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

iii 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 Original version
6-3-99 Change to Rev A electrical schematic (reactors added).
7-12-99 Rev 2 Add LCD front panel drawing
7-29-99 Rev 3 Update panel layout drawing, reactors added
1-28-00 Rev 4 Update to SBC card cage and Rev B electrical schematics, add electrical safety caution
4-21-00 Rev 5 Changed Electrical and panel drawings to reflect modernized mag panel
5-16-00 Rev 6 Added rev A schematics to include 20 pocket ATC option. Axis parameters include
MB18/19 models
8-01-00 Rev 7 Added rev B schematic (only page 2 changed) to show dual output transformer replacing
the separate worklight transformer.
1-19-01 Rev 8 Added rev C schematic (removed RH specifics), removed pick and place ATC.
3-5-01 Rev9 Updated axis parameter listings
8-01-01 Rev10 Convert to Sigma 2. Electrical prints, panel layout, axis parameters
10-7-02 Rev11 Convert to Centurion 7 control and include VKM
4-14-03 Rev12 Added front panel connection diagrams
5-21-04 Rev13 Updated schematics. 24V EOC light, added KD relay.
1-18-05 Rev14 Update schematics, axis drive parameters, power connection alert
8-4-05 Rev15 Change from G5 to F7 spindle drives July-August 2005
5-3-06 Rev15.1 File corrections, revision E schematics.
4-5-07 Rev16 Update to sourcing Centurion 7 Interface. Schematics, I/O listings, parts list.
1-23-08 Rev17 Update electrical prints to Rev A. 110 VAC K1 & K2, notes for UL compliance.
4-4-08 Update logo
7-28-08 Rev18 Update electrical prints to B. Replace Fuses with Circuit Breakers.
10-23-08 rev19 Couple small wire changes to schematic. Update parts list. replace FP pics and
connections drawings.
10-30-08rev19 update FP connections and assembly.
11-10-08rev19 Change CB25AC to 8 amps.
11-14-08rev19 Change Main Fuse 50amps to a Circuit Breaker
04-21-09 rev20 changed the manual rev, schematics have the new 3 color Cycle Light. Some other
schematic changes. Updated parts list.
12-2-10 rev21 Added front panel cabinet fan to 8200 connection diagram. Misc schematic updates.
7-3-12 rev22 Updated to include Sigma5 axis drives and current motherboards, 11-12 updated I/O
listings.
6-26-13 rev 23 Updated mag panel, and schematics (to RevE) to represent Sigma5 axis motors.
7-31-13 rev 24 Update schematics to rev F per UL requirements (ADDED CBS-ABC) for F7 drive.
9-17-13 rev 25 Update schematics and panel parts to include Yaskawa A1000 spindle drive.
1-13-14 rev 26 Update front panel connections, schematic, etc to represent 8200 revB control, 8200b. 1-
20-14, updated pages 6 & 11 of schematic.
9-23-14 rev 27 Updated schematics and panel parts per September 2014 specifications.
5-23-15 rev 28 Updated schematics and panel parts for RL-177 safety relay, MA-495 cycle light.

iv 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.

v Rev.28
 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

vi Rev.28
 Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS

Machine Schematic

1 Rev.28
 Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS

2 Rev.28
 Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS

3 Rev.28
 Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS

4 Rev.28
 Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS

5 Rev.28
 Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS

6 Rev.28
 Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS

7 Rev.28
 Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS

8 Rev.28
 Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS

9 Rev.28
 Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS

10 Rev.28
 Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS

11 Rev.28
 Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS

12 Rev.28
 Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS

13 Rev.28
 Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS

This page intentionally unused.

14 Rev.28
 Electrical Manual
MB 8200b With Sigma5 Axis, A1000 Spindle
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS

8200b Control Front Panel Connections

15 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

17 27

6
34
22
24

35

7-15 29 21 29 28 30

5 – Diodes installed across DC relay coils

16 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 7538 C7.5 (SBC) DELUXE INTERFACE ASSY 1 EA SOURCING

2 CB00076 CABLE – YASKAWA DRIVE TO CONTROL 3 EA ONE PER AXIS
3 CO00288 5mm LEFT ORIENTED EUROSTYLE 2- 1 EA 5 VDC POWER
4 CO00289 7.5mm RIGHT ORIENTED EUROSTYLE 1 EA 24 VDC POWER
5 DI00020 DIODE-1N4007 2 EA ACROSS DC COILS
6 CB00182 60AMP MAIN CIRCUIT BREAKER 1 EA MAIN CB1 ABC
CB00116 SINGLE POLE 1AMP CIRCUIT BREAKER 1 EA CB 5
CB00129 THREE POLE 1AMP CIRCUIT BREAKER 1 EA CB 16AC
CB00118 SINGLE POLE 3AMP CIRCUIT BREAKER 1 EA CB 14, 24
CB00166 SINGLE POLE 4AMP CIRCUIT BREAKER 1 EA CB 30
CB00175 SINGLE POLE 6AMP CIRCUIT BREAKER 1 EA CB 12
CB00116 SINGLE POLE 1AMP CIRCUIT BREAKER 1 EA CB 10F
7 - 15

CB00139 TWO POLE 5AMP CIRCUIT BREAKER 1 EA CB 11AC

CB00150 TWO POLE 8AMP CIRCUIT BREAKER 1 EA CB 25AC
CB00183 SINGLE POLE 1AMP DC CIRCUIT BREAKER 1 EA CB RR
CB00117 SINGLE POLE 2AMP CIRCUIT BREAKER 1 EA CB 24A
CB00156 THREE POLE 30AMP CIRCUIT BREAKER 1 EA CB 20ABC
CB00153 THREE POLE 10AMP CIRCUIT BREAKER 1 EA CB 19ABC
SEE SCHEMATIC PAGE 2 3 EA CB XABC, YABC, ZABC
CB00157 THREE POLE 40AMP CIRCUIT BREAKER 1 EA CB SABC
16 PR00038 BREAK OUT BOARD W/O LED 4 EA J1-J4
17 PS00076 POWER SUPPLY-5.0A/24V 2 EA 24 VDC replacement
18 PS00077 POWER SUPPLY-2.5A/5V 1 EA 5 VDC replacement
19 RL00074 RELAY- 24 V coil 1 EA
RR
20 RL00075 BASE 1 EA
21 RL00173 CONTACTOR-52AMP AF 52-30 2 EA K1, K2
22 RL00102 * CONTACTOR-STANDARD SINGLE MOTOR 3 EA K8,K21,K22 (for K8 see #24)
23 RL00177 RELAY-SAFETY 1 EA
24 RL00156 * OVERLOAD-1.3AMP 1 EA K8 (use with #22)
25 RL00130 RELAY, 24V SINGLE 3 EA CR12, 28, OILER
26 RL00164 RELAY, SOLID STATE 1 EA CR1A
27 SW00199 DISCONNECT-63 AMP 1 EA P3-63
28 TB00024 TERMINAL BLOCK 9080 M4/6G SQUARE D 21 EA
29 TB00030 TERMINAL BLOCK-4POS 160857 40 EA
30 TB00043 BLOCK-3 POLE POWER DISTRIBUTION 6 EA
31 TB00044 TERMINAL BLOCK-WAGO 280-633 21 EA
32 TR00075 TRANSFORMER .5 KVA 50/60 HZ 1 EA + 2 Ea. TB-62 finger guards
33 PS00117 A1000 SPINDLE DRIVE, 7.5 KW 1 EA
34 AM00090 1 KW SIGMA5 AXIS DRIVE 3 EA X,Y,Z
35 RE00106 RESISTOR, 50 OHM 225 WATT 1 EA
36 9547-1 RESISTOR, 15 OHM WITH BRACKETS ASSY 1 EA

* ABB components replace Moeller. Ensure overloads and aux contacts are compatible when replacing parts.

17 Rev.28
 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
Not used(Unused / when use it as a
H1-07 Terminal S7 function selection 0F 06
pass-through mode.)
H1-08 Terminal S8 function selection 17 Fast stop (N/C) 08
H4 Multi-Function Analog Outputs
Multi-Function Analog 1(Analog Terminal
H4-01 103 Output current 102
Monitor Selection)
L3 Stall Prevention Function
Disabled - The drive decelerates at the
selected Dec time.If the load is too large
L3-04 StallP deceleration selection 0 1
or the Dec time is too short, an OV fault
may occur.
L3-24 Inertia conversion motor acceleration time 0.168 sec 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.

18 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

VKM4 MB/RH20 MB/RH30

P# X Y Z X Y Z X 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

19 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

Inputs Outputs

01 Estopped 01 Software E-Stop

04 Up To Speed 02 Mist Coolant
05 Tool Change 03 Flood Coolant
06 Lube Fault 04 Spindle CW
07 Wait Channel 05 Spindle CCW
08 Zero Speed 06 Spindle OK
09 Drive Fault 07 Drawbar Enable
10 Spindle Reverse 08 Tool Change
11 Digitizing 09 Allow Reset
12 X Home Switch 10 Delayed Reset
13 Air Pressure 11 Spindle Latch
18 Remote C-Start 12 Rotary Clamp
20 ToolOut Btn RHs 15 Drawbar RHs
21 Door is Open 30 Misc Mcode
22 Setup Button 31 End of CycleLight
23 Edit Switch 32 Misc Mcode 1
24 Y Home Switch 33 Misc Mcode 2
27 Chiller Fault 34 Misc Mcode 3
33 BackGear Reverse 35 Misc Mcode 4
36 Z Home Switch 36 Spindle Reverse
37 X Axis Drive OK 37 Xaxis Drv Enabled
38 Y Axis Drive OK 38 Yaxis Drv Enabled
39 Z Axis Drive OK 39 Zaxis Drv Enabled
40 A Axis Drive OK 40 Aaxis Drv Enabled
41 B Axis Drive OK 41 Baxis Drv Enabled
50 Rmt HDW FOV1 42 Axis Drvs Enabled
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. DESCRIPTION QTY REMARKS
1 FP-117 8200b SERIES FRONT PANEL ASSY 1

Front view

2
4

5 5

Rear view

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 Part # Description Qty

1 FP-117 8200b Front Panel Assy 1
2 9461-3 Front Panel Handwheel with Cable Assy 0 or 1
3 TBD Enable Switch Assy 1
4 TBD E-Stop Switch Assy 1
5 TBD Override knob for Feedrate or Spindle 2

22 Rev.28