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Electrical Manual
MB With Sigma5 Motors, UL wiring, and
A1000 Spindle Drive, 8200b Control
Rev.28
6-23-2015
Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
ii
Rev.28
Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
Table of Contents
Transformer Connection Alert ....................................................................................................................... v
Electrical Safety Rules ................................................................................................................................. vi
Machine Schematic....................................................................................................................................... 1
8200b Control Front Panel Connections ................................................................................................. 15
Electrical Panel Layout................................................................................................................................ 16
Electrical Parts List .................................................................................................................................. 17
Yaskawa A1000 Spindle Drive Parameters ................................................................................................ 18
Yaskawa Axis Drive Parameters................................................................................................................. 19
Sigma 5 Axis Drive Parameters For MB/VKM Series ............................................................................. 19
MB/VKM Series CNC I/O Listing................................................................................................................. 20
8200b Series Front Panel ........................................................................................................................... 21
Front view ................................................................................................................................................ 21
Rear view................................................................................................................................................. 21
8200b Panel Assembly Parts List ............................................................................................................... 22
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Rev.28
Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
History
4-21-99
6-3-99
7-12-99 Rev 2
7-29-99 Rev 3
1-28-00 Rev 4
4-21-00 Rev 5
5-16-00 Rev 6
8-01-00 Rev 7
1-19-01 Rev 8
3-5-01 Rev9
8-01-01 Rev10
10-7-02 Rev11
4-14-03 Rev12
5-21-04 Rev13
1-18-05 Rev14
8-4-05 Rev15
5-3-06 Rev15.1
4-5-07 Rev16
1-23-08 Rev17
4-4-08
7-28-08 Rev18
10-23-08 rev19
10-30-08rev19
11-10-08rev19
11-14-08rev19
04-21-09 rev20
12-2-10 rev21
7-3-12 rev22
6-26-13 rev 23
7-31-13 rev 24
9-17-13 rev 25
1-13-14 rev 26
9-23-14 rev 27
5-23-15 rev 28
Original version
Change to Rev A electrical schematic (reactors added).
Add LCD front panel drawing
Update panel layout drawing, reactors added
Update to SBC card cage and Rev B electrical schematics, add electrical safety caution
Changed Electrical and panel drawings to reflect modernized mag panel
Added rev A schematics to include 20 pocket ATC option. Axis parameters include
MB18/19 models
Added rev B schematic (only page 2 changed) to show dual output transformer replacing
the separate worklight transformer.
Added rev C schematic (removed RH specifics), removed pick and place ATC.
Updated axis parameter listings
Convert to Sigma 2. Electrical prints, panel layout, axis parameters
Convert to Centurion 7 control and include VKM
Added front panel connection diagrams
Updated schematics. 24V EOC light, added KD relay.
Update schematics, axis drive parameters, power connection alert
Change from G5 to F7 spindle drives July-August 2005
File corrections, revision E schematics.
Update to sourcing Centurion 7 Interface. Schematics, I/O listings, parts list.
Update electrical prints to Rev A. 110 VAC K1 & K2, notes for UL compliance.
Update logo
Update electrical prints to B. Replace Fuses with Circuit Breakers.
Couple small wire changes to schematic. Update parts list. replace FP pics and
connections drawings.
update FP connections and assembly.
Change CB25AC to 8 amps.
Change Main Fuse 50amps to a Circuit Breaker
changed the manual rev, schematics have the new 3 color Cycle Light. Some other
schematic changes. Updated parts list.
Added front panel cabinet fan to 8200 connection diagram. Misc schematic updates.
Updated to include Sigma5 axis drives and current motherboards, 11-12 updated I/O
listings.
Updated mag panel, and schematics (to RevE) to represent Sigma5 axis motors.
Update schematics to rev F per UL requirements (ADDED CBS-ABC) for F7 drive.
Update schematics and panel parts to include Yaskawa A1000 spindle drive.
Update front panel connections, schematic, etc to represent 8200 revB control, 8200b. 120-14, updated pages 6 & 11 of schematic.
Updated schematics and panel parts per September 2014 specifications.
Updated schematics and panel parts for RL-177 safety relay, MA-495 cycle light.
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Rev.28
Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
Transformer Connection Alert
CAUTION: MACHINE WILL BE DAMAGED IF MAIN POWER PHASE-TO-PHASE
VOLTAGE EXCEEDS 240 VAC OR IF POWER IS CONNECTED INCORRECTLY.
If a transformer is used at the machine or in the building, the ground wire going into the machine must be
connected to a neutral point within the secondary windings of the transformer and to earth ground as
shown below. This is to insure stable phase voltage. A transformer case ground is not adequate.
Computer controlled machines require properly grounded and stable power in order to operate correctly.
To determine if the secondary windings within the transformer are properly grounded:
Disconnect transformer from power supply and machine.
Check resistance between transformer ground wire and each secondary leg.
If resistance is more than 3 ohms, then the transformer ground wire is not connected
to a neutral point within the secondary windings.
In no case may conduit or wire raceways be used as ground.
Use nonconductive conduit or drop cord to route power into machine.
Do not attach conductive conduit to electrical panel. This is to prevent a ground loop
condition that can cause erratic control operation.
The ground wire must be attached to the ground terminal bar inside the
machine electrical panel. The ground bar is labeled ‘PE’.
Measure the voltage from each phase to ground. The ‘wild’ phase needs to be
attached to L2 on the machine main disconnect switch.
Phase-to-phase voltage must not exceed 240 VAC as machine damage will result.
If voltage exceeds 240 VAC, it must be reduced before connecting to machine.
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Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
Electrical Safety Rules
Read and understand the following list of cautions before attempting to perform service on this
equipment. Failure to observe these rules can result in death or serious injury.
Caution
•
Beware of High Voltage present within the machine’s electrical cabinet
•
Do not attempt to service electrical components unless you are qualified to work on them
safely
•
Only qualified personnel should attempt to make current and voltage readings
•
Always turn the main power off before servicing components within the electrical cabinet
•
Always keep hands and fingers away from live electrical terminals
•
Remove jewelry while servicing the machine to avoid shorting any electrical circuits
•
Allow all components to discharge before servicing them, wait at least 15 seconds after
powering off, before servicing
FAILURE TO FOLLOW THESE RULES CAN RESULT IN SERIOUS INJURY OR DEATH
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Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
Machine Schematic
1
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Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
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Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
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Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
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Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
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Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
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Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
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Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
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Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
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Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
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Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
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Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
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Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
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MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
This page intentionally unused.
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Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
8200b Control Front Panel Connections
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Rev.28
Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
Electrical Panel Layout
Actual machine may vary
7-15
32
23
17
33
26
19-20
25
36
29
16
1,3,4
18
27
17
2
6
34
22
24
35
7-15
29
21
29
28
30
5 – Diodes installed across DC relay coils
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Rev.28
Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
Electrical Parts List
1
2
3
4
5
6
7 - 15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
7538
CB00076
CO00288
CO00289
DI00020
CB00182
CB00116
CB00129
CB00118
CB00166
CB00175
CB00116
CB00139
CB00150
CB00183
CB00117
CB00156
CB00153
C7.5 (SBC) DELUXE INTERFACE ASSY
CABLE – YASKAWA DRIVE TO CONTROL
5mm LEFT ORIENTED EUROSTYLE 27.5mm RIGHT ORIENTED EUROSTYLE
DIODE-1N4007
60AMP MAIN CIRCUIT BREAKER
SINGLE POLE 1AMP CIRCUIT BREAKER
THREE POLE 1AMP CIRCUIT BREAKER
SINGLE POLE 3AMP CIRCUIT BREAKER
SINGLE POLE 4AMP CIRCUIT BREAKER
SINGLE POLE 6AMP CIRCUIT BREAKER
SINGLE POLE 1AMP CIRCUIT BREAKER
TWO POLE 5AMP CIRCUIT BREAKER
TWO POLE 8AMP CIRCUIT BREAKER
SINGLE POLE 1AMP DC CIRCUIT BREAKER
SINGLE POLE 2AMP CIRCUIT BREAKER
THREE POLE 30AMP CIRCUIT BREAKER
THREE POLE 10AMP CIRCUIT BREAKER
SEE SCHEMATIC PAGE 2
CB00157 THREE POLE 40AMP CIRCUIT BREAKER
PR00038
BREAK OUT BOARD W/O LED
PS00076
POWER SUPPLY-5.0A/24V
PS00077
POWER SUPPLY-2.5A/5V
RL00074
RELAY- 24 V coil
RL00075
BASE
RL00173
CONTACTOR-52AMP AF 52-30
RL00102 * CONTACTOR-STANDARD SINGLE MOTOR
RL00177
RELAY-SAFETY
RL00156 * OVERLOAD-1.3AMP
RL00130
RELAY, 24V SINGLE
RL00164
RELAY, SOLID STATE
SW00199
DISCONNECT-63 AMP
TB00024
TERMINAL BLOCK 9080 M4/6G SQUARE D
TB00030
TERMINAL BLOCK-4POS 160857
TB00043
BLOCK-3 POLE POWER DISTRIBUTION
TB00044
TERMINAL BLOCK-WAGO 280-633
TR00075
TRANSFORMER .5 KVA 50/60 HZ
PS00117
A1000 SPINDLE DRIVE, 7.5 KW
AM00090
1 KW SIGMA5 AXIS DRIVE
RE00106
RESISTOR, 50 OHM 225 WATT
9547-1
RESISTOR, 15 OHM WITH BRACKETS ASSY
1 EA
3 EA
1 EA
1 EA
2 EA
1 EA
1 EA
1 EA
1 EA
1 EA
1 EA
1 EA
1 EA
1 EA
1 EA
1 EA
1 EA
1 EA
3 EA
1 EA
4 EA
2 EA
1 EA
1 EA
1 EA
2 EA
3 EA
1 EA
1 EA
3 EA
1 EA
1 EA
21 EA
40 EA
6 EA
21 EA
1 EA
1 EA
3 EA
1 EA
1 EA
SOURCING
ONE PER AXIS
5 VDC POWER
24 VDC POWER
ACROSS DC COILS
MAIN CB1 ABC
CB 5
CB 16AC
CB 14, 24
CB 30
CB 12
CB 10F
CB 11AC
CB 25AC
CB RR
CB 24A
CB 20ABC
CB 19ABC
CB XABC, YABC, ZABC
CB SABC
J1-J4
24 VDC replacement
5 VDC replacement
RR
K1, K2
K8,K21,K22 (for K8 see #24)
K8 (use with #22)
CR12, 28, OILER
CR1A
P3-63
+ 2 Ea. TB-62 finger guards
X,Y,Z
* ABB components replace Moeller. Ensure overloads and aux contacts are compatible when replacing parts.
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Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
Yaskawa A1000 Spindle Drive Parameters
Parameters for 7.5 HP Spindle motor
Parameter
Value
Comment
Default
C1 Acceleration and Deceleration Times
C1-01
Acceleration time 1
3.0 sec
10.0 sec
C1-02
Deceleration time 1
2.0 sec
10.0 sec
C1-03
Acceleration time 2
5.0 sec
10.0 sec
C1-09
Emergency stop time
2.0 sec
10.0 sec
C6 Carrier Frequency
C6-01
Duty Cycle
0
HD(CT)
1
C6-02
Carrier frequency selection
03
Fc = 8.0 kHz
01
E1 Motor 1 V/f Pattern Characteristics
E1-04
Max. output frequency
112.2 Hz
60.0 Hz
E1-05
Max. voltage
220.0 VAC
230.0 VAC
E1-08
Mid output frequency voltage
12.1 VAC
12.7 VAC
E1-10
Min. output frequency voltage
2.2 VAC
2.3 VAC
E1-13
Base voltage
220.0 VAC
0.0 VAC
E2 Motor 1 Setup
E2-01
Motor rated current
20.00 A
26.60 A
E2-02
Motor rated slip
3.27 Hz
1.30 Hz
E2-03
Motor no-load current
6.58 A
8.00 A
E2-05
Motor line-to-line resistance
0.722 Ohm
0.288 Ohm
E2-06
Motor leak inductance
18.7 %
15.5 %
E2-07
Saturation Comp 1
0.41
0.50
E2-08
Saturation Comp 2
0.66
0.75
E2-11
Motor rated output
5.50 kW
7.50 kW
H1 Multi-Function Digital Inputs
17
Not used(Unused / when use it as a
pass-through mode.)
Fast stop (N/C)
H4 Multi-Function Analog Outputs
Multi-Function Analog 1(Analog Terminal
H4-01
Monitor Selection)
L3 Stall Prevention Function
103
Output current
L3-04
StallP deceleration selection
0
L3-24
Inertia conversion motor acceleration time
0.168 sec
H1-07
Terminal S7 function selection
0F
H1-08
Terminal S8 function selection
06
08
102
Disabled - The drive decelerates at the
selected Dec time.If the load is too large
1
or the Dec time is too short, an OV fault
may occur.
0.175 sec
This listing contains the spindle drive parameters that have been changed by Milltronics Manufacturing.
All other parameters remain unchanged and are the factory default settings by Yaskawa.
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Rev.28
Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
Yaskawa Axis Drive Parameters
Sigma 5 Axis Drive Parameters For MB/VKM Series
X
VKM4
Y
Z
000
0000H
0001H
0000H
0000H
0001H
0000H
0000H
0000H
0001H
100
700
700
500
370
430
360
430
430
570
101
400
400
400
1000
900
1000
950
900
960
102
300
300
300
300
300
300
300
300
300
103
165
200
200
113
200
200
200
200
200
170
1400H
1400H
1400H
1400H
1400H
1400H
1400H
1400H
1400H
212
2540
2540
2499
2540
2540
1270
2500
2500
1875
300
369
369
369
362
362
181
362
361
270
401
70
70
70
30
35
40
40
30
25
409
350
1000
1000
660
1000
1000
1000
1000
1000
506
0
0
30
0
0
30
0
0
30
50A
8100H
8100H
8100H
8100H
8100H
8100H
8100H
8100H
8100H
50B
6548H
6548H
6548H
6548H
6548H
6548H
6548H
6548H
6548H
600
0
0
15
0
0
20
0
0
20
P#
MB/RH20
X
Y
Z
19
MB/RH30
X
Y
Z
Rev.28
Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
MB/VKM Series CNC I/O Listing
Outputs
Inputs
01 Software E-Stop
02 Mist Coolant
03 Flood Coolant
04 Spindle CW
05 Spindle CCW
06 Spindle OK
07 Drawbar Enable
08 Tool Change
09 Allow Reset
10 Delayed Reset
11 Spindle Latch
12 Rotary Clamp
15 Drawbar RHs
30 Misc Mcode
31 End of CycleLight
32 Misc Mcode 1
33 Misc Mcode 2
34 Misc Mcode 3
35 Misc Mcode 4
36 Spindle Reverse
37 Xaxis Drv Enabled
38 Yaxis Drv Enabled
39 Zaxis Drv Enabled
40 Aaxis Drv Enabled
41 Baxis Drv Enabled
42 Axis Drvs Enabled
01 Estopped
04 Up To Speed
05 Tool Change
06 Lube Fault
07 Wait Channel
08 Zero Speed
09 Drive Fault
10 Spindle Reverse
11 Digitizing
12 X Home Switch
13 Air Pressure
18 Remote C-Start
20 ToolOut Btn RHs
21 Door is Open
22 Setup Button
23 Edit Switch
24 Y Home Switch
27 Chiller Fault
33 BackGear Reverse
36 Z Home Switch
37 X Axis Drive OK
38 Y Axis Drive OK
39 Z Axis Drive OK
40 A Axis Drive OK
41 B Axis Drive OK
50 Rmt HDW FOV1
51 Rmt HDW FOV2
52 Rmt HDW Axis1
53 Rmt HDW Axis2
54 Rmt HDW SetCoord
31 EndofCylLight
62 Attention Light
63 Alarm Light
20
Rev.28
Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
8200b Series Front Panel
ITEM
STOCK NO.
1
FP-117
DESCRIPTION
8200b SERIES FRONT PANEL ASSY
QTY
REMARKS
1
Front view
1
3
2
4
5
5
Rear view
3
2
4
21
Rev.28
Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
8200b Panel Assembly Parts List
Item
1
2
3
4
5
Part #
FP-117
9461-3
TBD
TBD
TBD
Description
8200b Front Panel Assy
Front Panel Handwheel with Cable Assy
Enable Switch Assy
E-Stop Switch Assy
Override knob for Feedrate or Spindle
22
Qty
1
0 or 1
1
1
2
Rev.28