKC1/8B8-470J Kowa Ohme 4 RA1 4
34
35
36 Chemical condenser SMC-CE041A47 2 Cl01ÿ 102 1
37 <
38 Laminated ceramic B37988-J5104-Z Siemens (ZSU 10 C103 -u
condenser type)
39
40

MAZATROL TI only * AA
5
FANUC 2 3
MAZATROL 5

6-11
 *1
n
i
ITIdÿniv=-

(Electrical Parts List for MPS-530)

Draw. Standard.
No. Parts Name Type Maker Q'ty Remark

1 Circuit diagram 1-353050 o

2 Print board 1-829039 (MPS-530) 1
3
4
5
6 DIC terminal block DIC-152-10P Honda Tsushin DIC
7 Short bar DIC- I 28 2 DIC
8
9 Connector FCN364P024AG Fujitsu 1 CN506N
10 Connector FCN364J024AG Fujitsu 1 CN506N
11 Connector FCN365P040AG Fujitsu 1 CN500N
12 Connector FCN365P032AG Fujitsu 1 CN501N
13 Connector
14 Metal fixture FCN360A2 Fujitsu 4 CN500N
CN501N
15 Metal fixture FCN360A Fujitsu 2 CN506N
16
17 Support P-11-16M Kowa(M3x 1 6mm) 2
18
19
20
21 TTL-LSIC 74LS138 TI 2 N1 ,N2
22
23 HC-MOSIC 74HC368 TI 11 N3-N13
24
25 Photo coupler TLP52I-4-GB Toshiba 16 PC 1—16
26
27 Painted insulation RD50Ss2KJ Kowa Ohm * R1-64
resistance
28 ditto RD50Ss2R4KJ Kowa Ohme AA R65-128
29 ditto RD25U470J Kowa Ohme AAA R65-128
30 ditto RD25U10KJ Kowa Ohme 1 R129
31 Resistance RKC1 /8B8-470J Kowa Ohme 8 RA1-8 I
network
32 ditto RKC1/8B8-1KJ Kowa Ohme 8 RA9-16
33
34 Painted insulation RD25U22KJ Kowa Ohme 64 R1 29-192
resistance
35
36 Mica condenser CQ921H472M 64 C1-64
37
38 Chemical condenser SMC-CE041A47 2 C101 ,102
39 i
40 Laminated ceramic B37988-J5 1 04-Z Siemens A*** 0103-
condenser (Z5U type) I
* A* A** A AAA j
MAZATR0L TI only 64 64 10
FANUC 32 32 32 10 I
MAZATROL 8 56 8 13

6-12E
 I
11

7. MAZAK SERVODRIVER CIRCUIT DRAWING AND PARTS LIST

7-1 Circuit Diagrams

7-2 Parts Lists

1
t

1
7-1
 RH3
SERVO DRIVER PARTS ARRANGEMENT PLANT
lOOfl 20W Cement resister
(SERVO BOARD EXCLUDED)
4 TD C7"

IK Neon lamp
D 0
BN-7-AC 200V Red (Sato Parts) O
Terminal
board
CE1
o
pi
o
CDCD
o i—§1 O f—tl
10 11 10 u o
10 A
O CD
z;
7 8 9 7 8 9
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EH

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CD
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(CO 'CM'
<DV3) > o
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O a OH CH
o Vsns
<1
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1
5
2
6
3
4
1
5
2
6
3
+
(SV2)
(
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CD
co
RCF
DR1 DR 2 o o
<
a CE2
CTR

oCD
PM1 10 A
PM 2
a
a
EH CD OO CD OQ CD 00 CD (Cffll)
CD
>
O (EUP) (£UN) (EVP) EVN:
o o (SV3)
o o o o PH
+ a*
H
G
(fur)
0.47 0.47 CD
rQ
(BUN)
5 W 51 K
(BVP) (BVN) CHH n\ Dn
=t 2 OW 5 Oil 3
JL n
Parts used
RCF : RM10TA-H
PM1 : QM20DX—H
ENB401D14A
3

11
EH 1 Upper
d£ Paste up an IFIOAI
sticker on the side *•
ZTU—R.B.UN IT 10W 0.1 il of the respective
PM 2 :QM20DX-H Arrange so that 5W51K will be .fuse holders.
DR1 : LY 3—DC 24V placed on the upper side.
DR 2 : LY 3 —DC 2 4V RI-12 Lower
Mounting dimensions are the same as
CE 1 : 220//F4 00V those of the MV2.
CE 2 : 2 20//F4 00V ]: Sealed printed letters
Outside dimensions are also about
CTR : P 4—0 0 4 3 2
CHH : P 4-00 4 33 the same as those of the MV2.
RH1 : 2 0W5012
RH2 : 1 0W0. 1 a O: Mark tube symbols -
Markings, which will be vertical
to this drawing, must be indicated so as to be
 GENERAL SERVO DRIVER CONNECTION DIAGRAM

CN1 ZTU-DRi V
CN3
H N CO rtf* Ifl ID CN2
ffl ffl C2 ffl CQ ffl
<1 (M W lf3 LTD CO O O
H N co vn o’ co co CO CO CO CO T-» LTD C— fr- N OJ
<ÿpa<ica<jpa<ieQPa<!pacq •< m <! ca
'
<! pa <! m <* ffl <i es
n
Cover soldered parts on the -e»
CN2 and CN3 cable side with 0)
g
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transparent tube. (><)CX)(X)(XX)(XX) (X) o ft! QJ
a rH e>
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T3
QJ
QJ
£ QJ 2 £ u pa a
S. to edJ•J .g ag —I -g Hg
3
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(X) CX) CX) CX) CX)

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P4-00432 |CTR|
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Enamel resistance
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(DV3) 00 NSKG415 wxjCN)lre
Op ENB401 D 14 A
§ Enamel resistance
(CH0)
i»eiOA
O
(TGA) DR1 x 3 pcs. RM 1 OTA—II Neon lamp 22 400V P 4-00433
0
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(JG|) Red x 2 pcs. 0 CHH|
re ropm
P
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I
1S1886
(1) denotes black .lines with 1,25mm.
(Beamex S, 1.25mm?
(50/0.18), Furukawa Electric.) ZTU-DRIV Board
&L {DRl) (DR1)
LY3(Omron)
DR1
Alarm fuse
A15 (Alarm
n
(2) Other unspecified lines are of 0.3mm . CNI Signals
OJ Signal Signal
3
—
I
pa
I
IS1886
w B16 contact) (3) (jxj)
denotes twisted wires. Pin
A1 -15V
Pin
R1 -15V
(+2j) (DR2) DR2 SV1 (Load side) A2 OV R2 OV
LY3(Omron) A3 + 1 5V 13 3 A 15V
A4 F.A! B4 P/V
R (Power side) A5 V CMD B5 VG.ND
A6 OV B6 0V
A7 Servo ON B7 Open'
A 8 Servo-alarm B8 A
 SURVO DRIVER CONTROL PLATE CIRCUIT DIAGRAM
(ZTU-DRIV)
Servo ON A 7 o-
-t- 15V CN2
B7 O- i 4016 1B4B1 X 5
R78+15V A3O-
zo DB2
+1 5V

Servo Alarm A8(>hrt?

B8 ---
I

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\V2
p 13

i
A495
Q1

+15V
R64W 24021
i! ::
R72 TD62104
10K
10K lBÿii
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l
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4.7 K
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4073

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10K
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Z1069L 22K
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56Kt-jD32
S. ON
R61 5.6 K

R60
( Survo ON)

£-0-
!
+15V
R95
10K 3.3 K
-15V «
ZDl 2.2 K
—cf—vft-*
24V P79
Zener
05Z24Y
+15
t CN2
02
A495
4 7K
R80
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A80-

B80-
1120
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C20iz 4700/U.'16V

7°.. D B 4 rD40 li 1866

>'-;o
7m-220011
V2

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5+12
i
6ÿ 11 O-H
4.7 K :
4011 Fuse break!
A
R39 16V
R66 22K f5 10 C27\ 'R
[-0"U| -w- IS 1886
v3
R69 3_v
rlrrtW IK >C46
( Overheat )

111 20
028* 2200/16V
( 9? a-*.) *i+15V TIT 7
4069 i!86 F-A(Fuse break)
CN1 3 Mÿÿ©R76
A T.|.

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jCN 3 H IK wrw
R67 Q i“ j.rtrR4 2
0. 01//F
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LED 2
in i o- n -1 7815
C3iar --
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+15V ,.048 i 151 R13 10K
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7
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R56
V4-

R91
R57j—
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*Non-designated OPAMP is
001ÿT-U00K 10k +15V
UPC451C
AS [-OT
R52 VR21Tjflk 3 R55 R2 -OT
(OFFSET) 4.7 K
i El 1158
30.O-...5W
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A4 O- OV RJ6T-1K +i 1)24 D23 1886 .3 8 5
B4
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SERVO DRIVER CONTROL PLATE MOUNTING FIXTURES
(ZTU-DRIV 3) -
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(3) (B15) means mark specification
(4) ZTU-DRIV PLATE
CN1 Signal Chart

Pin Pin Signal

No. Signal
No.
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A8 Survo Alarm B8 Spare
 SURVO DRIVER CONTROL PLATE CIRCUIT DIAGRAM
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20W
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i R5
4.7 K
2SD987
(NEC)
400V

5 W 5 IK
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8

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9
40 11 RIO
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47K
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15011 PCI
R 3 < 2 20 K rHi
R4 * R5 i
R7
k ' 1886 Alarm fuse

I 10K I 4.7K
100 K 1886 lA1 K .LED
o2
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(3-phase 200V, i*
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P-C.B.
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t M '/zf'L5
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/
- 6mm
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886 To transformer
Regeneration OFF in 4V R3
2 2 OK
AA/V C4 I R8 —+ 1 02
iA12- ->
AC8V RH8
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R2
} 1 O 40 1 1 I R13 RH6

C5
MAA
47 K 1K
L ED 1
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777
2SA495
5W5 IK
RI-15
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40 ID
1 4A
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R9
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100K
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2SD987
(NEC) B
C
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4.7 K QM 1 5HA—Ii
40 11 R10
R6 8 2.2 K N1
E
R13 5W51K -
A/VV >9

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C3
0.33///25V
2 2K N2-

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2SD987 o e
+V cc
r To CN 2
ZNRl C2
100///25V
R11
IK 1 4
4- 0A15' A 15
ERZ- R2 40 11 +1 rtti) N1 o
( 7 ivi ) 3
C 1 4 DK361rAA/V-j R10 R 9 R8 To CN2
47 K
ICl 2.2 K
N2 o [__TLP52_1-1 _] 0B1& B16
R3 220 K PCI
R4 t4.7K
R5 n n K. ' 1886 Alarm fuse
) 100K 1886 1K
LED 1
D2 Alarm contact

i 1 OK A 1 2* >ÿ

1 OK D3
LWVJ T LR 1 0 2 (3 phase 200V,
IK Rli
© ‘T input fuse )

<sr n
R1
R12 A 1 5»
AW) Fix with silicon
10 0///25V 2 2K 3.3// 2 5V
3 PCI P.C.B.
( 7iM ) LWVJ(Tan ta1 um)L 521-1 B 1 6 5W5 1 K \
Cl R6 (v/zrt
Tgr 4
(Note) IC power is all +Vcc Have a clearance 5 - 6mm
 r- h- ZNRl
Mazak YAMAZAXI MAZAK
VvV
MADE IN JAPAN_
-fc R13 5W5IK
Fix by screw Q2

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PARTS FIXING DRAW (1/3)

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7-18
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7-2 Parts list

A. ZTU Parts list (machine unit) for 400W driver unit MV-4

Nos Parts Name Specification Type/Remark Maker Req'rd

Q’ty
1 Metal plate for B2-05859 1
machine unit
2 Metal fixture B4-05860 1
for fuse
3 Side plate (1) B3-06074 1
4 Side plate (2) B3-06075 1
3 Product seal C4-02986 1
6 Transformer P4-00432 22Vk 1
7 Choke coil P4-00433 ImHIOA 1
8 Parts seal C4-03026 1 set
9 Print board ZTU-DRIV-3 Driver plate 1 set
10 Print board ZTU-R.B.UNIT Regeneration 1 set
control plate I
11
12 Tr module QM20DX-H Mitsubishi 2
13 Di module RM10TA-H Mitsubishi 1
14
15 Relay LY3-1013F LY3 DC 24V Tateishi 2
16 Relay socket PTF 11A Tateishi 2
17 Relay pin PYC-A1 Tateishi 4
18
19 Aluminum 220y 400V Lag terminal type Nichikon 2
electrolytic C
20 Diode IS 1880 Toshiba 2
21 Hollow 200 20W Tokyo Denon 1
resistance
22 Hollow 0.10 10W Tokyo Denon 1
resistance
23 Mica condenser O.lyF 50V Tokyo Denon 1
24 Alarm fuse PL4 10A 10A Daito 6
Tsushin
25 Fuse receiver PL4-1S (Braun) Daito 3
26 Tsushin
27 Terminal unit F-15 Mibu Denki 13
28 End plate F-15E Mibu Denki 2
29 Metal fixture FK-1 Mibu Denki 2
30 Channel base BLF-A Mibu Denki 150mm
31 Protection cover CF-15 Mibu Denki 110mm
32 Mark band NPF Mibu Denki 110mm
33
34 Z lap ENB401D-14A Fuji Denki 4
35 Condenser MMH0.47yF 0.47pF Nissei 2
36
37 Wire Beamex S(Black) 1.25mm2 (50/0.18) Furukawa 1.5m
Denko
38 Wire KiV1.25 (Yellow Fujikura 30cm
green) Densen
39 Locking support LCBS-6NS Kitagawa
Kogyo
4 1
40
7-19 )
 i
I I 1ÿ=

Req'rd
Nos. Parts Name Specification Type/Remark Maker Q 1 tv

41 Transparent tube Sumi tube 24> 0.6 m

42 ditto ditto 4<j) O 0.3 &
43 Heat resisting Beamex SO.3mm 1.5 m
wire (Braun)
44 ditto ditto (Red) 2.5 m
45 ditto ditto (Orange) 1.5 m
46 ditto ditto (Yellow) 1•5 m
47 ditto ditto (Green) 1.5 m
48 ditto ditto (Blue) 6.1 m
49 ditto ditto (Purple) 0.5 m
50 ditto ditto (Grey) 0.5 m
51 ditto ditto (Black) 1.5 m
52
53 Spark killer NSKG415 Nissei 1
54 Neon lamp BN-7-AC200V(Red) Sato Parts 1
55 Cement resister MH20A101K 100ft 20W Tokyo Denon 1
with fixing
metal

7-20
 i
I1
B. ZTU Parts list (print board) for DRIV-3

Nos. Parts Name Specification Type/Remark Maker Req'rd

Q'ty
1 Plate ZTU-DRIV-3 1
2
3 Type 360 connector FCN-364P016-AG Fujitsu 2
4 Type 360 connector FCN-361J016-AG Fujitsu 1
5 Type 360 connector FCN-364P032-AG Fujitsu 1
6 Type 360 connector FCN-361J032-AG Fujitsu 1
7
8
9 Metal fixture FCN-360A1 Fujitsu
6
10
11 IC M57903L Mitsubishi 4
12 IC for power source TA78015P +15V 1A Toshiba 2
13 IC for power source PPC7915H -15V 1A NEC 2
14 CMOS TC 4011 BP NEC 1
15 CMOS 4016 BP NEC 1
16 CMOS 4069 UBP NEC 1
17 CMOS 4073 BP Toshiba 2
18
19
20 Comparator PA311TC Fairchild 1
21 Operating amplifier yPC451 NEC 3
22
23
24 Radiator icl625-ST Ryosan 2
25
26 LED TLR102 Red 7
27 LED TLG102 Green 1
28
29
30 Volume PJ6T-1K Nihon Teikolci 1
31 Volume PJ6T-10K Nihon Teikoki 2
32
33
34
35 Transistor 2SA 495 Toshiba 2
36 Transistor alley TD62104P Toshiba 2
37
38
39 Diode staff 1B4B1 Toshiba 5
40

7-21
 i
ITIdÿdrC

Req'rd
Nos. Parts Name Specification Type/Remark Maker Q’ty

41 Diode IS 1886 Toshiba 14

42 Diode IS 1588 Toshiba 26
43 Zener diode 058 24Y 24V zener Toshiba 1
44
45
46 Photo coupler TLP521-1 Toshiba 1
47
48 Test pin WP-4 Yamaichi 5
49
50 Condenser 4700y/16V (A) Aluminum Rubicon 2
51 Condenser 2200y/16V (A) Aluminum Rubicon 2
52 Condenser 470y/50V (A) Aluminum Rubicon 4
53 Condenser 100y/25V (A) Aluminum Rubicon 4
54 Condenser 47y/35V (A) Aluminum Rubicon 5
55 Condenser 10y/25V (A) Aluminum Rubicon 2
56 Condenser 10y/25V (A) Tantalum 1
57 Condenser 4.7y/25V (A) Tantalum 1
58 Condenser O.Oly Ceramic 18
59
60 Condenser O.ly Plastic film 8
61 Condenser 0.033y Plastic film 1
62 Condenser O.Oly Plastic film 11
63 Condenser 1500P Plastic film 1
64 Condenser 1000P Plastic film 2
65
66 Resister 5W 30ft Cement Tokyo Denon 2
67 Resister 5W ion Cement Tokyo Denon 2
68
69 Resister 1/4W ioon 1
70 Resister 330D 1
71 Resis ter 560n 1
72 Resister 8200 1
73 Resister 1 K 7
74 Resis ter 2.2 K 2
75 Resister 3.3 K 3
76 Resister 3.9 K 1
77 Resister 4.7 R 6
78 Resister 5.6 K 2
79 Resister 6.8 K 1
80 Resister 10 K 31
81 Resister 15 R 1 <
82 Resister 22 R
Resister
14
83 33 R 3
84 Resister 47 K
Resister
4
85 56 K 1
86 Resister 100 K
Resister
3
87 150 K 1
88 Resister 220 K 2
89 Resister 680 R 2

7-22 to 7-2 i
 n
1
I I Ii=§4====§X
C. ZTU Parts list (machine unit) for 3 kW Driver MV-30

Nos. Parts Name Specification Type/Remark

Req'rd
Maker
Q'ty
1 Machine unit B2-06064-2 SPC 2.3t 1
2 Cover for machine B3-06065-2 SPC 1.2t 1
unit
3 Front cover B3-0653 3 SPC 1.2t 1
4
5 Transformer for P4-00432 1
power source
6
7 Choke transformer 2mH30A For MV20 Hotta Denki 1
8
9
10
11
12
13 EF type radiator H415 Mizutani 1
14
15 Product seal C4-02979 1
16 Parts seal C4-03010 1 set I
17
18
19
20
21 Print board ZTU-DRIV-3 1 set
22 Print board ZTU-R.B. UNIT 1 set
34
24
25 Tr module QM50DY-H Mitsubishi 2
26 Tr module QM15HA-H Mitsubishi 1
27 Di module RM15TA-H Mitsubishi 1
28
29 Relay AP6242 HG4-DC24V Matsushita 2
30
31
32 Terminal unit F-15 Mibu 6
33 End plate F-15E Mibu 2
34 Protection cover CF-15 Mibu 100mm
35 Terminal unit F-35 Mibu 8
36 End plate F-35E Mibu 2
37 Protection cover CF-35 Mibu 100mm
Mibu 2 •f
38 Metal fixture FK-1
39 Channel base BLF-A Mibu 200mm
40 Mark band NPF Mibu 200mm

1
7-24
 I
1 I h===L==§=ÿ,

Req ’rd
Nos. Parts Name Specification Type/Remark Maker
Q’ty

41 Alarm fuse PL4 type fuse Daito 6

15A Tsbushin
42 Alarm fuse socket PL4-1S (Braun) ditto 3
43
44 Neon lamp BN-7-AC200V(Red) Sato Parts 1
45
46 Diode IS 1886 Toshiba 2
47 Z lap ENB401D14A Fuji Denki 4
48 Spark killer NSKG415 Nissei 1
49
50 Aluminum electrolytic 220y 400V Lag terminal Nicbicon 4
condenser type
51 Mica condenser 0.47y 63V 4
52
53 GZG type resister 40W 150 Nihon Teikoki 2
54 Hollow resister 20W 200 Tokyo Denon 1
55 Hollow resister 10W 10 K0 Tokyo Denon 1
56 Hollow resister 10W 0.10 Tokyo Denon 3
57
58 Carbon resister 1/4W 1000 0
59 Carbon resister 1/4W 1 KO 1
60
61 Thermal relay THK20-6.6A Mitsubishi 1/1.lkW
1 unit
62 Thermal relay THK20-11A Mitsubishi 1/1 .8kW
1 unit
63 Thermal relay THK20-15A Mitsubishi 1/2.6kW
1 unit
64
65 Maintain lock 1-480319-0 AMP 1
connector
66 ditto 1-480318-0 AMP 1
67
68 Swivel bush KG-012 Kitagawa 1 piece
Kogyo
69 Locking support LCBS-6NS 10
70 ditto
71 Wire Beamex S(Black) 0.75 Furukawa 0.3m
Denko
72 Wire Beamex S(Black) 1.25 ditto 1.5m t
(50/0.18) l
73 Wire KiV (Yellow 1.25 Fujikura 0.3m
green) Densen
74 Cable clamp NK-5N Kitagawa 1
Kogyo
75 Cable clamp NK-6N ditto 1
76 Silicon glass tube 6 <J> Nissei 0.5m
77
78 No.110 tab terminal 170048-2 AMP 4
79 Sleeve for the above 170823-9 AMP 4
80

7-25
 n
n
=
ITioÿdK
D. ZTU-DRIV-3 Parts list (Print Board)

Nos. Parts Name Specification Type/Remark Maker

Req 1 rd
Q'ty
1 Plate ZTU-DRIV-3 1
2
3 Type 360 connector FCN-364P016-AG Plate Fujitsu 2
4 Type 360 connector FCN-361J016-AG Cable Fujitsu 1
5 Type 360 connector FCN-364P032-AG Plate Fujitsu 1
6 Type 360 connector FCN-361J032-AG Cable Fujitsu l
7
8
9 Metal fixture FCN-360A1 Fuj itsu 6
10
11 IC M57903L Mitsubishi 4
12 IC for power source TA78015P +15V 1A Toshiba 2
13 IC for power source PPC7915H -15V 1A NEC 2
14 CMOS TC 4011 BP NEC 1
15 CMOS 4016 BP NEC 1
16 CMOS 4069 UBP NEC 1
17 CMOS 4073 BP Toshiba 2
18
19
20 Comparator VA3UTC Fairchild 1
21 Operating amplifier PPC451 NEC 3
22
23
24 Radiator 1C 1625-ST Ryosan 2
25
26 LED TLR 102 Red 7
27 LED TLG 102 Green 1
28
29
30 Volume PJ6T IK Nihon Teikoki 1
31 Volume PJ6T-10K Nihon Teikok : 2
32
33
34
35 Transistor 2SA 495 Toshiba 2
36 Transistor ally TD62104P Toshiba 2
37
38
39 Diode staff 1B4B1 Toshiba 5
40

J
J
7-26 J
 =”=.== ===.=
§I

Nos. Req 'rd

Parts Name Specification Type/Remark Maker Q'ty
41 Diode LS 1886 Toshiba 14
42 Diode IS 1588 Toshiba 26
43 Zener diode 05824Y 24V Zener 1
44
45
46 Photo coupler TLP521—1 Toshiba 1
47
48 Test pin Type WP-4 Yamaichi 5
49
50 Condenser 4700p/16V (A) Aluminum Rubicon 2
51 Condenser 2200p/16V (A) Aluminum Rubicon 2
52 Condenser 470p/50V (A) Aluminum Rub icon 4
53 Condenser 100p/25V (A) Aluminum Rubicon 4
54 Condenser 47u/35V (A) Aluminum Rubicon 5
55 Condenser 10p/25V (A) Aluminum Rubicon 2
56 Condenser 10u/25V (A) Tantalum 1
57 Condenser 4.7p/25V (A) Tantalum 1
58 Condenser O.Oly Ceramic 18
59
60 Condenser 0.1M Plastic film 10
61 Condenser 0.033M Plastic film 1
62 Condenser 0.01M Plastic film 11
63 Condenser 1500P Plastic film 1
64 Condenser 1000P Plastic film 2
65
66
67 Resister 5W ion Cement Tokyo Denon 4
68
69 Resister 1/4W 100ft 1
70 Resister 330ft 1
71 Resister 560ft 1
72 Resister 820ft 1
73 Resister 1 Kft 7
74 Resister 2.2K 2
75 Resister 3.3K 3
76 Resister 3.9K 1
77 Resister 4.7K 6
78 Resis ter 5.6K 2
79 Resister 6.8K 1
80 Resister 10 K 31 V
81 Resister 1/4W 15K 1
82 Resister 22K 13
83 Resis ter 33K 4
84 Resister 47K 4
85 Resis ter 56K 1
86 Resister 100K 3
87 Resister 150K 2
88 Resister 220K 1
89 Resister 680K 2
1
7-27 to7-28
 r
-i-
I I l==ls=l==iV
E. ZTU Driver Parts List

Nos. Parts Name Specification Type/Remark Maker

Req'rd
Q'ty
1 Print board ZTU-R.B. UNIT I
2
3 C-MOS 1C TC4011 Toshiba I
4 Photo coupler TLP521-1 Toshiba L
5 Transistor 2SA495 Toshiba 1
6 Transister 2SD987 NEC 1
7
8 Z lap ERZ-C14DK361 Matshushita 1
9 Diode IS 1886 Toshiba 2
10 Diode IS 1588 Toshiba 1
11 LED TLR102A Toshiba 1
12 Aluminum electrolytic 100y/25V (A) 2
condenser
13 ditto 10p/25V (A) 1
14 Gold oxide plated 5W 5OK 1
resister
15 Resister 1/2W 150 Radial 1
resister
16 Resister 1/4W 1 K ditto 2
17 Resister 2.2K ditto 2
18 Resister 4.7K ditto 1
19 Resister 10 K ditto 2
20 Resister 22 K ditto 1
21 Resister 47K Radial 1
resister
22 Resister 100K ditto 1
23 Resister 220K ditto 1
24
25 Condenser 0.33p 25V Tantalum 1

7-29E J
s’
.*

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tf
i
i

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»

i
Mazak
YAMAZAKI MAZAK CORPORATION LOS ANGELES NORTH SALES& TECHNICAL CENTER
I Norifune, Oguchi-cho, Niwa-gun, 20933 Plummer street,
Aichi-pref., Japan chatsworth, CA 91311
Phone: Oguchl (0587)95-1 1 31 Phone: 81 8-998-0926
TPIPV I5Q777 Facsimile: 81 8-998- 1 1 96
Cable: "MAZAK" NAGOYA JAPAN
Facsimile: 0587-95-2717 PHOENIX SALES & TECHNICAL CENTER
3928 East Alriane.
MAZAK SALES& SERVICE,INC. Phoenix, AZ 85034
8025 Production Drive, Florence, Phone 602-244-2494
Kentucky 41042 U.S.A. Facsimile: 602-231-0120
Phone: 606-727-5700,
Telex: 214674 SEATTLE SALES & TECHNICAL CENTER
Facsimile 606-727-5865/5833 7857 South 1 80th Street,
Bldg. #1 , Kent, WA 98032
CHICAGO REGIONAL TECHNICAL CENTER Phone: 206-251-6015
600 North, Wheeling Road Facsimile: 206-251 -901 4
Ml, Prospect, Illinois 60056
Phone: 312-298-9797 YAMAZAKI MAQUINAS HERRAMIENTAS,
Facsimile: 312-699-2373 S.A. DE C.V.
HARTFORD REGIONAL TECHNICAL CENTER Aguascalientes #1 79
Colonia Hipodromo Condesa,
10 Bidwell Road Mexico, D.F MEXICO
South Windsor, Conneclicul 06074 Phone: 5-74-98-10
Phone: 203-528-951 1 Facsimile 5-74-98-10
Facsimile 203-528-2995
NEW JERSEY SALES & TECHNICAL CENTER YAMAZAKI MACHINERY EUROPE N.V.
355 Eisenhower Parkway, Grauwmeer Research Park
7,
Suile C Livingston, NJ 07039 3030 Leuven,
Phone: 201-535-4380 BELGIUM
Facsimile: 201-535-4383 Phone: 16-28-1611
Telex: 62552 MAZAK B
NEW YORK SALES & TECHNICAL CENTER Facsimile: 32-16-22-4587
Tech 1 1 0 center, 1 1 0 Bi-Country Boulevard, YAMAZAKI MACHINERY DEUTSCHLAND GMBH
Suile 1 07 Farmingdale, Esslinger Strasse 4,
New York 1 1 735 7320 Goppingen, Deutschland
Phone: 51 6-420-5980 Phone: 7161-68057/8
Facsimile: 51 6-420-5984 Telex: 727653
ATLANTA REGIONAL TECHNICAL CENTER Facsimile: 7161-73613
1 964 Providence Court YAMAZAKI MACHINERY DEUTSCHLAND GMBH
College Park, Georgia 30337
Phone: 404-996-1030 FRANKFURT SALES & TECHNICAL CENTER
Facsimile: 404-996-3533 Norden Strasse 46
6082 Morfelden-Walldorf
ORLANDO SALES & TECHNICAL CENTER Deutschland
Bay Colony Technology Center Phone: 61057-1025
4501 Vineland Road, Suite 1 1 1 Telex. 4185773
Orland, Florida 32811 Facsimile 610-571272
Phone: 305-843-4224
Facsimile: 305-425-5291 YAMAZAKI MACHINERY DEUTSCHLAND GMBH
MAZAK SALES & SERVICE WEST DUSSELDORF SALES & TECHNICAL. CENTER
Siemensring 89, D-4156 Willich 1
1333 West 190th Street Gewerbegebiet Muenchheide
Gardena. California CA 90248 Deutchland
Phone: 213-327-7172 Phone: 2-154-427041 -3
Facsimile: 213-538-4087 Facsimile: 2154-4308
SAN FRANCISCO SALES & TECHNICAL CENTER YAMAZAKI MACHINERY U.K. LTD.
1 497 North,Milpitas Boulevard. Milpitas, BADGEWORTH DRIVE
California 95035 WORCESTER WR4 9NF
Phone: 408-946-4991 UNITED KINGDUM
Facsimile: 408-946-7381 Phone: 0905-57272
HOUSTON REGIONAL TECHNICAL CENTER Telex: 51 338889
Facsimile 44905-57644
770 North Belt East.
Houston, Texas 77060 MAZAK SERVICE FRANCE <
Phone: 713-931-7770 B.P 451 2/5, rue des chasseurs ZJ de
Facsimile: 713-931-6191 Ville la Grand 74108
DALLS SALES & TECHNICAL CENTER ANNEMASSE CEDEX
Phone 50-37-45-58
2030 North Highway 360,
Grand Prairie, Texas 75050 Facsimile 50-3773-62
Phone: 214-647-0655
Facsimile: 21 4-641 -2968

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Printed in Japan