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MAINTENANCE MANUAL
FOR
Mazatrol
M-32
Start-Up Procedure

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MAINTENANCE MANUAL
for

BMlffillOIL
START-UP PROCEDURE

PUBLICATION NO. :H731MA0010E

Serial No.:

[PRECAUTIONS]
(Tr" Before operating this machine, please read this manual with care and fully understand
the contents of the manual so that the machine can exert its performance safely.
Although the contents of this manual are closely checked for perfection, if there is any
ambivalent point, incorrect description, or omission, contact us, please.
fp'?3In order to explain the details, all the illustrations contained in this manual do not
necessarily show the covers, doors, safety guards, or shields. Therefore, be sure to
restore all the specified covers, shields, etc., and observe the contents of the manual
when operating this machine. If this precaution is ignored, a serious accident may incur,
resulting in damage to the important units of the machine and other accessories.
fTrThis manual is subject to modifications and changes as required for the improvement
in, and the change in the specification of, the machine and the CNC equipment, as
well as for usability of the manual itself. The modifications and changes are indicated
by updating the manual numbers in a revised version.
(T'rWhen your manual is damaged or lost, and a new material is needed, inform us of
the "manual number."
If the manual number is not identified, inform us of the following:
1. Name of the machine 2. Number of the machine 3. Name of the manual

2? Contact the Technical Center (TC) or the Service Center (SC) of Yamazaki Mazak for
operations of this machine and replacement of the manual.

Issue of the manual: Manual Publication Team of Engineering Generalization Section,

Yamazaki Mazak Co., Ltd.
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PREFACE
I We have developed 32-bit microprocessor based tion necessary to start up the M-32" when it is install
MAZATROL M-32 and will soon start delivery to mar ed in the client shop and the information related to the
kets. This manual was compiled for an aid to the field peripherals of the M-32.
service engineers. The manual covers only the informa

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CONTENTS
Page
1. OUTLINE 1
2. SYSTEM STARTING UP PROCEDURE 1
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3. M-32 CONTROLLER CARDS 6
4. FLOPPY DISKS 7
5. MEMORY CAPACITY 8E

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H731MA0010E
04. 1991. 5001
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 Mazak
1. OUTLINE 1-2 Battery
Before you start up the M-32, the points differing from Because the M-32 uses RAM area to store the system
the conventional M-2 should be well understood. software, parameters, macro programs, and programs,
the following three types of batteries are used for the
1-1 System Software back-up battery.
Conventionally, M-2 had a resident system software in 1) On-board battery (Ni-Cd battery)
the ROM. For S-RAM on memory card
a Back-up time: More than two months

The new M-32 comes with the system software in the
3.5" floppy disk (system disk). The system software is 2) Battery pack (Ni-Cd battery)
unloaded from the system disk to the D-RAM when 9 For S-RAM on CPU card
power is turned on. Therefore, the M-32 has the floppy Back-up time: More than two months
disk drive (FDD) as the standard device. 3) Lead battery
!
The FDD is also used to facilitate reading and writing o For D-RAM storing system software (on MC-442
of parameters, macro programs, and option setting card)
data. a Back-up time: Three days
Note: The FDD cannot be used for read/write opera Battery charging time:
tions for the user programs and PLC ladder. For Ni-Cd battery ..150 hours
this purpose, micro disk, cassette deck, and/or Lead battery ... 24 hours
taper reader/punch must be used in the same
manner as they are used with M-2.
I

2. SYSTEM STARTING UP PROCEDURE

M-32 M-32 (1) Confirmation or installation of Ni-Cd battery

Initial start-up For domestic
After when system down
Confirmation of NC card setting pins
installation
Confirmation or installation of Ni-Cd battery
Batteries: For memory card, a battery is installed on
1 x MC442, MC471, and MC472.
Confirmation of NC card setting pins
2 Connection of connectors for lead battery (1) For system software, a battery is installed in the battery
Turning off the circuit breaker for hydraulic box.
3 motor, etc. or press the emergency stop (2) The M-32 is shipped with batteries set on each card
button because the life of batteries is longer than two months.
I
4 Turning on main power supply (3) Battery replacement procedure:
5 Turning on power supply to NC (4) 1) Turn off the power to the NC.
Confirming phase sequence of power
I 9
supply. (5) 2) Remove the card or battery box for which the bat
Turning off NC power supply and turning
tery is to be replaced.
IQ (6) 3) Replace the battery after removing the battery
breaker back ON.
Turning on NC power supply again and mounting screws.
11 (7)
release the emergency stop button Note: Although the memory cards and the CPU card
6 Clearing RAM (initial clearj x has the capacitor for memory back-up, replace
7 Reading parameter disk. x the battery in a short period (within 30 minutes)
8 Reading system disk. (8) to protect the information in memory.
12 Deleting all programs. x
13 Deleting all macro programs x
Reading option parameters and macro
14 x
programs.
15 Completion (9)

Setting pin confirmation:

Confirm the pin setting when the NC is shipped with batteries removed of after the replacement of a card.
MC442

{
V77?L
SPRT
Setting pin Standard setting
r tE3
SMAP S5VB Bus battery power supply OFF
SBAT On-board battery power supply ON
EQ MC442 card
i 22 SSC Super capacitor ON
SDBA V77),

S5VB SMBA
EZasBAT CH.
E2 OOOOO CNP41
_SSC 12345
ThT
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MC472(471)

{
QU SPC
JI ] Sig[ J2 ] 5VB
BAT Setting pin Standard setting I
BERR 5VB Bus battery power supply OFF
BTAL
& BAT On-board battery power supply ON
a
MC472 card SSC Super capacitor ON
ra
to

CH.1 t

LED 1 2 3 o

(2) Connection of connectors for lead battery

Connect the connector (CNM-41) of the battery (PE20-6R) to the CNP41 connector on the NC card MC442. t

12 3 4 10

D n t

fl a CM S> *
AVR
Battery (

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3
5 5
PD21
PE20-6R

+ 24
RG
P-OFF'i 1 BAT
P-ON
PM-71
2 GND
COM 3 MEM
ACOUTI 4 GND Charger I
ACOUTI 5 NC
ACG
o AC1N
CNP11-PM .x 6
7
FG
AC-H
AC1N LLi '8 AC-N
XT
Control unit
CNM41

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(card side)
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Note:

t 5 Insert the connector correctly.

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(connector side) Connector plug-ln location
S'" MC442 card
e
Viewed from the top (

(3) Turning off the circuit breaker for hy-draulic (4) Turning on main power supply.
motor, etc. , Turn on the main circuit breaker of the machine. >
(
To check the phase sequence of the primary power (5) Turning on power supply to NC. )
supply, it is necessary to turn off the power to NC. Press the proper pushbutton switch on the NC opera [
Turning off the circuit breaker for 3-phase 200 VAC line tion panel.
(
is rifecessary to prevent the motors from starting even
I
if the NC power is turned on. (

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(6) Confirming phase sequence of power, supply.
Confirm the power supply phase sequence with the
indicator on the spindle controller FR-SF.
ADDRESS
IVIazak
The FR-SF does not have the special phase sequence
indicating LEDs which were provided on the conven
tional controller FR-SE and previous models.
DAT/

a*
/_/ /_/ /_/ IJ /_/ /_/ m
/_/. /_/. /_/ L/. /_/ /_/. L J [ 1
LED4 LED5 LED6 LED7 LED8 LED9 f
ff \89 8'SS8\ L
12 3 4 - J
o o o o - - JLS
ON \ BBSBQ3
o o o o OFF
'k,i II <= <=>
SW1 SW2 SW3 SW4 sws b IQ cm an
MODE UP DOWN SET l f

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je> 9P
Indicator: LED4 LED9 -
Setting switches: SW1 SW4. Pushbutton switches - mu
I SW5 .Selector switch
Ail of these switches should usually be in the OFF setting.

i Confirmation Procedure /
1) Turn on power supply to the machine /
_ccI
2) Press the SW1 i u ui /
IJ 1 1 1 1 n in
3) Press the SW2 or SW3 and display address 4U.
Check the phase sequence with the indication of LED7. '
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Iu u U
ui u
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I u or

uU i u
Address 4 U Confirmation Note
is displayed
Normal n i D
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Reverse
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= DB1= r
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<= -1
[ = I ,
c=3 aa <~~>.f|iiiniiniihni j
aaa

ragpljl Note: In case of spindle rotation

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FR-SF total view

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(7) Turning off NC power supply and turning )ld} Reading parameter disk.
breaker back ON. Procedure:
Turn ON the circuit breaker, which.has been turned off 1) Insert the parameter & macro disk (BND212W800)
in step 3 above, again. into the floppy disk drive. (With the labeled side fac
(8) Turning on NC power supply again. ing the right side)
(9) Clearing RAM (initial clear). 2) Flip down the system reset toggle switch on the I
Procedure M.C111 card.
1) Remove the system disk from the floppy disk drive Or turn on the power to the NC. . &
Or confirm that the floppy disk drive has no disk in 3) Parameter data reading begins with the floppy disk i
it. drive access lamp illuminating, At the completion of
2) Change the setting of the ' DIP switches on the' reading, the lamp goes off. ,
MC111 and MC121 cards to the RAM clear setting. Note: Parameter data can be read within a very short
See the DIP switch setting table below. time.
:f3) Flip down the system reset toggle switch on the 4) The CRT displays the following message after the ;

' MC111 card.

Or turn on the power to the NC.
completion of reading.
FLD LOADING END or FLD LOADING COM
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Note: Operate only one toggle switch. PLETED
4) Memory clear will be finished in several seconds. At (11) Reading system disk
the completion of memory clear, the green LED on Start up the system by uploading the system software
the MC111 card lights up. from the floppy disk to the MC442 card RAM. \
5) Return the DIP switch setting to the original setting. Procedure:
1) Insert the system disk (BND212W001) into the
DIP Switch Setting Table floppy disk drive. (With the labeled side facing the i.
hr.tai nc iU right side)
\
MC111 MC121 2) Flip down the system reset toggle switch on the
Hc|q MC111 card.
Or turn on the power supply to the NC.
S 1
2 5 1
2
3
The system software is uploaded with the operation
Normal
Setting
O
O
6
3
4 5
4 step 2) above.
v
o_
O
5
6 & 6
7
At the completion of uploading, approximately 15
seconds after the start of loading, the CRT displays
_o_ 8 O 8
OFF ON
the position screen.
OFF ON
During the system loading process, other operations
7T ik are disabled. i

aax
2 -8O l3 Note: If setup is unsuccessful, that is, if the MC442s
FQT RAM Q red LED DB, fourth from the top, is lit, then this
clear 5 o_ 5
o 6 O.
o_ 7
6
K
indicates that the S-RAM backup battery has
run down and that the parameter/system mac
B o_ 8
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OFF ON OFF OF roprogram has disappeared: in that case, there
fore, procedural steps 9 through 15 must be
carried out once again.
(12) Deleting all programs.
LED (green) MC111 MC121 Procedure:
1) Select the PROGRAM FILE display. (See the
operating manual)
I
'CJ 2) Press theIALL ERASE I menu key.
V
3) Key in as indicated below following the message.
o |0
DIP switch
I BBSBS
4) The indication for the number of used blocks
Of
Y
V becomes zer 'and the program deletion operation '
i
ends.
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System reset toggle switch V

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(13) Deleting all macro programs. (14) Loading the parameter/macroprogram floppy
Procedure: \ disk or the option floppy disk.
1) Change the option parameter to select the MACRO 1) Insert the parameter/macroprogram (BND212W800)
PROGRAM display. floppy disk or th8 option floppy disk into the drive.
a) Select the PARAMETER display. Note: The option floppy disk is prestored with the
EEROM of MC111 before shipment from the
CRT
j factory. Therefore, reloading of this disk is not
CUTTING USER MACHINE PREVIOUS NEXT
COND PAGE PAGE required unless an MC111 malfunction occurs
2) Flip down the system reset toggle switch on the
i=DCzi[=)[?pc=]c=][=][=Dan

a
b) After pressing the menu key,indicated above, key
MC111 card. Or turn on the power supply to the
NC.
After the completion of stdp 2) above, the data is
automatically loaded.
. in as follows, and the option,parameters will be dis- When the loading completes, the following mes
. played.
sages are displayed.
. 0000 Option disk Option-FLD Loading Completed
Macro disk FLD Loading Completed
c) Set 1 for option parameter number 0108. 3) Remove the option disk or the macro disk from the
d) Turn on the power to the NC again. floppy disk drive and insert the system disk f'
2) Select the PROGRAM FILE display. (BND212W001) instead.'
The micro program list are displayed. 4) Return the setting for parameter 0108 to 0 in the
3) Press the I ALL ERASE I menu key., same procedure as in 1) of 13.
4) Key-in as follows according to the instruction as 5) ptart up the system by resetting the system or turn
I - ;:*' given by messages. The program deletion operation
ends with the indication for the number of blocks
' on the power again.
(15) After completion
used data becoming 1. Although the above steps complete the system setup
procedure, it is required that following the setup proce
a 0000
is i
dure, the Mazak microdisk unit be connected To the
system first and then the parameter/macroprogram .
Note: One block is used for MDI area.
floppy disk be inserted into the drive to load the
parameter, test, or other programs.
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3. M-32 CONTROLLER CARDS

3.5 inch floppy disk drive

MC712 : I/O control processor

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Access
LED DIP switches CNP41 e
lamp

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1
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1
P SI
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Togg e
switches

1 2 3 4 7 8 9 10 T
6 M-32 Card in rack
ty-
- AVR : Power supply
.10 MC301B : Manual pulse handle interface, contact
point I/O interface
9 MC303B : Contact point I/O interface, Analog I/O
interface
: Slot for expansion interface
6 MC611 : Servo mechanism and spindle control
interface
5 MC724 : CRT controller t
4 MC471 : Large capacity memory (option)
MC4.72 or MC474 depending on capacity
3 MC442 : Main memory (control program, param
eter, macro)
(Standard, expansion 2 types)
2 MC121 : Additional processor (MAZATROL)
1 MC111 : Main processor (EIA)
1 MC413#1 : System control program, ROM pack i
(MC415: EIA option)
MC411/3#2 : Machine control program (sequence
fT ladder) ROM pack
BATT : Battery box for RAM back-up for 1

MC111 and MC121

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4. FLOPPY DISKS
The M-32 uses 3.5", 2HD floppy disks.
Note: The CMT uses 3.5", 2DD floppy disks.
The M-32 comes with software floppy disks.
Standard: Two floppy disks
Option: Three floppy disks
System disk: Control software for NC
(BND212W001)
Parameter, macro disk: Parameters and macros
(BND212W800)
Option disk: Disk for setting NC options
In addition to the floppy disks mentioned above, one
for the CMT (Mazak Microdisk) is also furnished along
with the system. This floppy disk contains parameters,
test programs, tool files, and tool data.
The floppy disk drive in the NC unit is only for mainte
nance purpose and, therefore, it cannot be used for
loading part programs, tool data, etc.
(1) Rewriting parameter/macro disk
Information saved on the parameter/macro disk can be
rewritten from the MAINTENANCE screen. After
changing the NC parameters, it is necessary to rewrite
the disk following the procedure below. The disk must
always be updated to save the latest data.
1) Display the MAINTENANCE screen.
a) Press the MNT key to display the MAINTENANCE
screen.
IVERSION| PLC | SERVO |SPINDLE| PLC-i'F | LADDER |
The menu changes as indicated above.
b) Press the emergency stop button to place the con
trol in the emergency stop state.
i.
c) Press the menu key IVERSIONI .
CRT
i The following message is displayed.
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d) Press the m menu key then key in Pi] fY] pTi Pi] |%1
This causes the floppy disk utility menu (show
below) to be displayed, and display selection is
complete.
' | READ P | WRITE P | CMP P | READ M |WRITE M | CMP M |
I The menu changes as indicated above. This completes
the screen selection.
2) Save the NC parameter data to the floppy disk.
i a) Insert the parameter disk into the floppy disk drive.
b) Press the menu keylWRiTE p|.
The CRT displays the message Now writing, wait
and the saving starts.
After the completion of saving, the message disap
pears.
;i3) After the completion of the saving, verify the saved
data against the memory data.
a) Press the menu key ICMP PI.
The CRT displays the message Now comparing,
wait and the verify operation starts.
When the saved data has no wrong data, message
Compare ok is displayed.
4) The steps above complete the rewriting operation.
Mazak
(2) Other menu keys used for maintenance oper
ation for parameter/macro disk.
| READ P | WRITE P | CMP P | READ M | WRITE M | CMP V | IFORMAT I |
READ: To upload the data from the floppy disk to the
NC memory.
(READ P Ifor parameter data
I READ Ml for macros J!
After inserting a floppy disk, press the required menu
key. Message Now reading, wait appears when the
uploading begins. As soon as the uploading completes,
the message disappears.
WRITE: To save the memory data onto a floppy disk.
The required procedure is the same as in the reading
operation.
Message displayed: Now writing, wait
CMP: To verify the data saved on the floppy disk
against the memory data.
The verify operation is required after uploading or sav
ing the data.
The required procedure is the same as in the reading
operation.
Message displayed: Now comparing, wait
When there is no data mismatch found in the verify
operation, message Compare ok is displayed.
FORMAT: To format a floppy disk to be used on the
M-32.
Floppy disk formatting operation is necessary when
using a new disk.
Procedure:
a) Set a floppy disk to be formatted in the FDD.
b) Press the IFORMATI menu key.
Press INPUT key after typing (-999) ( )
c) Key in as follows as indicated by the message.
E
The following message appears and formatting
begins.
Now formatting, wait
The massage disappears when the formatting is
|FORMAT | completed.
Note: If the [j key is pressed after pressing any data
other than 9999, the formatting is not carried
out.
d) Save the data to the floppy disk as needed.
macirs,
5. MEMORY CAPACITY
The M-32 has the following five different memory
capacities; memory capacity is determined by the card
set in the rack.
rz
Program storage
Card capacity
A type Standard MC442 Standard type MAZATROL EIA/ISO
600 blocks 76 m
B type Option MC442 Expansion type MAZATROL EIA/ISO I
1,916 blocks 243 m
C type Option B type + MC471 MAZATROL EIA/ISO
5,330 blocks 676 m
i
D type Option Btype + MC472 MAZATROL EIA/ISO
15,570 blocks 1,977 m
E type Option Btype + MAZATROL EIA/ISO
(MC472 + MC474) 25.8 10 blocks 3,277 m

The MC474 card is installed above the MC472 card.

A type: 32 programs
128 sets of tool offset data
160 tools
B (C, D, E) type: 256 programs
512 sets of tool offset data
Tools selectable from 160, 480 and i
960
If a tool number 480 or 960 is selected, the memory
area for storing programs is reduced accordingly.