Full Index 03 01

Property of HURCO Machine Tool Products
This CD - ROM may not be reproduced or copied in any way.
The Contents of this CD – ROM are to be used by

AUTHORIZED Field Service Technicians only.
If you have any Questions or Comments about the content or format of this
CD, Please contact Don Schmedake @ Hurco Machine Tool Products
Phone Number (317) 293-5309, Ext. 2648
E - Mail Address schmedaked@hurco.com
Table of Contents
Revised 03_01_01
New Updates to this CD – Rom
03_01_01
1) D8582, D8613, D8697, D8703, D8706

2) SWB 20, SWB 21
3) TIN 1162, TIN1163
4) FSB 1283
5) DP0031
6) New Version of Yaskawa Sigma - Win
12_29_00
1) FSB 1259C, FSB 1275B, FSB1281, FSB1282
2) TIN 1156. TIN1157, TIN 1158, TIN 1159, TIN 1160, TIN 1161
3) SWB 018, SWB 019
4) DP0027, DP0029, DP0032, DP0033, DP0034, DP0035, DP0036, DP0037,
DP0038, DP0039, DP0040, DP0041, DP0042, DP0043, DP0044
5) Engineering Documents D8465, D8558, D8655, D8694, D8699, D8700, D8701
6) Created new page for DPxxxx Parameter Documents to allow for new machine
parameters.
7) Created a Folder called “Misc_PDF_Files”. In this folder you will find Machine
Footprints, etc.
8) Added new folder to MAX_Exec \ Ver2.xx \ MAX3_MAX4 Directory for new
Parameter Diskettes. ( 427-0004-021, 427-0004-024 )
9) PDF Format Part Listing & Wiring Diagrams. V*X24, V*X30, and V*X40 are
linked through the Index, in a folder named “Linked” All frames have an unlinked
Index and Drawings Folder.
Hurco Machine Tool Products
Field Service Documents
Table of Contents
Axis & Spindle Drives Controls Machine Frames
Fanuc B and BX BMC 10 – 15
Hurco Silver Face MAX 1 BMC 20 – 50, OEM 1, V1
Max 400 MAX 2 BMC 20 –50, OEM 2, V2
Randtronics MAX 32 BMC 2416 / V*X24
Servodynamics MAX 3 BMC 3017 / VMX30
Siemens MAX 3 ISA BMC 4020
Yaskawa MAX 4 VTC40
Servo Dynamics Axis Drive Retrofits ULTIPATH V*X50
(Reserved) ULTIMAX Customer Information BMC 6434
(Reserved) OPTIKEY Option Part Numbers Hawk Bed Mills
ULTIMAX 2.xx Documents Kneemills
WinMax Service Manual M1 - MD
NEW!!! CONVERSION CHART M2 – MD3
MHP
SLV 40
Machine Options Machine Config Miscellaneous Parameters

Control Common Procedures Max 3 Ver. 1.xx - 2.xx – MAX 4Ver. 2.xx
Other Options Geometry Specifications
Probes Serial Number Identification
Rotary Table
Spindles Hurco Field Software Technical

Service Bulletins Bulletins Information Notices
Field Service
Parts Install PMA ULTIMAX Ver. 2.xx Parts List
Suggested Lubes Procedures Checklist Retention Knob
Machine Configuration Sheets
Knee Mills
Hawk 5
Bed Mills
Hawk 30
Hawk 40
Hawk
Hawk
Machining Centers
BMC2416
BMC3017
BMC4020
BMC6434 40T / 50T
VTC40
BMC
BMC
BMC
Hawk 5M
Hawk5SSM
CONFIGURATION SHEET C2004.XLS
REV LEVEL L
HAWK 5M
ASIA
REVISED 01/28/00
Customer Name ________________________________ Sales Order Number _________________________

Data Entry_____________________________________ Order Date_________________________________
Work Order Reference ___________________________ Requested Ship Date_________________________
NOTE: Enter all Shop Orders as MAKE w/an Order Policy of F Scheduled Ship Date_________________________
VERIFICATION Comments: _______________________________

Master Schedule__________________ By ________ _________________________________________
Lead Time:_________________ Planner Code_____ _________________________________________
BASE PART NUMBER: HAWK5MASIADSP CHANGE OPTIONS: A = Add D = Delete
1. REQUIRED BASIC CONFIGURATION (select one)

Page 1
1_____002-4200-213 Ass'y, Hawk 5M Asia (New Structure) (486)
2_____KM5-0201-004 Ass’y, Hawk 5M Asia (Pentium)
2. OPTIONS
Page 1
1_____002-4014-001 Worklight
2_____517-0001-004 Air Conditioner
3_____002-3415-002 Corrosion Inhibitor
4_____002-4050-002 Ass'y, Table Guard
5_____415-0250-904 16MB RAM (Specify Quantity)
6_____002-4321-005 Rotary Table Ass'y, Complete Technara TB200
w/ D.C. Motor
7_____002-4311-007 Ass'y, Hurco Rotary Table DC Baldor
8_____002-4414-002 Option, H5M Rotary Table ISA Electric's Only
9_____707-1011-051 Tailstock, Kitigawa TS-180 for TB-180 R.T.
Page 2
1_____115-894-8 8" Faceplate w/o T-Slots*
4_____115-894-13 8" Faceplate w/ T-Slots*
7_____102-004 5c Collet Option
8_____007-3001-005 Kit, Dual Screen Color Upgrade
9_____707-1021-001 Scroll Chuck for TB200 RT
Page 3
1_____007-3402-001 Pkg., 3.5” MAX/PC Comm
3. OPTIONAL SOFTWARE (OPTIKEY)

Page 1
1_____007-4124-001 3D Mold
2_____007-4124-003 Ultipockets
3_____007-4124-002 Insert Pockets
4_____007-4124-007 DXF
*To Be Used With 002-4311-007 Only.
Serial Number:__________________ Page 1 of 1

REV LEVEL L
HAWK 5M
EUROPE
REVISED 01/28/00


BASE PART NUMBER: HAWK5MEUROPEDSP CHANGE OPTIONS: A = Add D = Delete

Page 1
1_____002-4200-212 Ass'y, Hawk 5M UK (New Structure) (486)
2_____KM5-0201-002 Ass'y, Hawk 5M UK (Pentium)
2. OPTIONS
Page 1
1_____002-4014-001 Worklight
4_____602-0003-007 6" Vise
7_____002-4321-005 Rotary Table Ass'y, Complete Technara TB200
w/ D.C. Motor
Page 2
Page 3
1_____007-3402-001 Pkg., 3.5” MAX/PC Comm

Page 1
1_____007-4124-001 3D Mold
2_____007-4124-003 Ultipockets
3_____007-4124-002 Insert Pockets
4_____007-4124-007 DXF
*To Be Used With 002-4311-007 Only .

REV LEVEL L
HAWK 5M
USA
REVISED 01/28/00


BASE PART NUMBER: HAWK5MUSADSP CHANGE OPTIONS: A = Add D = Delete

Page 1
1_____002-4200-211 Ass'y, Hawk 5M USA (New Structure) (486)
2_____KM5-0201-001H Ass'y, Hawk 5M USA (Pentium)
2. OPTIONS
Page 1
1_____002-4014-001 Worklight
3_____802-2706-002 Power Drawbar M16X2
5_____602-0003-007 6" Vise
6_____002-4050-002 Ass'y, Table Guard
8_____707-1011-048 Rotary Table, 7" TB-180 DC Technara
Page 2
3_____002-2489-001 Ass'y, 208/230/575V
Page 3
4_____007-3402-001 Pkg., 3.5” MAX/PC Comm

Page 1
1_____007-4124-001 3D Mold
2_____007-4124-003 Ultipockets
3_____007-4124-002 Insert Pockets
4_____007-4124-007 DXF
*To Be Used With 002-4311-007 Only.

REV LEVEL K
HAWK 5SSM
ASIA
REVISED 01/28/00


BASE PART NUMBER: HAWK5SSMASIADSP CHANGE OPTIONS: A = Add D = Delete
1. REQUIRED BASIC CONFIGURATION 3. OPTIONAL SOFTWARE (OPTIKEY)

Page 1 Page 1
1_____002-4200-208 Ass'y, Hawk 5 SSM Asia (486) 1_____007-4124-001 3D Mold
2_____KM5-0101-004 Ass'y, Hawk 5 SSM Asia (Pentium) 2_____007-4124-003 Ultipockets
3_____007-4124-002 Insert Pockets
2. OPTIONS 4_____007-4124-007 DXF
Page 1
1_____517-0001-004 Air Conditioner**
2_____802-2706-002 Power Drawbar M 16 X 2
3_____007-3402-001 Pkg., 3.5” MAX/PC Comm
5_____002-4219-002 Mouse (Use ONLY with SSM Console)
6_____002-4219-001 Kit, Dual Screen Mono Upgrade
7_____602-0003-007 6" Vise
8_____002-4050-002 Ass'y, Table Guard
Page 2
1_____002-4321-005 Rotary Table Ass’y, Complete Technara TB200
w/ D.C. Motor
Page 3
2_____002-4219-003 Chip Pan Ass’y
3_____002-4219-004 Mist Coolant Ass’y
4_____002-4219-005 Work Light Ass’y
5_____002-4219-006 Heat Exchanger Ass’y***
6_____002-4219-007 Kit, 5SSM Upgrade to 5M
* To Be Used With 002-4311-007 Only.

** Required for Temp. over 105° degrees F.
*** Required for Temp. 95°-105° degrees F.

REV LEVEL K
HAWK 5SSM
EUROPE
REVISED 01/28/00


BASE PART NUMBER: HAWK5SSMEURDSP CHANGE OPTIONS: A = Add D = Delete

Page 1 Page 1
1_____002-4200-209 Ass'y, Hawk 5 SSM UK (486) 1_____007-4124-001 3D Mold
2_____KM5-0101-002 Ass'y, Hawk 5 SSM UK (Pentium) 2_____007-4124-003 Ultipockets
3_____007-4124-002 Insert Pockets
2. OPTIONS 4_____007-4124-007 DXF
Page 1
1_____517-0001-004 Air Conditioner**
2_____802-2706-002 Power Drawbar M 16 X 2
3_____007-3402-001 Pkg., 3.5” MAX/PC Comm
7_____602-0003-007 6" Vise
w/ D.C. Motor
Page 2
Page 3
1_____002-4219-003 Chip Pan Ass’y
3_____002-4219-005 Work Light Ass’y

** Required for Temp. over 105° F.
*** Required for Temp. 95°-105° F.

REV LEVEL M
HAWK 5SSM
USA
REVISED 01/28/00


BASE PART NUMBER: HAWK5SSMUSADSP CHANGE OPTIONS: A = Add D = Delete

Page 1 Page 1
1_____002-4200-207 Ass'y, Hawk 5 SSM USA (486) 1_____007-4124-001 3D Mold
2_____KM5-0101-001H Ass'y, Hawk 5SSM USA (Pentium) 2_____007-4124-003 Ultipockets
3_____007-4124-002 Insert Pockets
2. OPTIONS 4_____007-4124-007 DXF
Page 1
1_____517-0001-004 Air Conditioner**
2_____802-2706-002 Power Drawbar M 16 X 2
3_____007-3402-001 Pkg., 3.5” MAX/PC Comm
7_____602-0003-007 6" Vise
8_____002-4050-002 Ass'y, Table Guard
Page 2
w/ D.C. Motor
Page 3
2_____002-4219-003 Chip Pan Ass’y
4_____002-4219-005 Work Light Ass’y

** Required for Temp. over 105° F.
*** Required for Temp. 95°-105° F.

REV LEVEL J
HAWK 30/SSM
REVISED 1/28/00


Master Schedule __________________By ________ _________________________________________
Lead Time: _________________Planner Code_____ _________________________________________
BASE PART NUMBER: H30 CHANGE OPTIONS: A = Add D = Delete

H30E
H30A
1. REQUIRED BASIC CONFIGURATION (SELECT ONE) 3. OPTIONAL SOFTWARE
_____H30-0102-001H HAWK 30/SSM USA ------007-4124-001 3D Mold

_____H30-0102-002 HAWK 30/SSM UK
_____H30-0102-004 HAWK 30/SSM ASIA ------007-4124-002 Insert Pockets
------007-4124-007 DXF
------007-4124-011 NCPP (Requires 007-3010-006 or
007-3010-009 ISNC)
2.OPTIONS ------007-4124-003 Ultipockets
------007-4124-021 Ultipro II
--------002-3014-001 Ass’y,Rotary Table TB200 Complete -----007-0020-001 Ultinet
-------002-3014-002 TB200 Rotary Table Only
-------002-3014-003 Rotary Table Interface
-------003-1023-002 Ass’y,SSM Console Keyboard
-------003-1024-001 Ass’y, Remote Jog Control
-------007-3010-005 MAX4 DSM Upgrade
-------007-3010-003 KIT,MAX4 DSM DELIGHT PACKAGE
-------002-4219-002 MOUSE(USE ONLY WITH SSM CONTROL)
-------415-0250-904 16MB RAM (SPECIFY QUANITY )
-------007-3010-006 ISNC (MAX 4DSM ONLY)
-------007-3010-009 ISNC(Slim SSM ONLY)
Serial Number:______________ Page 1 of 1

11REV LEVEL J
HAWK 40/SSM
REVISED 1/28/00


BASE PART NUMBER: H40 CHANGE OPTIONS: A = Add D = Delete

H40E
H40A
_____H40-0102-001H HAWK 40/SSM USA -----007-4124-001 3D Mold

_____H40-0102-002 HAWK 40/SSM UK
_____H40-0102-004 HAWK 40/SSM ASIA
-----007-4124-002 Insert Pockets
-----007-4124-007 DXF
2. OPTIONS -----007-4124-011 NCPP (Requires 007-3010-006 or
007-3010-009 ISNC )
-----007-4124-003 Ultipockets
------002-3014-001 Ass’y,Rotary Table TB200 Complete -----007-4124-021 Ultipro II
------002-3014-002 TB200 Rotary Table Only -----007-0020-001 Ultinet
------002-3014-003 Rotary Table Interface
------003-1023-002 Ass’y,Console Keyboard
-----003-1024-001 Ass’y,Remote Jog Control
-----007-3010-005 MAX4 DSM Upgrade
------007-3010-003 KIT,MAX4 DSM DELIGHT PACKAGE
------415-0250-904 16MB RAM (SPECIFY QUANTITY)
------007-3010-006 ISNC(MAX 4 DSM ONLY)
------007-3010-009 ISNC(Slim SSM Only)
------002-4219-002 MOUSE(USE ONLY WITH SSM CONTROL

11REV LEVEL F
BMC2416/DSM
REVISED 1/28/00


BASE PART NUMBER: B24M CHANGE OPTIONS: A = Add D = Delete

B24ME
B24MG
B24MA
1. REQUIRED BASIC CONFIGURATION (SELECT ONE)
___ _ B24-0809-001 H BMC2416/DSM USA 3.OPTIONAL SOFTWARE

_____ B24-0809-002 BMC2416/DSM UK
_____ B24-0809-003 BMC2416/DSM GERMANY
---------B24-0809-004 BMC2416/DSM ASIA -----007-4124-001 3D MOLD
-----007-4124-002 INSERT POCKETS
-----007-4124-007 DXF
-----007-4124-011 NCPP
2.OPTIONS (REQUIRES 007-3010-006 ISNC)
-----007-4124-003 ULTIPOCKETS
------007-3010-003 Kit,MAX4 DSM Delight Package -----007-4124-008 RIGID TAPPING
------007-3010-006 ISNC -----007-4124-021 ULTIPRO II
-----002-4321-010 ASSY,ROTARY TASBLE TB 200 COMPLETE ------007-0020-001 ULTINET
-----002-4321-014 TB 200 ROTARY TABLE ONLY
-----002-4321-013 ROTARY TABLE INTERFACE
------007-3010-012 PROBE KIT,(YASKAWA)
------007-3010-014 PROBE KIT,(SIEMENS)
NOTE;PROBES WILL BE SUPPLIED BY DISTRIBUTER)

CONFIGURATION SHEET C2062XLS
11REV LEVEL E
BMC2416/SSM
REVISED 1/28/00


BASE PART NUMBER: B24S CHANGE OPTIONS: A = Add D = Delete

B24SE
B24SG
B24SA
_____B24-0409-001 H BMC2416/SSM USA 3. OPTIONAL SOFTWARE

_____B24-0409-002 BMC2416/SSM UK
_____B24-0409-003 BMC2416/SSM GERMANY
--------B24-0409-004 BMC2416/SSM ASIA ------007-4124-001 3D MOLD
------007-4124-002 INSERT POCKETS
----- 007-4124-007 DXF
2. OPTIONS ----- 007-4124-011 NCPP(REQUIRES 007-3010-006 OR
------003-1023-002 Ass’y,SSM Console Keyboard 007-3010-009 ISNC)
------003-1024-001 Ass’y,Remote Jog Control(SSM ONLY) ----- 007-4124-003 ULTIPOCKETS
------007-3010-007 MAX4 DSM UPGRADE ---- 007-4124-008 RIGID TAPPING
-----007-3010-003 KIT,MAX4 DSM DELIGHT PACKAGE ---- 007-4124-021 ULTIPRO II
---- 007-3010-006 ISNC (MAX4 DSM ONLY) ----- 007-0020-001 ULTINET
-----007-3010-009 ISNC(SLIM SSM ONLY)
-----002-4321-010 ASSY,ROTARY TABLE TB200 COMPLETE
-----002-4321-014 TB200 ROTARY TABLE ONLY

REV LEVEL N CONFIGURATION SHEET C2012.XLS
BMC30HT/M
USA
REVISED 01/28/00


BASE PART NUMBER: BMC30HTM CHANGE OPTIONS: A = Add D = Delete
1. REQUIRED BASIC CONFIGURATION 2. OPTIONS (Cont'd.)

PAGE:1 PAGE:4
1_____002-4300-003 USA w/ Yaskawa 1_____003-1018-003 Ass'y, Scale Option (Yaskawa)
2_____B30-0505-001H USA w/ Siemens 2_____007-3010-001 Option, ISNC
3_____003-1005-006 Ass’y, Chip Conveyor
2. OPTIONS 4_____003-1005-007 Ass’y, Washdown
PAGE:1 5_____707-1021-001 Scroll Chuck for TB200 RT
1_____003-1016-008 Ass'y, "Frame A" BT Option (USA & Europe Only) 6_____707-1021-002 Scroll Chuck for TB250 RT
2_____002-4126-001 NAS 979 Test Part 7_____003-1016-011 Ass’y, Headgrowth Compensation
3_____002-3415-001 Corrosion Inhibitor* (Front Mounted Fans)
4_____003-1005-005 Ass'y, Chip Conveyor & Wash Down Option 8_____007-3402-001 Pkg., 3.5” MAX/PC Comm
(Includes Chip Conveyor Ass'y & Washdown Ass'y)
5_____002-3502-001 Renishaw Part Probe** 3. OPTIONAL SOFTWARE)
6_____002-3502-003 Renishaw Tool Probe** PAGE:1
7_____002-3502-008 Part Probe, Marposs CATV40** 1_____007-4124-001 3D Mold
8_____002-3502-009 Part Probe, Marposs CATV50** 2_____007-4124-002 Insert Pockets
9_____002-3502-010 Tool Probe, Marposs ** 3_____007-4124-007 DXF
PAGE:2 4_____007-4124-011 NCPP
1_____002-3502-012 Part Probe, Marposs BT40** (Must Order 007-3010-001)
2_____415-0250-903 8MB RAM (order2) 5_____007-4124-003 Ultipockets
3_____415-0250-904 16MB RAM (order2) 6_____007-4124-008 Rigid Tapping
4_____002-4321-003 Rotary Table Ass'y, Complete Technara 7---------007-4124-020 UltiPro(for machines with v2.10 only-
TB200 w/ A.C. Motor machine control must be Pentium
5_____002-4321-004 Rotary Table Ass'y, Complete Technara based)
TB250 w/ A.C. Motor 8---------007-0020-001 UltiNet Option (if v2.00,v2.01 or v2.02
6_____002-4311-006 Ass'y, Hurco Rotary Table AC Yaskawa on machine then must order007-4121-040
(MUST Order 003-1016-005) Upgrade Pkg: If v1.xx on machine then must
7_____002-4414-001 Option, Rotary Table ISA Electrics Only (BMC) order 007-4121-041 Upgrade Pkg)
8_____707-1011-051 Tailstock, Kitigawa TS-180 for TB-180 R.T. 4 SOFTWARE UPGRADE PACKAGES
9_____707-1011-052 Tailstock, Kitigawa TS-250 for TB-250 R.T. PAGE:1
PAGE:3 1--------007-4121-040 V2.10 Software Upgrade Pkg(DO NOT order
1_____115-894-8 8" Faceplate w/o T-Slots**** for v1.xx systems)
2_____115-894-10 10" Faceplate w/o T-Slots**** 2--------007-4121-041 V2.10 Software Upgrade Pkg(for v1.xx
systems
3_____115-894-12 12" Faceplate w/o T-Slots**** only)
4_____115-894-13 8" Faceplate w/ T-Slots**** 3---------007-4121-042 UltiPro Upgrade Pk for v1.xx w/486 machines
5_____115-894-14 10" Faceplate w/ T-Slots**** (Includes Pentium & v2.10- order only for
6_____115-894-15 12" Faceplate w/ T-Slots**** v1.xx systems w/486)
7_____003-1016-005 5c Rotary Option Install 4---------007-4121-043 UltiPro & UltiNet Upgrade Pkg for v1.xx w/486
8_____002-4134-001 Adapter T250 Rotary Table Ass'y machines(Includes Pentium&v2.10- order
9_____007-3001-005 Kit, Dual Screen Color Upgrade only for v1.x systems w/486)
NOTE: Pentium board 007-3003-001T must be

* All Non-Domestic Machines ordered separately if not included in an upgrade
** Must Select Software Pkg. 007-4124-004 kit.

REV LEVEL M CONFIGURATION SHEET C2013.XLS
BMC30HT/M
ASIA
REVISED 02/19/98


BASE PART NUMBER: BMC30HTMASIADSP CHANGE OPTIONS: A = Add D = Delete
1. REQUIRED BASIC CONFIGURATION) 4.SOFTWARE UPGRADE PACKAGES

Page 1 PAGE:1
1_____002-4300-019 Asia w/ Yaskawa 1-------007-4121-040 V2.10 Software Upgrade Pkg (DO NOT order
2_____B30-0505-004 Asia w/ Siemens for v1.xx systems)
2-------007-4121-041 V2.10 Software Upgrade Pkg(for v1.xx
2. OPTIONS system only)
Page 1 3-------007-4121-042 UltiPro Upgrade Pkg for v1.xx w/486
1_____003-1005-005 Ass'y, Chip Conveyor & Wash Down Option machines(Includes Pentium &v2.10-
(Includes Chip Conveyor Ass'y & Washdown Ass'y) order only for v1.xx systems w/486)
2_____003-1018-003 Ass'y, Scale Option (Yaskawa) 4--------007-4121-043 UltiPro & UltiNet Upgrade Pkg for v1.xx w/486
3_____007-3010-001 Option, ISNC machines (Includes Pentium & v2.10-
4_____007-3001-005 Kit, Dual Screen Color Upgrade order only for v1.x systems w/486)
5_____003-1005-006 Ass’y, Chip Conveyor
6_____003-1005-007 Ass’y, Washdown NOTE: Pentium board 007-3003-001T must be
7_____415-0250-903 8MB RAM (order2) ordered separately if not included in an upgrade kit.
8_____415-0250-904 16MB RAM (order2)

9_____003-1016-011 Ass’y, Headgrowth Compensation
(Front Mounted Fans)
Page 2
1_____007-3402-001 Pkg., 3.5” MAX/PC Comm
2_____003-1016-020 Kit,8k Spindle With Coolant
3_____003-1016-016 Kit,12k Spindle With Coolant
4_____003-1016-017 Kit,12k Spindle Non-Coolant
3. OPTIONAL SOFTWARE
Page 1
1_____007-4124-001 3D Mold
2_____007-4124-002 Insert Pockets
3_____007-4124-007 DXF
4_____007-4124-011 NCPP
(Must Order 007-3010-001)
5_____007-4124-003 Ultipockets
6_____007-4124-008 Rigid Tapping
7_____007-4124-020 UltiPro(for machines with v2.10 only-
8_____007-0020-001 UltiNet Option(If v2.00, v2.01 or v2.02 on
machine then must order 007-4121-040
Upgrade Pkg: If v1.xx on machine then
must order 007-4121-041 Upgrade Pkg)
NOTE: NON-CURRENT PRODUCT

REV LEVEL Q
BMC30HT/M
GERMANY
REVISED 01/28/00


BASE PART NUMBER: BMC30HTMEURODSP CHANGE OPTIONS: A = Add D = Delete
1. REQUIRED BASIC CONFIGURATION
--------B30-0805-003 GERMANY W/SIEMENS MAX4

-------B30-0812-003 GERMANY W/YASKAWA MAX4
2. OPTIONS
-------_003-1005-006 Ass'y, Chip Conveyor

_____003-1018-003 Ass'y, Scale Option (Yaskawa)
_____007-3010-006 ISNC
_____415-0250-903 8MB RAM (order MULTIPLES OF 2)

_____003-1016-011 Ass’y, Headgrowth Compensation
_____007-3402-001 Pkg., 3.5” MAX/PC Comm
--------003-1016-021 KIT,8K SPINDLE WITH COOLANT(YASKAWA)
-------003-1016-016 KIT,12K SPINDLE WITH COOLANT
-------003-1016-017 KIT,12K SPINDLE NON-COOLANT
NOTE(PROBES WILL BE SUPPLIED BY DISTRIBUTER)
_____007-4124-001 3D Mold
_____007-4124-002 Insert Pockets
_____007-4124-007 DXF
_____007-4124-011 NCPP(Requires 007-3010-006)
_____007-4124-003 Ultipockets
_____007-4124-008 Rigid Tapping
-------007-4124-021 UltiPro II (for machines with v2.11 & up only-

Machine control must be Pentium based)
-------007-0020-001 UltiNet Option (If v2.00,v2.01 or v2.02 on
must order 007-4121-041 Upgrade Pkg)

REV LEVEL Z CONFIGURATION SHEET C2009WO.XLS
BMC3017HT/M
SUPERCEDES BMC30/M
USA
REVISED 01/28/00


Master Schedule__________________By ________ _________________________________________
Lead Time:_________________Planner Code_____ _________________________________________
BASE PART NUMBER: BMC30M CHANGE OPTIONS: A = Add D = Delete

1. REQUIRED BASIC CONFIGURATION 2. OPTIONS (Cont'd.)
_____B30-0804-001H USA(COLOR)MAX4(SIEMENS) _____003-1018-003 Ass'y, Scale Option (Yaskawa)

-------B30-0811-001H USA COLOR MAX4(YASKAWA)
2. OPTIONS _____003-1005-006 Ass’y, Chip Conveyor
_____003-1005-007 Ass’y, Washdown
_____003-1016-008 Ass'y, "Frame A" BT Option (USA & Europe Only) _____707-1021-001 Scroll Chuck for TB200 RT
_____002-4126-001 NAS 979 Test Part _____707-1021-002 Scroll Chuck for TB250 RT
_____002-3415-001 Corrosion Inhibitor* _____003-1016-011 Ass’y, Headgrowth Compensation
_____003-1005-005 Ass'y, Chip Conveyor & Wash Down Option (Front Mounted Fans)
(Includes Chip Conveyor Ass'y & Washdown Ass'y) --------007-3402-001 Pkg.,3.5”MAX/PCComm
_____002-3502-001 Renishaw Part Probe** ------003-1016-021 KIT,8K SPINDLE WITH COOLANT
(YASKAWA)
_____002-3502-003 Renishaw Tool Probe**
_____002-3502-008 Part Probe, Marposs CATV40** --------003-1016-016 Kit,12K Spindle with Coolant
_____002-3502-009 Part Probe, Marposs CATV50** -------003-1016-017 Kit,12K Spindle Non-Coolant
-------007-3010-003 Kit, MAX4 DSM Delight Package
-------007-3010-006 ISNC
_____002-3502-010 Tool Probe, Marposs ** _____007-3010-012 PROBE KIT,(YASKAWA)
_____007-3010-014 probe kit,(siemens)
_____002-3502-012 Part Probe, Marposs BT40**
_____415-0250-903 8MB RAM (order MULTIPLES OF 2) 3. OPTIONAL SOFTWARE
--------002-4321-010 ASS’Y, ROTARY TABLE TB200 COMPLETE --------007-4124-001 3D Mold
-------002-4321-011 ASS’Y,ROTARY TABLE TB250 COMPLETE --------007-4124-002 Insert Pockets
-------002-4321-014 TB200 ROTARY TABLE ONLY --------007-4124-007 DXF
-------002-4321-015 TB250 ROTARY TABLE ONLY --------007-4124-011 NCPP (Requires 007-3010-006 )
------002-4321-013 ROTARY TABLE INTERFACE --------007-4124-003 Ultipockets
_____002-4311-006 Ass'y, Hurco Rotary Table AC Yaskawa --------007-4124-008 Rigid Tapping
(MUST Order 003-1016-005) --------007-4124-021 UltiPro II (for machines with v2.11&up only
_____002-4414-001 Option, Rotary Table ISA Electric’s Only (BMC) machine control must be Pentium based)
_____707-1011-051 Tailstock, Kitigawa TS-180 for TB-180 R.T. --------007-0020-001 UltiNet Option(if v2.00,v2.01 or v2.02
_____707-1011-052 Tailstock, Kitigawa TS-250 for TB-250 R.T. on machine then must order 007-4121-040
_____115-894-8 8" Faceplate w/o T-Slots**** Upgrade Pkg.;If v1.xx on machine then must order
_____115-894-10 10" Faceplate w/o T-Slots**** 007-4121-041 Upgrade Pkg)
_____115-894-12 12" Faceplate w/o T-Slots****
_____115-894-13 8" Faceplate w/ T-Slots****
_____003-1016-005 5c Rotary Option Install
_____002-4134-001 Adapter T250 Rotary Table Ass'y

REV LEVEL W CONFIGURATION SHEET C2011.XLS
BMC30/M
EUROPE
REVISED 01/28/00


BASE PART NUMBER: BMC30MEUROPEDSP CHANGE OPTIONS: A = Add D = Delete
1. REQUIRED BASIC CONFIGURATION 3. OPTIONAL SOFTWARE
_____007-4124-001 3D Mold
_____B30-0804-002 UK (COLOR)MAX4(SIEMENS) _____007-4124-002 Insert Pockets
_____B30-0804-003 GERMANY(COLOR)MAX4(SIEMENS) _____007-4124-007 DXF
--------B30-0811-002 UK(COLOR)MAX4(YASKAWA) _____007-4124-011 NCPP (Requires 007-3010-006)
--------B30-0811-003 GERMANY(COLOR)MAX4(YASKAWA)
2. OPTIONS _____007-4124-003 Ultipockets
_____007-4124-008 Rigid Tapping
_____003-1005-006 Ass'y, Chip Conveyor
_____003-1018-003 Ass'y, Scale Option (Yaskawa) ----------007-4124-021 UltiProII (for machines with v2.11& up only
_____415-0250-903 8MB RAM (order MULTIPLES OF 2) machine control must be Pentium based)
--------415-0250-904 16MB RAM(ORDER MULTIPLES OF 2)
_____003-1016-011 Ass’y, Headgrowth Compensation ----------007-0020-001 UltiNet Option(if v2.00,v2.01 or v2.02 on
(Front Mounted Fans) must order 007-4121-041 Upgrade Pkg)
_____007-3402-001 Pkg., 3.5” MAX/PC Comm
--------003-1016-021 Kit,8K Spindle with Coolant(YASKAWA)
-------003-1016-016 Kit,12K Spindle with Coolant
-------003-1016-017 Kit,12K Spindle Non-Coolant
------007-3010-003 Kit,MAX4 DSM Delight Package
-----007-3010-006 ISNC
-----002-4321-010 ASS’Y,ROTARY TABLE TB200 COMPLETE
-----002-4321-011 ASS’Y,ROTARY TABLE TB250 COMPLETE
-----007-3010-012 PROBE KIT,(YASKAWA)
-----007-3010-014 PROE KIT,(SIEMENS)
NOTE;(PROBES WILL BE SUPPLIED BY DISTRIBUTER)

REV LEVEL W CONFIGURATION SHEET C2010.XLS
BMC30/M
ASIA
REVISED 01/28/00


BASE PART NUMBER: BMC30MASIADSP CHANGE OPTIONS: A = Add D = Delete
_____007-4124-001 3D Mold
_____B30-0804-004 ASIA(COLOR)MAX4(SIEMENS) _____007-4124-002 Insert Pockets
-------B30-0811-004 ASIA(COLOR)MAX4(YASKAWA) _____007-4124-007 DXF
2. OPTIONS _____007-4124-011 NCPP (Reqiures 007-3010-006)
_____007-4124-003 Ultipockets
_____003-1005-005 Ass'y, Chip Conveyor & Wash Down Option _____007-4124-008 Rigid Tapping
(Includes Chip Conveyor Ass'y & Washdown Ass'y) --------007-4124-021 UltiPro II (for machines with v2.11& up only-
_____003-1018-003 Ass'y, Scale Option (Yaskawa) machine control must be Pentium based)
_____003-1005-006 Ass’y, Chip Conveyor --------007-0020-001 UltiNet Option(If v2.00,v2.01 or v2.02 on
_____003-1005-007 Ass’y, Washdown machine then must order 007-4121-040
_____415-0250-903 8MB RAM (order MULTIPLES OF 2) Upgrade Pkg ; If v1.xx on machine then must
_____415-0250-904 16MB RAM (order MULTIPLES OF 2) order 007-4121-041 Upgrade Pkg)
_____007-3402-001 Pkg., 3.5” MAX/PC Comm
--------003-1016-021 Kit,8K Spindle with Coolant(YASKAWA)
--------003-1016-016 Kit,12K Spindle with Coolant
--------003-1016-017 Kit,12K Spindle Non-Coolant
--------007-3010-003 Kit, MAX4 DSM Delight Package
--------007-3010-006 ISNC
------ -002-4321-010 ASS’Y,ROTARY TABLE TB200 COMPLETE
-------002-4321-011 ASS’Y,ROTARY TABLE TB250 COMPLETE
-------002-4321-014 TB200 ROTARY TABLE ONLY
-------002-4321-015 TB250 ROTARY TABLE ONLY
-------002-4321-013 ROTARY TABLE INTERFACE
-------007-3010-012 PROBE KIT,(YASKAWA)

REV LEVEL W
BMC3017/SSM
SUPERCEDES BMC30/SSM
USA
REVISED 01/28/00


Lead Time: ______________Planner Code_____ _________________________________________
BASE PART NUMBER: B3SM CHANGE OPTIONS: A = Add D = Delete

------B30-0903-001H USA W/SIEMENS(SLIM CONTROL)
------B30-0911-001H USA W/YASKAWA(SLIM CONTROL) ____007-4124-001 3D Mold
2. OPTIONS _____007-4124-007 DXF
_____007-4124-011 NCPP (REQUIRES 007-3010-006 OR
____003-1005-005 Ass'y Chip Conveyor and Wash Down Option 007-3010-009 ISNC)
(Includes Chip Conveyor Ass'y & Washdown Assy') _____007-4124-003 Ultipockets
_____415-0250-903 8MB RAM (order multiples of 2) _____007-4124-008 Rigid Tapping
_____415-0250-904 16MB RAM (order multiples of 2) --------007-4124-021 UltiProII (for machines with v2.11 & up
_____007-3402-001 Pkg., 3.5” MAX/PC Comm only-machine control must be
_____003-1016-008 BT Tooling Ass'y (UK & Germany ONLY) Pentium based)
_____002-4321-010 Ass'y, Rotary Table TB200 Complete -------007-0020-001 UltiNet Option(if machines v2.00,v2.01
_____002-4321-014 TB200 Rotary Table Only or v2.02 on machine then must order
_____002-4321-013 Rotary Table Interface 007-4121-040Upgrade Pkg. If v1.xx on
_____003-1005-006 Ass’y, Chip Conveyor machine then must order 007-4121-041
_____003-1005-007 Ass’y, Washdown Upgrade Pkg.)
_____707-1021-001 Scroll Chuck for TB200 RT

--------003-1016-021 Kit,8k Spindle With Coolant(YASKAWA)

------003-1016-016 Kit,12k Spindle With Coolant
------003-1016-017 Kit,12k Spindle Non-Coolant
------003-1023-002 Ass’y,SSM Console Keyboard
------003-1024-001 Ass’y,Remote Jog Control (SSM ONLY)
------007-3010-008 MAX4 DSM UPGRADE
------007-3010-006 ISNC(MAX4 DSM ONLY)
-----007-3010-009 ISNC (SLIM SSM ONLY)
-----007-3010-014 PROBE KIT,(SIEMENS)
NOTE;PROBE WILL BE SUPPLIED BY DISTRIBUTER)

REV LEVEL V
BMC30/SSM
UK,GERMANYAND ASIA
REVISED 01/28/00


Lead Time: ______________Planner Code_____ _________________________________________
BASE PART NUMBER: B3SME CHANGE OPTIONS: A = Add D = Delete

B3SMG
B3SMA

------B30-0903-002 UK W/SIEMENS(SLIM CONTROL)
------B30-0903-003 GERMANY W/SIEMENS(SLIM CONTROL) _____007-4124-001 3D Mold
-----B30-0903-004 ASIA W/SIEMENS(SLIM CONTROL) _____007-4124-002 Insert Pockets
-----B30-0911-002 UK W/YASKAWA(SLIM CONTROL) _____007-4124-007 DXF
-----B30-0911-003 GERMANY W/YASKAWA(SLIM CONTROL) _____007-4124-011 NCPP (REQUIRES 007-3010-006 OR
----B30-0911-004 ASIA W/YASKAWA(SLIM CONTROL) 007-3010-009 ISNC )
_____007-4124-003 Ultipockets
2. OPTIONS _____007-4124-008 Rigid Tapping
--------007-4124-021 UltiProII (for machines with v2.11 & up
_____003-1005-005 Ass'y Chip Conveyor and Wash Down Option only-machine control must be
(Includes Chip Conveyor Ass'y & Washdown Assy') Pentium based)
_____415-0250-903 8MB RAM (order multiples of 2) -------007-0020-001 UltiNet Option(if machines v2.00,v2.01
_____415-0250-904 16MB RAM (order multiples of 2) or v2.02 on machine then must order
_____007-3402-001 Pkg., 3.5” MAX/PC Comm 007-4121-040Upgrade Pkg. If v1.xx on
_____003-1016-008 BT Tooling Ass'y (UK & Germany ONLY) machine then must order 007-4121-041
Upgrade Pkg.)
_____002-4321-010 Ass'y, Rotary Table TB200 Complete
_____002-4321-014 TB200 Rotary Table Only
_____002-4321-013 Rotary Table Interface
_____003-1005-006 Ass’y, Chip Conveyor
_____003-1005-007 Ass’y, Washdown
------003-1016-016 Kit,12k Spindle With Coolant
------003-1016-017 Kit,12k Spindle Non-Coolant
------003-1023-002 Ass’y,SSM Console Keyboard
------003-1024-001 Ass’y,Remote Jog Control (SSM ONLY )
------007-3010-008 MAX4 DSM UPGRADE
------007-3010-006 ISNC (MAX4 DSM ONLY)
------007-3010-009 ISNC (SLIM SSM ONLY )

REV LEVEL Y CONFIGURATION SHEET
BMC4020HTDSM
USA
REVISED 01/28/00



1. REQUIRED BASIC CONFIGURATION (Select One) 3. OPTIONAL SOFTWARE
--------B40-0805-001H USA(COLOR)MAX4 W/SIEMENS

--------B40-0813-001H USA(COLOR)MAX4 W/YASKAWA _____007-4124-001 3D Mold
2. OPTIONS _____007-4124-002 Insert Pockets
_____007-4124-007 DXF
_____003-1005-005 Ass'y Chip Conveyor and Wash Down Option _____007-4124-011 NCPP (Requires 007-3010-006)
(Includes Chip Conveyor Ass'y & Washdown Ass'y)
_____003-1016-008 BT Tooling Ass'y _____007-4124-003 Ultipockets
_____415-0250-903 8MB RAM (Order multiples of 2) _____007-4124-008 Rigid Tapping
_____415-0250-904 16MB RAM (Order multiples of 2) _____007-4124-021 UlitPro II (for machines with v2.11& up only-
machines
_____007-3402-001 Pkg., 3.5” MAX/PC Comm control must be Pentium based)
--------007-0020-001UltiNet Option (if v2.00,v2.01or v2.02 on
machine
then must order 007-4121-040 Upgrade Pkg.
_____002-4321-010 Ass’y, Rotary Table TB200 Complete ifv.xx on machine then must be order 007-4121
_____002-4321-011 Ass'y, Rotary Table TB250 Complete 041 Upgrade Pkg.)
____002-4321-014 TB200 Rotary Table Only

_____003-2015-003 Conversion from 6500 RPM to 8000 RPM Spindle

Option
_____003-1005-007 Ass’y, Washdown
_____003-2018-001 Ass’y, Scale Option

-------003-1016-021 Kit,8k Spindle With Coolant (Siemens))
--------003-1016-018 Kit,12k Spindle With Coolant (Siemens)
-------003-1016-019 Kit,12k Spindle Non-Coolant (Siemens)
--------007-3010-003 Kit, MAX4 DSM Delight Package
-------007-3010-006 ISNC

REV LEVEL AA CONFIGURATION SHEET
BMC4020HT/DSM
UK, GERMANY AND ASIA
REVISED 01/28/00


Lead Time: ___________________Planner Code_____ _________________________________________
BASE PART NUMBER: B42ME CHANGE OPTIONS: A = Add D = Delete

B42MG
B42MA
1. REQUIRED BASIC CONFIGURATION (Select One) 3. OPTIONAL SOFTWARE

--------B40-0805-002 UK(COLOR)MAX4 W/SIEMENS
------ -B40-0805-003 GERMANY(COLOR)MAX4 W/SIEMENS _____007-4124-001 3D Mold
------- B40-0805-004 ASIA(COLOR)MAX4 W/SIEMENS _____007-4124-002 Insert Pockets
--------B40-0813-002 UK(COLOR)MAX4 W/YASKAWA _____007-4124-007 DXF
------- B40-0813-003 GERMANY(COLOR)MAX4 W/YASKAWA _____007-4124-011 NCPP (Requires 007-3010-006)
------ B40-0813-004 ASIA(COLOR)MAX4 W/YASKAWA
_____007-4124-003 Ultipockets
2. OPTIONS _____007-4124-008 Rigid Tapping
--------007-4124-021 UltiPro II (for machines with v2.11& up only-
_____003-1005-005 Ass'y Chip Conveyor and Wash Down Option machine control must be Pentium
(Includes Chip Conveyor Ass'y & Washdown Ass'y) based)
_____003-1016-008 BT Tooling Ass'y (UK & Germany ONLY) --------007-0020-001 UltiNet Option (if v2.00,v2.01 orv2.02
_____415-0250-903 8MB RAM (order multiples of 2) on machine then must order 007-4121-040
_____415-0250-904 16MB RAM (order multiples of 2) Upgrade Pkg: If v1.xx on machine then must
_____007-3402-001 Pkg., 3.5” MAX/PC Comm order 007-4121-041 Upgrade Pkg)
--------002-4321-010 Ass’y, Rotary Table TB200 Complete

_____002-4321-011 Ass'y, Rotary Table TB250 Complete

_____003-2015-003 Kit, Conversion from 6500 RPM to 8000 RPM

Spindle

_____003-1005-007 Ass’y, Washdown
------003-1016-019 Kit,12k Spindle Non-Coolant (Siemens)

------007-3010-003 Kit,Max 4 DSM Delight Package

REV LEVEL AA CONFIGURATION SHEET
BMC4020HT/DSM
UK, GERMANY AND ASIA
REVISED 01/28/00
------007-3010-006 ISNC

REV LEVEL V
BMC4020/SSM
USA
REVISED 01/28/00


BASE PART NUMBER: B42S CHANGE OPTIONS: A = Add D = Delete

.-------B40-0905-001H USA (SLIM CONTROL) W/SIEMENS
-------B40-0913-001H USA(SLIM CONTROL) W/YASKAWA _____007-4124-001 3D Mold
2. OPTIONS _____007-4124-007 DXF
_____007-4124-011 NCPP (REQUIRES 007-3010-006 OR
_____003-1005-005 Ass'y, Chip Conveyor & Wash Down Ass'y Option 007-3010-009 ISNC )
(Includes Chip Conveyor Ass'y & Washdown Ass'y) _____007-4124-003 Ultipockets
_____003-1016-008 BT Tooling Ass'y _____007-4124-008 Rigid Tapping
_____415-0250-903 8MB RAM (order2) -------007-4124-021 UltiPro II (for machines with v2.11 &
up
_____415-0250-904 16MB RAM (order2) only-machine control must be
_____007-3402-001 Pkg., 3.5” MAX/PC Comm Pentium based)
_____002-4321-010 Ass'y, Rotary Table TB200 Complete -------007-0020-001 UltiNet Option (If v2.00,v2.01 or v2.02on
_____002-4321-011 Ass'y, Rotary Table TB250 Complete machine then must order 007-4121-040
_____002-4321-014 TB200 Rotary Table Only Upgrade pkg: If v1.xx on machine then
_____002-4321-015 TB250 Rotary Table Only must order 007-4121-041 Upgrade Pkg)
_____003-1005-007 Ass’y, Washdown

Spindle
-------003-1016-021 Kit,8k Spindle With Coolant(YASKAWA)

--------003-1016-018 Kit,12k Spindle With Coolant
--------003-1016-019 Kit,12k Sindle Non-Coolant
--------003-1023-002 Ass’y,SSM Console Keyboard
--------003-1024-001 Ass’y,Remote Jog Control (SSM ONLY )
-------007-3010-008 MAX4 DSM UPGRADE
-------007-3010-006 ISNC (MAX4 DSM ONLY )
------007-3010-009 ISNC (SLIM SSM ONLY )
,

REV LEVEL V
BMC4020/SSM
ASIA
REVISED 01/28/00


BASE PART NUMBER: B42SA CHANGE OPTIONS: A = Add D =

Delete

--------.B40-0905-004 ASIA (SLIM CONTROL) W/SIEMENS
--------B40-0913-004 ASIA (SLIM CONTROL) W/YASKAWA _____007-4124-001 3D Mold
2. OPTIONS _____007-4124-007 DXF
_____007-4124-011 NCPP (REQUIRES 007-3010-006 OR
_____003-1005-005 Ass'y, Chip Conveyor & Wash Down Ass'y Option 007-3010-009 ISNC )
(Includes Chip Conveyor Ass'y & Washdown Ass'y) _____007-4124-003 Ultipockets
_____415-0250-903 8MB RAM (order multiples of 2) _____007-4124-008 Rigid Tapping
_____415-0250-904 16MB RAM (order multiples of 2) ---------007-4124-021 UltiPro II (for machines with v2.11 & uponly
_____007-3402-001 Pkg., 3.5” MAX/PC Comm machine control must be
_____002-4321-010 Ass'y, Rotary Table TB200 Complete Pentium based)
_____002-4321-011 Ass'y, Rotary Table TB250 Complete -------007-0020-001 UltiNet Option (if v2.00,v2.01 or v2.02
_____002-4321-014 TB200 Rotary Table Only on machine then must order 007-4121-040
_____002-4321-015 TB250 Rotary Table Only Upgrade Pkg)
_____003-1005-007 Ass’y, Washdown


Spindle
--------003-1016-018 Kit,12k Spindle With Coolant
--------003-1016-019 Kit,12k Spindle Non-Coolant
--------003-1023-002 Ass’y,SSM Console Keyboard
--------003-1024-001 Ass’y,Remote Jog Control (SSM ONLY )
-------007-3010-008 MAX4 DSM UPGRADE
------007-3010-006 ISNC (MAX4 DSM ONLY )
-----007-3010-009 ISNC (SLIM SSM ONLY )

CONFIGURATION SHEET C2063XLS
11REV LEVEL G
BMC6434/DSM
REVISED 1/28/00
Customer Name ________________________________ Sales Order Number

_________________________
Data Entry_____________________________________ Order
Date_________________________________
Work Order Reference ___________________________ Requested Ship
Date_________________________
NOTE: Enter all Shop Orders as MAKE w/an Order Policy of F Scheduled Ship
Date_________________________

Lead Time: _________________Planner Code_____ ________________________________________

B64ME
B64MG
B64MA
----007-4124-001 3D MOLD
_____B64-0807-001 H BMC6434/DSM USA ----007-4124-002 INSERT POCKETS
_____B64-0807-002 BMC6434/DSM UK
_____B64-0807-003 BMC6434/DSM GERMANY
---------B64-0807-004 BMC6434/DSM ASIA ----007-4124-007 DXF
----007-4124-011 NCPP
(REQUIRES 007-3010-006ISNC
----007-4124-003 ULTIPOCKETS
2.OPTIONS ----007-4124-008 RIGID TAPPING
----007-4124-021 ULTIPRO II
------007-3010-003 Kit,MAX4 DSM Delight Package ----007-0020-001 ULTINET
------007-3010-006 ISNC
------003-6011-001 Ass’y,Chip Conveyor
( Option Ordered By The Distributor)
------002-4321-018 Ass’y,Rotary Table TT250 Complete
------002-4321-010 Ass’y,Rotary Table TB 200 Complete
-----002-4321-011 Ass’y,Rotary Table TB250 Complete
------002-4321-017 Rotary Table Only TT250
------002-4321-014 Rotary Table Only TB200
------002-4321-015 Rotary Table TB250
------002-4321-016 Rotary Table Interface TT250
------002-4321-013 Rotary Table Interface TB200 and
TB250
------003-6005-004 Ass’y,Linear Scale
------007-3010-012 Probe Kit,(YASKAWA)

11REV LEVEL A
BMC6434/DSM/50T
REVISED 1/28/00



B65ME
B65MG
B65MA
_____B65-0815-001H BMC6434/DSM USA

_____B65-0815-002 BMC6434/DSM UK
_____B65-0815-003 BMC6434/DSM GERMANY
_____B65-0815-004 BMC6434/DSM ASIA
2. OPTIONS ____007-4124-001 3D MOLD

____007-4124-002 INSERT POCKETS
____007-3010-003 KIT,MAX4 DSM DELIGHT PACKAGE ____007-4124-007 DXF
____007-3010-006 ISNC ____007-4124-011 NCPP
____003-6011-001 ASS’Y,CHIP CONVEYOR (REQUIRES 007-3010-006 ISNC)
(OPTION ORDERED BY THE DISTRIBUTOR) ____007-4124-003 ULTIPOCKETS
____002-4321-018 ASS’Y,ROTARY TABLE TT250 COMPLETE ____007-4124-008 RIGID TAPPING
____002-4321-010 ASS’Y,ROTARY TABLE TB 200 COMPLETE ____007-4124-021 ULTIPRO II
____002-4321-011 ASS’Y,ROTARY TABLE TB 250 COMPLETE ____007-0020-001 ULTINET
____002-4321-017 ROTARY TABLE ONLY TT250
____002-4321-014 ROTARY TABLE ONLY TB200
____002-4321-015 ROTARY TABLE TB250
____002-4321-016 ROTARY TABLE INTERFACE TT250
____002-4321-013 ROTARY TABLE INTERFACE TB200 AND
TB250
____003-6005-004 ASS’Y,LINEAR SCALE
____007-3010-012 PROBE KIT,(YASKAWA)
NOTE: PROBES WILL BE SUPPLIED BY DISTRIBUTOR
____003-1016-034 CHILLER HEAD THERMAL COMPENSATION

CONFIGURATION SHEET C2068
REV LEVEL D
VTC40
REVISED 1/28/00


Master Schedule__________________By ________ _________________________________________
Lead Time:_________________Planner Code_____ _________________________________________
BASE PART NUMBER: B6L CHANGE OPTIONS: A = Add D = Delete

. ----007-4124-001 3D MOLD
------B6L-0810-001H VTC40USA MAX 4(COLOR) ----007-4124-002 INSERT POCKETS
----007-4124-007 DXF
----007-4124-011 NCPP
(REQUIRES 007-3010-006 ISNC)
----007-4124-003 ULTIPOCKETS
2.OPTIONS ----007-4124-008 RIGID TAPPING
----007-4124-021 ULTIPRO II
------007-3010-003 Kit, MAX4 DSM Delight Package ----007-0020-001 ULTINET
-----007-3010-006 ISNC
Serial Number:______________ Page 1

CONFIGURATION SHEET C2068
REV LEVEL D
VTC40
REVISED 1/28/00
Serial Number:______________ Page 2

FANUC
D8387 757-4001-060 Fanuc Orient Card Setup Procedure

D8391 757-4001-065 BMC20/50 Fanuc Servo Amplifier Setup Procedure
D8396 757-4001-073 Fanuc AC3CS 18P and 22P Spindle Drive
Configuration & Setup Procedure
D8399 757-4001-061 Fanuc Digital Spindle Drive Setup Procedure
D8405 757-4001-062 Fanuc Analog Spindle Drive Setup Procedure
HURCO
ENGINEERING DOCUMENT
757-4001-060 Rev. C D8387
06/15/89
SUBJECT: FANUC SPINDLE DRIVE ORIENT CARD SETUP PROCEDURE FOR BMC 20/50
1. INTENT
To provide a standardized method of adjusting the Fanuc Orient Card used in the Fanuc Spindle Drive on BMC 20/50
Machining Centers.
II. APPLICABILITY
Applicable to all BMC 20/50 Machining Centers. This procedure should be used within HURCO facilities and at Customer
facilities to assure correct setup of the Orient Card.
Ill. FORMAT
Page 2 - Variable Resistor Data
Page 3 thru 4 - LED Indicator Data, Jumper settings, Adjustment Procedure.

ORIENT CARD VARIABLE RESISTOR DATA:
RVI TS Offset - Tachometer offset. Provides compensation for the difference of the slow down time in normal and reverse
rotating direction. The standard setting is 5 divisions. Adjust until the difference of the slow down time between
normal and reverse direction is less than 0.1 seconds.
RV2 MS Peak Level - Set to the position where LED 3 (MS Peak Level) starts flickering while depressing SWI (Initializing
button) Note that it is best to set this in the Low gear range first.
RV3 Slowdown Reference - Slowdown speed reference. Set according to the distance between the rotation centerline of the
magnetizing element and the center of the sensor head face. Standard setting is 4.5 divisions.
RV4 AMS Peak Level - AMS signal level amplitude value. Set according to the distance between the rotation centerline of
the magnetizing element and the center of the sensor head face. Standard setting is 4.5 divisions.
RV5 Slowdown Time (High Gear) - Adjusts slowdown time in High Gear range. LED 4 (Slowdown Period) should turn
on a moment prior to the spindle stopping.
RV6 Gain (High Gear) - Position loop gain adjust. Turn CW to achieve maximum gain that doesn't cause any overshoot
when the spindle stops.
RV7 In Position (High Gear) - Fine in position adjust. LED 5 (In Position Fine) should turn on during the time LED 6 (In
Position) is on. LED 6 turns on when spindle is within 1 degree, LED 5 turns on when spindle is within +/- .1 degree.
RV8 Slowdown Time (Low Gear) - Same as RV5 except for Low Gear.
RV9 Gain (Low Gear) - Same as RV6 except for Low Gear.
RV 1O In Position (Low Gear) - Same as RV7 except for Low Gear.
RV 11 Position Shift - Spindle Stop Position Shift - Adjusts the stop position of the spindle. This position can be adjusted
within a range of +/- 1-degree.
RV12 (AC & DC) - High Gain - Standard setting value of 7 divisions for RV12 AC and 0 divisions for RV12 DC.
ORIENT CARD LED INDICATOR DATA:
LED I - Orientation in progress - Lights when spindle orientation command is given.
LED 2 - Low Gear - Lights when clutch gear Low signal is turned on.
LED 3 - MS Peak Level - Lights when the peak values of the magnetic flux detection signal (MS) exceeds +/- 1OV.
LED 4 - Slowdown Period - Lights when the spindle approaches the stop position and enters the low speed rotation area
during orientation.
LED 5 - In Position Fine - Lights when spindle is within .1 degrees of orient position.
LED 6 - In Position - Lights when spindle is within 1 degree of the aimed adjusting position after completion of spindle
orientation.
LED 7 - Test Mode Lights when setting terminal SH101 pins are shorted.
Check Orient card Jumpers
SH 01 = open SH 02 = 2 – 3 SH 03 = 1 – 2 SH 04 = 2 – 3 SH 05 = 2 – 3
ADJUSTMENT PROCEDURE:
1. Adjust the gap between the magnetizing element and the sensor head, so that the minimum gap value is 1.5mm (+/-
.5mm.)
2. Select “ATC Diagnostics” , press “ENTER” “488” , “ENTER”. Select the “Spindle Orient” diagnostics softkey. This will
put the spindle into one of the two gear ranges. The range can be determined by the status of LED 2.
3. Move the shunt on the orient card (SH101) to test. Verify that LED 7 turns on.
4. Depress the Test button (SW1) to command the spindle to orient while adjusting RV2 so LED 3 just starts to flicker on.
Note that a more precise adjustment is obtained in the Low gear range.
5. Adjust the In Position pot (RV 7 or RV 10) so both LED's 5 and 6 are on after releasing SW1.
6. Adjust the gain pot (RV 6 or RV 9) so that no overshoot occurs after commanding an orient via SW1.
7. Adjust slowdown pot (RV 5 or RV 8) so that LED 5 just flashes prior to LED's 5 and 6 turning on.
8. When current gear range orient adjustment is complete use softkey to put spindle into the other gear range.
9. Perform the same adjustments as in steps 4 thru 7 to obtain the correct orient adjustment in this gear range.
10. After adjustments, cancel the test mode by removing the shunt shorting the pins of SH101. Make sure that LED 7 turns
off and then exit the Orient diagnostics.
11. Go to Manual mode and jog the Z-axis up to the plus limit switch. Then select “Lock Spindle.”
12. Enter ATC Diagnostics and move the magazine right.
13. Jog the Z-axis down near the top of the tool changer magazine.
14. Looking from directly under the spindle visually inspect the alignment of the spindle centerline to the magazine
centerline. Adjust the position shift pot (RV 11) located on the orient card so as they are in alignment.
757-4001-073 Rev. C PIN 10218
05/19/89 D 8396
SUBJECT: FANUC AC3S/18P/22F SPINDLE DRIVE SETUP PROCEDURE
1. INTENT
To provide a standardized procedure for the configuration and adjustment the Fanuc Spindle Drives used on BMC 20/50
VI type Machining Centers.
II. APPLICABILITY
Applicable to all BMC 20/50 VI Machining Centers. This procedure to be used within HURCO facilities and should be
used at Customer facilities to assure correct Spindle Drive setup.
Ill. FORMAT
PAGES 2 to 4 - AC3S SETUP PROCEDURE
PAGES 5 to 6 - 18P/22P SETUP PROCEDURE
NOTE: Several versions of Fanuc Firmware have been used in the Digital Spindle Drive, only some of these versions will work
with HURCO Machines. The following is a description of the firmware that we have seen used to date:
AC3S: (BMC 20 V1 no winding select)

The Proms are located in sockets MD30 (Top Prom 9810) and MC30 (Bottom Prom 9810). The proms have a version
code suffix. Version C will function properly.
18P:
The Proms are located in sockets MD30 (Right Hand Prom 9629-001, Left Hand Prom 9629-002). Version L functions
properly. Version M does not, and should not be used.
IV. AC3S SETUP PROCEDURE
1. Verify that the Shunt Jumpers are configured as shown below:

JUMPER DESCRIPTION SETTING
S1 Switches Control Circuit Mode DRIVE
S2 Maximum Speed Setting C
S3 Maximum Speed Setting C
S4 Setting For Gain Switching Circuit OFF (Top two pins set normal operation)
S5 Setting For Gain Switching Circuit OFF (Top two pins set normal operation)
2. Turn "ON Main Disconnect to Machine.
3. Verify RV5 (Gain) is at 50% and RV4 (5 Volt adi.) at +5 VDC +/- 0.1 VDC.
4. Adjust RV3 (Offset of speed detection circuit) to obtain 0 mV +/- 0.1 mV at TS3.
5. Set the Parameters shown on Pages 3 and 4 by method listed below:
NOTE: THE ADJUSTING BUTTONS AND DISPLAY ARE ARRANGED ON THE PCB AS SHOWN BELOW. THESE
BUTTONS ENABLE ARE TO CONFIRM AND ENTER THE PARAMETERS.
DISPLAY ADJUSTMENT BUTTONS

MODE UP
88888
DATE DOWN
SET
A. Depress all 4 buttons. "MODE", "UP", DOWN", and "DATA SET", for more than one (1) second.
B. The display will go from Blank to FFFFF".
C. Release the buttons.
NOTE: The current parameter is displayed when "MODE' is depressed. Using 'UP" or 'DOWN' while 'MODE' is depressed will
display the parameter numbers. Release “MODE” and the data is displayed for that Parameter number. When all
buttons are OFF for approximately 5 Seconds the speed will be displayed.
D. To alter data:
1. Select the Parameter to be changed.
2. Release "MODE" button.
3. Use "UP" or "DOWN' to increment or decrement the data.
4. After replacing all the data with the modified data, depress 'DATA SET' until the Display changes to 88888. The
new data is toggled into memory.
CAUTION: YOU MUST Depress "DATA SET and hoId to get all "88888 on- the Display.
If this is not done all altered data will be lost.
PARAMETER LIST
MODE CONTENTS SET DATA
F-01 MACHINE READY SIGNAL (MRDY) 0000 (Ready disabled)

ENABLE/DISABLE
F-02 ENABLE/DISABLE SPEED OVERRIDE Locked Out (N/A)
F-03 SPEED OVERRIDE RANGE Looked Out (N/A)
F-06 OUTPUT LIMIT PATTERN SETTING 0001 (Limits Accel/Decel Output Limit)
F-07 OUTPUT LIMIT SETTING 0100 (Sets Max Output)
F-08 DELAY TIME BEFORE MOTOR SHUT-OFF 0005 (Sets delay to 200 ms)
F-09 USE/NON-USE OF (MRDY) SIGNAL 0000 (Mrdy not used)
F-10 CW VELOCITY DEVIATION OFFSET SET for 1000 RPM at Spindle
F-11 CCW VELOCITY DEVIATION OFFSET SET for IEOO RPM at Spindle
F-12 ORIENT VELOCITY DEVIATION OFFSET 0128
F-13 Replaced by RVI Adjust RVI (CCW Max Speed)

F-14 Replaced by RV2 Adjust RV2 (CW Max Speed)
F-15 RPM AT MAXIMUM COMMAND VOLTAGE 0080 (D IOV DAC = F15 x 100)
F-16 ARRIVE SIGNAL DETECTION RANGE 0015 (Command speed x F16%)
F-17 VELOCITY DETECTION RANGE LEVEL 0003 (Max speed x Fi7%)
F-18 TORQUE LIMIT SETTING VALUE 0050 (Max rated torque x F18%)
F-19 ACCEL/DECEL TIME 0010 (Time in see. x 2)
F-20 DECEL TIME (REGEN POWER LIMIT) 0040
F-21 HIGH GEAR VELOCITY PHASE P COMP. 0020
F-22 LOW GEAR VELOCITY PHASE P COMP. 0020
F-23 HIGH GEAR ORIENT PHASE P COMP. 0040
F-24 LOW GEAR ORIENT PHASE P COMP. 0040
F-25 HIGH GEAR VELOCITY PHASE I COMP. 0010
F-26 LOW GEAR PHASE I VELOCITY COMP. 0010
F-27 HIGH GEAR ORIENT PHASE I COMP. 0010
F-28 LOW GEAR ORIENT PHASE I COMP. 0010

MODE CONTENTS SET DATA
F-29 Speed Detect offset adjust Locked Out (N/A)
F-30 Speed Detect Adjust Locked Out (N/A)
F-31 RIGID TAP MODE SETTING 0000 (Sets torque limit)
F-32 NORMAL MOTOR VOLTAGE SET 0010
F-33 ORIENT MOTOR VOLTAGE SET 0010
F-34 RIGID TAP MOTOR VOLTAGE SET 0100
F-35 ZERO SPEED DETECT LEVEL 0075 (Max speed x F35/100%)
F-36 LOAD DETECT LEVEL 0090 (Max level x F36%)
F-37 DECEL TORQUE TIME CONSTANT 0000 (O Ms)
6. Program Spindle for CW rotation of 1000 and 6000 RPM.
7. Adjust RV1 for 6000 RPM at Spindle. Verify with Digital Tachometer. (Note: Potentiometer is very sensitive).
8. Adjust Parameter F-10 for 1000 RPM at Spindle. Verify with Digital Tachometer.
9. Repeat Steps 7 and 8 untiI both the 1000 and 60" -RPM are correct.
10. Program Spindle for CCW rotation of 1000 and 6000 RPM.
11. Repeat Steps 7 thru 9 using RV2 and F-11 instead of RVI and F-10.
12. Check the following speeds with a digital tachometer and verify they are within the acceptable range.
PROGRAMED RPM ACCEPTABLE RANGE

60 RPM +/- 5 RPM
1000 RPM +/- 5 RPM
3000 RPM +/- 5 RPM
6000 RPM +/- 5 RPM
13. Set Orient Card per Engineering Document 757-4001-060.

V. 18P/22P SPINDLE DRIVE SETUP PROCEDURE:
Note: When new Proms are installed follow steps below. Otherwise start at step 2.
1. Move jumper to Drive position.

2. Power up.
3. Preset functions:
Press all 4. buttons and hoId. to get all F’s.
MODE DATA MODE DATA MODE DATA

F-00 0000 F-14 0128 F-28 0030
F-01 0000 F-15 0060 F-29 NOTE 1
F-02 0000 F-16 0015 F-30 0000
F-03 0000 F-17 0003 F-31 0000
F-04 0000 F-18 0050 F-32 0010
F-05 0001 F-19 0010 F-33 0010
F-06 0001 F-20 006e F-34 0100
F-07 0100 F-21 0050 F-35 0075
F-08 0005 F-22 0050 F-36 0000
F-09 0000 F-23 0100 F-37 0000
F-10 0128 F-24 0100 F-38 0000
F-11 0128 F-25 0030 F-39 0000
F-12 0128 F-26 0030 F-40 0000
F-13 0128 F-27 0030
NOTE 1: Adjust data so that terminal TS-3 is 0 V +/- 0.1 mV with motor stopped.
4. Move jumper to test position.
5. Turn power on to machine.
6. Read out should display 1’s to F’s
7. Press all 4 buttons and hold to get all F’s.
8. Press Mode" button and select F22
9. Press "Data Set, and hold until display reads “GOOD.”
10. Power down.
11. Enter a program 1000 RPM and 6000 for (BMC 30/40), 1000 and 4000 for BMC
12. Run spindle at the maximum RPM (4000 or 6000 RPM) on CRT.
13. Adjust F-13 to get 6000 +/-5RPM. or 4000 +/- 5 RPM at spindle. Verify with digital tachometer.
14. Run spindle at 1000 RPM on CRT.
15. Adjust F-10 to get 1000 RPM at spindle.
16. Repeat steps 11 thru 15 until low end reads 1000 RPM and high end reads 6000 or 4000 RPM +/- 5 RPM.
17. Enter program to run -1000 and -4000 RPM or -6000 RPM.
18. Run spindle at -4000. -6000 on CRT.
19. Adjust F-14 to get -4000, -6000 +/- 5 RPM at spindle.
20. Run spindle at -1000 on CRT.
21. Adjust F-11 to get -1000 at spindle,
22. Repeat steps 17 thru 21 until low end reads -1000 and high end reads -4000, -6000 +/- 5 RPM.
23. Press 'Data Set' and hold to get 88888 on display.
Caution: If you don't set data.- the Parameters will revert to previous settings when machine is powered down.
24. Check the following speeds with a digital tachometer:
PROGRAMED RPM ACCEPTABLE RANGE
60 RPM 5 RPM
1000 RPM 5 RPM
3000 RPM 5 RPM
4000 RPM 5 RPM
6000 RPM 5 RPM
25. Set up Orientation Card per Engineering Document 757-4001- 080.
Alarms
AL-17 = MEMORY LOSS. (LOSS of PARAMETERS)
Follow ENG DOC # 757-4001-073 ( This document)
If this does not clear, you may have a bad memory chip.
CP28 is the memory chip, HURCO STOCK # 330-271
HURCO
757-4001-061 Rev. C D8399
08/16/89
SUBJECT: FANUC DIGITAL SPINDLE DRIVE SETUP PROCEDURE FOR BMC 30/50
1. INTENT
To provide a standardized procedure for the configuration and adjustment the Fanuc Digital Spindle Drive
used on BMC 30/50 type Machining Centers.
2. APPLICABILITY
Applicable to all BMC 30/50 Machining Centers. This procedure to be used within HURCO facilities and
should be used at Customer facilities to assure correct Spindle Drive setup.
NOTE: Several versions of Fanuc Firmware have been used in the Digital Spindle Drive, only a few of these
versions will work with HURCO Machines. The following is a description of the firmware that we have
seen used to date:
The Proms are located in sockets MD3@ (right hand prom 9601-001) and MC30 (left hand side prom 9601-
002). The proms have a version code suffix. Versions B, E, R, P & L will function properly.
Version F is a maybe.
Versions D, S and T should not be used, as they will cause problems.
Version 9630-001 & -002 “L” is ok. It is unknown if Version “M” is functional.
FANUC AC SPINDLE DRIVE DIGI.TAL SETUP PROCEDURE.-
1. Check drive for damage.
2. Inspect PCB for any abnormality.
3. Move jumper to Test position.
4. Turn machine On.
5. Read out should display l's thru F's.
6. Press all 4 buttons and hold to get all F's.
7. Press & hold Mode key and select F-22.
8. Press Data Set and hold until display reads Good.
9. Power down.
10. Move jumper to Drive Position.
11. Power up.
12. Preset functions:
Press all 4 buttons and hold to get F's. Set data:
F-00 = 0000 F-14 = 0128 F-28 = 0030

F-01 = 0000 F-15 = Note 2 F-29 = Note 3
NOTES F-02 = 0000 F-16 = 0015 F-30 = 0000
#1 0001 (BMC 30/40) F-03 = 0000 F-17 = 0003 F-31 = 0000
0000 (BMC 50) F-04 = 0000 F-18 = 0050 F-32 = 0010
F-05 = Note 1 F-19 = 0010 F-33 = 0010
#2 0060 (BMC 30/40) F-06 = 0001 F-20 = 0060 F-34 = 0100
0045 (BMC50) F-07 = 0100 F-21 = 0050 F-35 = 0075
F-08 = 0005 F-22 = 0050 F-36 = 0000
#3 Adjust data so that terminal F-09 = 0000 F-23 = 0100 F-37 = 0000
TS-3 is 0mv with motor stopped F-10 = 0128 F-24 = 0100 F-38 = 0000
F-11 = 0128 F-25 = 0030 F-39 = 0000
F-12 = 0128 F-26 = 0030 F-40 = 0000
F-13 = 0128 F-27 = 0030
13. Enter a program to run 1010 and 4000 RPM for BMC 30/40 or 710 and 3000 for BMC 50.
14. Run spindle at 4000 RPM (3000 BMC 50) on CRT.
15. Adjust F-13 to get 4000 to 4004 (3000 to 3004 BMC 50) at spindle.
16. Run spindle at 1010 RPM (710 BMC 50) on CRT.
17. Adjust F-10 to get 1010 (710 BMC 50) at spindle.
18. Repeat steps 14 thru 17 until low end reads 1010 RPM (710 BMC 50) and high end reads 4000 to 4004
RPM (3000 to 3004 BMC 50).
19. Put in program to run -1010 and -4000 RPM (-710 and -3000 BMC 50).
20. Run spindle at -4000 (-3000 BMC 50) on CRT.
21. Adjust F-14 to get -4000 (-3000 BMC 50) at spindle.
22. Run spindle at -1010 (-710 BMC 50) on CRT.
23. Adjust F-11 to get -1010 (-710 BMC 50) at spindle.
24. Repeat steps 20 thru 23 until low-end reads -1010 (-710 BMC 50) and high end reads -4000 (-3000 BMC 50).
25. Press Data Set and hold to get “88888” on the display. Caution: If you don't set data, the parameters will
reset to previous settings when machine is powered down.
26. Check speeds at top and bottom of both gear ranges with a digital tachometer.
27. Set up Orientation Card per Engineering Document 757-4001-060.

HURCO AMPS, SILVER FACE
D8173 757-1002-051 Adjustment Procedure - Axis Assembly, HURCO

Servo Amp
Manufacturing Document
757-1002-051 D8173
SUBJECT : ADJUSTMENT PROCEDURE - HURCO SERVO AMPLIFIER ASSEMBLY
1. INTENT: To provide procedural adjustments for the HURCO Servo Amplifier.
II. SCOPE: All Field Service and Production 002-1690-001 thru -003 axis assemblies.
III. TOOLING REQUIREMENT: A. Digital Volt Meter, B. oscilloscope, Isolated Ground
IV PROCEDURE
The three set-up adjustment controls on each axis drive assembly are the Signal control, the Balance control and the
Response control. These controls are located on the front of the axis drive assembly. The proper adjustment procedure
for each control is as follows:
A. Response Control
1. Attach an oscilloscope across motor output.
2. Move the Current Limit switch on the logic board down to the 5 ampere position.
3. Turn the Response control clockwise until the motor oscillates. (Monitor O-Scope)
4. Then turn the control counterclockwise until the oscillation stops. After motor oscillation stops, turn the
Response control approximately five more turns counterclockwise.
5. Move the Current Limit switch back up to its normal position.
B. Balance Control
1. Connect a DVM across the DAC command signal from the servo control board.
2. With the machine in the OPERATE model adjust the Balance control to produce a zero reading on the
DVM. (+ 0.09 VDC)
C. Signal Control
1. Leave the DVM connected across the DAC signal to adjust the Signal control.
2.a. B-Series Machines - With the axis running at a feed rate of 25 inches per minute, adjust the Signal control
to produce a .9 (+ .010) volt reading on the DVM.
b. BX-Series Machines - With the axis running at a feed rate of 25 inches per minute, adjust the signal
control to produce a .650 volt (+ .010) reading on the DVM.
c. D-Series Machines - With the axis running at a feed rate of 40 inches per minute, adjust the signal control
to produce a .90 volt (+ .010) reading on the DVM.
D. Final Check
1. Tool calibrate, table zero. Ensure C.R.T. is 0.0000. (+ .0001)
2. Ensure all axes will rapid traverse (250 IPM for B & Bx, 400 IPM for D Control) over its full axis
travel, plus and minus direction.
Program a position data block and -rapid traverse "X" and "Y" axis over its full travel. For "Z",
program a drill data block, 250 IPM B & Bx, 400 IPM D Control, and drill over its full axis travel.
MAX 400 AMP
D8147 757-4001-116 BMC-40SLV MAX 400 Servo Amp Setup Procedure

757-4001-116 REV: B ECN #

R
09/08/92 CAD #D8147
SUBJECT: ELECTROCRAFT MAX 400 SERVO AMPLIFIER SET-UP

PROCEDURE
Rev. PIN No. Rev. Description Date

A Original Issue
B Updated to current specs, Added MHP 09/08/92
I. INTENT
To provide a standardized set-up and adjustment procedure for the Electrocraft MAX 400
amplifiers for the BMC-40 SLV.
II. APPLICABILITY
Applicable to all BMC-40SLV and MHP-20/30 Machining Centers. This procedure is to be

used within Hurco facilities by Manufacturing during the manufacture of all BMC-40SLV and
MHP-20/30 Machining Centers.
III. TOOLING REQUIREMENTS
Digital Voltmeter (DVM)

Potentiometer Adjustment Tool
IV. FORMAT
Pages 2 to 3: BMC-40SLV Procedure

Pages 4 to 5: MHP-20/30 Procedure
Responsible Reviewed
________________________________ _______ _______________________________ _______

Originator Date Mgr. Product Engineering Date
V. PROCEDURE FOR BMC-40SLV
A. SET UP
1. Preset amplifiers as follows:
ILIM - Full CW
RMSI - Full CW, 4 turns CCW
BAL - Full CW, 8 turns CCW
LAG - Full CW, 8 turns CCW
TACH - Full CW, 8 turns CCW
VCS - Full CW
(All potentiometers are 16 turn pots)
2. Remove the amplifier covers and verify jumpers are set as follows:
P8 1 to 2 - Isolates drive common from chassis ground.

P9 2 to 3 - Shield is connected to chassis ground.
3. Turn power on and calibrate machine: select <EXIT> softkey,

<MANUAL>, <POWER>, <START>, <CALIBRATE MACHINE>
softkey, <START>, <START> again when prompted to calibrate the ATC.
4. Move axes to mid travel.
5. Adjust axis DAC offset pots:
a. Select <CHANGE TOOL OR DIAGNOSTICS> softkey, <ATC

AND MACHINE DIAGNOSTICS> softkey, <ENTER>, 101,
<ENTER> to display the Spindle/Axis Diagnostic Setup Screen.
b. Select <AXIS BALANCE ADJUSTMENT>, (X, Y or Z axis),

<START>. The Dual Axis PCB will output an open loop DAC
command voltage of approximately 9.7 mV, alternating plus and
minus at three (3) second intervals.
c. Connect the DVM to P1-1 and P1-2 (DAC) of the appropriate

amplifier with the meter set on the millivolt scale.
d. Adjust the corresponding pot on the Dual Axis PCB's to achieve the
same voltage reading in the plus and minus directions, usually 9.7 mV
but voltage varies between amplifiers.
e. Return machine to the closed-loop servo mode in Manual Mode, press

<EXIT>, <MANUAL>.
f. Adjust the BALANCE pot on the amplifier to 0.0000 mV +/- 0.0002

mV.
2
g. Repeat for other axes.
6. Adjust the LAG pot CW until the axis motor begins to oscillate, then CCW
until the oscillation stops, and an additional two (2) turns CCW. An
oscilloscope may be used to view the transition between stable and unstable.
7. With the voltmeter set on the 2 Volt scale and connected across P1-1 and
P1-2, jog the axis at 40 ipm plus and minus. Adjust the TACH pot to
0.951 Volts +/- 0.001 Volt. An adjustment to the BALANCE pot may be
necessary to get the same reading in both directions.
B. AXIS CURRENTS
1. Depress <EMERGENCY STOP>.
2. With the DVM set on the 10 Amp DC scale, connect the meter in series with
the motor wire from P3-4 of the amplifier. Verify meter lead connections.
3. Release <EMERGENCY STOP>. Run the axes in both directions at

100 ipm over full axis travel. Record results below:
LOWEST HIGHEST MAX ALLOWABLE

X+
X-
Y+
Y-
Z+
Z-
NOTE: Currents greater than the MAX ALLOWABLE indicate a mechanical

problem causing the axis to bind.
COMPLETED BY: ______________________________ DATE: _________________
VI. PROCEDURE FOR MHP-20/30
A. SET UP
ILIM - Full CW
3
VCS - Full CW
P8 2 to 3 - Low Impedance Isolation. Drive common is isolated from

chassis ground through a 15 ohm resistor.
Replace the amplifier covers.
3. Turn power on.
4. Change display to show axis lag: release <EMERGENCY STOP>, select

<MODE SELECT>, 5, <RESET>, <RESET>, TM4, <ENTER>,
<MODE SELECT>, 0. Axis lag is displayed on the bottom right of the
screen.
5. Adjust BALANCE on the amplifiers to get 0.0000 +/- 0.0002 on the Lag
Display. This adjustment will allow the axes to reference.
6. Reference machine: select R, <CYCLE>.
7. Adjust the LAG Pot: turn the LAG pot CW until the motor begins to
oscillate, then CCW until the oscillation stops, and then an additional three
(3) turns CCW. An oscilloscope may be used to view the transitions
between stable and unstable.
8. Adjust the Lag Display: select 1, turn the Axis Feedrate Pot full CW. Jog
the axis plus (+) and minus (-) and observe the Lag Display. Adjust the
TACH and/or VCS to obtain 0.0150 +/- 0.0001 on the Lag Display. (May
require a slight BALANCE Pot adjustment to achieve the same reading in
both directions.)
9. Repeat for all 3 axes.
10. Run axis at 400 ipm full travel to verify proper operation and smoothness of
axes. Reset Lag Display on the drive if axis does not operate smoothly at
400 ipm.
B. AXIS CURRENTS
4
2. Set the DVM to the 10 Amp DC scale, connect the meter in series with the
motor wire from P3-4 of the amplifier. Verify meter lead connections.
3. Release <EMERGENCY STOP>. Run axes in both directions at 100 ipm

over full axis travel.
MACHINE AXIS TOLERANCE

MHP-20 X&Y 3-5 AMPS
Z+ 6-8 AMPS
Z- 3-5 AMPS
MHP-30 X&Y 5-7 AMPS
Z+ 6-10 AMPS
Z- 3-7 AMPS
If necessary, adjust gibs to achieve above specifications and record results in

the table below.
LOWEST HIGHEST
X+
X-
Y+
Y-
Z+
Z-
NOTE: Currents that do not fall within the tolerances specified indicate a mechanical
problem.
5
RANDTRONICS / SERVOMATE
D8171 757-1002-001 Servo Amp Adjustment

D8172 757-1002-002 Rand Tronics Servo Amp Set Up Procedure for MD1
D8333 757-3050-006 Servo Amp Setup Procedure, BMC10(L)/15
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SERVO DYNAMICS
FSB 1230 Servo Dynamics Setup, BMC30

D8477 757-4002-096 Servo Dynamics DC Servo Drive Set-up Procedure
with MAX3 ISA Control
D8564 757-4002-157 Servo Dynamics Setup, Hawk Bedmills
D_Special Westamp / Servodynamics Setup
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For Internal Use Only - Not for Distribution
757-4002-096 REV: B CAD# D8477
R
SUBJECT: Servo Dynamics DC Servo Drive Set-up Procedure with MAX3

ISA Control
Ronald M. England 7/26/96 Michael Caron 7/30/96_

________________________________ _______ _______________________________ ______
Originator Date Mgr. Controls and Integration Date
Rev. ECN Rev. Description Rev. By Date Appd By Date
A 13749 Release
B 13933 1) Page 3, step III-B was “Cut off W1 DEO 12/20/96
and W2 (zero ohm resistors). 2) Page 3,
RMS Pot measurement was U3-pin 5 to
TP1. 3) Page 3, Added step III-G
2
I. INTENT
To provide a Standardized procedure for the system set-up and configuration of the Servo
Dynamics DC servo drive.
II. APPLICABILITY
Applies to Hawk 5/SSM knee mill and BMC 30/SSM machining center with Ultimax 3 ISA
control.
III. PRE POWER-UP
A. Remove the x-axis servo card from the drive chassis.
B. B1 Remove shunt jumper assembly from center area of board located at reference
designator “NC LIM”.
C. Verify A/B jumper is in the “B” position for differential input mode.
D. Preset the pots as follows:
Pots Measurement Hawk 5/SSM BMC 30/SSM

Aux. Pot TP2 to TP1 fully CCW (0-2Ω) fully CCW (0-2Ω)
Sig. Pot TP3 to TP1 mid-range (approx. 10 KΩ) 5 KΩ
Tach Pot TP4 to TP1 7 KΩ x-axis: 4.55KΩ
y-axis: 4.61KΩ
z-axis: 4.95KΩ
CMP Pot TP5 to TP1 fully CCW, then 10 turns CW fully CCW, then 10 turns CW
(approx. 1 KΩ) (approx. 1 KΩ)
CL Pot J3-1 to J3-3 fully CCW, then 11 turns CW fully CW
(X/Y) or 7 turns CW (Z) (approx. 2.3KΩ)
RMS Pot fully CW fully CW
(R65) B2
Bal. Pot do not adjust at this time do not adjust at this time
E. Replace the servo card in the servo drive chassis.
F. Repeat steps A thru E for the y-axis and z-axis servo cards.
G. B3 Install shunt regulator assembly to amplifier chassis just above power capacitor.
Connect power lead wires across power capacitor terminals (BLK wire to BLK,
RED wire to RED).
IV. POWER UP
A. UltiMAX3 Control Parameter Verification
Load parameters from Engineering Document 757-4002-048 per machine type.
3
1. In Manual mode, select the <CHANGE TOOL OR DIAGNOSTICS> softkey
followed by the <ATC & MACHINE DIAGNOSTICS> softkey.
2. Select each axis softkey to load the Axis Tuning Parameters.
3. If an Axis Tuning Parameter needs to be changed, then enter the correct value per
the Engineering Document 757-4002-048.
4. After completing all changes for an axis, select the <BEGIN TUNE> softkey
followed by the <STORE PARAMETERS> softkey.
5. Press the <EXIT> softkey to return to the ATC & Machine Diagnostics screen.
6. Press the Auxiliary mode Key.
7. Select the <SYSTEM CONFIGURATION> softkey.
8. Insert the Machine Configuration diskette into the floppy drive.
9. Select the <BACKUP MACHINE CONFIGURATION> softkey.
10. When complete, remove the diskette from the floppy drive and store in a safe
location.
B. Servo Drive Configuration
1. Select POWER ON and CYCLE START pushbuttons.
2. Select the X-axis and jog to the approximate mid-travel position.
3. Balance and DAC adjustments:
Do not adjust the VR pots on the MX4 board. Leave them at their calibrated
factory settings. The range of adjustment available within the Servo Dynamics
drive is sufficient to balance axis offsets.
a. In manual mode, select the <CHANGE TOOL OR DIAGNOSTICS> softkey

b. Press <ENTER><101><ENTER> to display the spindle/servo diagnostics

setup screen.
c. Select the <TOGGLE FOLLOWING ERROR DISPLAY> softkey, then the

<AXIS BALANCE ADJUST> softkey.
d. Select the appropriate softkey to choose the axis to be balanced.
4
e. At the prompt, press the START button followed immediately by the
MOTION HOLD button to provide 0V from the DAC.
f. Adjust the BAL pot on the servo card until the encoder counts on the CRT
stop.
4. Release MOTION HOLD and select the <EXIT> softkey.
5. In MANUAL MODE, select the x-axis.
6. Adjust the CMP pot until the axis oscillates. Turn CCW until oscillation stops.
Continue CCW 1-1/2 more turns.
7. In the control cabinet, connect a volt meter between J1-1 and J1-2 (DAC input) on
the servo card.
8. In MANUAL MODE, select <CHANGE TOOL OR DIAGNOSTICS> softkey.
9. Set rapid detent to 10% of the maximum rapid traverse for the axis being configured
(i.e. if max rapid is 500ipm, then set rapid detent to 500 * 0.10 = 50ipm). Turn axis
feed rate pot to detent position.
10. While jogging the axis back and forth. Adjust the SIG pot for a maximum absolute
value of 0.95V.
12. Readjust BAL pot if necessary.
Note: It may be necessary to alternately readjust the signal and

balance pots to achieve proper balance and DAC settings.
11. Disconnect the volt meter.
13. Repeat steps 1 thru 12 for the y-axis and z-axis.
5
757-4002-096 REV: B CAD# D8477
R
SUBJECT: Servo Dynamics DC Servo Drive Set-up Procedure with MAX3

ISA Control
Ronald M. England 7/26/96 Michael Caron 7/30/96_

________________________________ _______ _______________________________ ______
Originator Date Mgr. Controls and Integration Date
A 13749 Release
B 13933 1) Page 3, step III-B was “Cut off W1 DEO 12/20/96
and W2 (zero ohm resistors). 2) Page 3,
RMS Pot measurement was U3-pin 5 to
TP1. 3) Page 3, Added step III-G
2
I. INTENT
To provide a Standardized procedure for the system set-up and configuration of the Servo
Dynamics DC servo drive.
II. APPLICABILITY
Applies to Hawk 5/SSM knee mill and BMC 30/SSM machining center with Ultimax 3 ISA
control.
III. PRE POWER-UP
A. Remove the x-axis servo card from the drive chassis.
B. B1 Remove shunt jumper assembly from center area of board located at reference
designator “NC LIM”.
C. Verify A/B jumper is in the “B” position for differential input mode.
D. Preset the pots as follows:
Pots Measurement Hawk 5/SSM BMC 30/SSM

Aux. Pot TP2 to TP1 fully CCW (0-2Ω) fully CCW (0-2Ω)
Sig. Pot TP3 to TP1 mid-range (approx. 10 KΩ) 5 KΩ
Tach Pot TP4 to TP1 7 KΩ x-axis: 4.55KΩ
y-axis: 4.61KΩ
z-axis: 4.95KΩ
CMP Pot TP5 to TP1 fully CCW, then 10 turns CW fully CCW, then 10 turns CW
(approx. 1 KΩ) (approx. 1 KΩ)
CL Pot J3-1 to J3-3 fully CCW, then 11 turns CW fully CW
(X/Y) or 7 turns CW (Z) (approx. 2.3KΩ)
RMS Pot fully CW fully CW
(R65) B2
Bal. Pot do not adjust at this time do not adjust at this time
E. Replace the servo card in the servo drive chassis.
F. Repeat steps A thru E for the y-axis and z-axis servo cards.
G. B3 Install shunt regulator assembly to amplifier chassis just above power capacitor.
Connect power lead wires across power capacitor terminals (BLK wire to BLK,
RED wire to RED).
IV. POWER UP
A. UltiMAX3 Control Parameter Verification
Load parameters from Engineering Document 757-4002-048 per machine type.
3
1. In Manual mode, select the <CHANGE TOOL OR DIAGNOSTICS> softkey
2. Select each axis softkey to load the Axis Tuning Parameters.
3. If an Axis Tuning Parameter needs to be changed, then enter the correct value per
the Engineering Document 757-4002-048.
4. After completing all changes for an axis, select the <BEGIN TUNE> softkey
followed by the <STORE PARAMETERS> softkey.
5. Press the <EXIT> softkey to return to the ATC & Machine Diagnostics screen.
6. Press the Auxiliary mode Key.
7. Select the <SYSTEM CONFIGURATION> softkey.
8. Insert the Machine Configuration diskette into the floppy drive.
9. Select the <BACKUP MACHINE CONFIGURATION> softkey.
10. When complete, remove the diskette from the floppy drive and store in a safe
location.
B. Servo Drive Configuration
1. Select POWER ON and CYCLE START pushbuttons.
2. Select the X-axis and jog to the approximate mid-travel position.
3. Balance and DAC adjustments:
Do not adjust the VR pots on the MX4 board. Leave them at their calibrated
factory settings. The range of adjustment available within the Servo Dynamics
drive is sufficient to balance axis offsets.
a. In manual mode, select the <CHANGE TOOL OR DIAGNOSTICS> softkey

b. Press <ENTER><101><ENTER> to display the spindle/servo diagnostics

setup screen.
c. Select the <TOGGLE FOLLOWING ERROR DISPLAY> softkey, then the

<AXIS BALANCE ADJUST> softkey.
d. Select the appropriate softkey to choose the axis to be balanced.
4
e. At the prompt, press the START button followed immediately by the
MOTION HOLD button to provide 0V from the DAC.
f. Adjust the BAL pot on the servo card until the encoder counts on the CRT
stop.
4. Release MOTION HOLD and select the <EXIT> softkey.
5. In MANUAL MODE, select the x-axis.
6. Adjust the CMP pot until the axis oscillates. Turn CCW until oscillation stops.
Continue CCW 1-1/2 more turns.
7. In the control cabinet, connect a volt meter between J1-1 and J1-2 (DAC input) on
the servo card.
8. In MANUAL MODE, select <CHANGE TOOL OR DIAGNOSTICS> softkey.
9. Set rapid detent to 10% of the maximum rapid traverse for the axis being configured
(i.e. if max rapid is 500ipm, then set rapid detent to 500 * 0.10 = 50ipm). Turn axis
feed rate pot to detent position.
10. While jogging the axis back and forth. Adjust the SIG pot for a maximum absolute
value of 0.95V.
12. Readjust BAL pot if necessary.
Note: It may be necessary to alternately readjust the signal and

balance pots to achieve proper balance and DAC settings.
11. Disconnect the volt meter.
13. Repeat steps 1 thru 12 for the y-axis and z-axis.
5
Siemens
D8478 757-4002-097 Siemens I/R Module, Servo Drive &

Spindle Drive Setup Procedure W/ ULTIMAX 3
ISA Control.
D8566 757-4002-159 Siemens I/R Module, Servo Drive & Spindle
Drive Setup Procedure W/ ULTIMAX 3 ISA
Control.
D8567 757-4002-160 SIEMENS I/R Module, Servo Drive, and
Spindle Drive Setup, VTC40
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R
757-4002-097 CAD #D8478
SUBJECT: Siemens I/R Module, Servo Drive, and Spindle Drive Setup
Procedure with Ultimax 3 ISA Control. Applicable Machining Centers:
BMC30M, BMC30HT, BMC30SSM, BMC4020HT and BMC4020SSM.
RECORD OF CHANGES
Responsible Reviewed/Approved
Dan Ornelas 6/20/96

Originator Date Mgr. Control Systems Engineering Date
Engineering Document 757-4002-097 CAD #D8478
Revision ECN # Revision Description Rev By Date Appd Date

By
A 13709 Original Release
B 13760 Change P-31 = 15, P-146 = -500, and P-242 = 6 DEO 7/23/96 MFC 7/30/96
C 13933 1) Page 7, section VII-E-4 was ...until the axis DEO 12/16/96 MFC 12/17/96
stops rotating. 2) Page 8, section VIII was
...FA0 for motor P/N. Section X added Z=opt.
3) Attachment “A” and Attachment “B”
Page 1, P-027 was 20 RPM and Page 4, P-144
was 1.00 degree. 4) Added BMC30SSM.
5) Page 6, section VII-B-1, reworked “KP”
adjustment procedure.
D 14012 1) Page 9, section XII-A, BMC30’s Drive code SAW 7/14/97 DEO 7/14/97
Parameter added 13. 2) Page 11, section XIV-
B4, Spindle RPM Range acceptability table was
added.
E 14098 1) Page 6, Revised “TN” adjustment procedure DEO 9/16/97
for fine-tuning. 2) Page 8, Added spindle motor
option K03. 3) Page 13, section A1,
parameter P1-149 was 29H (uni-directional). 4)
Attachment “B” for BMC4020 machines, P-149
was 29H.
I. INTENT
Page 2 757-4002-097 Rev. E
To provide a standardized method of configuration and adjustment with Siemens I/R module,
servo drives, and spindle drives being used on Ultimax 3 ISA type machining centers.
II. APPLICABILITY
Specific to all BMC30M, 30HT, 4020HT, and 4020SSM Ultimax 3 type machining centers using
software version 1.62 or later. This is the only procedure to be used within Hurco facilities and
should be used at customer installations to help achieve factory proven performance.
III. INDEX
Page 3 I/R Module Startup Sequence

Page 5 ULTIMAX 3 Control Parameter Verification, Servo
Page 5 Servo Drive Start-up Sequence
Page 6 Servo Drive Adjustments and Tuning
Page 8 Hurco/Siemens Part Identification Table, Servo
Page 8 ULTIMAX 3 Control Parameter Verification, Spindle
Page 8 Hurco/Siemens Part Identification Table, Spindle
Page 9 Spindle Start-up Sequence
Page 9 Identify Drive and Motor Type
Page 10 Parameter List, Manual Entry
Page 10 Spindle Zero RPM and Maximum RPM Calibration
Page 12 Orient Zero Mark Setup with Motor Encoder
Page 13 Orient Zero Mark Setup with Motor Encoder & Proximity Sensor
Page 15 Re-initialize Spindle Drive
Attachment A Siemens Spindle Parameter List, BMC30HT & BMC30M
Attachment B Siemens Spindle Parameter List, BMC4020HT & BMC4020SSM
IV. I/R MODULE START-UP SEQUENCE
CAUTION: During this procedure high voltage will be present once the I/R module has been
powered up. It will take approximately 5 minutes to discharge when power is removed. Begin
sequence with control power turned OFF. Do not disconnect or reconnect wires or connections
unless power is OFF and the DC link has discharged.
A. Remove all external interface wiring (X161 and X121), the DC link connections, as well as
signal ribbon cables. This isolates the module from the effects of possible problems from
other modules and any other external wiring errors.
B. Visually check to make sure that all I/O, ribbon, and power cables are securely terminated at
the proper locations. Also verify that the 600VDC bus bar links are securely terminated.
They are located behind a plastic protective front cover.
C. Verify configuration of dip switch S1, access located through top of the module case.
Configure the module to indicate “fault” when applicable. The internal relay will energize if
power is ON and no fault is present. Switch settings are as follows:
Page 3 757-4002-097 Rev. E

S1-1 OFF
S1-2 ON
S1-3 OFF
S1-4 OFF
S1-5 OFF
S1-6 OFF
D. Apply main power to terminal at location U1, V1, and W1 via CB4 (32A). Measure line
voltage across each phase, it should be 380VAC to 420VAC (Reading may be as high as
440VAC which is acceptable when there is a no load condition). No LED’s will illuminate at
this time.
E. Reinstall external wiring connectors at X161 and X121. This will prepare the module for
power-up operation.
F. Reapply three phase main power via CB4 (32A). This will verify that the module is
functioning properly. The DC link will be enabled and the green and yellow LED’s will
illuminate. The red fault LED should remain extinguished.
LED Status Indicator
G1 - Unit Not Ready R1 R3
Y1 - Unit Ready
R1 - +/- 15V Too Low
G1 Y1
R2 - Supply Undervoltage, Phase Failure,
- or Control Axis Fault
R3 - 5V Too Low R2 R4
R4 - DC Link Voltage Too High
G. Verify low voltage power supply is functioning properly by measuring the following test
points with respect to ground (X141-15).
X141-7 24 +/- 1 VDC

X141-45 15 +/- 0.5 VDC
X141-44 -15 +/- 0.5 VDC
X141-10 -24 +/- 1 VDC
H. Enable control power from the ULTIMAX Control by selecting MANUAL Mode; F7
(“Reset Servos and Spindle”); depress <POWER ON>. At this point the Drive Enable
signal is enabled and DC link voltage is present at the bus. The green LED will be
extinguished and the yellow LED will remain illuminated. At this point the I/R Module is
considered operational.
V. ULTIMAX 3 CONTROL PARAMETERS VERIFICATION, SERVO
Page 4 757-4002-097 Rev. E

Load parameters from the latest Engineering Document published to date (757-4002-048) per
machine type.
A. On the Ultimax Control select: MANUAL Mode; F2 (“Change Tool or Diagnostics”); F7

(“ATC and Machine Diagnostics”); <ENTER>, 103, <ENTER>.
B. Select each axis softkey to review and/or load the Axis Tuning Parameters.
C. If an Axis Parameter needs to be changed then simply enter the correct values per the
referenced Engineering Document.
D. After completing all changes for an axis, select the BEGIN TUNE softkey followed by the
STORE PARAMETERS softkey.
E. Press the EXIT softkey to return to the ATC & Machine Diagnostics screen.
F. Press the Auxiliary mode key.
G. Select the SYSTEM CONFIGURATION softkey.
H. Insert the Machine Configuration diskette into the floppy drive.
I. Select the BACKUP MACHINE CONFIGURATION softkey.
J. When compete, remove the diskette from the floppy drive and store in safe location.
VI. SERVO DRIVE START-UP SEQUENCE
CAUTION: During this procedure high voltage will be present once the Servo modules have been
powered up. It will take approximately 5 minutes to discharge when power is removed. Begin
sequence with control power turned OFF. Do not disconnect or reconnect wires or connections
unless power is OFF and the DC link has discharged. Also the following procedure requires that
the I/R Module be operational as a prerequisite. Bracket notation [ ] describes the second axis on
a 2-axis module when applicable.
A. Beginning with the leftmost module, isolate any module to the right by removing the ribbon
harness, I/O, and the DC link connections. This isolates the module from the effects of
possible problems from other modules or any external wiring errors.
B. Preset motor controller settings via internally located switches. Remove the controller PCB
front panel by loosening top and bottom captive screws. Carefully pull the controller PCB
assembly out of its module. Preset the controller switches as follows:
System Switch S1 [S4] Switch S2 [S5] Switch S3 [S6]

Page 5 757-4002-097 Rev. E
BMC30M ALL switch Bits 1, 6, 9 ON Bit 8 ON
jumpers OPEN Bits 2-5, 7, 8, 10 OFF Bits 1-7 OFF
BMC30HT ALL switch Bits 1, 9 ON Bit 8 ON
jumpers OPEN Bits 2-8, 10 OFF Bits 1-7 OFF
BMC4020HT ALL switch Bits 1, 9 ON Bit 8 ON
BMC4020SSM ALL switch Bits 1, 9 ON Bit 8 ON
Description
S1 [S4] Tachometer Matching Switch
S2 [S5] Bit 1 Motor Rotation Direction vs. Voltage polarity
Bits 2-5 Current Limit
Bits 6-9 Current Gain
Bit 10 Velocity Mode vs. Current Mode
S3 [S6] Bits 1-7 Factory Default Settings
Bit 8 Current Controller Integrator Active
C. Switch presetting for motor controller is complete. Reinstall the controller PCB assembly
into the module. Be careful to align the assembly in the card guide and “seat” it firmly into
the rear connector. Re-secure the retaining screws at the top and bottom of the front panel.
VII. SERVO DRIVE ADJUSTMENTS AND TUNING
A. Visually check and make sure the ribbon harness, I/O, and the DC link connections are
securely terminated at the proper locations for the module under test.
B. Axis amplifier “Proportional Gain” adjustment. This adjustment is used to best match the
servo axis performance to the requirements of the machine and controller.
1.C5 Initially adjust the potentiometer labeled “KP” to 30-50% from zero in a clockwise
direction. Zero being the hardstop when rotating the potentiometer fully counter clockwise.
Adjust “KP” until motor starts to oscillate, then back off until it stops. After it stops, turn
the pot slightly 10% counter clockwise (25% is typically a good final setting for this
adjustment).
C. E1 Axis amplifier “Integral Gain” adjustment. This adjustment is used to best match the servo
axis performance to the requirements of the machine and controller.
1. Adjust the potentiometer labeled “TN”, to approximately 70% from zero in a clockwise
direction. Zero being the hardstop when rotating the potentiometer fully counter
clockwise.
2. Connect a digital voltmeter (DVM) to drive test point “W” (positive lead) and test point
“M” (common) for specific axis under adjustment.
3. Program the given axis to move back and forth at 50 IPM and observe the stability of
speed regulator current expressed as a voltage.
4. Fine adjust the “Integral Gain Adjustment” potentiometer labeled “TN” until the
Page 6 757-4002-097 Rev. E
voltage measured at drive test points becomes stable (typically +/-10mV fluctuation is
adequate).
D. The “AD” potentiometer serve the purpose of “Low Speed Adaption” which is non-
functional in our application because we are not setting S3 [S5] bit 5 ON. Therefore just
leave this potentiometer at the factory default setting.
E. Axis amplifier “Drift” adjustment. This adjustment minimizes motor rotation when a 0V
command is issued in velocity loop. Do not adjust the VR potentiometer on the MX4
board! Leave them at their factory setting. The range of adjustment available from the
Siemens Servo modules is sufficient to balance servo offset.
1. On the ULTIMAX Control select: MANUAL Mode; F2 (“Change Tool or
Diagnostics”); F7 (“ATC and Machine Diagnostics”); <ENTER>, 101, <ENTER>; F6
(“Toggle Following Error Display”); F7 (“Axis Balance Adjust”).
2. Select the appropriate softkey to choose the axis to be balanced.
3. At the prompt, press the START push-button, followed immediately by pressing

MOTION HOLD to provide a zero voltage signal from the selected MX4 DAC
channel. (The machine control loop is now open for this channel. The presence of
system unbalance will be immediately apparent by the drift of the values in the Following
Error display).
4. C1 Adjust the uppermost potentiometer labeled “DRIFT” to minimize axis rotation. In this
mode it is impossible to guarantee no rotation. Verify the quality of the null by
observing minimal change in the counts being displayed in the Standing (Zero
Speed) Following Error column.
F. Axis amplifier “Tachometer” adjustment. This adjustment is used in the velocity loop and
made to scale the motor speed with reference to the voltage applied at speed command input
terminals X331 [X332] 56 and 14.
1. Run a setup machine program so that the axis moves back and forth at 10% of maximum
feedrate. (Example: BMC 4020 Max. feedrate (X, Y) = 19,990 and
(Z) = 15,000 mmpm, therefore 10% would be 1,999 and 1,500 mmpm respectively.
2. Then adjust the potentiometer labeled “T”, tachometer, until the DAC output measured
at terminals X331 [X332] 56 and 14 = +.95 +/- 0.005 and -95 +/- 0.005.
G. At this point repeat steps in Sections VI and VII for any additional axis module in the system.
Once all axis modules have been setup and tested the system is ready to become operational.
VIII. HURCO/SIEMENS PART IDENTIFICATION TABLE, SERVO
System Torque Hurco P/N Siemens Motor P/N Rated Siemens Drive P/N
Page 7 757-4002-097 Rev. E
Nm (Motor) Speed RPM
C2
BMC30 6.5 402-6011-018 1FT5066-1AF71-4FG0 3000 6SN1123-1AA00-0AA0 (1-axis)
6SN1118-0AD11-0AA0 (1-axis)
6SN1123-1AB00-0AA0 (2-axis)
6SN1118-0AE11-0AA0 (2-axis)
BMC30HT 10.0 402-6011-002 1FT5072-1AF71-1FG0 C2 3000 6SN1123-1AA00-0BA0 (1-axis)
6SN1118-0AD11-0AA0 (1-axis)
6SN1123-1AB00-0BA0 (2-axis)
6SN1118-0AE11-0AA0 (2-axis)
BMC4020HT 10.0 402-6011-002 1FT5072-1AF71-1FG0 C2 3000 6SN1123-1AA00-0BA0 (1-axis)
6SN1118-0AD11-0AA0 (1-axis)
6SN1123-1AB00-0BA0 (2-axis)
6SN1118-0AE11-0AA0 (2-axis)
BMC4020SSM 10.0 402-6011-002 1FT5072-1AF71-1FG0 C2 3000 6SN1123-1AA00-0BA0 (1-axis)
6SN1118-0AD11-0AA0 (1-axis)
6SN1123-0AB00-0BA0 (2-axis)
6SN1118-0AE11-0AA0 (2-axis)
IX. ULTIMAX 3 CONTROL PARAMETERS VERIFICATION, SPINDLE
Spindle Parameters are loaded by default (WITH SOFTWARE VERSION 1.62). These
parameters must be verified against the latest control parameters published to date (757-
4002-048). DSP parameters may be edited in the “Tune Axis Parameter” screen.
Depress <ENTER>, 103, <ENTER> while in the “ATC and Machine Diagnostics” screen of
MANUAL machine mode.
X. HURCO/SIEMENS PART IDENTIFICATION TABLE, SPINDLE
System Power Hurco P/N Siemens Motor Motor Spindle X’mission Siemens Drive P/N
(HP) (Motor) P/N RPM RPM Ratio
BMC30M 15 HP 402-6011-001 1PH6137-4NB49-Z 8000 8000 1.00 6SN1123-1AA00-0GA0
Z=L69+K83+K03 E2 6SN1121-0BA13-0AA0
BMC30HT 15 HP 402-6011-001 1PH6137-4NB49-Z 8000 8000 1.00 6SN1123-1AA00-0GA0
E2
Z=L69+K83+K03 6SN1121-0BA13-0AA0
BMC4020HT 20 HP 402-6011-015 1PH6163-4NB49-Z 6500 6500 1.00 6SN1123-1AA00-0FA0
Z=L69+K83+K03 E2 6SN1121-0BA13-0AA0
BMC4020SSM 20 HP 402-6011-015 1PH6163-4NB49-Z 6500 8125 1.25 6SN1123-1AA00-0FA0
E2
Z=L69+K83+K03 6SN1121-0BA13-0AA0
XI. SPINDLE START-UP SEQUENCE
A. The following procedure requires that the I/R Infeed Module be operational as a
prerequisite. The I/R Infeed Module is the DC power source for the Spindle Module.
B. Visually check to make sure that all I/O, encoder, ribbon, and power cables are securely
terminated at the proper locations. Also verify that the 600VDC bus bar links are securely
Page 8 757-4002-097 Rev. E
connected. They are located behind a plastic protective front cover. CAUTION: Once
the drive system has been powered up high voltage is present. It will take approximately 5
minutes to discharge when power is removed.
C. Apply power to system via CB4 (32A), Spindle Module LED display should indicate
“P-095” the first time the module unit is initiated.
XII. IDENTIFY DRIVE AND MOTOR TYPE
A. Enter “Drive Code” into Parameter “P-095”, identifies drive type to drive software. This
can be accomplished by pressing the “P” key on spindle keypad then the “+” or “-” key to
increment or decrement the value as required. Once the proper value from table below is
entered simply press “P” to place the system back into parameter mode.
System Parameter P-095 “Drive Code”

D1
BMC30M 13(..0LA0), 8(..0GA0)
D1
BMC30HT 13(..0LA0), 8(..0GA0)
BMC4020HT 10
BMC4020SSM 10
B. Enter “Motor Code” into Parameter “P-096”, identifies motor type to drive software.
This can be accomplished by pressing the “P” key on spindle keypad then the “+” or “-”
key to increment or decrement the value as required. Once the proper value from table
below is entered simply press “P” to place the system back into parameter mode.
System Parameter P-096 “Motor Code”

BMC30M 133
BMC30HT 133
BMC4020HT 134
BMC4020SSM 134
C. Verify “Encoder Pulse Code” value in Parameter “P-098”. The motor measuring system
should have encoder pulses per revolution equal to 2048. If the value differs, change
value from spindle keypad by using the “+” or “-” key to increment or decrement the
value as required.
D. Go to “Initialization” parameter “P-097”. Change the parameter value by pressing the

“+” key on the keypad. The display should indicate “1”, then change to “P-000”. The
LCD’s should now indicate the “status” of the module with intermittently flashing
“P-000”. At this point specific functions and features can be implemented.
XIII. PARAMETER LIST, MANUAL ENTRY
At this point proceed through the Parameter List in Attachment A (BMC30HT & BMC30M) or
Attachment B (BMC4020HT & BMC4020SSM) and verify each parameter and change any
parameter as necessary from the list. Several parameters are predetermined from firmware and
require no change. These parameters can be identified with notation “mot 1” or “mot2” in
Page 9 757-4002-097 Rev. E
description column. It is important that all parameters agree with appropriate Parameter List for
proper operation.
A. In order to change machine specific parameters disable write protection by changing

parameter “P-051” to “4H”.
B. Toggle through each parameter in Attachment A or Attachment B and change the values
to correspond to value settings in the list.
C. After all parameter value settings have been incorporated and verified transfer the data
into the drives EPROM by changing the value or parameter “P-052” to “1” to store the
changes. Once the data has been stored parameter “P-052” will return to “0”.
D. Finally enable write protection parameter “P-051” to “0H” so that changes cannot be
made inadvertently.
E. Repeat this procedure whenever a change is necessary.
XIV. SPINDLE ZERO RPM AND MAXIMUM RPM CALIBRATION
A. To achieve the Spindle Zero Drift (spindle velocity of Zero RPM) proceed as follows:
Do not adjust the VR potentiometers on the MX4 board! Leave them at their factory
settings. The range of adjustment available from the Siemens Spindle Module is sufficient
to balance spindle offset.
1. To ensure that the Spindle is in the Closed Loop Velocity mode, on the Ultimax
Control select: Auxiliary Mode; F4 (“System Config.”); F4 (“Display Machine
Config.”); <ENTER>, 100, <ENTER>; F4 (“Spindle”); F1 (“Physical
Parameter”). Make change to Closed Loop Velocity if necessary.
2. On the Ultimax Control select: MANUAL Mode; F2 (“Change Tool or

Diagnostics”); F7 (“ATC and Machine Diagnostics”); <ENTER>, 101,
<ENTER>; F6 (“Toggle Following Error Display”); F7 (“Axis Balance Adjust”);
and F4 (“Spindle”).
3. When the START CYCLE push-button is depressed, the Ultimax Control

executes the following signal sequence - each stage lasting a few seconds, and its
results (in counts) displayed on the Ultimax screen:
Zero signal: small (+) signal; small (-) signal. Cycle repeats.
When the program starts, press the MOTION HOLD BUTTON, this will hold
the DAC at zero output. The spindle will probably rotate slowly, indicating a need
for balance.
4. Adjust parameter “P-015”, Offset Correction Speed Setpoint at the spindle drive.
Increase or decrease the hexadecimal value as necessary until the spindle stops
rotating. It will be necessary to use parameters “P-051” and “P-052” to invoke
Page 10 757-4002-097 Rev. E
this change. Verify the quality of the null by observing no change in the
counts being displayed in the Following Error column and no physical
spindle rotation.
B. To calibrate The Maximum Spindle Speed parameter (ensuring that the Ultimax Control
reflects true Spindle speed), proceed as follows:
1. In MANUAL Mode, set the Manual Spindle Speed value to the maximum spindle
speed of the machine. Note this commanded (desired) value.
2. The machine must now be put back into Open Loop mode. On the Ultimax
Control, select: AUXILIARY Mode; F4 (“System Configuration”); F4 (“Display
Machine Configuration”); <ENTER>, 100, <ENTER>; F4 (“Spindle”); F1
(“Physical Parameters”); and F5 (“Open Loop”).
3. Obtain a tachometer reading of Spindle RPM. Note this measured value.
4. It is likely that there will Programmed RPM Acceptable RPM Range D2

be a discrepancy between 65 (4020HT) 64-66*
the commanded or rated 80 (SSM, 30’s) 79-81*
RPM and the measured 2000 (Both) 1998-2002
Spindle speeds. To offset 4000 (4020HT) 3996-4004
this situation you may use 6000 (SSM, 30’s) 5994-6006
the following formula to 6500 (4020HT) 6493-6507
8000 (SSM, 30’s) 7992-8008
adjust the DAC voltage.
(*) Rounded to whole number
Calculate this new
required voltage value (to two decimal places), and enter it into the Ultimax
screen. Use <ENTER>, 100, <ENTER> screen.
New “Max DAC” Voltage = (Desired RPM / Measured RPM) s Old “Max
DAC” Voltage
(Example: Measured spindle speed = 5980 RPM with original DAC voltage on
MAX3 screen of 9.5, but 6000 RPM is desired. DAC voltage value should be
changed to 6000/5980 s 9.5 = 9.53V).
5. The Spindle Drive RPM setup is complete.
XV. ORIENT ZERO MARK SETUP WITH MOTOR ENCODER
A. Procedure will work properly with motor encoder when spindle has a 1:1 ratio and a
timing belt is used for transmission to ensure no motion loss. To achieve an orient zero
mark proceed as follows
1. When using motor encoder, the spindle should be set for the shortest approach
from either direction. This is accomplished by setting parameter.
“P-149” to “21H”.
Page 11 757-4002-097 Rev. E
2. Parameter “P-131” defines the number of encoder counts between two references
signals taking into account the 1:1 ratio. Set parameter to “2048”. When the
drive unit is powered up, the position counter is checked during the first one or
two revolutions of the spindle.
3. Parameter “P-141” set to “0H”, assigns motor encoder evaluation when required
to orient spindle.
4. Request transfer of switching parameters “P-141” for positioning by setting

parameter “P-143” to “1”. The parameter is automatically reset to “0”.
5. Remove spindle drive key.
6. Install ATC Setup Taper into the spindle and flange into the ATC.
7. Move ATC to “right” position from the Ultimax Control/ Select: MANUAL
Mode; F2 (“Change Tool or Diagnostics”); F1 (“Magazine Right”).
8. Set the ATC height from Ultimax Control, select: MANUAL Mode; F2 (“Change
Tool or Diagnostics”); F7 (“ATC and Machine Diagnostics”); <ENTER, 101,
<ENTER>; Select the correct position, jog the Z-axis down until it is properly
aligned with the tool changer. Proper alignment is achieved when the Z-axis is
positioned at a height relative to the tool changer which allows tools to be taken
from and returned to the tool changer. When the Z-axis is aligned, press softkey
F1 (“Store Z Position”).
9. Rotate the spindle at least one complete revolution by hand to a position so the
drive key may be re-installed.
10. Initialize the Internal Zero Mark by setting parameter “P-129” to “1H”, it will
then automatically reset back to “0H”. The new Zero Mark Offset is
automatically stored in parameter “P-130”.
11. Record the position actual value for zero mark offset from parameter “P-140”.
12. Move ATC to “left” position from the Ultimax Control. Select: MANUAL
Mode; F2 (“Change Tool or Diagnostics”); F8 (“Magazine Left”).
B. Verify orient zero mark setup.
1. In MANUAL Mode, set the Manual Spindle Speed value to 3000 RPM.
2. Depress <SPINDLE ON>, <START>. Allow the spindle to reach desired speed.
Depress <SPINDLE OFF> to stop the spindle.
Page 12 757-4002-097 Rev. E

3. On the Ultimax Control select: MANUAL Mode; F6 (“Orient Spindle”). Depress
<CYCLE START>, spindle will orient itself the zero mark position.
4. Observe parameter “P-140”, actual value zero mark offset. The value should be
(+) or (-) 1 count from the value recorded in step XV(A)11. Also on the
MANUAL display SPINDLE field will indicate ORIENTED. If orient command
is out of tolerance then repeat steps in section XV.
XVI. ORIENT ZERO MARK SETUP WITH MOTOR ENCODER & PROXIMITY SENSOR
A. Procedure will work properly with motor encoder and proximity switch when spindle has
a 1:1.25 ratio and a timing belt is used for transmission to ensure no motion loss. To
achieve an orient zero mark proceed as follows:
1.E3 When using a proximity switch, the spindle is set for the shortest approach from
either direction. This is accomplished by setting parameter “P1-149” to “21H”.
2. Parameter “P-131” defines the number of encoder counts between two reference
signals taking into account the 1:1.25 ratio. Set parameter to “1638”. When the
drive unit is powered up, the position counter is checked during the first one or
two revolutions of the spindle.
3. Parameter “P-141” set to “2H”, assigns proximity switch with motor encoder
evaluation when required to orient spindle.
4. Request transfer of switching parameters “P-141” for position by setting

5. Remove spindle drive key.
6. Install ATC Setup Tool taper into the spindle and flange into the ATC.
6. Move ATC to “right” position from the Ultimax Control. Select: MANUAL Mode;
F2 (“Change Tool or Diagnostics”); F1 (“Magazine Right”).
8. Set the ATC height from Ultimax Control, select: MANUAL Mode; F2 (“Change
Tool or Diagnostics”); F7 (“ATC and Machine Diagnostics”); <ENTER, 101,
<ENTER>; Select the correct position, jog the Z-axis down until it is properly
aligned with the tool changer. Proper alignment is achieved when the Z-axis is
positioned at a height relative to the tool changer which allows tools to be taken
from and returned to the tool changer. When the Z-axis is aligned, press softkey
F1 (“Store Z Position”).
Page 13 757-4002-097 Rev. E
10. Initialize the Internal Zero Mark by setting parameter “P-129” to “1H”, it will
then automatically reset back to “0H”. The new Zero Mark Offset is
automatically stored in parameter “P-130”.
11. Record the position actual value for zero mark offset from parameter “P-140”.
12. Move ATC to “left” position from the Ultimax Control. Select: MANUAL
Mode; F2 (“Change Tool or Diagnostics”); F8 (“Magazine Left”).

4. Observe parameter “P-140”, actual value zero mark offset. The value should
be (+) or (-) 1 count from the value recorded in step XVI(A)11. Also on the
MANUAL display SPINDLE field will indicate ORIENTED. If orient command
is out of tolerance then repeat steps in section XV.
Page 14 757-4002-097 Rev. E

XVII. RE-INITIALIZE SPINDLE DRIVE
If for some reason it is necessary to re-initialize the spindle drive, reset all parameters to the
original factory settings, perform the following steps:
A. Set parameters: “P-051” to “4H”

“P-097” to “0H”
“P-052” to “1H” it will automatically reset back to “0H”
B. Power the system down, wait until the LCD’s extinguish. Then power the system back
up, the LCD readout will display parameter “P-095”.
C. To restart and re-initialize the drive begin again at the beginning of these procedures for
Siemens spindle drive.
Page 15 757-4002-097 Rev. E

ATTACHMENT “A”
SIEMENS SPINDLE PARAMETER LIST, BMC30HT, BMC30M, & BMC30SSM
P No. DESCRIPTION DIMENSION SETTING

P-000 Operating display - N/A
P-001 Speed setpoint RPM N/A
P-002 Speed actual value RPM N/A
P-003 Motor voltage V N/A
P-004 Utilization % N/A
P-006 DC link voltage V N/A
P-007 Motor current A N/A
P-008 Motor reactive power kVA N/A
P-009 Motor active power KW N/A
P-010 Motor temperature °C N/A
P-011 Status of the binary inputs hex N/A
P-012 Normalization, DAU nact display % 100.0
P-013 Normalization, DAU P/Pmax display % 100.0
P-014 Speed for max. motor useful speed mot 1 RPM 8000
P-015 Offset correction, speed setpoint hex (*)
P-016 Ramp-up time, RFG s 0.01
P-017 Ramp-down time, RFG s 0.01
P-018 Smoothing time, speed setpoint smoothing ms 5
P-019 Degree of rounding-off, speed setpoint dec 0
P-020 Diagnostics, speed actual value hex N/A
P-021 nmin for “nact < nmin” signal mot 1 RPM 80
P-022 Shutdown speed, pulse cancellation mot 1 RPM 2
P-023 nx for “nact < nx” signal mot 1 RPM 6000
P-024 Normalization, setpoint V 9.5
P-026 Normalization, DAU M/Mrated % 100.0
P-027 Toler, bandwidth for “nact = nset” signal mot 1 RPM 30 C3
P-028 Diagnostics hex N/A
P-029 Speed limiting RPM 8000
P-030 Min. steady-state speed RPM 0
P-031 P gain, speed controller mot dec 15.0 B1
1
P-032 Integral action time, speed controller mot 1 ms 20
P-033 Encoder resolution for NC dec 3
P-035 Smoothing time, torque setpoint mot 1 ms 3
P-036 Encoder phase error correction dec 0
P-037 Changeover speed, motor encoder evalu. mot 1 RPM 32000
P-038 Hysteresis, P-037 mot 1 RPM 50
P-039 1st torque limit value mot 1 % 125
P-040 Regenerative limiting mot 1 % 100
(*) Different value for each machine.
Page 1 Rev. E
ATTACHMENT “A”

P-041 2nd torque limit value mot 1 % 50
P-042 Changeover speed for P-040 mot 1 RPM 500
P-044 Selection, torque setpoint smoothing hex 1H
P-045 Switch-in speed, torque setpoint smooth mot 1 RPM 4000
P-047 Mdx for “Md < Mdx” signal mot 1 % 90
P-048 Normalization, torque setpoint % 100
P-049 Offset, torque setpoint hex 0H
P-050 Changeover speed from Md1 to Md2 mot 1 RPM 2100
P-051 Write protection hex N/A
P-052 Transfer parameters into FEPROM hex N/A
P-053 Control word hex 11H
P-054 M19, speed setpoint normalization RPM 525
P-055 M19, speed setpoint offset correction hex 0H
P-056 M19, changeover speed RPM 525
P-058 Switch-off threshold, rounding-off M19 RPM 0
P-062 M19 changeover threshold, I comp., speed cont. RPM 4
P-063 Max. motor temperature °C 150
P-064 Fixed temperature °C 0
P-065 Timer stage, motor temperature alarm s 240
P-066 Address, DAU 1 hex 3044H
P-067 Shift factor, DAU 1 dec 0
P-072 Address, DAU 4 hex C04H
P-074 Offset, DAU 4 hex 0H
P-081 Terminal function assignment E1 dec 1
Page 2 Rev. E
ATTACHMENT “A”

P-091 Frequency filter 1, HPC Hz 300
P-092 Quality filter 1, HPC dec 1.00
P-093 Offset correction, speed setpoint HPC hex 0H
P-094 Normalization, speed setpoint HPC RPM 65
P-095 Power section code number dec 8
P-096 Motor code number mot 1 dec 133
P-097 Initialization hex 1H
P-098 Encoder pulse number, motor measuring system dec 2048
P-099 Firmware release dec 2.30
P-101 Setpoint for open-loop torque controlled operation % N/A
P-103 Frequency, torque setpoint filter mot 1 Hz 300
P-104 Quality, torque setpoint filter mot 1 dec 1.00
P-106 Smoothing time, speed setpoint, HPC ms 100
P-107 Frequency, filter 2 HPC Hz 300
P-108 Quality, filter 2 HPC dec 1.00
P-109 Torque limit, HPC % 100
P-110 Regenerative limit, HPC % 100
P-111 P-gain, speed controller HPC dec 10.0
P-112 Integral action time, speed controller HPC ms 20
P-113 Channel selection, speed setpoint hex 3H
P-114 Normalization, speed setpoint, C axis RPM 65
P-115 Offset correction, speed setpoint, C axis hex 0H
P-116 Correction, P-gain, current controller mot 1 dec 0
P-117 Selection, torque setpoint filter mot 1 hex 0H
P-118 Type, torque setpoint filter mot 1 hex 0H
P-119 Flux adaptation HPC % 100
P-120 Changeover speed, current contr. adapt. mot 1 RPM 2200
P-121 Position reference value 1 dec 0
P-123 Position reference value, incremental dec 256
P-126 Bandwidth, integrator enable speed controller dec 10.0
Page 3 Rev. E
ATTACHMENT “A”

P-128 Actual position reference value dec N/A
P-129 Setting the internal zero mark hex 0H
P-130 Zero mark offset dec (*)
P-131 Max. pulse number between 2 zero marks dec 2048
P-132 Absol. pos. act. value without zero mark offset dec N/A
P-133 Difference between 2 external zero marks dec N/A
P-134 Initiation point for P-136 degr. 10.0
P-135 Initiation point for P-137 / P-138 degr. 2.0
P-136 P gain, gradient 1 hex 220H
P-138 P gain, gradient 2 (HMS) hex 44H
P-139 Multiplier for braking parabola hex 100H
P-140 Absol. pos. actual value with zero mark offset dec N/A
P-141 Changeover parameter, positioning hex 0H
P-142 Flag for speed increase hex 0H
P-143 Transfer parameter P-141 hex 0H
P-144 Response bandwidth, relay 1 degr. 2.00 C3
P-145 Response bandwidth, relay 2 degr. 5.00
P-146 Search speed for spindle positioning RPM -500 B1
P-147 Position counter status regarding the BERO dec N/A
P-148 Motion window, spindle positioning degr. 1.0
P-149 Start-up parameter C axis/position hex 21H
P-150 Board identification hex 300H
P-152 Transfer parameter into the EEPROM hex N/A
P-154 Oscillation setpoint 1 RPM 0
P-156 Oscillation interval time 1 ms 1000
P-159 Motor moment of inertia mot 1 kgm2 0.085
P-160 Rated motor output mot 1 kW 7.9
P-161 Rated motor current mot 1 A 43.6
P-162 Rated motor voltage mot 1 V 159.0
P-163 Rated motor speed mot 1 RPM 525
P-164 Rated motor frequency mot 1 Hz 18.8
P-165 Motor no-load voltage mot 1 V 136.0
P-166 Motor no-load current mot 1 A 18.6
P-167 Stator resistance, cold mot 1 mΩ 139
Page 4 Rev. E
ATTACHMENT “A”

P-168 Rotor resistance, cold mot 1 mΩ 101
P-169 Stator leakage reactance mot 1 mΩ 196
P-170 Rotor leakage reactance mot 1 mΩ 272
P-171 Main field reactance mot 1 mΩ 4150
P-172 Upper speed Xh characteristic mot 1 RPM 2200
P-173 Speed at the start of field weakening mot 1 RPM 1525
P-174 Max. motor speed mot 1 RPM 8000
P-175 Gain factor Xh characteristic mot 1 % 128
P-176 Stall torque reduction factor mot 1 % 100
P-177 Start calculation, motor 1 (P-096) hex N/A
P-179 Select, min/max memory hex 0H
P-180 Enable motor changeover (star/delta) hex 0H
P-181 Address for min/max memory hex D02H
P-182 Min. value min/max memory hex N/A
P-183 Max. value min/max memory hex N/A
P-185 Address for monitoring 1 hex C06H
P-186 Threshold for monitoring 1 hex 0H
P-187 Pull-in delay, monitoring 1 s 0.00
P-188 Drop-out delay, monitoring 1 s 0.00
P-189 Hysteresis, monitoring 1 hex 1H
P-195 Lower adaptation speed mot 1 RPM 1000
P-196 Upper adaptation speed mot 1 RPM 1200
P-198 P gain, upper adaptation speed mot 1 dec 24.0
P-199 Reduction factor, P gain mot 1 % 100
P-201 Integral action time, upper adapt. speed mot 1 ms 80
P-202 Reduction factor, integral action time mot 1 % 100
P-203 Control word, speed controller adapt. mot 1 dec 0
P-206 Selection, transient recorder hex N/A
P-207 Set transient recorder hex N/A
P-208 Address for start condition hex N/A
P-209 Threshold for start condition hex N/A
P-210 Address for stop condition hex N/A
P-211 Threshold for the stop condition hex N/A
P-212 Address, signal 1 hex N/A
Page 5 Rev. E
ATTACHMENT “A”

P-214 Start trace output hex N/A
P-215 Shift factor, signal 1 dec N/A
P-217 Trigger signal 1 hex N/A
2
P-219 Motor moment of inertia mot 2 kgm 0.085
P-232 Upper speed, Xh characteristic mot 2 RPM 2200
P-237 Start calculation, other motor hex N/A
P-239 Start calculation, motor 2 (P-238) dec N/A
P-241 Programmable, signal 1 dec 2
P-242 Programmable, signal 2 dec 6 B1
P-247 Control word signal hex 0H
P-248 Delay time, fault message F-11 ms 750
P-249 Memory loc. segment, monitor hex N/A
P-250 Memory loc. address, monitor hex N/A
P-251 Value display, monitor memory location hex N/A
P-254 Display of active functions 1 hex N/A
Page 6 Rev. E
ATTACHMENT “A”

P-262 nx for “nact < nx” signal RPM 6000
P-263 Toler. bandw. for “nact = nset” signal mot 2 RPM 20
P-264 Speed limiting mot 2 RPM 8000
P-265 P gain, speed controller mot 2 dec 32.0
P-267 Changeover speed, mot. encoder select. mot 2 RPM 32000
P-268 Hysteresis, P-267 mot RPM 50
2
P-269 1st torque limit mot % 100
2
P-271 2nd torque limit mot 2 % 50
P-273 Hysteresis P-272 mot 2 RPM 20
P-274 Switch-in speed, torque setpoint smoothing mot 2 RPM 4000
P-275 Hysteresis P-274 mot RPM 50
2
P-280 Select, torque setpoint filter mot 2 hex 0H
P-281 Type of torque setpoint filer mot 2 hex 0H
P-285 P-gain, upper adaptation speed mot 2 dec 24.0
P-286 Reduction factor, P-gain mot 2 % 100
P-288 Integral action time, upper adaptation speed mot 2 ms 80
P-291 Max. motor temperature (degrees Celsius) mot 2 deg.C 150
P-299 Checksum parameters hex (*)
P-311 Current for I/F open-loop control % 40.0
P-312 Frequency for I/F open-loop control Hz 0.0
P-313 Selection, I/F open-loop control dec 0H
Page 7 Rev. E
ATTACHMENT “A”

P-316 Display P-gain, current controller dec N/A
P-340 Speed deviation, slip monitoring % 10.0
P-341 Torque reduction, slip monitoring % 50.0
P-343 Delay time, slip monitoring ms 200
P-344 Torque reduction speed, slip monitoring %/ms 0.50
P-345 Torque increase speed, slip monitoring %/ms 0.10
P-346 Hysteresis to P-340 % 0.00
P-347 Speed deviation, actual slip monitoring % N/A
Page 8 Rev. E
ATTACHMENT “B”
SIEMENS SPINDLE PARAMETER LIST, BMC4020HT & BMC4020SSM

P-027 Toler, bandwidth for “nact = nset” signal mot 1 RPM 30 C3
P-031 P gain, speed controller mot dec 15.0 B1
1
(*) Different value for each machine. (**) Different value for HT vs. SSM, see last page for values.
Page 1 Rev. E
ATTACHMENT “B”

P-049 Offset, torque setpoint hex OH
Page 2 Rev. E
ATTACHMENT “B”

P-093 Offset correction, speed setpoint HPC hex OH
Page 3 Rev. E
ATTACHMENT “B”

P-131 Max. pulse number between 2 zero marks dec (**)
P-141 Changeover parameter, positioning hex (**)
P-149 Start-up parameter C axis/position hex 21H E4
P-159 Motor moment of inertia mot 1 kgm2 0.170
Page 4 Rev. E
ATTACHMENT “B”

P-201 Integral action time, upper adapt. speed mot 1 ms 80
Page 5 Rev. E
ATTACHMENT “B”

2
Page 6 Rev. E
ATTACHMENT “B”

P-268 Hysteresis, P-267 mot RPM 50
2
P-269 1st torque limit mot 2 % 100
P-274 Switch-in speed, torque setpoint smoothing mot 2 RPM 4000
P-275 Hysteresis P-274 mot RPM 50
2
Page 7 Rev. E
ATTACHMENT “B”

Page 8 Rev. E
ATTACHMENT “B”
ORIENT SPECIFIC FUNCTIONS FOR “HT” VS. “SSM”
P No. BMC4020HT BMC4020SSM

P-131 2048 1638
P-141 0H 2H
Page 9 Rev. E
R
757-4002-159 CAD #D8566
Procedure with Ultimax ISA Control. Applicable Machining Centers:
BMC30M, BMC30HT, BMC30SSM, BMC4020HT and BMC4020SSM.
Scott Wrobleski 4/01/98

RECORD OF CHANGES

By
A 14256 Original Release SAW 04/14/9
8
Page 2 757-4002-159 Rev. A

I. INTENT
To provide a standardized method of configuration and adjustment with Siemens I/R

module, servo drives, and spindle drives being used on Ultimax 3 ISA type machining
centers.
II. APPLICABILITY
Specific to all BMC3017 and BMC 4020 Ultimax type machining centers using software
version 2.0 or later. This is the only procedure to be used within Hurco facilities and
should be used at customer installations to help achieve factory proven performance.
III. INDEX

Page 5 ULTIMAX Control Parameter Verification, Servo
Page 8 ULTIMAX Control Parameter Verification, Spindle
Attachment A Siemens Spindle Parameter List, BMC3017’s
Attachment B Siemens Spindle Parameter List, BMC4020’s
CAUTION: During this procedure high voltage will be present once the I/R module has
been powered up. It will take approximately 5 minutes to discharge when power is
removed. Begin sequence with control power turned OFF. Do not disconnect or
reconnect wires or connections unless power is OFF and the DC link has discharged.
A. Remove all external interface wiring (X161 and X121), the DC link connections, as
well as signal ribbon cables. This isolates the module from the effects of possible
problems from other modules and any other external wiring errors.
B. Visually check to make sure that all I/O, ribbon, and power cables are securely
terminated at the proper locations. Also verify that the 600VDC bus bar links are
securely terminated. They are located behind a plastic protective front cover.
Page 3 757-4002-159 Rev. A

C. Verify configuration of dip switch S1, access located through top of the module
case. Configure the module to indicate “fault” when applicable. The internal relay
will energize if power is ON and no fault is present. Switch settings are as follows:
S1-1 OFF
S1-2 ON
S1-3 OFF
S1-4 OFF
S1-5 OFF
S1-6 OFF
D. Apply main power to terminal at fuse block location. Measure line voltage across
each phase, it should be 380VAC to 420VAC (Reading may be as high as 440VAC
which is acceptable when there is a no load condition). No LED’s will illuminate at
this time.
E. Reinstall external wiring connectors at X161 and X121. This will prepare the
module for power-up operation.
functioning properly. The DC link will be enabled and the green and yellow LED’s
will illuminate. The red fault LED should remain extinguished.
G1 - Unit Not Ready

Y1 - Unit Ready G1 Y1
- or Control Axis Fault R2 R4
R3 - 5V Too Low
G. Verify low voltage power supply is functioning properly by measuring the following
test points with respect to ground (X141-15).
X141-7 24 +/- 1 VDC
X141-45 15 +/- 0.5 VDC
X141-44 -15 +/- 0.5 VDC
X141-10 -24 +/- 1 VDC
(“Reset Servos and Spindle”); depress <POWER ON>. At this point the Drive
Enable signal is enabled and DC link voltage is present at the bus. The green LED
will be extinguished and the yellow LED will remain illuminated. At this point the
I/R Module is considered operational.
Page 4 757-4002-159 Rev. A

Load parameters from the latest Engineering Document published to date (757-4002-
048) per machine type.
A. On the Ultimax Control select: AUXILLARY Mode; <ENTER>, 100, <ENTER>.

B. Select F2 (“Servo Tuning”).
C. Select each axis softkey to review and/or load the Axis Tuning Parameters.
D. If an Axis Parameter needs to be changed then simply enter the correct values per
the referenced Engineering Document.
E. Press the EXIT softkey twice to return to the Auxillary Screen.
F. Select the SYSTEM CONFIGURATION softkey.
G. Insert the Machine Configuration diskette into the floppy drive.
H. Select the BACKUP MACHINE CONFIGURATION softkey.
I. When compete, remove the diskette from the floppy drive and store in safe
location.
CAUTION: During this procedure high voltage will be present once the Servo modules
have been powered up. It will take approximately 5 minutes to discharge when power is
Also the following procedure requires that the I/R Module be operational as a
prerequisite. Bracket notation [ ] describes the second axis on a 2-axis module when
applicable.
A. Beginning with the leftmost module, isolate any module to the right by removing the
ribbon harness, I/O, and the DC link connections. This isolates the module from
the effects of possible problems from other modules or any external wiring errors.
B. Preset motor controller settings via internally located switches. Remove the
controller PCB front panel by loosening top and bottom captive screws. Carefully
pull the controller PCB assembly out of its module. Preset the controller switches
as follows:

BMC3017M ALL switch jumpers Bits 1, 6, 9 ON Bit 8 ON
OPEN Bits 2-5, 7, 8, 10 OFF Bits 1-7 OFF
BMC3017HT ALL switch jumpers Bits 1, 9 ON Bit 8 ON
OPEN Bits 2-8, 10 OFF Bits 1-7 OFF
BMC4020HT ALL switch jumpers Bits 1, 9 ON Bit 8 ON
BMC4020SSM ALL switch jumpers Bits 1, 9 ON Bit 8 ON
Page 5 757-4002-159 Rev. A

Description
C. Switch presetting for motor controller is complete. Reinstall the controller PCB
assembly into the module. Be careful to align the assembly in the card guide and
“seat” it firmly into the rear connector. Re-secure the retaining screws at the top
and bottom of the front panel.
A. Visually check and make sure the ribbon harness, I/O, and the DC link connections
are securely terminated at the proper locations for the module under test.
B. Axis amplifier “Proportional Gain” adjustment. This adjustment is used to best
match the servo axis performance to the requirements of the machine and
controller.
1. Initially adjust the potentiometer labeled “KP” to 30-50% from zero in a
clockwise direction. Zero being the hardstop when rotating the potentiometer
fully counter clockwise. Adjust “KP” until motor starts to oscillate, then back off
until it stops. After it stops, turn the pot slightly 10% counter clockwise (25% is
typically a good final setting for this adjustment).
C. Axis amplifier “Integral Gain” adjustment. This adjustment is used to best match
the servo axis performance to the requirements of the machine and controller.
1.Adjust the potentiometer labeled “TN”, to approximately 70% from zero in a
fully counter clockwise.
2. Connect a digital voltmeter (DVM) to drive test point “W” (positive lead) and test
point “M” (common) for specific axis under adjustment.
3. Program the given axis to move back and forth at 50 IPM and observe the
stability of speed regulator current expressed as a voltage.
voltage measured at drive test points becomes stable (typically +/-10mV
fluctuation is adequate).
D. The “AD” potentiometer serve the purpose of “Low Speed Adaption” which is
non-functional in our application because we are not setting S3 [S5] bit 5 ON.
Therefore just leave this potentiometer at the factory default setting.
E. Axis amplifier “Drift” adjustment. This adjustment minimizes motor rotation when a
0V command is issued in velocity loop. Do not adjust the VR potentiometer on
the MX4 board! Leave them at their factory setting. The range of adjustment
available from the Siemens Servo modules is sufficient to balance servo offset.
Page 6 757-4002-159 Rev. A

1. On the Ultimax Control select: AUXILLARY Mode; <ENTER>, 100, <ENTER>;
F3; (“Machine Test and Setup”); F3 (“Axis Balance Adjust”).
channel. (The machine control loop is now open for this channel. The
presence of system unbalance will be immediately apparent by the drift of the
values in the Following Error display).
4. Adjust the uppermost potentiometer labeled “DRIFT” to minimize axis rotation.
In this mode it is impossible to guarantee no rotation. Verify the quality of the
null by observing minimal change in the counts being displayed in the
Standing (Zero Speed) Following Error column.
F. Axis amplifier “Tachometer” adjustment. This adjustment is used in the velocity

loop and made to scale the motor speed with reference to the voltage applied at
speed command input terminals blocks (X331 [X332]), terminals 56 and 14.
1. Run a setup machine program so that the axis moves back and forth at 10% of
maximum feedrate. (Example: BMC 4020 Max. feedrate (X, Y) = 19,990 and
(Z) = 15,000 mmpm, therefore 10% would be 1,999 and 1,500 mmpm
respectively.
2. Adjust the potentiometer labeled “T”, tachometer, until the DAC output
measured at terminals blocks (X331 [X332]) terminals 56 and 14 = (+.95 +/-
0.005) forward and (-95 +/- 0.005) reverse.
G. At this point repeat steps in Sections VI and VII for any additional axis module in
the system. Once all axis modules have been setup and tested the system is ready
to become operational.
System Torque Hurco P/N Siemens Motor P/N Rated Speed Siemens Drive P/N
Nm (Motor) RPM
BMC30 6.5 402-6011-018 1FT5066-1AF71-4FG0 3000 6SN1123-1AA00-0AA0 (1-axis)
6SN1118-0AD11-0AA0 (1-axis)
6SN1123-1AB00-0AA0 (2-axis)
6SN1118-0AE11-0AA0 (2-axis)
BMC30HT 10.0 402-6011-002 1FT5072-1AF71-1FG0 3000 6SN1123-1AA00-0BA0 (1-axis)
6SN1118-0AD11-0AA0 (1-axis)
6SN1123-1AB00-0BA0 (2-axis)
6SN1118-0AE11-0AA0 (2-axis)
BMC4020HT 10.0 402-6011-002 1FT5072-1AF71-1FG0 3000 6SN1123-1AA00-0BA0 (1-axis)
6SN1118-0AD11-0AA0 (1-axis)
6SN1123-1AB00-0BA0 (2-axis)
6SN1118-0AE11-0AA0 (2-axis)
BMC4020SSM 10.0 402-6011-002 1FT5072-1AF71-1FG0 3000 6SN1123-1AA00-0BA0 (1-axis)
6SN1118-0AD11-0AA0 (1-axis)
6SN1123-0AB00-0BA0 (2-axis)
6SN1118-0AE11-0AA0 (2-axis)
Page 7 757-4002-159 Rev. A

Spindle Parameters are loaded by default. These parameters must be verified against
the latest control parameters published to date (757-4002-048). DSP parameters may
be edited in the “Servo Tuning Screen”.
On the Ultimax Control select: AUXILLARY Mode; <ENTER>, 100, <ENTER>; F6
(“Servo Tuning”); F3 (“Spindle”).
System Power Hurco P/N Siemens Motor Motor Spindl X’mission Siemens Drive P/N
(HP) (Motor) P/N RPM e RPM Ratio
BMC30M 15 HP 402-6011-001 1PH6137-4NB49-Z 8000 8000 1.00 6SN1123-1AA00-0GA0
Z=L69+K83+K03 6SN1121-0BA13-0AA0
BMC30HT 15 HP 402-6011-001 1PH6137-4NB49-Z 8000 8000 1.00 6SN1123-1AA00-0GA0
Z=L69+K83+K03 6SN1121-0BA13-0AA0
BMC4020HT 20 HP 402-6011-015 1PH6163-4NB49-Z 6500 6500 1.00 6SN1123-1AA00-0FA0
Z=L69+K83+K03 6SN1121-0BA13-0AA0
BMC4020SSM 20 HP 402-6011-015 1PH6163-4NB49-Z 6500 8125 1.25 6SN1123-1AA00-0FA0
Z=L69+K83+K03 6SN1121-0BA13-0AA0
prerequisite. The I/R Infeed Module is the DC power source for the Spindle
Module.
B. Visually check to make sure that all I/O, encoder, ribbon, and power cables are
securely terminated at the proper locations. Also verify that the 600VDC bus bar
links are securely connected. They are located behind a plastic protective front
cover. CAUTION: Once the drive system has been powered up high voltage is
present. It will take approximately 5 minutes to discharge when power is removed.
C. Apply power to system via fuse blocks, Spindle Module LED display should indicate
A. Enter “Drive Code” into Parameter “P-095”, identifies drive type to drive software.
This can be accomplished by pressing the “P” key on spindle keypad then the “+”
or “-” key to increment or decrement the value as required. Once the proper value
from table below is entered simply press “P” to place the system back into
parameter mode.
BMC30M 13(..0LA0), 8(..0GA0)
BMC30HT 13(..0LA0), 8(..0GA0)
BMC4020HT 10
BMC4020SSM 10
Page 8 757-4002-159 Rev. A
parameter mode.
BMC30M 133
BMC30HT 133
BMC4020HT 134
BMC4020SSM 134
C. Verify “Encoder Pulse Code” value in Parameter “P-098”. The motor measuring
system should have encoder pulses per revolution equal to 2048. If the value
differs, change value from spindle keypad by using the “+” or “-” key to increment
or decrement the value as required.
D. Go to “Initialization” parameter “P-097”. Change the parameter value by pressing
the “+” key on the keypad. The display should indicate “1”, then change to “P-
000”. The LCD’s should now indicate the “status” of the module with intermittently
flashing “P-000”. At this point specific functions and features can be implemented.
At this point proceed through the Parameter List in Attachment A (BMC30HT &
BMC30M) or Attachment B (BMC4020HT & BMC4020SSM) and verify each parameter
and change any parameter as necessary from the list. Several parameters are
predetermined from firmware and require no change. These parameters can be
identified with notation “mot 1” or “mot2” in description column. It is important that all
parameters agree with appropriate Parameter List for proper operation.
A. In order to change machine specific parameters disable write protection by

changing parameter “P-051” to “4H”.
B. Toggle through each parameter in Attachment A or Attachment B and change the
values to correspond to value settings in the list.
C. After all parameter value settings have been incorporated and verified transfer the
data into the drives EPROM by changing the value or parameter “P-052” to “1” to
store the changes. Once the data has been stored parameter “P-052” will return to
“0”.
D. Finally enable write protection parameter “P-051” to “0H” so that changes cannot
be made inadvertently.
A. To achieve the Spindle Zero Drift (spindle velocity of Zero RPM) proceed as
follows:
Do not adjust the VR potentiometers on the MX4 board! Leave them at their
factory settings. The range of adjustment available from the Siemens Spindle
Module is sufficient to balance spindle offset.
Page 9 757-4002-159 Rev. A

Control select: Auxiliary Mode; <ENTER>, 100, <ENTER>; F1 (“CNC Config”);
F4 (“Spindle”). Make change to Closed Loop Velocity if necessary.
2. AUXILLIARY Mode; <ENTER>, 100, <ENTER>; F6 (“Servo Tuning”); F4
(“Spindle”);. F5 (“Toggle Following Eror”).
3. When the program starts, press the MOTION HOLD BUTTON, this will hold the
DAC at zero output. The spindle will probably rotate slowly, indicating a need
for balance.
4. Adjust parameter “P-015”, Offset Correction Speed Setpoint at the spindle
drive. Increase or decrease the hexadecimal value as necessary until the
spindle stops rotating. It will be necessary to use parameters “P-051” and “P-
052” to invoke this change. Verify the quality of the null by observing no
change in the counts being displayed in the Following Error column and
no physical spindle rotation.
B. To calibrate The Maximum Spindle Speed parameter (ensuring that the Ultimax
Control reflects true Spindle speed), proceed as follows:
1. In MANUAL Mode, set the Manual Spindle Speed value to the maximum
spindle speed of the machine. Note this commanded (desired) value.
4. It is likely that there will be a Programmed RPM Acceptable RPM Range

discrepancy between the 65 (4020HT) 64-66*
commanded or rated RPM 80 (SSM, 30’s) 79-81*
and the measured Spindle 2000 (Both) 1998-2002
speeds. To offset this 4000 (4020HT) 3996-4004
6000 (SSM, 30’s) 5994-6006
situation you may use the
6500 (4020HT) 6493-6507
following formula to adjust 8000 (SSM, 30’s) 7992-8008
the DAC voltage. Calculate (*) Rounded to whole number
this new required voltage
value (to two decimal places), and enter it into the Ultimax screen. Use
<ENTER>, 100, <ENTER> screen.
DAC” Voltage
Example: Measured spindle speed = 5980 RPM with original DAC voltage on
changed to (6000/5980 s 9.5 = 9.53V).
Page 10 757-4002-159 Rev. A

timing belt is used for transmission to ensure no motion loss. To achieve an orient
zero mark proceed as follows
1. Change parameter “P-51” to “4H”.

“P-149” to “21H”.
3. Parameter “P-131” defines the number of encoder counts between two
references signals taking into account the 1:1 ratio. Set parameter to “2048”.
When the drive unit is powered up, the position counter is checked during the
first one or two revolutions of the spindle.
4. Parameter “P-141” set to “0H”, assigns motor encoder evaluation when
required to orient spindle.
6. Put an empty Tool Holder in the Spindle.
8. From the ATC Diagnostics screen Move the Spindle to Tool Change Height,
and Open the Magazine Door. Make sure the current magazine position does
not have a tool in it.
9. Depress the E-stop, then disconnect the main air supply.
10. Locate the air cylinder that moves the ATC arm left and right. Disconnect the
airline on the back (extend port) of the air cylinder.
11. By hand, move the magazine to the right so the tool holder in the spindle goes
all of the way into the magazine and is properly oriented. Make sure the orient
key is on the spindle is toward the tool changer.
12. Write down the value in the Siemens Parameter “P-140”.__________
13. Change the value in parameter “P-130” to the value you wrote down above.
14. Change the value in parameter “P-52” to “1”. The parameter is automatically
reset to “0”.
15. Cange parameter “P-51” back to “0H”.
16. Reconnect the airline to the ATC arm cylinder, and reconnect the main air
supply.

Page 11 757-4002-159 Rev. A

be (+) or (-) 1 count from the value recorded in step XV(A)11. Also on the
MANUAL display SPINDLE field will indicate ORIENTED. If orient command is
out of tolerance then repeat steps in section XV.
A. Procedure will work properly with motor encoder and proximity switch when spindle
has a 1:1.25 ratio and a timing belt is used for transmission to ensure no motion
loss. To achieve an orient zero mark proceed as follows:
“P-149” to “21H”.
references signals taking into account the 1:1.25 ratio. Set parameter to
“1638”. When the drive unit is powered up, the position counter is checked
during the first one or two revolutions of the spindle.
6. Put an empty Tool Holder in the Spindle.
and Open the Magazine Door. Make sure the current magazine position does
not have a tool in it.
9. Depress the E-stop, then disconnect the main air supply.
10. Locate the air cylinder that moves the ATC arm left and right. Disconnect the
airline on the back (extend port) of the air cylinder.
11. By hand, move the magazine to the right so the tool holder in the spindle goes
all of the way into the magazine and is properly oriented. Make sure the orient
key is on the spindle is toward the tool changer.
reset to “0”.
16. Reconnect the airline to the ATC arm cylinder, and reconnect the main air
supply.
Page 12 757-4002-159 Rev. A

If for some reason it is necessary to re-initialize the spindle drive, reset all parameters to
the original factory settings, perform the following steps:
A. Set parameters:“P-051” to “4H”
“P-097” to “0H”
B. Power the system down, wait until the LCD’s extinguish. Then power the system
back up, the LCD readout will display parameter “P-095”.
C. To restart and re-initialize the drive begin again at the beginning of these
procedures for Siemens spindle drive.
Page 13 757-4002-159 Rev. A

ATTACHMENT “A”
SIEMENS SPINDLE PARAMETER LIST, ALL BMC3017’s

P-027 Toler, bandwidth for “nact = nset” signal mot 1 RPM 30
Page 1 757-4002-159 Rev. A

ATTACHMENT “A”

P-049 Offset, torque setpoint hex 0H
Page 2 757-4002-159 Rev. A

ATTACHMENT “A”

P-093 Offset correction, speed setpoint HPC hex 0H
P-120 Changeover speed, current contr. Adapt. mot 1 RPM 2200
Page 3 757-4002-159 Rev. A

ATTACHMENT “A”

2
Page 4 757-4002-159 Rev. A

ATTACHMENT “A”

P-201 Integral action time, upper adapt. Speed mot 1 ms 80
Page 5 757-4002-159 Rev. A

ATTACHMENT “A”

2
Page 6 757-4002-159 Rev. A

ATTACHMENT “A”

P-274 Switch-in speed, torque setpoint mot 2 RPM 4000
smoothing
P-288 Integral action time,uper adaptation speed mot 2 ms 80
Page 7 757-4002-159 Rev. A

ATTACHMENT “A”

Page 8 757-4002-159 Rev. A

ATTACHMENT “B”

Page 1 757-4002-159 Rev. A

ATTACHMENT “B”

Page 2 757-4002-159 Rev. A

ATTACHMENT “B”

P-116 Correction, P-gain, current controller mot 1 % 0
Page 3 757-4002-159 Rev. A

ATTACHMENT “B”

P-131 Max. pulse number between 2 zero marks dec (**)
P-141 Changeover parameter, positioning hex (**)
P-146 Search speed for spindle positioning RPM -500
2
Page 4 757-4002-159 Rev. A

ATTACHMENT “B”

Page 5 757-4002-159 Rev. A

ATTACHMENT “B”

2
Page 6 757-4002-159 Rev. A

ATTACHMENT “B”

P-274 Switch-in speed, torque setpnt smoothing mot 2 RPM 4000
Page 7 757-4002-159 Rev. A

ATTACHMENT “B”

Page 8 757-4002-159 Rev. A

ATTACHMENT “B”
ORIENT SPECIFIC FUNCTIONS FOR “HT” VS. “SSM”
P No. BMC4020HT BMC4020SSM

P-131 2048 1638
P-141 0H 2H
Page 9 757-4002-159 Rev. A

R
757-4002-160 CAD #D8567
Procedure with Ultimax ISA Control for VTC-40.
Scott Wrobleski 10/05/98

RECORD OF CHANGES

By
filename: D8567.DOC 757-4002-160 Rev.A Page 2

I. INTENT
To provide a standardized method of configuration and adjustment with Siemens I/R

module, servo drives, and spindle drives being used on Ultimax 4 ISA type machining
centers.
II. APPLICABILITY
Specific to VTC-40 Ultimax type machining centers using software version 2.0 or later.
This is the only procedure to be used within Hurco facilities and should be used at
customer installations to help achieve factory proven performance.
III. INDEX

Page 5 ULTIMAX Control Parameter Verification, Servo
Page 7 ULTIMAX Control Parameter Verification, Spindle
Attachment A Siemens Spindle Parameter List, VTC40
CAUTION: During this procedure high voltage will be present once the I/R module has
been powered up. It will take approximately 5 minutes to discharge when power is
A. Remove all external interface wiring (X161 and X121), the DC link connections, as
well as signal ribbon cables. This isolates the module from the effects of possible
problems from other modules and any other external wiring errors.
B. Visually check to make sure that all I/O, ribbon, and power cables are securely
terminated at the proper locations. Also verify that the 600VDC bus bar links are
securely terminated. They are located behind a plastic protective front cover.

C. Verify configuration of dip switch S1, access located through top of the module
case. Configure the module to indicate “fault” when applicable. The internal relay
will energize if power is ON and no fault is present. Switch settings are as follows:
S1-1 OFF
S1-2 ON
S1-3 OFF
S1-4 OFF
S1-5 OFF
S1-6 OFF
D. Apply main power to terminal at fuse block location. Measure line voltage across
each phase, it should be 380VAC to 420VAC (Reading may be as high as 440VAC
which is acceptable when there is a no load condition). No LED’s will illuminate at
this time.
E. Reinstall external wiring connectors at X161 and X121. This will prepare the
module for power-up operation.
functioning properly. The DC link will be enabled and the green and yellow LED’s
will illuminate. The red fault LED should remain extinguished.
G1 - Unit Not Ready

Y1 - Unit Ready G1 Y1
- or Control Axis Fault R2 R4
R3 - 5V Too Low
G. Verify low voltage power supply is functioning properly by measuring the following
test points with respect to ground (X141-15).
X141-7 24 +/- 1 VDC
X141-45 15 +/- 0.5 VDC
X141-44 -15 +/- 0.5 VDC
X141-10 -24 +/- 1 VDC
(“Reset Servos and Spindle”); depress <POWER ON>. At this point the Drive
Enable signal is enabled and DC link voltage is present at the bus. The green LED
will be extinguished and the yellow LED will remain illuminated. At this point the
I/R Module is considered operational.

Load parameters from the latest Engineering Document published to date (757-4005-
017) per machine type.
A. On the Ultimax Control select: AUXILLARY Mode; <ENTER>, 100, <ENTER>.

B. Select F6 (“Servo Tuning”).
C. Select each axis softkey to review and/or load the Axis Tuning Parameters.
D. If an Axis Parameter needs to be changed then simply enter the correct values per
the referenced Engineering Document.
E. Press the EXIT softkey twice to return to the Auxillary Screen.
F. Select the SYSTEM CONFIGURATION softkey.
G. Insert the Machine Configuration diskette into the floppy drive.
H. Select the BACKUP MACHINE CONFIGURATION softkey.
I. When compete, remove the diskette from the floppy drive and store in safe
location.
CAUTION: During this procedure high voltage will be present once the Servo modules
have been powered up. It will take approximately 5 minutes to discharge when power is
Also the following procedure requires that the I/R Module be operational as a
prerequisite. Bracket notation [ ] describes the second axis on a 2-axis module when
applicable.
A. Beginning with the leftmost module, isolate any module to the right by removing the
ribbon harness, I/O, and the DC link connections. This isolates the module from
the effects of possible problems from other modules or any external wiring errors.
B. Preset motor controller settings via internally located switches. Remove the
controller PCB front panel by loosening top and bottom captive screws. Carefully
pull the controller PCB assembly out of its module. Preset the controller switches
as follows:

VTC-40 ALL switch jumpers Bits 1, 6, 9 ON Bit 8 ON
OPEN Bits 2-5, 7, 8, 10 OFF Bits 1-7 OFF
Description
C. Switch presetting for motor controller is complete. Reinstall the controller PCB
assembly into the module. Be careful to align the assembly in the card guide and
“seat” it firmly into the rear connector. Re-secure the retaining screws at the top
and bottom of the front panel.
A. Visually check and make sure the ribbon harness, I/O, and the DC link connections
are securely terminated at the proper locations for the module under test.
B. Axis amplifier “Proportional Gain” adjustment. This adjustment is used to best
match the servo axis performance to the requirements of the machine and
controller.
1. Initially adjust the potentiometer labeled “KP” to 30-50% from zero in a
fully counter clockwise. Adjust “KP” until motor starts to oscillate, then back off
until it stops. After it stops, turn the pot slightly 10% counter clockwise (25% is
typically a good final setting for this adjustment).
C. Axis amplifier “Integral Gain” adjustment. This adjustment is used to best match
the servo axis performance to the requirements of the machine and controller.
1.Adjust the potentiometer labeled “TN”, to approximately 70% from zero in a
fully counter clockwise.
2. Connect a digital voltmeter (DVM) to drive test point “W” (positive lead) and test
point “M” (common) for specific axis under adjustment.
3. Program the given axis to move back and forth at 50 IPM and observe the
stability of speed regulator current expressed as a voltage.
voltage measured at drive test points becomes stable (typically +/-10mV
fluctuation is adequate).
D. The “AD” potentiometer serve the purpose of “Low Speed Adaption” which is
non-functional in our application because we are not setting S3 [S5] bit 5 ON.
Therefore just leave this potentiometer at the factory default setting.
E. Axis amplifier “Drift” adjustment. This adjustment minimizes motor rotation when a
0V command is issued in velocity loop. Do not adjust the VR potentiometer on
the MX4 board! Leave them at their factory setting. The range of adjustment
available from the Siemens Servo modules is sufficient to balance servo offset.
1. On the Ultimax Control select: AUXILLARY Mode; <ENTER>, 100, <ENTER>;
F3; (“Machine Test and Setup”); F3 (“Axis Balance Adjust”).
channel. (The machine control loop is now open for this channel. The

presence of system unbalance will be immediately apparent by the drift of the
values in the Following Error display).
4. Adjust the uppermost potentiometer labeled “DRIFT” to minimize axis rotation.
In this mode it is impossible to guarantee no rotation. Verify the quality of the
null by observing minimal change in the counts being displayed in the
Standing (Zero Speed) Following Error column.
F. Axis amplifier “Tachometer” adjustment. This adjustment is used in the velocity

loop and made to scale the motor speed with reference to the voltage applied at
speed command input terminals blocks (X331 [X332]), terminals 56 and 14.
1. Run a setup machine program so that the axis moves back and forth at 10% of
maximum feedrate. (Example: VTC40 Max. feedrate (X, Y, Z) = 24,000 mmpm,
therefore 10% would be 2400 and 1,500 mmpm.
2. Adjust the potentiometer labeled “T”, tachometer, until the DAC output
measured at terminals blocks (X331 [X332]) terminals 56 and 14 = (+.95 +/-
0.005) forward and (-95 +/- 0.005) reverse.
G. At this point repeat steps in Sections VI and VII for any additional axis module in
the system. Once all axis modules have been setup and tested the system is ready
to become operational.
System Torque Hurco P/N Siemens Motor P/N Rated Speed Siemens Drive P/N
Nm (Motor) RPM
VTC-40 (X,Y) 10.0 402-6011-036 1FT5102-1AC71-1FG0 2000 6SN1123-1AA00-0CA0 (3-axis)
VTC-40 (Z) 10.0 402-6011-038 1FT5102-1AC71-1FH0 2000
Spindle Parameters are loaded by default. These parameters must be verified against
the latest control parameters published to date (757-4005-017). DSP parameters may
be edited in the “Servo Tuning Screen”.
On the Ultimax Control select: AUXILLARY Mode; <ENTER>, 100, <ENTER>; F6
(“Servo Tuning”); F3 (“Spindle”).
System Power Hurco P/N Siemens Motor Motor Spindle X’mission Siemens Drive P/N
(HP) (Motor) P/N RPM RPM Ratio
VTC-40 20 HP 402-6011-035 1PH7-137- 8000 10000 0.80 6SN1123-1AA00-0LA0
2ND020BA0
prerequisite. The I/R Infeed Module is the DC power source for the Spindle
Module.

B. Visually check to make sure that all I/O, encoder, ribbon, and power cables are
securely terminated at the proper locations. Also verify that the 600VDC bus bar
links are securely connected. They are located behind a plastic protective front
cover. CAUTION: Once the drive system has been powered up high voltage is
present. It will take approximately 5 minutes to discharge when power is removed.
C. Apply power to system via fuse blocks, Spindle Module LED display should indicate
A. Enter “Drive Code” into Parameter “P-095”, identifies drive type to drive software.
parameter mode.
VTC-40 13
parameter mode.
VTC-40 411
C. Verify “Encoder Pulse Code” value in Parameter “P-098”. The motor measuring
system should have encoder pulses per revolution equal to 2048. If the value
differs, change value from spindle keypad by using the “+” or “-” key to increment
or decrement the value as required.
D. Go to “Initialization” parameter “P-097”. Change the parameter value by pressing
the “+” key on the keypad. The display should indicate “1”, then change to “P-
000”. The LCD’s should now indicate the “status” of the module with intermittently
flashing “P-000”. At this point specific functions and features can be implemented.
At this point proceed through the Parameter List in Attachment and verify each
parameter and change any parameter as necessary from the list. Several parameters
are predetermined from firmware and require no change. These parameters can be
identified with notation “mot 1” or “mot2” in description column. It is important that all
parameters agree with appropriate Parameter List for proper operation.
A. In order to change machine specific parameters disable write protection by

changing parameter “P-051” to “4H”.
B. Toggle through each parameter in Attachment A or Attachment B and change the
values to correspond to value settings in the list.
C. After all parameter value settings have been incorporated and verified transfer the
data into the drives EPROM by changing the value or parameter “P-052” to “1” to
store the changes. Once the data has been stored parameter “P-052” will return to
“0”.
D. Finally enable write protection parameter “P-051” to “0H” so that changes cannot
be made inadvertently.
A. To achieve the Spindle Zero Drift (spindle velocity of Zero RPM) proceed as
follows:
Do not adjust the VR potentiometers on the MX4 board! Leave them at their
factory settings. The range of adjustment available from the Siemens Spindle
Module is sufficient to balance spindle offset.
Control select: Auxiliary Mode; <ENTER>, 100, <ENTER>; F1 (“CNC Config”);
F4 (“Spindle”). Make change to Closed Loop Velocity if necessary.
2. AUXILLIARY Mode; <ENTER>, 100, <ENTER>; F6 (“Servo Tuning”); F4
(“Spindle”);. F5 (“Toggle Following Eror”).
3. When the program starts, press the MOTION HOLD BUTTON, this will hold the
DAC at zero output. The spindle will probably rotate slowly, indicating a need
for balance.
4. Adjust parameter “P-015”, Offset Correction Speed Setpoint at the spindle
drive. Increase or decrease the hexadecimal value as necessary until the
spindle stops rotating. It will be necessary to use parameters “P-051” and “P-
052” to invoke this change. Verify the quality of the null by observing no
change in the counts being displayed in the Following Error column and
no physical spindle rotation.
B. To calibrate The Maximum Spindle Speed parameter (ensuring that the Ultimax
Control reflects true Spindle speed), proceed as follows:
1. In MANUAL Mode, set the Manual Spindle Speed value to the maximum
spindle speed of the machine. Note this commanded (desired) value.

4. It is likely that there will be a Programmed RPM Acceptable RPM Range
discrepancy between the 65 64-66*
commanded or rated RPM 3000 2997-3003
and the measured Spindle 6500 6493-6507
speeds. To offset this 10000 9990-10010
situation you may use the
following formula to adjust
the DAC voltage. Calculate this new required voltage value (to four decimal
places), and enter it into the Ultimax screen. Use <ENTER>, 100, <ENTER>
screen.
DAC” Voltage
Example: Measured spindle speed = 5980 RPM with original DAC voltage on
changed to (6000/5980 s 9.5 = 9.5312V).
timing belt is used for transmission to ensure no motion loss. To achieve an orient
zero mark proceed as follows

“P-149” to “21H”.
references signals taking into account the 1:1 ratio. Set parameter to “2048”.
When the drive unit is powered up, the position counter is checked during the
first one or two revolutions of the spindle.
6. Rotate the spindle at least one complete revolution by hand.
7. Put an empty Tool Holder in the Magazine Position 1
8. Rotate the Magazine to Position 1.
and write down the position______.
10. Move the Z-Axis up about 1” and set this as the new Tool Change height.
11. Move X & Y to Tool Change Position.
12. Move the Tool Shifter down.
13. Move the Tool Holder down.
14. Rotate Load Arm to 60 degree.
15. Unclamp the Spindle.
16. Rotate the Exchange Arm.
17. Slowly jog the Z-Axis down, until the spindle keys are lined up and are in the
tool holder.
reset to “0”.
22. Move Z-Axis back up to Tool Change Height.
23. Move the Tool Changer back to Home Position.
24. Change the Tool Change Height Back to the value in step 9.

be (+) or (-) 1 count from the value recorded in step XV(A)11. Also on the
A. Procedure will work properly with motor encoder and proximity switch when spindle
has a 1:1.25 ratio and a timing belt is used for transmission to ensure no motion
loss. To achieve an orient zero mark proceed as follows:
“P-149” to “21H”.
references signals taking into account the 1:1.25 ratio. Set parameter to
“1638”. When the drive unit is powered up, the position counter is checked
during the first one or two revolutions of the spindle.
6. Rotate the spindle at least one complete revolution by hand.
7. Put an empty Tool Holder in the Magazine Position 1
8. Rotate the Magazine to Position 1.
9.From the ATC Diagnostics screen Move the Spindle to Tool Change Height,
and write down the position______.
10. Move the Z-Axis up about 1” and set this as the new Tool Change height.
11. Move X & Y to Tool Change Position.
12. Move the Tool Shifter down.
13. Move the Tool Holder down.
14. Rotate Load Arm to 60 degree.
15. Unclamp the Spindle.
16. Rotate the Exchange Arm.
17. Slowly jog the Z-Axis down, until the spindle keys are lined up and are in the
tool holder.
reset to “0”.
22. Move Z-Axis back up to Tool Change Height.
23. Move the Tool Changer back to Home Position.
24. Change the Tool Change Height Back to the value in step 9.
If for some reason it is necessary to re-initialize the spindle drive, reset all parameters to
the original factory settings, perform the following steps:
A. Set parameters:“P-051” to “4H”
“P-097” to “0H”
B. Power the system down, wait until the LCD’s extinguish. Then power the system
back up, the LCD readout will display parameter “P-095”.
C. To restart and re-initialize the drive begin again at the beginning of these
procedures for Siemens spindle drive.

ATTACHMENT “A”
SIEMENS SPINDLE PARAMETER LIST

Page 13 757-4002-160 Rev. A

ATTACHMENT “A”

Page 14 757-4002-160 Rev. A

ATTACHMENT “A”

P-090 Control word hex 2DH
P-116 Correction, P-gain, current controller mot 1 % 0
Page 15 757-4002-160 Rev. A

ATTACHMENT “A”

P-146 Search speed for spindle positioning RPM -500
2
P-162 Rated motor voltage mot 1 V 322
P-165 Motor no-load voltage mot 1 V 296
Page 16 757-4002-160 Rev. A

ATTACHMENT “A”

Page 17 757-4002-160 Rev. A

ATTACHMENT “A”

2
P-222 Rated motor voltage mot 2 V 322
P-225 Motor no-load voltage mot 2 V 296
Page 18 757-4002-160 Rev. A

ATTACHMENT “A”

P-274 Switch-in speed, torque setpnt smoothing mot 2 RPM 4000
Page 19 757-4002-160 Rev. A

ATTACHMENT “A”

Page 20 757-4002-160 Rev. A

YASKAWA
D8079 757-4002-008 MAX 3 BMC 20/50 SPINDLE AMP SETUP
D8080 757-4002-007 MAX 3 SERVO AMP SETUP PROCEDURE
D8276 757-4001-093 YASKAWA SPINDLE AMP SETUP, BMC 20/50, MHP’S
D8332 757-3050-005 YASKAWA SPINDLE DRIVE SETUP, BMC10 (L) /15
D8376 757-4001-121 BMC40 SLV HIGH TORQUE SPINDLE OPTION
D8432 757-4002-059 YASKAWA DIGITAL SERVO DRIVE SETUP, ISA CONTROL
30M, 30HTM, 40M, 40/50M, 50/50M
D8433 757-4002-060 YASKAWA DIGITAL SPINDLE DRIVE SETUP, ISA
CONTROL, 30M, 30HTM, 30SSM, 40M, 40/50M, 50/50M
DP015 757-4005-015 INSTALLATION PROCEDURES AND PARAMETER
SETTINGS FOR MACHINES WITH YASAWA SIGMA DRIVES
AND ULTIMAX 4 ISA SOFTWARE V2.XX
D8597 757-4002-182 YASKAWA DIGITAL SPINDLE DRIVE SETUP, Ver. 2.xx, MAX 4
D8613 704-0020-035 Yaskawa Sigma Servo Pack Drive Parameter Diskettes
SPECIAL YASKAWA Sigma II Manuals
SPECIAL Sigma Win Manual
Yaskawa Sigma II Part Numbers by Machine Type
DP0030 757-4005-030 Yaskawa 626M5 Spindle Drive Setup Procedure With Ultimax 4
DP0031 757-4005-031 INSTALLATION PROCEDURES FOR YASKAWA SIGMA II
D8706 757-4002-288 Setup and Test Procedures for Dynapath DMC1000 and Hurco CS50
Bedmills with Yaskawa SDGH Axis Drives
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
757-4002-008 REV: C ECN #
R
10/28/92 CAD#D8079
SUBJECT: BMC 20/50 ULTIMAX 3 YASKAWA SPINDLE AMPLIFIER SETUP

PROCEDURE
Rev. ECN No. Rev. Description Date

D Draft copy - These parameters are preliminary and subject 10/28/92
to change and refinement as required.
I. INTENT
To provide a standardized procedure for the configuration and adjustment of the Yaskawa
spindle drives used on BMC 20/50 Ultimax 3 type machining centers.
II. APPLICABILITY
Applicable to all BMC 20/50 Ultimax 3 type machining centers using software version 1.10
or later. This is the only procedure to be used within HURCO facilities and should be used at
III. FORMAT
Page 1 - Ultimax 3 Control Parameters

Pages 1 thru 2 - Drive Setup
Pages 3 thru 4 - Orient Setup
________________________________ _______ _______________________________ _______

IV. ULTIMAX 3 CONTROL PARAMETERS
The following spindle parameters should be loaded by default on power up as determined by

the "Machine Type" switches on the Control Rely PCB. These parameters must be checked
and may be edited in the Tune Axis Parameter screen. Type "<ENTER>, 1, 0, 3, <ENTER>"
while in the ATC Diagnostics screen in the manual machine mode. The control power must be
on and the machine must be calibrated before the Tune Axis Parameters screen can be entered.
BMC 20: 5.5KW 6K 5.5KW 10K 7.5KW 6K 7.5KW 10K

Integral 2500 2500 2500 2500
Proportional 4000 4000 4000 4000
State Velocity 1500 2250 1500 2250
Derivative 3000 4500 3000 4500
Acceleration 140000 180000 140000 180000
F Error Halt 0.75 0.75 0.75 0.75
Cal Integral 0 0 0 0
Tap Decel 95000 120000 95000 120000
BMC 25/30/40: 11KW 4K 11KW 6K 11KW 10K

Integral 2500 2500 2500
Proportional 4000 4000 4000
State Velocity 1500 1500 1500
Derivative 3000 3000 ????
Acceleration 100000 100000 ?????
F Error Halt 0.75 0.75 0.75
Cal Integral 0 0 0
Tap Decel 65000 65000 ??????
2
BMC 50: 15KW 4K 15KW 6K
Integral 2500 2500
Proportional 4000 4000
State Velocity 1500 ?????
Derivative 3000 ????
Acceleration 55000 ?????
F Error Halt 0.75 0.75
Cal Integral 0 0
Tap Decel 35000 ??????
V. DRIVE SETUP
A. Verify SCN1-CN1 spindle harness has been modified per Engineering Document
757-4002-024, if the harness part number is 423-6800-001/002 Revisions A-D.
B. Prior to power up, remove Orient card and verify that there is a shunt jumper from P1-C
and from B-C.
C. Reinstall the Orient card and turn power on. Check configuration screen.
D. Set control constants per table 1. The Spindle Drive LED display should read zero.
Depress the NO./DATA key then the mode key 2 times and the display should display
CN-01, which stands for control constant one. Press the NO./DATA key to display the
factory preset control constant. If the constant needs to be changed, use the MODE / >
key to position to the digit which needs to be changed. When you have positioned to the
digit which requires changing, it will start blinking. Use the ^ key to change the value of
the preset value. Once you have the correct value programmed, press and hold the
HOME/SET button until all the numbers have quit flashing. Press NO./DATA to return
to CN-01. If the value does not need to be changed, press the HOME/SET key to index
to the next control constant.
3
E. Repeat step 3 for all 40 control constants referring to the table below:
Table 1:
Single Winding Dual Winding
CN-# CODE DESCRIPTION 5.5KW 7.5KW 11KW 15KW
01 PNORH SPEED CONTROL P (H GEAR) 30 30 30 30
02 PNORL SPEED CONTROL P (L GEAR) 30 30 30 30
03 PNORTH SPEED CONTROL P (H GEAR ORT) 30 30 30 30
04 PNORTL SPEED CONTROL P (L GEAR ORT) 30 30 30 30
05 NDAJ MOTOR SPEED ADJUSTMENT 1.1 1.1 1.1 1.1
06 SMADJ SPEEDOMETER SIG LVL ADJ 1.00 1.00 1.00 1.00
07 LMADJ LOAD METER SIG LVL ADJ 1.0 1.0 1.0 1.0
08 LMFS LOAD METER FULL SCALE 200 200 200 200
09 EXTLIM EXTERNAL OPER TORQUE LIMIT 05 05 05 05
10 TSFS SOFT STRT TIME OF SPEED REF 0.1 0.1 0.1 0.1
11 EMGTIM EMG STP TIMER 10 10 10 10
12 INORH SPEED CONTROL I (H GEAR) 100 100 100 100
13 INORL SPEED CONTROL I (L GEAR) 100 100 100 100
14 IORTH SPEED CONTROL I (H GEAR ORT) 200 200 200 200
15 IORTL SPEED CONTROL I (L GEAR ORT) 200 200 200 200
16 NEDTL OPERATION LVL OF SPD DET SI 10 10 10 21
17 DNDTL HYSTERISIS WIDTH OF SPD DET 01 01 01 1.3
18 TDETL OPER LVL TORQUE DECT SGNL 30 30 30 30
19 PTAP SPEED CNTRL P (SERVO MODE) 40 40 40 40
20 ITAP SPEED CNTRL I (SERVO MODE) 100 100 100 100
21 N100 MOTOR RATED SPEED 8000 8000 6000 4800
*22 HGEAR H GEAR RATIO (SPIN/MOTOR) See See See See
*23 MGEAR M GEAR RATIO (SPIN/MOTOR) Chart Chart Chart Chart
*24 LGEAR L GEAR RATIO (SPIN/MOTOR) #1 #1 #2 #3
25 MOTOR MOTOR CODE SELECTION 0002 0003 0038 0031
26 SELCD1 SELECT CODE 1 (OPER COND) 26A4 06A4 06A4 06A4
27 SELCD2 SELECT CODE 2 (OPER COND) 0007 0007 0007 0007
28 ACCTLI TORQUE LIMIT LVL (MTR SIDE) 120 120 120 120
29 DECTLI TORQUE LIMIT LVL (BRK SIDE) 120 120 120 120
30 DI2LIM 12 RATE LIMIT 04 04 01 01
31 IWLVLL MAGNETIC FLUX LOWER LIMIT 30 30 30 30
32 IWGAIN MAGNETIC FLUX COMP LEVEL 30 30 30 30
33 PHAIWE MAGNETIC FLUX LVL AT ORIENT 50 50 50 70
34 PHAILM MAGNETIC FLUX UPPER LEVEL 100 100 100 100
35 PHITAP MAGNETIC FLUX LW LVL @ SER 70 70 70 70
36 CNBTAP BASE SPEED OF SERVO MODE 1.0 1.0 1.0 1.0
37 NORT ORIENTATION SPEED 03 03 03 03
38 NCRP CREEP SPEED 1.5 1.5 1.5 1.5
39 AGREE SPEED AGREE SIGNAL WIDTH 15 15 15 15
40 OFFSET ANALOG SPD REF OFFSET ADJ Setup Setup Setup Setup
4
NOTE: CONTROL CONSTANTS CANNOT BE SET IF AN ORIENT COMMAND HAS BEEN
ISSUED OR THE SPINDLE IS IN ORIENT POSITION. (ORT LIGHT ON ORIENT
CARD)
CHART #1 CHART #2 CHART #3

10,000 RPM = 1.25 10,000 RPM = 1.50 6,000 RPM = 1.25
6,000 RPM = .75 6,000 RPM = 1.00 4,000 RPM = .83
4,000 RPM = .67
F. Turn spindle on in manual mode (LG light of orient PCB should be on with winding
selection models). Ensure proper spindle rotation and operation. Program and run a
speed above 2000 RPM, check HG.
G. Adjust spindle drive DAC offset (balance) per Engineering Document 757-4002-026.
V. ORIENT SETUP
A. Presets
1. Shunt Jumpers
NORM/TEST NORM
AUTO/N.C. AUTO
S/M/L DIA. S-DIA for BMC-20, 25, 30, 40 40SLV
M-DIA for BMC-50
INP/FS200 INP
FS200/FS1378 FS1378
2. Potentiometers
IPF-RNG Full CCW

F-OFS DO NOT ADJUST
R-OFS DO NOT ADJUST
L-BIAS Mid Range
*M-BIAS Mid Range
BIAS Mid Range
LVL Full CCW
L-G Mid Range
*M-G Mid Range
H-G Mid Range
L-SPD Mid Range
*M-SPD Mid Range
H-SPD Mid Range
L-T Mid Range
H-T Mid Range
5
* These potentiometers should not effect orient operation, software will select
HIGH or LOW during orient.
B. Adjust the gap between the magnetizing element and the sensor head, so that the gap
value is 1.5mm +/- 0.5mm.
C. Run the spindle at approximately 150 RPM in manual mode. Adjust the LVL pot CW
to obtain flashing LVL-1 and LVL-2 LED's. Continue CW until the O-LVL (Over
level) red LED begins to flash, then CCW so that O-LVL does not light.
NOTE: IF the magnet and sensor are correctly mounted LVL-1 will flash first then
LVL-2 with each (clockwise) rotation of the spindle. Also, the INP LED will
come on with LVL-1 and go off as LVL-2 goes off.
D. Enter ATC Diagnostics, <ENTER>, 101, <ENTER>, and select the <Spindle Orient>
diagnostics softkey. Move the NORM/TEST shunt from NORM to TEST. The Test
mode LED and the H-G LED should both be on. Press and hold the test button. Adjust
H-SPD to obtain the motor speed (+/- 2 RPM) indicated on the spindle drive display
per Chart #4.
Release the test button and observe the INP (In Position) and O-END (Orient End)
LEDs, should both be on.
Chart #4:
Spindle Drive Type

5.5 KW 11 KW 15 KW
7.5 KW
Spindle 4000 N/A 225 180
Max 6000 200 150 NEED
RPM 10000 120 90 N/A
E. Press the test button and hold for approx. 3 seconds, release the button and observe the
CRP (creep) LED. Adjust the H-T pot to obtain a short blink from the CRP LED just
prior to the O-END LED coming on.
NOTE: If the machine does not have a winding select contactor, skip to Step H.
F. Select <Spindle Orient> diagnostics softkey, <START> to change to low gear. The
L-G LED should be on. Press and hold the test button. Adjust L-SPD to obtain the
motor speed (+/- 2 RPM) indicated on the spindle drive display per Chart #4. Release
the test button and observe the INP and O-END LEDs, both should be on.
G. Press the test button and hold for approximately 3 seconds, release the button and
observe the CRP LED. Adjust the L-T pot to obtain a short blink from the CRP LED
just prior to the O-END LED coming on. The IPF LED is inoperative in the test mode.
6
H. After adjustments, cancel the test mode by moving the NORM/TEST shunt to NORM.
Exit Orient diagnostics.
I. Go to manual mode and jog the Z axis to the plus limit switch. Then lock the spindle.
J. Enter ATC Diagnostics and move the magazine right. Jog the Z axis down near the top
of the tool changer magazine.
K. Looking from directly under the spindle visually inspect the alignment of the spindle
centerline to the magazine centerline. Loosen the Orient sensor collar and carefully
move the collar to obtain orient position. Use the BIAS pot to fine adjust alignment.
This adjustment allows only 2 degrees maximum. NOTE: This adjustment may need to
be re-checked after tool changer set-up.
7
757-4002-007 REV: B ECN #
R
27 APR 94 CAD#D8080
SUBJECT: BMC 20/50 ULTIMAX 3 YASKAWA SERVO AMPLIFIER SETUP

PROCEDURE

A 12504 Original Issue for use with Software version 1.13. 04 DEC 92
B 13005 Rewrite for V1.21 or greater (supercedes V1.13) 17 MAY 94
I. INTENT
To provide a standardized method of configuration and adjustment of the Yaskawa AC Servo Amplifiers
being used on the Linear Axes BMC 20/50 Ultimax 3 Machining Centers.
II. APPLICABILITY
Applicable to all BMC 20/50 Ultimax 3 Machining Centers with Executive Software Version V1.21 or
greater. This procedure is to be used by Manufacturing during the building process and by Customer
Service when installing or servicing BMC 20/50 Ultimax 3 Machining Centers.
III. INDEX
ULTIMAX 3 Control Parameter Verification - page 2

Linear Axis Yaskawa Servopack Configuration - page 2
DAC Offset Check - page 3
Axis Amplifier Balance Adjustment - page 5
Axis Command Voltage Setup - page 6
Axis Performance Verification - page 7
Axis Load Bar Calibration - page 9
Axis Travel Verification - page 9
Definitions - page 10
Hurco/Yaskawa Part Identification Table - page 10
Yaskawa Servopack PCB Layout - page 11
Axis Tuning Worksheet - page 12
________________________________ _______ _______________________________ _______
IV. ULTIMAX 3 CONTROL PARAMETER VERIFICATION
The Axis Tuning Parameters are automatically loaded upon power up as determined by the "Machine
Type" switch settings located on the Control Relay Panel PCB. Use Engineering Document 757-4002-
029 (Parameters for ULTIMAX 3 Software Version 1.21) to verify the Parameters.
A. In Manual mode, select the CHANGE TOOL OR DIAGNOSTICS softkey followed by the
ATC & MACHINE DIAGNOSTICS softkey.
B. Select each axis softkey to verify the Axis Tuning Parameters.
C. If an Axis Tuning Parameter needs to be changed then enter the correct value per the Engineering
Document.
J. When complete, remove the diskette from the floppy drive and store in a safe location.
V. LINEAR AXIS YASKAWA SERVOPACK CONFIGURATION
A. Verify/Set the Yaskawa Servopack configuration for each Axis as follows:
LINEAR AXES SWITCH SETTINGS

SW1 - Shunt Jumpers on 4 and 8 [All axes]
SW2 - Shunt Jumpers on 2 through 8 [All axes except 20LR X & Y]
SW2 - Shunt Jumpers on 1 through 8 [20LR X & Y, BMC30LR ALL]
SW3 - Shunt Jumpers on 1 and 4 [All axes]
SW4 - Shunt Jumpers on 1 through 4 and 8
LINEAR AXES ADJUSTMENT PRESETS

VR1 (DAC Coarse) - 2 of 10 Scale [All axes]
2
VR3 (Zero) - Midrange (5 of 10 Scale) [All axes]
VR4 (DAC Fine) - Midrange (5 of 10 Scale) [All axes]
VR5 (I Limit) - Full CW (10 of 10 Scale) [All axes]
VR6 (Gain) - X & Y Gain = 5 of 10 scale, Z Gain = 5 of 10 Scale
NOTE: Normally the factory settings of VR1 through VR6 will not need to be altered.
B. If an axis harmonic or resonance is audibly detected (a "ringing" as the axis moves the length of the
table at 100 IPM and continues "ringing" for a short period after the release of jog) then install a
jumper on SW3-7 to set a 1.2 msec Time Constant for the Servopack's f/V Filter (refer to the
Yaskawa Servopack PCB Layout Diagram for switch location). If the jumper is already installed
then remove it to set a 0.1 msec Time Constant.
VI. DAC OFFSET CHECK
A. In Input mode, change the machine's units to Metric (may have to select the ERASE ALL softkey).
B. Enable Control Power and jog each of the axes (including rotary) to the approximate mid-travel of
the axis.
C. Connect the positive lead of a Digital Volt Meter (DVM) to pin TM3-2 on the Yaskawa
Servopack of an axis and the negative lead to 0V (refer to the Yaskawa Servopack PCB Layout
Diagram for test point locations); use the mVDC scale.
D. In Manual mode, select the CHANGE TOOL OR DIAGNOSTICS softkey followed by the
E. Press "Enter 101 Enter" to display the Spindle/Servo Diagnostics Setup screen.
F. Select the AXIS BALANCE ADJUST softkey.
G. Select the appropriate softkey to choose the axis to be balanced.
H. At the prompt, press the Start pushbutton which begins the following three step, open-
loop,repetitive routine:
1. output a positive eight bits DAC (approx. +40 mVDC) command for 10 seconds
2. output a negative eight bits DAC (approx. -40 mVDC) command for 10 seconds
3. output zero bits DAC (approx. 0 mVDC) command for 10 seconds
NOTE: the actual voltages may vary slightly from one DSP Motion Controller PCB to
another and from one axis to another.
I. Using only the zero DAC command, the DVM reading should not exceed ± 15 mVDC DAC
Offset for each axis (go to step K for excessive DSP DAC Offset testing).
J. To quit the check, select another softkey or press the EXIT softkey.
K. Repeat the check for each machine axis; if all axes are within ± 15 mVDC then go to Section VII.
3
L. If the DAC Offset is greater than ± 15 mVDC then the excessive DAC Offset could be caused be
the DSP Motion Controller PCB, the CRP to MC/J1 harness, the Control Relay Panel PCB, the
CRP to Servopack harness, or the Yaskawa Servopack.
M. DAC Offset test for the DSP Motion Controller PCB:

1. Abort the Axis Balance Adjust test and disable Control Power.
2. Remove the CRP to MC/J1 harness at the DSP Motion Controller PCB.
3. Attach a 50-pin breakout board (Hurco P/N 415-0198-001) to J1 of the DSP Motion
Controller PCB.
4. Restore Control Power and access the Axis Balance Adjust test for the failed axis.
5. Measure the DAC Offset at the following pin-outs:
Axis Positive Negative
X J1-13 J1-45
Y J1-7 J1-38
Z J1-17 J1-46
Spindle J1-28 J1-43
a J2-13 J2-45
b J2-7 J2-38
6. If the DAC Offset for any of the axes exceeds ± 10 mVDC then the DSP Motion
Controller PCB is to be replaced.
N. DAC Offset test for the CRP to MC/J1 Harness:

2. Attach the CRP to MC/J1 harness to J1 of the DSP Motion Controller PCB and
remove the CRP to MC/J1 harness at the Control Relay Panel PCB.
4. Measure the DAC Offset at the following pin-outs at P11 of the CRP to MC/J1
harness:
X J11-13 J11-45
Y J11-7 J11-38
Z J11-17 J11-46
Spindle J11-28 J11-43
a J12-13 J12-45
b J12-7 J12-38
6. If the DAC Offset for any of the axes exceeds ± 15 mVDC then the harness (Hurco P/N
423-6806-025) is to be replaced.
O. DAC Offset test for the Control Relay Panel PCB:

2. Reattach the CRP to MC/J1 harness between the DSP Motion Controller PCB and the
Control Relay Panel PCB.
3. Disconnect the CRP to Servopack harness at the Control Relay Panel PCB for the
appropriate axis.
5. Measure the DAC Offset at the following pin-outs of the Control Relay Panel PCB:
4
X M2-15 M2-2
Y M4-15 M4-2
Z M6-15 M6-2
Spindle S1CN-3 S1CN-4
a M8-15 M8-2
b M10-15 M10-2
6. If the DAC Offset for any of the axes exceeds ± 15 mVDC then the Control Relay
Panel PCB (Hurco P/N 415-0224-004) is to be replaced.
P. DAC Offset test for the CRP to Servopack Harness:

2. Reattach the CRP to Servopack harness at the Control Relay Panel PCB.
3. Disconnect the CRP to Servopack harness at the Servopack for the appropriate axis.
5. Measure the DAC Offset at the following pin-outs of the Servopack harness:
X 14 15
Y 14 15
Z 14 15
Spindle 3 4
a 14 15
b 14 15
6. If the DAC Offset for any of the axes exceeds ± 15 mVDC then the CRP to Servopack
harness (Hurco P/N 423-6802-002) is to be replaced.
Q. If the tests in L, M, N, and O pass then replace the Yaskawa Servopack.
VII. AXIS AMPLIFIER BALANCE ADJUSTMENT
A. In Input mode, change the machine's units to Metric (may have to select the ERASE ALL softkey).
B. Enable Control Power and jog each of the axes (including rotary) to the approximate mid-travel of
the axis.
C. Connect the positive lead of a Digital Volt Meter (DVM) to pin TM3-3 on the Yaskawa
Servopack of an axis and the negative lead to 0V (refer to the Yaskawa Servopack PCB Layout
Diagram for test point locations); use the mVDC scale.
D. In Manual mode, select the CHANGE TOOL OR DIAGNOSTICS softkey followed by the
E. Press "Enter 101 Enter" to display the Spindle/Servo Diagnostics Setup screen.
F. Select the AXIS BALANCE ADJUST softkey.
5
G. Select the appropriate softkey to choose the axis to be balanced.
H. At the prompt, press the Start pushbutton which begins the following three step, open-
loop,repetitive routine:
1. output a positive eight bits DAC (approx. +40 mVDC) command for 10 seconds
2. output a negative eight bits DAC (approx. -40 mVDC) command for 10 seconds
3. output zero bits DAC (approx. 0 mVDC) command for 10 seconds
I. Using only the zero DAC command, adjust the VR3 (Zero) pot on the Yaskawa Servopack (refer
to the Yaskawa Servopack PCB Layout diagram for location) to obtain a reading of 0.0 mVDC (±
0.5 mVDC). Note that the final adjustment of VR3 should be between 2 and 8.
J. Select another axis softkey to balance the other axes or press the EXIT softkey to quit.
VIII. AXIS COMMAND VOLTAGE SETUP
B. Press "Enter 102 Enter" to display the Lead Screw Map Setup screen.
C. Select the LEADSCREW MAP DEFAULTS softkey to zero all axis compensation and then
select the EXIT softkey.
D. Select Manual mode followed by the CALIBRATE MACHINE softkey and press the Start
pushbutton.
E. After calibration, check the MACHINE display for 0.000 mm and the Marker Dot for each axis
(may have to jog an axis slightly to find the Marker Dot but not away from 0.000 mm). Due to the
system resolution, the Marker Dot does not have to be steady but may flash on and off at various
rates.
F. In Input, create a Metric Part Program with loop and repeats to move each axis one at a time from
0. mm to 200. mm at 1016. mm/min.
G. Connect the Positive Lead of a DVM to pin TM3-2 and the Negative Lead to 0V of the Yaskawa
Servopack to be setup (refer to the Yaskawa Servopack PCB Layout diagram for locations) to
measure the DAC voltage command; use the 2 VDC scale.
H. In Auto, select the RUN PROGRAM softkey and press the Start pushbutton. Verify that the axis
feed rate display shows 1016. mm/min.
I. Ignoring the polarity of the command, adjust the VR1 (DAC coarse adj) and/or the VR4 (DAC
fine adj) pot to obtain 0.950 VDC (±0.002 VDC) for only the larger of the two DAC voltages
measured. Adjust VR1, if necessary, so that the VR4 (fine adj) pot is left near its mid-
position setting.
6
J. Move the Positive Lead from TM3-2 to TM3-3 to measure the Motor Speed.
K. Ignoring the polarity, the positive and negative readings must be within ± 0.002 VDC; return to
Section VII to fine tune the Axis Balance for that axis if this value is exceeded.
L. If the LASER run shows a slight overshoot or undershoot or if the jog movements do not appear
smooth and precise, adjust the VR6 (Gain) pot slightly.
M. Repeat the setup for the each of the axes.
N. For Rotary axes, enter 10160. mm/min for the Rapid Detent value in Manual mode and execute
steps F through I above. Note that the voltage reading will be at 9.50 VDC.
IX. AXIS PERFORMANCE VERIFICATION
A. In Manual mode, select the CHANGE TOOL OR DIAGNOSTICS softkey.
B. Set the Manual Jog Feed to 1016. mm/min and the Rapid Detent feed to 10160. mm/min.
C. Select the ATC & MACHINE DIAGNOSTICS softkey.
D. Press "Enter 101 Enter" to display the Spindle/Servo Diagnostics Setup screen.
E. Select the TOGGLE LOAD BAR DISPLAY softkey, the TOGGLE ACTUAL DISPLAY
softkey, and the TOGGLE FOLLOWING ERROR DISPLAY softkey.
F. Select the EXIT softkey to return to the ATC & Machine Diagnostics screen.
G. Press "Enter 103 Enter" to display the Axis Tune Parameters screen. The additional fields
displayed are:
7
H. With the Axis Override pot at nominal, jog an axis for at least two seconds using the rapid button;
verify that the feed is 1016. mm/min and record the Following Error in the table for the selected
direction.
I. After axis motion has ceased, record the Within Tolerance time, the At Position time, and the
Axis Overshoot values in the appropriate table.
J. Repeat steps H and I for the opposite direction.
K. Verify that the Within Tolerance time is ± 50 msec between each direction; if the Within Tolerance
difference exceeds 50 msec then slightly adjust the VR3 (Zero) pot of the Yaskawa Servopack for
0.0000 mm Following Error with the axis at rest.
L. Verify that the Axis Overshoot is less than or equal to the In Position Tolerance parameter
(reference Hurco Engineering Document 757-4002-029, Parameters for ULTIMAX 3 Software
Version 1.21); if the Axis Overshoot exceeds the In Position Tolerance parameter:
1. select the appropriate axis softkey and decrease the Integral Limit parameter by one
2. select the BEGIN TUNE softkey
3. repeat steps H, I, and J
4. if no significant improvement results, reset the Integral Limit to its original value and
increase the Integral parameter by 10
7. when complete, select the STORE PARAMETERS softkey
8
M. Repeat steps H, I, and J for Rapid Detent jogging, verifying that the feed is 10160. mm/min.
N. Verify that the At Position time is less than 250 msec; if the At Position time exceeds 250 msec:
1. reverify Axis Balance Adjust procedures
2. inspect for mechanical problems such as a misalignment or a lube problem
3. for Z axis, the negative (down) motion should be optimized for At Position:
a. select the appropriate axis softkey and decrease the Integral Limit parameter by one
b. select the BEGIN TUNE softkey
c. repeat steps H, I, and J
d. when complete, select the STORE PARAMETERS softkey
O. Repeat steps H through N for each of the axes.
P. Verify that the Within Tolerance time for all axes is ± 100 msec.
Q. Select the EXIT softkey to return to the ATC & Machine Diagnostics screen.
R. If any of the Axis Tuning Parameters were edited, be sure to create a backup on the Machine
Configuration diskette.
X. AXIS LOAD BAR CALIBRATION
Axis Load Bar Calibration can be completed from the Axis Tuning Parameters screen with the Toggle
Load Bar display active.
A. Connect the Positive Lead of a DVM to pin TM3-4 and the Negative Lead to 0V of the Yaskawa
Servopack to be setup (refer to the Yaskawa Servopack PCB Layout diagram for locations) to
measure the amplifier current in terms of motor torque; use the 2 VDC scale.
[This voltage represents the motor torque; ± 3.0 VDC = 100%]
B. Manually jog the axis at 1200 mm/min or greater to produce a torque requirement or block the
axis with a piece of wood by carefully jogging the axis into the wood to load the axis to 40%. To
avoid damage to the spindle, do not place the wood directly against a tool holder or the spindle; use
the spindle head casting.
C. Adjust the CRP 3 Load Meter pot to match the number of bars displayed on the CRT to the
measured torque for the appropriate axis. One bar for every 130 mVDC measured.
D. Verify proper load bar display operation in both jog directions.
E. Repeat for each of the axes.
9
G. Press "Enter 101 Enter" to access the Spindle/Servo Diagnostics Setup screen.
H. Select the TOGGLE LOAD BAR DISPLAY softkey, the TOGGLE ACTUAL DISPLAY
I. Select the EXIT softkey to return to the ATC & Machine Diagnostics screen.
XI. AXIS TRAVEL VERIFICATION
A. Run the following programs to verify that Full Travel axis operation is smooth and that no
Following Errors occur.
BMC 20-50 CYCLE PROGRAM DISK PART NUMBER 704-2000-002
PROGRAM NAME DESCRIPTION

20FTX.HD3 BMC 20 X Axis Full Travel Servo Test
20FTY.HD3 BMC 20 Y Axis Full Travel Servo Test
20FTZ.HD3 BMC 20 Z Axis Full Travel Servo Test

10

XII. DEFINITIONS
A. Within Tolerance - length of time in milliseconds for the axis to remain within the In Position
Tolerance parameter after the axis was commanded to zero velocity. Factored with the Axis
Overshoot in encoder counts characterizes the amount of servo ringing present in the system.
B. In Position Tolerance - the number of encoder counts allowable on either side of the commanded
target that will be considered at the commanded position; the Integral term is active after the axis
motion is within this value. In contouring, an axis must stay within this bandwidth for 10 msec
before the Axis Ready signal is set and the next command is processed.
C. Axis Overshoot in Encoder Counts - the number of encoder counts that an axis overshot the
exact count of the final destination before servoing back to the final destination.
D. At Position Time - the length of time in milliseconds for an axis to reach the exact target encoder
count for the first time (prior to any overshoot) after being commanded to zero velocity.
E. System Resolution - one encoder count equals 0.0005 mm or 0.000019 in; the display resolution
is 0.001mm or 0.000039 in.
F. Integral - used to guarantee zero Following Error at the commanded position. In contouring
mode, an axis must stay within this bandwidth for 10 msec before the Axis Ready signal is set
and the next commanded target is processed. The Integral term guarantees Zero Following Error at
final destinations.
XIII. HURCO/YASKAWA PART IDENTIFICATION TABLE
BMC 20:
Linear Servo Drive - 402-6009-034 - Yaskawa CACR-SR05BB1BF-H
Linear Servo Motor - 402-6009-033 - Yaskawa USAFED-05FB1S-H
Line Filter - 402-6009-027 - Yaskawa LF-310
BMC 25 / 30:
Linear Servo Motor - 402-6009-035 - Yaskawa USAFED-09FB1S-H
11
BMC 40 and BMC 50:

Linear Servo Motor - 402-6009-037 - Yaskawa USAFED-20FB2T-H
XIV. YASKAWA SERVOPACK PCB LAYOUT
CACR-SRCA
REV B
OV
TM5
TM3 TM4
1
1 1
T
SW1 T T O
O O
1 8
8 8
T
O
SL4
8
SW4
1 RESET PUSHBUTTON
T
O
TROUBLE LED INDICATION
8 (7-SEGMENT)
SW2
VR9 IN
1 VR2 P
T VR10 MP
O VR11
VR12 5VP
8
VR13
IN-B
SW3 1
LOOP
T
O
8 ZERO
CUR
VR7
VR4
8 TO 1 VR8 SL6
TM2
8 TO 1 SL7
TM1
SL5
2CN 1CN
12
DEFAULT PARAMETER SETTINGS FINAL PARAMETER SETTINGS
X AXIS 1016 (+) 1016 (-) 10160 (+) 10160 (-) 1016 (+) 1016 (-) 10160 (+) 10160 (-)
Within
Tolerance
At
Position
Axis
Overshoot
Following
Error
Y AXIS 1016 (+) 1016 (-) 10160 (+) 10160 (-) 1016 (+) 1016 (-) 10160 (+) 10160 (-)
Within
Tolerance
At
Position
Axis
Overshoot
Following
Error
Z AXIS 1016 (+) 1016 (-) 10160 (+) 10160 (-) 1016 (+) 1016 (-) 10160 (+) 10160 (-)
Within
Tolerance
At
Position
Axis
Overshoot
Following
Error
a AXIS 1016 (+) 1016 (-) 10160 (+) 10160 (-) 1016 (+) 1016 (-) 10160 (+) 10160 (-)
Within
Tolerance
At
Position
Axis
Overshoot
Following
Error
b AXIS 1016 (+) 1016 (-) 10160 (+) 10160 (-) 1016 (+) 1016 (-) 10160 (+) 10160 (-)
Within
Tolerance
At
Position
Axis
Overshoot
Following
Error
13
757-4001-093 REV: D ECN #11978

03/05/92 CAD#D8276
SUBJECT: YASKAWA SPINDLE SET-UP PROCEDURE FOR BMC 20/50 AND

MHP-20/30
I. INTENT
To provide a standardized procedure for he configuration and adjustment of the

Yaskawa Spindle drives used on BMC 20/50 and MHP-20/30 type Machining Centers.
II. APPLICABILITY
Applicable to all BMC 20/50 and MHP-20/30 type Machining Centers. This procedure
is the only procedure to be used within Hurco facilities and should be used at
III. FORMAT
Pages 2 thru 4 : Drive Setup procedure

Pages 4 thru 6 : Orient Setup Procedure (BMC 20/50)
Pages 6 thru 8 : Orient Setup Procedure (MHP-20/30)
________________________________ _______ _______________________________ _______

IV. DRIVE SETUP PROCEDURE
1. Prior to power up remove Orient card and verify that there is a shunt jumper
from P1-C and from B-C. Ensure that Z-Spindle board is set as follows.
0 = OPEN
SW2 1 = CLOSED SW3
6 7 8 MILL TYPE 7 8 RPM
0 0 0 BMC 20 1 0 10K
0 1 0 BMC 30 0 1 6K
0 1 1 BMC 40 0 0 4K
1 0 0 BMC 50 1 1 3K
NOTE: SW2 and SW3 switch setting applicable to BMC mills only.
2. Reinstall the Orient card and turn power ON.
3. The LED display should read Zero. Depress the NO./DATA key then the mode
key 2 times and the display should display CN-01, which stands for control
constant one. Press the NO./DATA key to display the factory preset control
constant. If the constant needs to be changed, use the MODE / > key to position
to the digit which requires changing. It will then start blinking. Use the ^ key to
change the value of the preset value. Once you have the correct value
programmed press and hold the HOME/SET button until all the numbers have
quit flashing. Press NO./DATA to return to CN-01. If the value does not need to
be changed, press the HOME/SET key to index to the next control constant.
4. Repeat step 3 for all 40 control constants referring to the Table below:
MACHINE TYPE/DRIVE SIZE

MHP 20 30
BMC 20 20 30/40 50
CN# DESCRIPTION 5.5KW 7.5KW 11KW 15KW
01 SPEED CONTROL P (H GEAR) 30 30 20 30
02 SPEED CONTROL P (L GEAR) 30 30 20 30
03 SPEED CONTROL P (H GEAR ORT) 30 30 30 30
04 SPEED CONTROL P (L GEAR 30 30 30 30
ORT)
05 MOTOR SPEED ADJUSTMENT 01 01 01 01
06 SPEEDOMETER SIG LVL ADJ 01 01 01 01
07 LOADMETER SIG LVL ADJ .9 .9 .9 .9
08 LOAD METER FULL SCALE 120 120 120 120
09 EXTERNAL OPER TORQUE LIMIT 05 05 05 05
10 SOFT STRT TIME OF SPEED REF .1 .1 .1 .1
11 EMG STP TIMER 10 10 10 10
12 SPEED CONTROL I (H GEAR) 600 600 600 600
13 SPEED CONTROL I (L GEAR) 600 600 600 600
2
MACHINE TYPE/DRIVE SIZE
MHP 20 30
BMC 20 20 30/40 50
CN# DESCRIPTION 5.5KW 7.5KW 11KW 15KW
14 SPEED CONTROL I (H GEAR ORT) 200 200 200 200
15 SPEED CONTROL I (L GEAR ORT) 200 200 200 200
16 OPERATION LVL OF SPD DET SI 10 10 10 21
17 HYSTERISIS WIDTH OF SPD DET 01 01 01 1.3
18 OPER LVL TORQUE DECT SGNL 30 30 30 30
19 SPEED CONTROL P (SERVO 20 20 20 20
MODE)
20 SPEED CONTROL I (SERVO 100 100 100 100
MODE)
21 MOTOR RATED SPEED 8000 8000 6000 4800
22 H GEAR RATIO (SPIN/MOTOR) REF. REF. REF. REF.
23 M GEAR RATIO (SPIN/MOTOR) CHART CHART CHART CHART
24 L GEAR RATIO (SPIN/MOTOR) 1 1 2 3
25 MOTOR CODE SELECTION 0002 0003 0038 0031
26 SELECT CODE 1 (OPER COND) 22A4 02A4 02A4 06A4
27 SELECT CODE 2 (OPER COND) 0007 0007 0007 0007
28 TORQUE LIMIT LVL (MTR SIDE) 120 120 120 120
29 TORQUE LIMIT LVL (BRK SIDE) 120 120 120 120
30 12 RATE LIMIT 04 04 01 01
31 MAGNETIC FLUX LOWER LIMIT 30 30 30 30
32 MAGNETIC FLUX COMP LEVEL 30 30 30 30
33 MAGNETIC FLUX LVL AT ORIENT 50 50 50 70
34 MAGNETIC FLUX UPPER LEVEL 100 100 100 100
35 MAGNETIC FLUX LOW LVL @ SER 70 70 70 70
36 BASE SPEED OF SERVO MODE 02 02 02 01
37 ORIENTATION SPEED 03 03 03 03
38 CREEP SPEED 1.5 1.5 1.5 1.5
39 SPEED AGREE SIGNAL WIDTH 15 15 15 15
40 ANALOG SPD REF OFFSET ADJ 0 0 0 0

ISSUED OR THE SPINDLE IS RUNNING. (ORT LED LIT ON ORIENT CARD)
Chart #1 Chart #2 Chart #3

10,000 RPM= 1.25 10,000 RPM =1.50 6,000 RPM =1.25
6,000 RPM = .75 6,000 RPM = 1.00 4,000 RPM .73
4,000 RPM = .67
3
5. Turn Spindle ON at 1000 RPM, (LG LED ON Orient PCB should be lit on
Winding Selection models). Ensure proper Spindle rotation and operation.
6. NOTE: BMC 20/50 only.Calibrate machine, Load and Run LOOPTAP.HDB

program from Disk. Adjust bottom pot on DAC Flyer PCB while observing the
Digital readout on the Yaskawa drive to obtain a 5 RPM window between
Clockwise and Counterclockwise rotation.
7. Run Spindle at 1000 RPM, using the Digital Tachometer to verify RPM is
within+/- 5 RPM. If RPM is not within the specification adjust CN05 to obtain
correct RPM.
8. Run Spindle counterclockwise at 1000 RPM, use the Digital Tachometer to verify
RPM is within +/- 5 RPM. If RPM is not within this specification, adjust CN40 to
obtain correct RPM. Note that the spindle must be off to change CN40.
9. Repeat steps 7 and 8 until RPMs are within specifications.
V. ORIENT SETUP PROCEDURE (BMC 20/50)
1. Presets
A. Shunt Jumpers
NORM/TEST NORM
AUTO/NC AUTO
S/M/L DIA. S-DIA for BMC 20/30/40
M-DIA for BMC 50
INP/FS200 INP
B. Potentiometers
IPF-RNG Full CCW

F-OFS DO NOT ADJUST
R-OFS DO NOT ADJUST
L-BIAS Mid Range
*M-BIAS Mid Range
BIAS Mid Range
LVL Full CCW
L-G Mid Range
*M-G Mid Range
H-G Mid Range
L-SPD Mid Range
*M-SPD Mid Range
H-SPD Mid Range
L-T Mid Range
H-T Mid Range
4
* - These potentiometers should not effect Orient operation, Software will select
HIGH or LOW winding only.
2. Adjust the gap between the Magnetizing Element and the Sensor Head, so that
the Minimum gap value is 1.5mm +/- 0.5mm.
3. Run the Spindle at approximately 150 RPM in Manual Mode. Adjust the LVL pot
CW to obtain flashing LVL-1 and LVL-2 LED's. Continue CW until the O-LVL
(Over Level) red LED begins to flash, then CCW so that the O-LVL does not
light.
NOTE: If the Magnet and Sensor are correctly mounted LVL-1 will flash first then LVL-2
with each (clockwise) rotation of the Spindle. Also, the INP LED will come ON
with LVL-1 and go OFF as LVL-2 goes OFF.
4. Enter ATC Diagnostics, "Enter", "488", "Enter", and select the "Spindle Orient"
diagnostics softkey. Move the NORM/TEST shunt from NORM to TEST. The
Test Mode LED and the H-G LED should both be ON. Press and hold the Test
button. Adjust H-SPD to obtain the motor speed (+/- 2 RPM) indicated on the
Spindle Drive Display per the following chart. Release the Test button and
observe the INP (In Position) and O-END (Orient End) LED's both should be ON.
Machine Type
20 30/40 50
Maximum 4000 N/A 225 180
Spindle 6000 200 150 N/A
RPM 10000 120 90 N/A
5. Press the Test button and hold for approx. 3 seconds, release the button and
observe the CRP (Creep) LED. Adjust the H-T potentiometer to obtain a short
blink from the CRP LED just prior to the O-END LED coming on. The IPF (In
position fine) LED is inoperative in the Test Mode.
6. Select the "Spindle Orient" diagnostics softkey and press start to activate
Winding Change. The L-G LED should now be ON. Press and hold the Test
button. Adjust L-SPD to obtain the motor speed (+\- 2 RPM) indicated o the
Spindle Drive Display per the above chart. Release the Test button and observe
the INP (In Position) and O-END (Orient End) LED's both should be ON.
7. Press the Test button and hold for approx. 3 seconds, release the button and
observe the CRP (Creep) LED. Adjust the L-T potentiometer to obtain a short
blink from the CRP LED just prior to the O-END LED coming on. The IPF (In
position fine) LED is inoperative in the Test Mode.
8. After adjustments, Cancel the Test Mode by moving the NORM/TEST shunt to
NORM. Exit Orient diagnostics.
9. Go to Manual Mode and jog the Z Axis to the Plus Limit Switch. Then Lock the
Spindle.
5
10. Enter ATC Diagnostics and move the Magazine right. Jog the Z Axis down near
the top of the Tool Changer Magazine.
11. Looking from directly under the Spindle visually inspect the alignment of the
Spindle centerline to the Magazine centerline. Loosen the Orient Sensor Collar
and carefully move the Collar to obtain Orient position. Use the BIAS pot to fine
adjust alignment. This adjustment allows only 2 degrees maximum. Using
"Spindle Orient" diagnostics, switch between L-G and H-G and ensure the orient
position is the same, adjust the L-BIAS as needed.
NOTE: This adjustment may need to be re-checked after Tool Changer set-up.
VI. ORIENT SET-UP (MHP)
1. Shunt jumpers
NORM/TEST NORM
AUTO/NC AUTO
S/M/L DIA. S-DIA. for MHP-20/30
INP/FS200 INP
FS200/FS1378 FS1378
2. Potentiometers
IPF-RNG Full CCW

F-OFS DO NOT ADJUST
R-OFS DO NOT ADJUST
L-BIAS Mid Range
*M-BIAS Mid Range
BIAS Mid Range
LVL Full CCW
L-G Mid Range
*M-G Mid Range
H-G Mid Range
L-SPD Mid Range
*M-SPD Mid Range
H-SPD Mid Range
L-T Mid Range
H-T Mid Range
* These potentiometers will not effect the orient operation, software will select
high and low windings only.
3. Adjust the magnetic sensor to get a gap of 1.5mm +/- 0.5mm between the
sensor and the magnet.
4. Run the spindle at approximately 150 RPM.
6
a. <Mode Select>
"3 - Program"
"N" "." <Enter>
<Event Type>
"9 - M Codes"
"M" "3" <Enter>
"S" "150" <Enter>
<Cycle Start>
5. Adjust the LVL pot CW until the LVL-1, LVL-2 and O-LVL (over level) LED's
begin flashing, then CCW until the O-LVL LED stops flashing.
NOTE: If the magnet and the sensor are mounted correctly, the LVL-1 LED will flash
before the LVL-2 LED with CW rotation of the spindle. Also, the INP LED will
come on with LVL-1 and go off when LVL-2 goes off.
6. Press "M" "5" <Enter> <Cycle Start> to stop the spindle.
7. Install the Orient Test Connector in place of CN1 on the spindle drive. Orient
switch in the OFF position and the HG/LG switch in the HG position.
8. Toggle the Orient switch to the ON position. Move the NORM/TEST jumper to
the TEST position. The Test and the HG LED's will both be on.
9. Press and hold the Test button. Adjust H-SPD to obtain the motor speed per the
following chart (+\- 2 RPM) indicated on the spindle drive display. Release the
Test button and observe the INP (In position) and O-END (Orient End) LEDs,
both should be on.
Machine Type
20 30/40
Maximum 4000 N/A 225
Spindle 6000 200 150
RPM 10000 120 90
10. Press and hold the Test button for approximately 3 seconds, release the button
and observe the CRP (Creep) LED. Adjust the H-T potentiometer to obtain a
short blink from the CRP LED just prior to the O-END LED coming on. The IPF
(In position fine) LED is inoperative in the Test Mode.
Note: If MHP-20 skip to Step 14.
11. Toggle the HG/LG switch on the Orient Test Connector to the LG position. The
Winding Select Contactor will latch on and the LG LED will turn on.
12. Press and hold the Test button. Adjust L-SPD to obtain the motor speed per
above chart (+\- 2 RPM) indicated on the spindle drive display. Release the Test
button and observe the INP and O-END LED, both should be on.
7
13. Press the Test button and hold for approximately 3 seconds, release the button
and observe the CRP LED. Adjust the L-T potentiometer to obtain a short blink
from the CRP LED just prior to the O-END LED coming on.
14. After adjustments, cancel the Test Mode by moving the NORM/TEST jumper to
NORM. Toggle the HG/LG switch on the Orient Test Connector to the HG
position, then toggle the ON/OFF switch to the OFF position. Remove the Orient
Test Connector and replace the CN1 cable.
15. Jog Z axis to -100mm, then orient the spindle. <Mode Select> "0 - Jog" "2 -
Fast" then move Z to the proper height. <Mode Select> "3 - Program" "N" "."
<Enter>
<Event Type> "9 - M Codes" "M" "19" <Enter> <Cycle Start>, the spindle will
orient. "M60" <Cycle Start> to move the spindle right.
16. Go to Jog Mode and select medium speed. Jog Z down near the ATC.
17. Looking from directly under the spindle, visually inspect the alignment of the
spindle centerline to the magazine centerline. Loosen the Orient Sensor Collar
and carefully move the collar to obtain proper orient position. Use the BIAS
potentiometer to fine adjust the alignment for HG and the L-BIAS potentiometer
for LG.
NOTE: This adjustment will have to be rechecked after the tool changer is
leveled and set-up.
18. Manually move the ATC to the left position, put air on the machine, then use
"M18" to cancel Orient.
19. Orient Test Connector:
NOTES:
Yaskawa 626MTIII Drive Error Code “ ICAN”
8
The ICAN error code is a Non Volatile Memory error in the Spindle Drive, and
parameters may be lost or scrambled. To correct this error code proceed as follows:
Performing the following steps will re-initialize the Drive and return it to out of the box
configuration.
1. Set the Drive Parameter Cn26 = AAAA
2. Power Off, wait 10 Min. Power On.
3. Set the Drive Parameter Cn25 (Motor Code) per Eng. Doc. 757-4002-093. Look up
your machine type as motor codes are different per machine and drive used.
4. Power Off, wait 10 Min. Power On.
Parameter Defaults are no loaded.
5. Follow Eng. Doc 757-4002-093 and set up the Spindle Drive per your machine
type.
9
757-3050-005 REV: B ECN #

R
03/07/86 CAD #D8332
SUBJECT: YASKAWA SPINDLE DRIVE SET-UP PROCEDURE
I. INTENT
To provide a procedure that outlines the proper adjustments and strapping of shunt connectors
involved in preparing the drive unit for operation on a BMC-10 (L) or BMC-15 machine.
II. SCOPE
The requirement for this procedure is to be included in the manufacturing steps of BMC-10(L)
and BMC-15 machines. This procedure is to be applied during initial power up of the
machine.
III. PROCEDURE
A. Visually inspect the drive unit for proper wiring and operation per inspection items and
description, page five.
B. Insure that the input voltage (X1, X2, X3 on T1) is within the parameters shown on page
six before connecting to the input of the drive unit.
C. Refer to page three for location of shunt connections. Proper strapping is shown as the
darkened squares next to shunt letters.
D. Verify installation of wire jumper from pin 2 to pin 3 of FANM terminal located on the
left hand center edge of the spindle drive control board.
E. Refer to page four insert showing potentiometer numbering system. Description of

potentiometer set-ups is on page two.
F. Set DS1 as shown on page two. Be sure to reinstall the metal locking bar and torque-seal
the plastic dust cap.
G. Document actual measured RPM at spindle in accordance with the spindle speed test
chart on page five.
________________________________ _______ _______________________________ _______

H. Pages six, seven and eight provide additional information concerning the operation of the
spindle drive unit.
I. After drive set-up has been completed, torque-seal all potentiometers except T DET.
ADJUSTMENT OF POTENTIOMETERS ON CONTROL CIRCUIT BOARD
Adjustment of N ADJ and N REV Adjustment of T DET
ADJUSTMENT OBJECTIVE: ADJUSTMENT OBJECTIVE:

Coincidence between speed command input Setting Torque detection level.
(voltage) and motor speed.
ADJUSTMENT PROCEDURE
ADJUSTMENT PROCEDURE: Adjust the T DET potentiometer to graduation 7.
With the motor driven at the maximum speed,
detect the speed with a tachometer, and adjust to
±15 RPM.
Adjustment of N GAIN picture
ADJUSTMENT OBJECTIVE:
Adjusting loop gain of speed control system.
The more the setting is brought near the 0
graduation, the lower and more stable the gain Adjustment of 13 RH Accel/Decel Time
becomes, but the slower becomes response, The
nearer the setting is adjusted, the quicker becomes The soft start time is the sum of the numerals
response, but larger becomes speed overshooting. indicated by the DIP switches in seconds.
Adjust it to the optimum gain taking into
consideration of the load conditions.
ADJUSTMENT BEFORE SHIPMENT

Graduation 5
Adjustment of N DET picture
Adjustment of speed coincidence detection level.
While the motor speed is adjusted with speed
commands, N DET lights at a certain speed which
is adjusted wit the N DET potentiometer. Adjust
the N DET potentiometer so that the N DET LED
lights at the intended goal speed. (ON at 70 RPM,
OFF at 90 RPM)
2
INSPECTION ITEMS AND DESCRIPTION
State Item Procedure Criteria Action

Run Stop
Power Check for Noise or Contact
Ο transistor noise and vibration not Yaskawa
cooling fan vibration present before representative
Power Visual Check Deposited dust Clean with
transistor of parts around vacuum
Ο* cooling fan and power cleaner
adjacent area transistor fan
Terminal Manual check Loose screws Tighten
screws in VS- of all mutual
Ο* 626MTII wiring
controller termminal
screws with
Phillips
screwdriver
Spindle Speed Test
Speed Actually measured Per- Speed Actually measured Per-

indication speed [rpm] missible indication speed [rpm] missible
[rpm] Forward Reverse range [rpm] [rpm] Forward Reverse range [rpm]
30 ± 0 30 ± 0
L 250 ± 1 L 240 ± 1
O 500 ± 3 O 450 ± 2
W 800 ± 4 W 800 ± 4
H 801 ± 4 H 801 ± 4
I 1850 ± 9 I 1540 ± 8
G 2900 ± 15 G 2400 ± 12
H 4000 ± 20 H 3300 ± 16
5
Power Supply Permissible Check point
voltage range
AC 180 - 220 V R, S, T terminals
+15 V 14.25 to 15.75 V Across CH27 - CH29
-15 V -14.25 to -15.75 V Across CH31 - CH29
+8 V 7.6 to 8.4 V Across CH28 - CH29
DC -8 V -7.6 to -8.4 V Across CH30 - CH29
-3 V -2.35 to -3.65 V Across CH33 - CH29
+30 V 25 to 29/VAC = 200 V Across CH25 - CH29
-30 V -25 to -29/VAC = 200 V Across CH34 - CH29
Note: Check terminals CHs are provided on the controller.
6
DESCRIPTION OF CONTROL SIGNALS
Signal Connector Contact and Functions of Output Signals

No. Pin No.
- When protective circuit for overcurrent or overload tripped, the
motor current is instantly interrupted and the motor stops after
running by inertial. Upon current interruption, [FALT] is output.
- The [FALT] relay may be selectively in the normally closed or

normally open mode. The contact is "C" type. (The normally
closed mode is the standard.)
Malfunction
[FALT] - While [FALT] is output, the motor cannot run.
- When [FALT] is used to reset [N COM], [FOR RN] or [REV RN],

displays a spindle alarm visual signal.
- [FALT] is sent to LEDs on the controller to light. For these, refer

to paragraph A-2.
- For the relationship between [FALT] and [RESET], refer to 8.

Malfunction reset [RESET] in Table A-3(c).
1CN - When the motor speed drops below a preset level, [N-DET] closes,
and the N-DET LED (green) lights.
- The speed detection level is set between 30 and 4000 rpm with
potentiometer (N-DET) in the controller.
Speed
Detection PICTURE
[N-DET]
- [N-DET] operates regardless of the run direction signals.
- [N-DET] can be used as the detection signal for the speed suitable
for clutch actuation or gear shifting.
- The standard setting is 6000 rpm.

- When the motor speed enters the preset range of [N COM],
[AGREE] closes, and AGREE LED (green) lights. However, while
a run signal is open or [Z-SPD] is closed, it is not output.
Speed
Coincidence - When this signal is used as an answer to S command in NC
[AGREE] program operation, the program is advanced to the next step.
PICTURE
7
Functions of Output Signals (Cont'd)

No. Pin No.
Excessive - Since [DEV] is output when the cutting tool takes and excessive
Speed cut or other conditions detrimental to the tool and the machine
Deviation develop. it can be used as a spindle alarm signal.
[DEV]
1CN - When torque increases above a specified level, [T-DET] closes,
and the "T-DET" LED (green) lights.
Torque
Detection - The torque detection level can be set between 0 and 120% with the
[T-DET] potentiometer (T-DET) in the controller
PICTURE
PICTURE
8
757-4001-121 REV: A ECN #12355

R
08/31/92 CAD #D8376
SUBJECT: BMC-40SLV HIGH TORQUE SPINDLE OPTION SET-UP

PROCEDURE

A 12355 Original Issue 08/31/92
I. INTENT
To provide a standardized set-up and adjustment procedure for the Yaskawa 626VM3
Varispeed Drive for the BMC-40SLV Machining Center with High Torque Option.
II. APPLICABILITY
Applicable to all BMC-40SLV Machining Centers with the High Torque Spindle
Option. This procedure is to be used within Hurco facilities by Manufacturing during the
manufacture of all BMC-40SLV Machining Centers with the High Torque Spindle Option.
Digital Tachometer Heat Gun

Honda Pin Extractor 2" of 1/8" Shrink Tubing
4 mm Hex Key #1 Phillips Screwdriver
IV. FORMAT
Pages 2 thru 5: Drive Set-up Procedure

Pages 6 thru 8: Orient Set-up Procedure
Kevin Sermersheim 09/01/92 Wayne E. Hawkins 09/01/92

V. PROCEDURE
A. PRESETS
1. Remove the Orient Card and verify that the double shunt jumper is in the
0VCOM position. This position connects the 0 volt common of the drive to be
used by the Hurco control for inputs to the drive. Verify that the Spindle Dual
Axis and the CRP PCBs are set as follows:
1 2 3 4 5 6 7 8
Z-S SW1 0 0 0 0 0 1 1 0
Z-S SW2 0 0 0 0 1 0 1 0
CRP SW1 1 1 0 0 1 0 0 0
2. Install the Orient card, rewire the CN5 connector as per Orient Procedure.
Turn power ON.
3. The LED display will read 0 (Motor Speed Display).
4. Preset the Control Constants
Press the DISPLAY key twice. The display will read C1-01
(Control Constant 01).
Press the DATA/ENTER key to view data. If the data needs to be changed,
use the > RESET key to select the digit to be changed and the ARROW UP or
ARROW DOWN key to change that digit.
Press and hold the DATA/ENTER key for (2) seconds to transfer the data to
the control.
Press DISPLAY, > RESET, the ARROW UP or ARROW DOWN to select
another Control Constant.
DRIVE/PROG - No operation
DSPL - Selects between U-Data Display and C-Control Constants
DATA/ENTER - When displaying an item - will display the data in that
location
When displaying data - transfers displayed data into the
control.
UP ARROW - Increases the selected digit by one (1)
DOWN ARROW- Decreases the selected digit by one (1)
> RESET - Selects digit one (1) position to the right Alarm reset
RUN - Run command
STOP - Stop command
FWD/REV - Selects direction of motor rotation
JOG - Jog command
2
Cn-No Description Preset Range
C1-01 Speed control P (H-gear) 030 1 - 255
C1-02 Speed control P (L-gear) 030 1 - 255
C1-03 Speed control P (H-gear, ORT) 030 1 - 255
C1-04 Speed control P (L-gear, ORT) 030 1 - 255
C1-05 Speed control P (Servo mode) (H-gear) 030 1 - 255
C1-06 Speed control P (Servo mode) (L-gear) 030 1 - 255
C1-07 Motor speed adjustment 1.0250 0.9 - 1.56
C1-08 Speedometer signal level adjustment 1.00 0.9 - 1.5
C1-09 Load meter signal level adjustment 0.90 0.9 - 1.5
C1-10 Load meter full scale 120 120 - 350
C1-11 External operation torque limit 010 5 - 150
C1-12 Soft start time of speed reference 00.1 0.1 - 25.5
C1-13 Speed control I (H-gear) 0100 10 - 1000
C1-14 Speed control I (L-gear) 0100 10 - 1000
C1-15 Speed control I (H-gear, ORT) 0100 10 - 1000
C1-16 Speed control I (L-gear, ORT) 0100 10 - 1000
C1-17 Speed control I (Servo mode) (H-gear) 0100 10 - 1000
C1-18 Speed control I (Servo mode) (L-gear) 0100 10 - 1000
C1-19 Operation level of speed detection signal 017 0- -100
C1-20 Hysteresis width of speed detection signal 01.00 0.0 - 10.00
C1-21 Operation level of torque detection signal 010 5 - 120
C1-22 Selection code 1 (user) 00000000 HEX
C1-31 Motor rated speed 06000 1000-MAXRPM
C1-32 H-gear ratio (Spindle speed/Motor speed) 1.6700 0.5 - 2.5
C1-33 M-gear ratio (Spindle speed/Motor speed) 1.6700 0.5 - 2.5
C1-34 L-gear ratio (Spindle speed/Motor speed) 1.6700 0.5 - 2.5
C1-35 Motor code selection 75 01H - FFH
C1-36 Torque limit level (motor side) 120 50 - 150
C1-37 Torque limit level (brake side) 120 50 - 150
C1-38 I2 rate limit 00.0 0.0 - 20.0
C1-39 Magnetic flux lower level 030 15 - 100
C1-40 Magnetic flux compensation level 50 25 - 50
C1-41 Magnetic flux upper level 100 60 - 120
C1-42 Magnetic flux lower level of servo mode 070 50 - 100
C1-43 Base speed of servo mode 1.00 1.00 - 5.00
C1-44 Speed agree signal width 15 10- 50
C1-45 Zero speed detection level 30 3 - 60
C1-46 DB interval 000 0 - 100
C1-47 Selection code 1 (preset) 00000001 HEX
C1-81 Speed reference offset adjustment (preset) *SETTING +/- 800
C1-82 Torque reference offset adjustment (preset) *SETTING +/- 800
C1-83 Control signal adjusted value 1 (preset) 1.0000 0.8 - 1.2
C1-85 Control signal adjusted value 3 (preset) *SETTING +/- 200
C1-87 Control signal adjusted value 5 (preset) *SETTING -0.9 - 1.1
C1-90 Control signal adjusted value 8 (preset) 10.0 0.0- 25.5
*SETTING - Factory setting, will vary
3
B. SET-UP
1. Turn spindle on in Manual Mode, verify proper spindle rotation (CW)and

operation, select <EXIT> softkey, <MANUAL>, <POWER>,
<START>, SPINDLE <ON> and <START>.
2. Calibrate machine, <CALIBRATE MACHINE> softkey, <START>, then

<START> again when prompted to calibrate the
ATC, and run a repeating tapping program at
500 RPM. Adjust bottom pot on the Z-Spindle PCB, while
observing the display on the drive, to obtain 5 RPM window between
3. Run spindle CW at 1000 RPM. Use a Digital Tachometer to verify RPM is

within +/- 5 RPM. If RPM is not within specification, adjust C1-07 to obtain
correct RPM.
NOTE: C1-07 may be changed while spindle is running.
4. Run spindle CCW at 1000 RPM. Use a Digital Tachometer to verify RPM is
correct RPM.
NOTE: C1-81 may not be changed while spindle is running.
5. Repeat steps 3 and 4 until both readings are within specification.
6. Run MACHINE WARM UP CYCLE in MANUAL MODE.
7. Record spindle speeds on following chart:
MACHINE PROGRAMMED ACTUAL SPEED ACCEPTABLE

TYPE SPEED CW CCW SPEED RANGE
BMC40SLV 100 RPM 95 - 105 RPM
1000 RPM 950 - 1050 RPM
10K RPM 3000 RPM 2850 - 3150 RPM
6000 RPM 5700 - 6300 RPM
SPINDLE 8000 RPM 7600 - 8400 RPM
10000 RPM 9500 - 10500 RPM
4
VI. CONTROL DATA DISPLAY
Display Description Data at Power On Unit

U1-01 Motor Speed 0 RPM
U1-02 Speed Command 0.00 %
U1-04 Torque Command 0.0 %
U1-05 Spindle Speed 0 RPM
U1-06 Primary Frequency Command 0.0 Hz
U1-07 Primary Current Signal 0.0 %
U1-08 DC Bus Voltage varies V
U1-16 Internal State varies HEX
U1-17 Interface Output State varies HEX
U2-04 Motor Temperature varies DEG C
U1-17 BIT DISPLAY U1-18 BIT DISPLAY

== == == == == == == == == ==
RDY EMGL FOR REV THL ZSPD AGR NDET TDET TLE
== == == == == == == == == ==
TLL SSC RST CHW PPI IP ORE CHWE ALMA ALM
== == == == == == == == == ==
ORT LGR MGR DAS CHWA AC0 AC1 AC2 AC3
F-Code Alarm Code Description

AC3 AC2 AC1 AC0
F - 000* 1 1 1 1 Winding changeover error***
F 001 1 1 1 1 Emergency stop error
F 100 1 1 1 0 Inverter over current
F 200 1 1 0 1 MCON error
F 300 1 1 0 0 Converter over current
F 400 1 0 1 1 Over voltage
F 500 1 0 1 0 Over speed
F 602 1 0 0 1 Under voltage
F 603 1 0 0 1 Power supply frequency error
F 700 1 0 0 0 Overload
F 800 0 1 1 1 Excessive speed deviation
F 901 0 1 1 0 Motor overheat
F 902 0 1 1 0 Thermo detector disconnection
F 904 0 1 1 0 Controller overheat
F b00 0 1 0 0 AD defective
F b01 0 1 0 0 CPU-AD defective
F C00 0 0 1 1 PG disconnection error
F E01 0 0 0 1 NVRAM error
CPF00** 0 0 0 0 CPF (Control function failure)
1 = ON, 0 = OFF
* A dash (-) after the F indicates the first malfunction.
** If Control Function Failure (CPF) occurs, cycle power OFF then ON to reset. If CPF
continues, replace the Control Board.
***This code applicable to winding select systems only.VII. ORIENT
A. PRESETS
1. Preset drive at following settings:

C1-01 Spindle Origin P0.00 +/- 2.00
C1-02 Position Control Proportional Gain (H) 010 1 - 99
C1-03 Position Control Proportional Gain (M) 010 1 - 99
C1-04 Position Control Proportional Gain (L) 010 1 - 99
C1-05 Positioning End Detection Width 00.5 0 - 20
C1-06 Positioning End Cancellation Width 05.0 0 - 20
C1-07 Orientation Speed 150 30 - 600
C1-09 Stop Position Bias Width 001.0 0.5 - 180
C1-10 ---------- 000 ----------
C1-11 ---------- 00 ----------
C1-12 ---------- 00000 ----------
C1-13 Selection Code 1 11010000 HEX
C1-18 Magnetic Flux Level at Orientation 080 15 - 100
C1-19 ---------- 000 ----------
C1-20 Selection Code 4 (Auto Tuning) varies ----------
C1-21 Magnetic Sensor Window Width 15 5 - 20
C1-22 9.990 ----------
2. Adjust the gap between the Magnet and the Magnetic Sensor for
1/5 mm +/- 0.5 mm.
3. Rewire CN5 of the magnetic sensor cable as follows:
a. Remove blank pins from 7, 9, 12 and 13. Discard the male pin from 13.
b. Remove the White and Black wires from 17 and 16. Fold pins back and
apply shrink tubing over individual wires to insulate them.
c. Remove Red wire from 15 and insert into 13.

Remove Black wire from 14 and insert into 12.
Remove Green wire from 19 and insert into 1.
Remove Shield wire from 20 and insert into 7.
d. Fill empty positions with female pins.
Black *
A 12 (+) Position Command
Red *
D 13 (-) Position Command
Green +
B 1 DC Return
Black +
C 9 +15 Volts
7 Ground
*/+ - Indicates twisted pairs
B. SET-UP
1. Turn power ON.
3. Select <EXIT>, <MANUAL>, <POWER>, <START>, <CALIBRATE

MACHINE> softkey, <START>, then <START> again when prompted to
calibrate the ATC.
3. Verify C3-01 data is 0.00. Change C3-13 data Bit 4 to 0. Display will read
11000000.
4. After the machine has calibrated, select <CHANGE TOOL OR

DIAGNOSTICS> softkey, <ATC AND MACHINE DIAGNOSTICS>
softkey, <ENTER>, 101, <ENTER>, <SPINDLE ORIENT
DIAGNOSTICS> softkey, <START>.
NOTE: The spindle will orient but the system will not look for an Orient
Complete signal, so Oriented display will not be back lit on the screen.
5. On the drive an error message F-d14 will appear, press the <STOP> and the
<RESET> buttons at the same time and the error will reset. The drive will
initialize the Auto Tune program. The spindle will rotate 3-5 revolutions at
35 RPM then slow to 5 RPM for 3-5 revolutions. When the spindle stops, the
orient position will be set.
NOTE: This spindle drive uses the spindle motor encoder in conjunction with
the magnetic sensor to orient the spindle. The drive looks for the relationship
of the magnetic sensor position to the encoder marker pulse and records the
position as the number of tics offset from the marker. If any one of the
variables, magnetic sensor, magneto collar, spindle, or spindle motor, is
moved or replaced the Auto Tune must be reset.
NOTE: The Automatic Tool Changer (ATC) must be aligned and leveled prior to
setting the ATC HEIGHT and making the fine adjustments to the orient position.
6. Exit to Manual Mode, press <MANUAL>, and orient the spindle, press
<SPINDLE ORIENT> softkey, <START>.
7. Jog Z axis to where the spindle nose is above the ATC tool seat.
8. Move the ATC magazine right, select <CHANGE TOOL OR

DIAGNOSTICS> softkey, <ATC AND MACHINE
DIAGNOSTICS> softkey,<MAGAZINE RIGHT> softkey, <START>.
9. Verify the centerline of the spindle nose keys is within +/-2.00 degrees of the
centerline of the ATC tool seat.
a. If yes, continue to step 10.
b. If not, turn Spindle Orient off, press SPINDLE <OFF>, loosen the
magneto collar, turn the collar to achieve proper alignment, then
retighten the collar. Move the ATC
magazine left, press <MAGAZINE LEFT>softkey,
<START>. Repeat steps 3 through 9.
10. To offset the orient position, select C3-01 on the drive and access the data,
change and enter the data to move the orient position, the drive allows for
+/- 2.00 degrees of compensation.
11. To set ATC height, enter machine diagnostics, select <CHANGE TOOL OR
DIAGNOSTICS> softkey, <ATC AND MACHINE DIAGNOSTICS>
softkey, <ENTER>, 101, <ENTER>.
12. Select Z axis, using the hand wheel, jog Z to where the nose of the spindle is
17/32 inches (0.53 inches) from the bottom inner edge of the ATC tool seat
flange. Press <STORE Z POSITION>, verify the Z AXIS position is the
same as the TARGET position displayed on the screen.
a. If yes, move ATC magazine left, press <MAGAZINE LEFT>

softkey, <START>. Spindle drive set up complete.
b. If not, move ATC magazine left, press <MAGAZINE LEFT>

softkey, <START>, move Z axis limit switch dogs up or down
10mm to achieve proper alignment, calibrate machine, move the ATC
magazine right and repeat step 12.
757-4002-059 REV: C ECN #13625

R
8 Feb. 96 CAD#D8432
SUBJECT: Yaskawa Digital Servo Drive Setup Procedure with Ultimax 3 ISA
Control. Applicable Machining Centers: 30M, 30HT/M, 40M, 40/50M,
50/50M.

A 13310 Original Release 03/09/95
B 13556 Update balance procedure and amplifier parameters 11/15/95
C 13625 Simplify balance procedure 02/08/96
I. INTENT
To provide a standardized method of configuration and adjustment of the Yaskawa Digital AC

Servo drives being used on the Linear Axes of BMC 30 - 50 Ultimax 3 ISA Machining Centers.
II. APPLICABILITY
Specific to BMC models 30M through 50/50M integrated with Ultimax 3 ISA Control, and running
Executive Software Version V1.52 or greater. This procedure is to be used by Manufacturing
during the building process and by Customer Service when installing or servicing BMC 30-50
Ultimax 3 ISA Machining Centers.
III. INDEX
ULTIMAX 3 Control Parameter Verification - page 2

Linear Axis Yaskawa Servopack Configuration - page 2
Axis Amplifier Balance Adjustment - page 3
Axis Performance Verification - pages 3 through 5
Axis Load Bar Calibration - page 5
Axis Travel Verification - page 6
Hurco/Yaskawa Part Identification Table - page 6
Definitions - page 7
Yaskawa Servopack General Layout - page 8
Axis Tuning Worksheet - page 9
Table of Yaskawa Axis Drive Settings - page 10

1
IV. ULTIMAX 3 CONTROL PARAMETER VERIFICATION
Load parameters from Engineering Document 757-4002-048, per machine type.
B. Select each axis softkey to load the Axis Tuning Parameters.
C. If an Axis Tuning Parameter needs to be changed then enter the correct value per the
Engineering Document.
J. When complete, remove the diskette from the floppy drive and store in a safe location.
V. LINEAR AXIS YASKAWA SERVOPACK CONFIGURATION
A. Verify/Set the Yaskawa Servopack parameters. (Please refer to the Axis Parameters Table on
page 10 of this document.)
B. A few key parameters will have to be changed from their default values. Using the Data
Entry buttons on the Servopack, change User Constants CN-01 (Bit 8), CN-03 (speed loop
gain), CN05 (speed loop integral time constant), CN-06 and CN 0A (PG frequency dividing
ratio setting) per machine type, using the Axis Parameters Table on page 10 of this
document. (Please refer to the instruction panel on the Servopack for proper button
sequencing.)
2
VI. AXIS AMPLIFIER BALANCE ADJUST
A. In Input mode, change the machine's units to Metric (may have to select the ERASE ALL
softkey).
B. Enable Control Power and jog each of the axes (including rotary) to the approximate mid-
travel of the axis.
C. In Manual mode, select the CHANGE TOOL OR DIAGNOSTICS softkey followed by the
E. Select the TOGGLE FOLLOWING ERROR DISPLAY softkey, then the AXIS
BALANCE ADJUST softkey.
F. Select the appropriate softkey to choose the axis to be balanced.
G. At the prompt, press the START pushbutton, followed immediately by pressing MOTION
HOLD to provide a zero voltage signal from the selected MX4 DAC channel.
(The machine control loop is now open for this channel. The presence of system unbalance
will be immediately apparent by the drift of the values in the Following Error display.)
H. In the Control Cabinet, connect a DVM between the Channel 1 (“TRF”) and Channel 3
(“SG”) test points of the desired axis amplifier (see page 8 for location of the test points).
Do not adjust the VR potentiometers on the MX4 board! Leave them at their calibrated factory settings.
The range of adjustment available within the Yaskawa Servo Amplifiers is sufficient to balance axis offsets.
I. Proceed as follows, using the four data entry keys on the axis amplifier:
1) Press SW4 (mode select). (The display should read CN-00.)

2) Press SW1+SW4 to display contents of this location. (The display should be 00-00, with
last digit blinking.)
3) Change value to 00-03 (Speed reference offset manual mode), using SW2.
4) Toggle SW4 until A. XXX (channel A input offset value) is displayed.
5) Using SW2 or SW3, change value to 000 (no offset on A input).
6) Toggle SW4 until b. XXX (channel B input offset value) is displayed.
Change the value of this offset by holding in either SW2 (“Forward”) or SW3
(“Reverse”), while monitoring the resulting voltage change on the DVM. If the
proper direction is selected, the voltage readings (typically less than 1.000vdc) will
slowly decrease. Axis balance occurs at the point when the DVM reading
changes sign. Since the true null will probably be overshot on the first attempt,
immediately select the opposite key and seek a minimum voltage reading. Repeat this
“rocking” technique until the best null is found (typical DVM readings will be
approximately 0.050v). At this point, the Following Error display on the Max
screen will show minimum drift. (Note: the DVM readings will never be totally
stable in this dynamic system --- work quickly!)
7) Press SW4 to store the value(s).
8) Press SW1+SW4 to return to the monitor mode, if desired.
3
H. To quit the check, select another softkey or press the EXIT softkey.
I. Repeat the check for each machine axis.
VII. AXIS PERFORMANCE VERIFICATION
A. In Manual mode, select the CHANGE TOOL OR DIAGNOSTICS softkey.
B. Set the Manual Jog Feed to 1016. mm/min and the Rapid Detent feed to 10160. mm/min.
C. Select the ATC & MACHINE DIAGNOSTICS softkey.
E. Select the TOGGLE LOAD BAR DISPLAY softkey, the TOGGLE ACTUAL DISPLAY
G. Press "Enter 103 Enter" to display the Axis Tune Parameters screen. The additional fields
displayed are:
H. With the Axis Override pot at nominal, jog an axis for at least two seconds using the rapid
button; verify that the feed is 1016. mm/min and record the Following Error in the table for
the selected direction.
I. Repeat steps H and I for the opposite direction.
4
J. Verify that the Axis Overshoot is less than or equal to the In Position Tolerance parameter
(reference Hurco Engineering Document 757-4002-048, Parameters for ULTIMAX 3
Software Version 1.52); if the Axis Overshoot exceeds the In Position Tolerance parameter:
1. select the appropriate axis softkey and decrease the Integral Limit parameter by one
4. if no significant improvement results, reset the Integral Limit to its original value and
increase the Integral parameter by 10
7. when complete, select the STORE PARAMETERS softkey
K. Repeat steps H, I, and J for Rapid Detent jogging, verifying that the feed is 10160. mm/min.
L. Verify that the At Position time is less than 250 msec. If not, proceed as follows:
1. reverify Axis Balance Adjust procedures
2. inspect for mechanical problems such as a misalignment or a lube problem
3. for Z axis, the negative (down) motion should be optimized for At Position:
a. select the appropriate axis softkey and decrease the Integral Limit parameter by one
b. select the BEGIN TUNE softkey
c. repeat steps H, I, and J
d. when complete, select the STORE PARAMETERS softkey
M. Repeat steps H through N for each of the axes.
N. Verify that the Within Tolerance time for all axes is ± 100 msec. of each other.
O. Select the EXIT softkey to return to the ATC & Machine Diagnostics screen.
P. If any of the Axis Tuning Parameters were edited, be sure to create a backup on the Machine
Configuration diskette.
VIII. AXIS LOAD BAR CALIBRATION
Axis Load Bar Calibration can be completed from the Axis Tuning Parameters screen with the
Toggle Load Bar display active.
A. Please refer to the Servopack general layout on page 8 of this document. Connect the
Positive Lead of a DVM or a ‘scope probe to test point TRF (Ch 1), and the Negative Lead
to test point SG (0v) of the Yaskawa Servopack to be set up. Use the 2.0v d.c. scale.
[This voltage represents the motor torque; ± 3.0 VDC = 100%].
B. Manually jog the axis at 1200 mm/min or greater to produce a meaningful torque
requirement, or block the axis with a piece of wood by carefully jogging the axis into the
wood to load the axis to 40%. To avoid damage to the spindle, do not place the wood
directly against a tool holder or the spindle; use the spindle head casting.
5
C. Adjust the Load Meter bar value in the machine configuration screen to match the number of
bars displayed on the CRT to the measured torque for the appropriate axis. One bar for
every 130 mVDC measured.
D. Verify proper load bar display operation in both jog directions.
E. Repeat for each of the axes.
G. Press "Enter 101 Enter" to access the Spindle/Servo Diagnostics Setup screen.
H. Select the TOGGLE LOAD BAR DISPLAY softkey, the TOGGLE ACTUAL DISPLAY
I. Select the EXIT softkey to return to the ATC & Machine Diagnostics screen.
IX. AXIS TRAVEL VERIFICATION
A. Run the following programs to verify that Full Travel axis operation is smooth and that no
Following Errors occur.
BMC 20-50 CYCLE PROGRAM DISK PART NUMBER 704-2000-002




X. HURCO/YASKAWA PART IDENTIFICATION TABLE
BMC 30/M:
Axis Drive 402-6009-089 (Yaskawa P/N CACR-SR10BE12G)
Axis Motor 402-6009-088 (Yaskawa P/N USAGED-09A22T)
Line Filter 402-6009-032 (Yaskawa P/N LF-315)
6
BMC 30/HT/M:
Axis Drive 402-6009-100 (Yaskawa P/N CACR-SR15BE12G-E)
BMC 40/M, 40/50/M & 50/50/M:

Axis Drive 402-6009-091 (Yaskawa P/N CACR-SR20BE12G-E)
XI. DEFINITIONS
A. Within Tolerance - length of time in milliseconds for the axis to remain within the In Position
Tolerance parameter after the axis was commanded to zero velocity. Factored with the Axis
Overshoot in encoder counts characterizes the amount of servo ringing present in the system.
B. In Position Tolerance - the number of encoder counts allowable on either side of the
commanded target considered at the commanded position; the Integral term is active after the
axis motion is within this value. In contouring, an axis must stay within this bandwidth for 10
msec before the Axis Ready signal is set and the next command is processed.
C. Axis Overshoot in Encoder Counts - the number of encoder counts that an axis overshot the
exact count of the final destination before servoing back to the final destination.
D. At Position Time - the length of time in milliseconds for an axis to reach the exact target
encoder count for the first time (prior to overshoot) after being commanded to zero velocity.
E. System Resolution - one encoder count equals 0.0005 mm or 0.000019 in; the display
resolution is 0.001mm or 0.000039 in.
F. Integral - used to guarantee zero Following Error at the commanded position. In contouring
mode, an axis must stay within this bandwidth for 10 msec before the Axis Ready signal is set
and the next commanded target is processed. The Integral term guarantees Zero Following
Error at final destinations.
7
XII. YASKAWA SERVOPACK GENERAL LAYOUT
Instruction / Information Panel
Status LEDs
Data Entry Keys Ch1 TRF
Ch2 VTG
Ch3 SG
Ch4 IN B
Ch5 IN A
- YASKAWA DIGITAL SERVOPACK OUTLINE -

(Essential Functions Only.)
2CN
1CN
Note - Circuit Breaker Located

Behind Circuit Board !
8
DEFAULT PARAMETER SETTINGS FINAL PARAMETER SETTINGS
X AXIS 1016 (+) 1016 (-) 10160 (+) 10160 (-) 1016 (+) 1016 (-) 10160 (+) 10160 (-)
Within
Tolerance
At
Position
Axis
Overshoot
Following
Error
Y AXIS 1016 (+) 1016 (-) 10160 (+) 10160 (-) 1016 (+) 1016 (-) 10160 (+) 10160 (-)
Within
Tolerance
At
Position
Axis
Overshoot
Following
Error
Z AXIS 1016 (+) 1016 (-) 10160 (+) 10160 (-) 1016 (+) 1016 (-) 10160 (+) 10160 (-)
Within
Tolerance
At
Position
Axis
Overshoot
Following
Error
a AXIS 1016 (+) 1016 (-) 10160 (+) 10160 (-) 1016 (+) 1016 (-) 10160 (+) 10160 (-)
Within
Tolerance
At
Position
Axis
Overshoot
Following
Error
b AXIS 1016 (+) 1016 (-) 10160 (+) 10160 (-) 1016 (+) 1016 (-) 10160 (+) 10160 (-)
Within
Tolerance
At
Position
Axis
Overshoot
Following
Error
9
Yaskawa Axis Drive Settings
(Factory 40/50M 40/50M 50/50M 50/50M

BMC Machine Series default 30M 30/HTM 40M w/b’screw w/o b’screw w/b’screw w/o b’screw
values) enc. enc. enc. enc.
Servo Motor Series (KW class) ----- 09 13 20 20 20 20 20
CN-01 User Constant (*) 0 *(see note) *(see note) *(see note) *(see note) *(see note) *(see note) *(see note)
CN-02 Reserved 0 0 0 0 0 0 0 0
CN-03 Speed Ref. (rpm/volt) 150 263 263 158 214 214 214 214
CN-04 Loop Gain (hz) 00040 00040 00040 00020 00040 00040 00040 00040
CN-05 Integral Time Const. (ms) 00020 00020 00020 00020 00020 00020 00020 00020
CN-06 Emerg. Stop Torque (%) 00221 00200 00200 00221 00150 00150 00150 00150
CN-07 Soft Start Time (ms) 00000 00000 00000 00000 00000 00000 00000 00000
CN-08 Fwd. Torque Limit (%) 00221 00217 00221 00221 00221 00221 00221 00221
CN-09 Rev. Torque Limit (%) 00221 00217 00221 00221 00221 00221 00221 00221
CN-0A PG Divide Ratio - X&Y (p/rev) 2500 4800 4800 5000 8192 4800 8192 4800
CN-0A PG Divide Ratio - Z (p/rev) (2500) 3000 3000 5000 8192 4800 8192 4800
CN-0B Zero Speed Level (rpm) 00020 00020 00020 00020 00020 00020 00020 00020
CN-0C Mode Switch (Torque ref. - %) 00200 00200 00200 00200 00200 00200 00200 00200
CN-0D Mode Switch (Speed ref. - rpm) 00000 00000 00000 00000 00000 00000 00000 00000
CN-0E Mode Switch (Accel. - 10*rpm/s) 00000 00000 00000 00000 00000 00000 00000 00000
CN-0F Zero Clamp Level (rpm) 00010 00010 00010 00010 00010 00010 00010 00010
CN-10 Jog Speed (rpm) 00100 00100 00100 00100 00100 00100 00100 00100
CN-11 PG Resolution (p/rev) 8192 8192 8192 8192 8192 8192 8192 8192
CN-12 Brake Delay Time (ms) 00020 00020 00020 00020 00020 00020 00020 00020
CN-13 Torque Ref. Gain 00030 00030 00030 00030 00030 00030 00030 00030
CN-14 Max Speed in Torq. Cont. (rpm) 03000 03000 03000 03000 03000 03000 03000 03000
CN-15 Brake Timing Speed Level (rpm) 00100 00100 00100 00100 00100 00100 00100 00100
CN-16 Brake Timing (10ms) 00050 00050 00050 00050 00050 00050 00050 00050
CN-17 Torque Ref. Filter Time (100us) 00004 00020 00004 00004 00004 00004 00004 00004
(*) On all machines, set bit 8 to 1 (default is 0). Cycle servo drive power Off/On to set bit (the circuit breaker on TB1 may be used). Refer to Yaskawa
Servo Drive tech manual for explanation of other bit values.
10
757-4002-060 REV: B ECN #13556

R
15 Nov. 95 CAD#D8433
SUBJECT: Yaskawa Digital Spindle Drive Setup Procedure with Ultimax 3 ISA
50/50M.

A 13310 Original Release REV/C 03/09/95 REV/E Rev/F
B 13556 Revised spindle balance procedure REV/D 11/15/95
I. INTENT
spindle drives used on Ultimax 3 ISA type machining centers.
II. APPLICABILITY
Specific to all BMC 30M, 30HT/M, 40M, 40/50M and 50/50M Ultimax 3 type machining centers
using software version 1.52 or later. This is the only procedure to be used within HURCO
facilities and should be used at customer installations to help achieve factory proven performance.
III. INDEX
Page 2 - Hurco / Yaskawa Part I.D. Table; Setup of Drive / Parameters

Page 3 - Spindle Zero and Max RPM Calibration
Page 4 - Orient Setup using the Motor’s Encoder
Page 5 - Orient Setup using a Magnetic Sensor
Page 6 - Loadmeter Calibration
Page 7 - Table of Yaskawa Spindle Drive General Settings
Page 8 - Table of Yaskawa Spindle Drive Orient Settings
Spindle parameters are loaded by default (WITH SOFTWARE VERSION 1.52).

These parameters must be checked to match the latest parameters published to date
(757-4002-029). DSP parameters may be edited in the Tune Axis Parameter screen.
Depress<ENTER> ,103, <ENTER> while in the ATC Diagnostics screen of Manual
machine mode.

V. HURCO / YASKAWA PART I.D. TABLE
System Power Hurco P/N Yaskawa Motor Spindle X’mission Yaskawa

Class Motor # RPM RPM Ratio Drive #
BMC 30M 10 HP 402-6009-092 08HHB11 8000 8000 1.00 27P50
BMC 30HT/M 15 HP 402-6009-097 11HHBX1 8000 8000 1.00 20110
BMC 40M 15 HP 402-6009-030 11CZ1 6000 6000 1.00 20110-M*
BMC 40/50M 15 HP 402-6009-030 11CZ1 6000 4000 0.67 20110-M*
BMC 50/50M 20 HP 402-6009-018 15CZ1 6000 4000 0.67 20150-M*
(*) With Orient Card # 621020.2 for magnetic sensor orient.
VI. SETUP OF DRIVE / PARAMETERS
A. Prior to powering up 30M and 30HT/M machines, verify that there is a shunt jumper on the
lowermost (EXT COM) of three 4-pin signal input selection blocks. On the 40M, 40/50M
and 50/50M machines, the uppermost of the blocks (0V COM) should be used. In the case
of a magnetic sensor orient system, remove (or look up and behind) the Orient card to verify
the connection.
B. If necessary, reinstall the Orient card and turn power on. Check the configuration screen.
C. Using the Yaskawa Digital Spindle Drive operator keypad, verify (and set, where necessary)
the User Control Constants for the appropriate BMC system per the Settings Tables on pages
7 and 8 of this document. The C1-xx constants alter the operation of the spindle motor
itself, while the C3-xx constants affect the performance of the Orient operation, when a
Magnetic sensor is used. (The C2-xx constants are used when Orient is performed using the
spindle motor’s encoder.)
[Please refer to p. 135 in the Yaskawa 626VM3 Operator’s Manual for a

description of operation of the Display unit and Operator’s Keypad.]
NOTE: CONTROL CONSTANTS CANNOT BE SET IF AN ORIENT COMMAND HAS

BEEN ISSUED OR THE SPINDLE IS IN ORIENT POSITION.
D. 1) Magnetic Orient Sensor Horizontal Adjustment: The gap between the pickup and the
rotating orientation sensor magnet should be 1.5mm +/- 0.5mm (a narrower gap is a more
desirable gap).
2) Vertical Adjustment: Ensure that the pickup and the rotating magnet are physically
centered (+/- 0.5mm). Shim the pickup mounting bracket, if necessary, to achieve proper
centering.
E. Turn spindle on in Manual Mode. Ensure proper spindle rotation and operation. [For
winding select only] Set a manual speed above 2000 RPM, run spindle and verify the
audible change-of-state by the Magnetic Contactor.
2
VII. SPINDLE ZERO RPM and MAXIMUM RPM CALIBRATION
A. To achieve the Spindle Null (spindle velocity of Zero RPM) proceed as follows:
1) Set VR4 of the DSP Board to the MID POINT by turning the pot fully clockwise then
back 16 turns.
2) To ensure that the Spindle is in the Closed Loop Velocity mode, on the Ultimax Control
select: Auxiliary Mode; F4 (“System Config.”); F4 (“Display Machine Config.”);
<ENTER>, 100, <ENTER>; F4 (“Spindle”); F1 (“Physical Parameters”). Make
change if necessary.
3) On the Ultimax Control, select: MANUAL Mode; F2 (“Change Tool or Diagnostics”);

F7 (ATC and Machine Diagnostics); <ENTER>, 101, <ENTER>; F6 (Toggle
Following error display): F7 (“Axis Balance Adjust”); and F4 (“Spindle”).
Location of trimpots 4) When the START CYCLE push-button is depressed, the Ultimax Control
on DSP card. executes the following signal sequence - each stage lasting a few seconds, and
its results (in counts) displayed on the Ultimax screen:
Pot Axis
Zero signal; small + signal; small - signal: Cycle repeat.
VR 1 x, a
VR 2 y, b 5) Adjust C1-11 on the spindle drive. Change the value until the spindle
VR 3 z changes direction then slowly adjust it again until it just changes direction
VR 4 again.s This is the best that you can null the spindle using the drive parameters.
6) Next when the program goes to the zero signal press the MOTION
HOLD BUTTON, this will hold the DAC at zero output. Now adjust VR4 on
the DSP board until the spindle following error display stops counting.
B. In order to insure specified minimum Spindle Following Error, proceed as

follows:
1) In Manual Mode, set the Manual Spindle Speed value to the maximum spindle speed of
the machine.
2) Depress <ENTER>, 101, <ENTER> while in the ATC Diagnostics screen of Manual
machine mode. Select the <TOGGLE FOLLOWING ERROR DISPLAY> softkey [F6].
3) While in the ATC Diagnostics screen of Manual Mode depress <ENTER>, 103,
<ENTER>. Now select the Depress <SPINDLE> softkey [F4].
Remember: While in the 103 screen, with the Following Error display turned on, the
Spindle Enable Relay (SER) will remain enabled with zero RPM commanded when the
<SPINDLE OFF> key is depressed.
To initially enable the spindle, depress <SPINDLE ON>, <START>, <SPINDLE OFF>.
To disable the spindle drive, depress the <RESET SERVOS AND SPINDLE> softkey.
3
4) Depress <SPINDLE ON>, <START>. The Following Error should be below + 2000°
at full speed. Depress <SPINDLE OFF> and verify that the Following Error value does not
become negative during the deceleration time. Re-verify the Spindle Parameters (tuning
values, as necessary from the 103 screen) if there is negative Following Error or Spindle
Overshoot during deceleration.
Note: A small negative Following Error may be displayed just as the spindle comes to a
stop; however, the spindle will servo to zero Following Error quickly.
C. To calibrate the Maximum Spindle Speed parameter (ensuring that the Ultimax Control
the machine. Note this commanded (desired) value.
2) The machine must now be put back into Open Loop mode. On the Ultimax Control,
select: AUXILIARY Mode; F4 (“System Configuration”);F4 (“Display Machine
Configuration”); <ENTER>, 100, <ENTER>; F4 (“Spindle”); F1 (“Physical
Parameters”); and F5 (“Open Loop”).
3) Obtain a tachometer reading of Spindle RPM. Note this measured value.
4) It is likely that there will be a discrepancy between the commanded and the measured
Spindle speeds. To correct this situation, adjust C1-12 until the spindle is running the rated
RPM. If the you can not get the spindle to run exactly at the rated RPM you may use the
following formula to adjust the DAC voltage. Use the <ENTER>, 100, <ENTER> screen.
Desired RPM
Using the formula, New “Max DAC” Voltage = Old “Max DAC” Voltage
Measured RPM
calculate this new required voltage value (to two decimal places), and enter it into the
Ultimax screen.
(Example: Spindle speed = 4175 rpm, but 4000 rpm is desired; DAC voltage on Max3
screen is 9.5v. DAC voltage value should be changed to 4000/4175*9.5 = 9.1v.)
D. The spindle drive RPM setup is complete.
VIII. ORIENT SETUP
Having modified the C2 (Encoder Orient) or C3 (Mag Sensor Orient) Parameters per
appropriate Machine type (refer to Section VI. C), perform a Spindle Self-Orient (using the
-Yaskawa Spindle Drive Keypad) as follows:
A. Motor Encoder Orient:
4
1) Remove spindle drive keys.
2) Install ATC Setup Tool taper into the spindle and flange into the ATC.
3) Move ATC to “right” position.
4) Set ATC Height using the “Machine Diagnostics” <Enter>, 101, <Enter> screen.
5) Press the Spindle Off button then rotate the spindle by hand, and install the drive key.
6) Record spindle motor position (counts) from spindle drive display U2-03 (V2-03).
7) Move ATC to “left” position.
8) Push “Emergency Stop” of the control.
9) Set Spindle Drive parameter C1-37 = 00001011 (change Bit 0 & 1 to 1).
10) Set Spindle Drive parameter C2-22 = 11000000 (change Bit 4 to 0).
11) Set Spindle Drive parameter d1-01 = 0001000000 (change Bit 6 to 1).
12) The Spindle drive will give Alarm F-d14 (Orient Tune-up Incomplete).
13) Press both “Reset” and “Stop” (of the Spindle Drive control panel) at the same time.
14) The Spindle Drive will execute automatic tuning and orient.
15) When autotune is complete, the Spindle Drive display will show the data of C2-01.
16) Enter the number recorded in step #6, above.
17) Reset Spindle Drive parameter d1-01 = 0000000000 (change Bit 6 to back to 0).
18) Reset Spindle Drive parameter C2-22 = 11010000 (change Bit 4 back to 1).
19) Reset Spindle Drive parameter C1-37 = 00001000 (Change Bits 0 and 1 to 0).
20) Orient is now set, and may be commanded by Ultimax.
B. Magnetic Sensor Orient:
1) Ensure that the Spindle magnet on orient collar is away from the magnetic sensor, and
Ultimax is not commanding Orient.
5
12) Set Spindle Drive parameter C3-01 = +/_ 0.8 (degrees).
Spindle Orient is now set, and may be commanded by Ultimax.
IX. LOADMETER CALIBRATION
A. Depress <ENTER>, 101, <ENTER> while in the ATC Diagnostics screen of Manual
machine mode. Select the <TOGGLE LOADBAR DISPLAY> softkey [F4]
B. While in the ATC Diagnostics screen of Manual Mode depress <ENTER>, 103,
<ENTER>.
C. The initial value of the Spindle Drive Loadmeter Parameters should already be set (per the
table on page 7). If not, set C1-17 to 1.00, and C1-18 to 200%.
D. Depress the “Data/Enter” and “Reset” keys simultaneously, to force the Spindle Drive unit
to output the “120% of Full Load” voltage signal to the Ultimax control. (C1-17 must be on
the display before pressing the keys!)
E. Count the number of Loadmeter bars displayed on the screen. Repeat Steps D and E, while
decreasing the C1-18 data value by ten each time, until 21 Loadbar Segments and
“OVERLOAD” are displayed on the screen.
Note: a 22nd Loadbar Segment will be displayed until the “OVERLOAD” value is reached.
F. Set the Spindle Drive display to V1-04 (% of Full Torque). Depress <SPINDLE ON>,
<START>. Verify that the screen display closely matches the drive display. (Each screen
Loadbar Segment is approximately 4%.)
G. Reset the machine, and the Spindle Drive setup is complete.
6
Yaskawa Digital Spindle Drive Settings
Machine 30M 30HT/M 40M 40/50M 50/50M

Motor 08HHB11 11HHBX1 11CZ1 11CZ1 15CZ1
COM Jmpr. EXT COM EXT COM 0V COM 0V COM 0V COM
Control Value Value Value Value Value
Constant Function (30M) (30HT/M) (40M) (40/50M) (50/50M)
C1 - 01 H gear Prop.Gain 030 030 030 030 030
- 02 H gear Int.Time 0600 0600 0600 0600 0600
- 03 L gear Prop.Gain 030 030 030 030 030
- 04 L gear Int.Gain 0600 0600 0600 0600 0600
- 05 H gear Sv.Prop.Gain 040 040 040 040 040
- 06 H gear Sv.Int.Time 0100 0100 0100 0100 0100
- 07 L gear Sv.Prop.Gain 020 020 020 020 020
- 08 L gear Sv.Int.Time 0100 0100 0100 0100 0100
- 09 Tq.Filt TCnst. 1.0 1.0 1.0 1.0 1.0
- 10 Soft St.Time 000.1 000.1 000.1 000.1 000.1
- 11 Analog Spd.Offset 0 0 0 0 0
- 12 Fine Spd.Adj. Note 1 Note 1 Note 1 Note 1 Note 1
- 13 Torque Offset 0 0 0 0 0
- 14 Torque Adj. 1.0 1.0 1.0 1.0 1.0
- 15 Speed Limiter 0 0 0 0 0
- 16 Spd.Meter Adj. 1.00 1.00 1.00 1.00 1.00
- 17 Load Meter Adj. 1.00 1.00 1.00 1.00 1.00
- 18 Loadmeter F.S. 200 200 200 200 200
- 19 Zero Spd.Det.Lvl. 30 30 30 30 30
- 20 Speed Agree Width 15 15 15 15 15
- 21 Spd.Det.Lvl. 013 013 013 013 013
- 22 Spd.Det.Width 1.00 1.00 1.00 1.00 1.00
- 23 Torque Det.Level 30 030 30 30 30
- 24 Ext.Trq.Lim.Level 005 005 005 005 005
- 25 Motor Code 6A 6b 34 34 36
- 26 Rated Motor Speed 08000 08000 6000 6000 6000
- 27 H gear Ratio 1.00 1.00 1.00 0.67 0.67
- 28 M gear Ratio 1.00 1.00 1.00 0.67 0.67
- 29 L gear Ratio 1.00 1.00 1.00 0.67 0.67
- 30 Mtr. Flux Low Lim. 030 030 030 030 030
- 31 SV Mode Flux Lev. 070 070 070 070 070
- 32 SV Md.H.gr Sp.Rat. 1.00 1.00 1.00 1.00 1.00
- 33 SV Md.Flux Lev. 070 070 070 070 070
- 34 SV Md.L.gr.Sp.Rat. 1.00 1.00 1.00 1.00 1.00
- 35 Zero Sp.Brake Time 000 000 000 000 000
- 36 Sel .Signal 1 10001000 10001000 10001000 10001000 10001000
- 37 Sel.Signal 2 00001000 00001000 00001000 00001000 00001000
-38 Sel.Signal 3 00100000 00100000 00100000 00100000 00100000
- 39 Sel.Signal 4 00000000 00000000 00000001 00000001 00000001
- 40 Sel.Signal 5 00000000 00000000 00000000 00000000 00000000
- 41 Intrnl.Sp.Instr.SPD1 0.00 0.00 0.00 0.00 0.00
C1 - 48 Intrnl.Sp.Instr.SPD8 0.00 0.00 0.00 0.00 0.00
Note 1: Adjust for correct commanded speed.
7
Yaskawa Digital Spindle Drive Settings (Orient)
Motor Encoder Orient Magnetic Sensor Orient

(C2 constants) (C3 constants)

C2 or C3 - 01 Pos’n origin (deg.) Note 1 Note 1 +/- 0.8 +/- 0.8 +/- 0.8
- 02 H gear Pos.Prop.Gain 15 15 09 09 09
- 03 M gear Pos.Prop.Gain 15 15 15 15 15
- 04 L gear Pos.Prop.Gain 15 15 15 15 15
- 05 H gear Spd.Prop.Gain 40 40 120 120 120
- 06 M gear Spd.Prop.Gain 100 100 100 100 100
- 07 L gear Spd.Prop.Gain 40 40 30 30 30
- 08 L gear Spd.Int.T.C. 100 100 100 100 100
- 09 Pos.Compl.Det.width 5 5 0.2 0.2 0.2
- 10 Pos.Comp.Cancl.width 10 10 1.0 1.0 1.0
- 11 Ort.Spd.(rpm) 400 400 400 400 400
- 12 BCD resolution 1.0 1.0 1.0 1.0 1.0
- 13 Arb.Stop Posn.Offset 0 0 2.0 2.0 2.0
- 14 Ort.Spd.Chg.Ratio 0 0 0 0 0
- 15 Soft Start Time 0 0 0 0 0
- 16 Flux Level 60 60 60 60 60
- 17 Ort.Spd.Red.Coeff. 0 0 0 0 0
- 18 ----- 0 0 0 0 0
- 19 ----- 0 0 0 0 0
C3 - 20 Sens.Sig.Std.Angle ----- ----- 5.0 5.0 5.0
C2 or C3 - 21 ----- 0 0 9.999 9.999 9.999
- 22 Select Signal 1 11010000 11010000 (tune) (tune) (tune)
- 23 Select Signal 2 00000000 00000000 00000000 00000000 00000000
- 24 Select Signal 3 10000000 10000000 10000000 10000000 10000000
C2 or C3 - 25 ----- (Stored vals.) (Stored vals.) (Stored vals.) (Stored vals.) (Stored vals.)
Note 1 - Set Orient position for ATC operation.
8
757-4002-060 REV: C ECN #13556

R
2 Mar. ‘96 CAD#D8433
50/50M.

B 13556 Revised Spindle Balance Procedure 11/15/95
C 13625 Simplified Spindle Balance Procedure 03/05/96
I. INTENT
II. APPLICABILITY
Specific to all BMC 30M, 30HT/M, 40M, 40/50M and 50/50M Ultimax 3 type machining centers
using software version 1.52 or later. This is the only procedure to be used within HURCO
III. INDEX
Page 2 - Hurco / Yaskawa Part I.D. Table; Setup of Drive / Parameters

Spindle parameters are loaded by default (WITH SOFTWARE VERSION 1.52).

These parameters must be checked to match the latest parameters published to date
(757-4002-029). DSP parameters may be edited in the Tune Axis Parameter screen.
Depress<ENTER> ,103, <ENTER> while in the ATC Diagnostics screen of Manual
machine mode.

BMC 30M 10 HP 402-6009-092 08HHB11 8000 8000 1.00 27P50
BMC 30HT/M 15 HP 402-6009-097 11HHBX1 8000 8000 1.00 20110
BMC 40M 15 HP 402-6009-030 11CZ1 6000 6000 1.00 20110-M*
BMC 40/50M 15 HP 402-6009-030 11CZ1 6000 4000 0.67 20110-M*
BMC 50/50M 20 HP 402-6009-018 15CZ1 6000 4000 0.67 20150-M*
A. Prior to powering up 30M and 30HT/M machines, verify that there is a shunt jumper on the
lowermost (EXT COM) of three 4-pin signal input selection blocks. On the 40M, 40/50M
and 50/50M machines, the uppermost of the blocks (0V COM) should be used. In the case
of a magnetic sensor orient system, remove (or look up and behind) the Orient card to verify
the connection.
7 and 8 of this document. The C1-xx constants alter the operation of the spindle motor


desirable gap).
centering.

2
Do not adjust the VR potentiometers on the MX4 board! Leave them at their calibrated factory settings.
The range of adjustment available from the Yaskawa Spindle Amplifier is sufficient to balance spindle offsets.

3) When the START CYCLE push-button is depressed, the Ultimax Control executes the
following signal sequence - each stage lasting a few seconds, and its results (in counts)
displayed on the Ultimax screen:
When the program starts, press the MOTION HOLD BUTTON, this will hold the DAC at
zero output. The spindle should be rotating slowly, indicating a need for balance.
5) Adjust C1-11 on the spindle drive. (To enter the desired mode, toggle the “Display”
button until the C1-XX screen is visible. Move the cursor to the XX position by toggling
the “Reset” (“ > “) button. Now advance from C1-XX to C1-11 by toggling the “up” or
“down” arrow keys. Change the value until the spindle slows down, then changes direction.
Now slowly adjust C1-11 one digit at a time, until until the spindle stops rotating.
Verify the quality of null by observing no change in the counts being displayed in the
Following Error column.
B. In order to insure specified minimum Spindle Following Error, proceed as follows:
the machine.
2) Depress <ENTER>, 101, <ENTER> while in the ATC Diagnostics screen of Manual
machine mode. Select the <TOGGLE FOLLOWING ERROR DISPLAY> softkey [F6].
3) While in the ATC Diagnostics screen of Manual Mode depress <ENTER>, 103,
<ENTER>. Now select the Depress <SPINDLE> softkey [F4].
Remember: While in the 103 screen, with the Following Error display turned on, the
Spindle Enable Relay (SER) will remain enabled with zero RPM commanded when the
<SPINDLE OFF> key is depressed.
To initially enable the spindle, depress <SPINDLE ON>, <START>, <SPINDLE OFF>.
To disable the spindle drive, depress the <RESET SERVOS AND SPINDLE> softkey.
3
4) Depress <SPINDLE ON>, <START>. The Following Error should be below + 2000°
at full speed. Depress <SPINDLE OFF> and verify that the Following Error value does not
become negative during the deceleration time. Re-verify the Spindle Parameters (tuning
values, as necessary from the 103 screen) if there is negative Following Error or Spindle
Overshoot during deceleration.
Note: A small negative Following Error may be displayed just as the spindle comes to a
stop; however, the spindle will servo to zero Following Error quickly.
RPM. If the you can not get the spindle to run exactly at the rated RPM you may use the
following formula to adjust the DAC voltage. Use the <ENTER>, 100, <ENTER> screen.
Desired RPM
Measured RPM
Ultimax screen.
VIII. ORIENT SETUP

4

5
<ENTER>.
<START>. Verify that the screen display closely matches the drive display. (Each screen
Loadbar Segment is approximately 4%.)
G. Reset the machine, and the Spindle Drive setup is complete.

6
Machine 30M 30HT/M 40M 40/50M 50/50M
Motor 08HHB11 11HHBX1 11CZ1 11CZ1 15CZ1
COM Jmpr. EXT COM EXT COM 0V COM 0V COM 0V COM
C1 - 01 H gear Prop.Gain 030 030 030 030 030
- 02 H gear Int.Time 0600 0600 0600 0600 0600
- 03 L gear Prop.Gain 030 030 030 030 030
- 04 L gear Int.Gain 0600 0600 0600 0600 0600
- 06 H gear Sv.Int.Time 0100 0100 0100 0100 0100
- 08 L gear Sv.Int.Time 0100 0100 0100 0100 0100
- 09 Tq.Filt TCnst. 1.0 1.0 1.0 1.0 1.0
- 10 Soft St.Time 000.1 000.1 000.1 000.1 000.1
- 14 Torque Adj. 1.0 1.0 1.0 1.0 1.0
- 16 Spd.Meter Adj. 1.00 1.00 1.00 1.00 1.00
- 17 Load Meter Adj. 1.00 1.00 1.00 1.00 1.00
- 18 Loadmeter F.S. 200 200 200 200 200
- 19 Zero Spd.Det.Lvl. 30 30 30 30 30
- 21 Spd.Det.Lvl. 013 013 013 013 013
- 22 Spd.Det.Width 1.00 1.00 1.00 1.00 1.00
- 23 Torque Det.Level 30 030 30 30 30
- 24 Ext.Trq.Lim.Level 005 005 005 005 005
- 25 Motor Code 6A 6b 34 34 36
- 27 H gear Ratio 1.00 1.00 1.00 0.67 0.67
- 28 M gear Ratio 1.00 1.00 1.00 0.67 0.67
- 29 L gear Ratio 1.00 1.00 1.00 0.67 0.67
- 30 Mtr. Flux Low Lim. 030 030 030 030 030
- 31 SV Mode Flux Lev. 070 070 070 070 070
- 32 SV Md.H.gr Sp.Rat. 1.00 1.00 1.00 1.00 1.00
- 33 SV Md.Flux Lev. 070 070 070 070 070
- 34 SV Md.L.gr.Sp.Rat. 1.00 1.00 1.00 1.00 1.00
- 36 Sel .Signal 1 10001000 10001000 10001000 10001000 10001000
- 37 Sel.Signal 2 00001000 00001000 00001000 00001000 00001000
-38 Sel.Signal 3 00100000 00100000 00100000 00100000 00100000
- 39 Sel.Signal 4 00000000 00000000 00000001 00000001 00000001
- 40 Sel.Signal 5 00000000 00000000 00000000 00000000 00000000
7


C2 or C3 - 01 Pos’n origin (deg.) Note 1 Note 1 +/- 0.8 +/- 0.8 +/- 0.8
- 02 H gear Pos.Prop.Gain 15 15 09 09 09
- 03 M gear Pos.Prop.Gain 15 15 15 15 15
- 05 H gear Spd.Prop.Gain 40 40 120 120 120
- 08 L gear Spd.Int.T.C. 100 100 100 100 100
- 09 Pos.Compl.Det.width 5 5 0.2 0.2 0.2
- 10 Pos.Comp.Cancl.width 10 10 1.0 1.0 1.0
- 11 Ort.Spd.(rpm) 400 400 400 400 400
- 12 BCD resolution 1.0 1.0 1.0 1.0 1.0
- 13 Arb.Stop Posn.Offset 0 0 2.0 2.0 2.0
- 16 Flux Level 60 60 60 60 60
- 18 ----- 0 0 0 0 0
- 19 ----- 0 0 0 0 0
C3 - 20 Sens.Sig.Std.Angle ----- ----- 5.0 5.0 5.0
C2 or C3 - 21 ----- 0 0 9.999 9.999 9.999
- 22 Select Signal 1 11010000 11010000 (tune) (tune) (tune)
- 23 Select Signal 2 00000000 00000000 00000000 00000000 00000000
- 24 Select Signal 3 10000000 10000000 10000000 10000000 10000000
C2 or C3 - 25 ----- (Stored vals.) (Stored vals.) (Stored vals.) (Stored vals.) (Stored vals.)
8
757-4002-060 REV: D ECN #13706

R
19-Jun-96 CAD#D8433
Control. Applicable Machining Centers: 30M, 30HT/M, 30/SSMD1, 40M,
40/50M, 50/50M.

C 13625 Simplified Spindle Balance Procedure MJW 03/05/96 MFC 3/5/96
D 13706 1)Added references to BMC 30/SSM, 2) Step RME 6/19/96
VII.A.5, added note, 3) Deleted step VII.B,
4) Step VII.C.4, revised spindle speed
tolerance, 5) Step VII.C.4, added note, 6) C1
Parameter Table, Added column for 50/50/M
with 4000rpm spindle, 7) C1 Parameter
Table, Changed settings for C1-25 thru 29 on
50/50 with 6000rpm spindle, 8) C2/C3
Parameter Table, Changed C2-02 and -05 on
30HT, 9) C2/C3 Parameter Table, Added
note 2, 10) Changed 30M C1-20 parameter,
was 15.
2
I. INTENT
II. APPLICABILITY
Specific to all BMC 30M, 30HT/M, 30/SSMD1, 40M, 40/50M and 50/50M Ultimax 3 type machining
centers using software version 1.52 or later. This is the only procedure to be used within HURCO
III. INDEX
Page 3 - Hurco / Yaskawa Part I.D. Table

Page 4 - Setup of Drive / Parameters
Spindle parameters are loaded by default (WITH SOFTWARE VERSION 1.52). These
parameters must be checked to match the latest parameters published to date (757-4002-029 or
757-4002-048). DSP parameters may be edited in the Tune Axis Parameter screen. Depress
<ENTER> ,103, <ENTER> while in the ATC Diagnostics screen of Manual machine mode.

BMC 30M 10 HP 402-6009-092 08HHB11 8000 8000 1.00 27P50
BMC 30HT/M 15 HP 402-6009-097 11HHBX1 8000 8000 1.00 20110
D1
BMC 30/SSM 10 HP 402-6009-092 08HHB11 8000 8000 1.00 27P50
BMC 40M 15 HP 402-6009-030 11CZ1 6000 6000 1.00 20110-M*
BMC 40/50M 15 HP 402-6009-030 11CZ1 6000 4000 0.67 20110-M*
BMC 50/50M 20 HP 402-6009-018 15CZ1 6000 4000 0.67 20150-M*

3
A. Prior to powering up 30M, 30HT/M and 30/SSM D1 machines, verify that there is a shunt
jumper on the lowermost (EXT COM) of three 4-pin signal input selection blocks. On the
40M, 40/50M and 50/50M machines, the uppermost of the blocks (0V COM) should be used.
In the case of a magnetic sensor orient system, remove (or look up and behind) the Orient card
to verify the connection.
8, 9 and 10 of this document. The C1-xx constants alter the operation of the spindle motor


desirable gap).
centering.
Do not adjust the VR potentiometers on the MX4 board! Leave them at their calibrated
factory settings. The range of adjustment available from the Yaskawa Spindle Amplifier is
sufficient to balance spindle offsets.
4
D2
Note: If it is not possible to achieve spindle null using the C1-11 parameter, slight
adjustment of the DSP pot may be necessary.
B.D3
RPM (±0.2%, max rpm * 0.002)D4. If the you can not get the spindle to run within the rated
RPM you may use the following formula to adjust the DAC voltage. Use the <ENTER>, 100,
<ENTER> screen. D5Note: Do not use this formula for machines with rigid tap.
Desired RPM
Measured RPM
5
Ultimax screen.
VIII. ORIENT SETUP
6
<ENTER>.
7
<START>. Verify that the screen display closely matches the drive display (each screen
Loadbar Segment is approximately 4%).
G. Reset the machine and the Spindle Drive setup is complete.
8
D1
Machine 30SSM 30M 30HT/M 40M 40/50M 50/50MD6 50/50M
Motor 08HHB11 08HHB11 11HHBX1 11CZ1 11CZ1 15CZ1 15CZ1
COM Jmpr. EXT COM EXT COM EXT COM 0V COM 0V COM 0V COM 0V COM
Control Value Value Value Value Value Value Value
Constant Function (30SSM) (30M) (30HT/M) (40M) (40/50M) (50/50M) (50/50M)
C1 - 01 H gear Prop.Gain 030 030 030 030 030 030 030
- 02 H gear Int.Time 0600 0600 0600 0600 0600 0600 0600
- 03 L gear Prop.Gain 030 030 030 030 030 030 030
- 04 L gear Int.Gain 0600 0600 0600 0600 0600 0600 0600
- 05 H gear Sv.Prop.Gain 040 040 040 040 040 040 040
- 06 H gear Sv.Int.Time 0100 0100 0100 0100 0100 0100 0100
- 07 L gear Sv.Prop.Gain 020 020 020 020 020 020 020
- 08 L gear Sv.Int.Time 0100 0100 0100 0100 0100 0100 0100
- 09 Tq.Filt TCnst. 1.0 1.0 1.0 1.0 1.0 1.0 1.0
- 10 Soft St.Time 000.1 000.1 000.1 000.1 000.1 000.1 000.1
- 11 Analog Spd.Offset 0 0 0 0 0 0 0
- 12 Fine Spd.Adj. Note 1 Note 1 Note 1 Note 1 Note 1 Note 1 Note 1
- 13 Torque Offset 0 0 0 0 0 0 0
- 14 Torque Adj. 1.0 1.0 1.0 1.0 1.0 1.0 1.0
- 15 Speed Limiter 0 0 0 0 0 0 0
- 16 Spd.Meter Adj. 1.00 1.00 1.00 1.00 1.00 1.00 1.00
- 17 Load Meter Adj. 1.00 1.00 1.00 1.00 1.00 1.00 1.00
- 18 Loadmeter F.S. 200 200 200 200 200 200 200
- 19 Zero Spd.Det.Lvl. 30 30 30 30 30 30 30
- 20 Speed Agree Width 20 20D10 15 15 15 15 15
- 21 Spd.Det.Lvl. 013 013 013 013 013 013 013
- 22 Spd.Det.Width 1.00 1.00 1.00 1.00 1.00 1.00 1.00
- 23 Torque Det.Level 30 30 030 30 30 30 30
- 24 Ext.Trq.Lim.Level 005 005 005 005 005 005 005
- 25 Motor Code 6A 6A 6b 34 34 35 35D7
- 26 Rated Motor Speed 08000 08000 08000 6000 6000 4800 4800 D7
- 27 H gear Ratio 1.00 1.00 1.00 1.00 0.67 0.83 1.25 D7
- 28 M gear Ratio 1.00 1.00 1.00 1.00 0.67 0.83 1.25 D7
- 29 L gear Ratio 1.00 1.00 1.00 1.00 0.67 0.83 1.25 D7
- 30 Mtr. Flux Low Lim. 030 030 030 030 030 030 030
- 31 SV Mode Flux Lev. 070 070 070 070 070 070 070
- 32 SV Md.H.gr Sp.Rat. 1.00 1.00 1.00 1.00 1.00 1.00 1.00
- 33 SV Md.Flux Lev. 070 070 070 070 070 070 070
- 34 SV Md.L.gr.Sp.Rat. 1.00 1.00 1.00 1.00 1.00 1.00 1.00
- 35 Zero Sp.Brake Time 000 000 000 000 000 000 000
Machine 30SSMD1 30M 30HT/M 40M 40/50M 50/50MD6 50/50M
- 36 Sel .Signal 1 10001000 10001000 10001000 10001000 10001000 10001000 10001000
- 37 Sel.Signal 2 00001000 00001000 00001000 00001000 00001000 00001000 00001000
-38 Sel.Signal 3 00100000 00100000 00100000 00100000 00100000 00100000 00100000
- 39 Sel.Signal 4 00000000 00000000 00000000 00000001 00000001 00000001 00000001
- 40 Sel.Signal 5 00000000 00000000 00000000 00000000 00000000 00000000 00000000
- 41 Intrnl.Sp.Instr.SPD1 0.00 0.00 0.00 0.00 0.00 0.00 0.00
C1 - 48 Intrnl.Sp.Instr.SPD8 0.00 0.00 0.00 0.00 0.00 0.00 0.00
10
757-4002-060 REV: E ECN #14012

R
14-Jul-97 CAD#D8433
40/50M, 50/50M.

D 13706 1)Added references to BMC 30/SSM, 2) Step RME 6/19/96 MFC 6/20/96
VII.A.5, added note, 3) Deleted step VII.B,
4) Step VII.C.4, revised spindle speed
tolerance, 5) Step VII.C.4, added note, 6) C1
Parameter Table, Added column for 50/50/M
with 4000rpm spindle, 7) C1 Parameter
Table, Changed settings for C1-25 thru 29 on
50/50 with 6000rpm spindle, 8) C2/C3
Parameter Table, Changed C2-02 and -05 on
30HT, 9) C2/C3 Parameter Table, Added
note 2, 10) Changed 30M C1-20 parameter,
was 15.
E 14012 Page 6, section VII-C, Spindle RPM Range SAW 7/14/97
acceptability table was added.
2
I. INTENT
II. APPLICABILITY
centers using software version 1.52 or later. This is the only procedure to be used within HURCO
III. INDEX

Spindle parameters are loaded by default (WITH SOFTWARE VERSION 1.52). These
parameters must be checked to match the latest parameters published to date (757-4002-029 or
757-4002-048). DSP parameters may be edited in the Tune Axis Parameter screen. Depress
<ENTER> ,103, <ENTER> while in the ATC Diagnostics screen of Manual machine mode.

BMC 30M 10 HP 402-6009-092 08HHB11 8000 8000 1.00 27P50
BMC 30HT/M 15 HP 402-6009-097 11HHBX1 8000 8000 1.00 20110
D1
BMC 30/SSM 10 HP 402-6009-092 08HHB11 8000 8000 1.00 27P50
BMC 40M 15 HP 402-6009-030 11CZ1 6000 6000 1.00 20110-M*
BMC 40/50M 15 HP 402-6009-030 11CZ1 6000 4000 0.67 20110-M*
BMC 50/50M 20 HP 402-6009-018 15CZ1 6000 4000 0.67 20150-M*

3
jumper on the lowermost (EXT COM) of three 4-pin signal input selection blocks. On the
40M, 40/50M and 50/50M machines, the uppermost of the blocks (0V COM) should be used.
In the case of a magnetic sensor orient system, remove (or look up and behind) the Orient card
to verify the connection.


desirable gap).
centering.
factory settings. The range of adjustment available from the Yaskawa Spindle Amplifier is
sufficient to balance spindle offsets.
4
D2
B.D3
RPM (±0.2%, max rpm * 0.002)D4. If the you can not get the spindle to run within the rated
RPM you may use the following formula to adjust the DAC voltage. Use the <ENTER>, 100,
Desired RPM
Measured RPM
5
D
calculate this new required Programmed RPM Acceptable RPM Range
voltage value (to two 80 (All) 79-81*
decimal places), and enter it 1000 (All) 999-1001
into Ultimax screen. 2000 (All) 1998-2002
4000 (All) 3996-4004
(Example: Spindle speed 6000 (BMC40) 5994-6006
= 4175 rpm, but 4000 rpm
8000 (BMC30’s) 7992-8008
is desired; DAC voltage on
Max3 screen is 9.5v. DAC voltage
value should be changed to 4000/4175*9.5 = 9.1v.)
VIII. ORIENT SETUP
6
7
<ENTER>.
8
D1
C1 - 01 H gear Prop.Gain 030 030 030 030 030 030 030
- 02 H gear Int.Time 0600 0600 0600 0600 0600 0600 0600
- 03 L gear Prop.Gain 030 030 030 030 030 030 030
- 04 L gear Int.Gain 0600 0600 0600 0600 0600 0600 0600
- 06 H gear Sv.Int.Time 0100 0100 0100 0100 0100 0100 0100
- 08 L gear Sv.Int.Time 0100 0100 0100 0100 0100 0100 0100
- 09 Tq.Filt TCnst. 1.0 1.0 1.0 1.0 1.0 1.0 1.0
- 10 Soft St.Time 000.1 000.1 000.1 000.1 000.1 000.1 000.1
- 13 Torque Offset 0 0 0 0 0 0 0
- 14 Torque Adj. 1.0 1.0 1.0 1.0 1.0 1.0 1.0
- 15 Speed Limiter 0 0 0 0 0 0 0
- 16 Spd.Meter Adj. 1.00 1.00 1.00 1.00 1.00 1.00 1.00
- 17 Load Meter Adj. 1.00 1.00 1.00 1.00 1.00 1.00 1.00
- 18 Loadmeter F.S. 200 200 200 200 200 200 200
- 19 Zero Spd.Det.Lvl. 30 30 30 30 30 30 30
- 21 Spd.Det.Lvl. 013 013 013 013 013 013 013
- 22 Spd.Det.Width 1.00 1.00 1.00 1.00 1.00 1.00 1.00
- 23 Torque Det.Level 30 30 030 30 30 30 30
- 24 Ext.Trq.Lim.Level 005 005 005 005 005 005 005
- 25 Motor Code 6A 6A 6b 34 34 35 35D7
- 27 H gear Ratio 1.00 1.00 1.00 1.00 0.67 0.83 1.25 D7
- 28 M gear Ratio 1.00 1.00 1.00 1.00 0.67 0.83 1.25 D7
- 29 L gear Ratio 1.00 1.00 1.00 1.00 0.67 0.83 1.25 D7
- 30 Mtr. Flux Low Lim. 030 030 030 030 030 030 030
- 31 SV Mode Flux Lev. 070 070 070 070 070 070 070
- 32 SV Md.H.gr Sp.Rat. 1.00 1.00 1.00 1.00 1.00 1.00 1.00
- 33 SV Md.Flux Lev. 070 070 070 070 070 070 070
- 34 SV Md.L.gr.Sp.Rat. 1.00 1.00 1.00 1.00 1.00 1.00 1.00
- 36 Sel .Signal 1 10001000 10001000 10001000 10001000 10001000 10001000 10001000
- 37 Sel.Signal 2 00001000 00001000 00001000 00001000 00001000 00001000 00001000
-38 Sel.Signal 3 00100000 00100000 00100000 00100000 00100000 00100000 00100000
- 39 Sel.Signal 4 00000000 00000000 00000000 00000001 00000001 00000001 00000001
- 40 Sel.Signal 5 00000000 00000000 00000000 00000000 00000000 00000000 00000000
10

Control Value Value Value Value Value Value

Constant Function (30SSM)D1 (30M) (30HT/M) (40M) (40/50M) (50/50M)
- 01 Pos’n origin (deg.) Note 1 Note 1 Note 1 +/- 0.8 +/- 0.8 +/- 0.8
- 02 H gear Pos.Prop.Gain 15 15 9D8 09 09 09
- 03 M gear Pos.Prop.Gain 15 15 15 15 15 15
- 04 L gear Pos.Prop.Gain 15 15 15 15 15 15
- 05 H gear Spd.Prop.Gain 40 40 120D8 120 120 120
- 06 M gear Spd.Prop.Gain 100 100 100 100 100 100
- 07 L gear Spd.Prop.Gain 40 40 40 30 30 30
- 08 L gear Spd.Int.T.C. 100 100 100 100 100 100
- 09 Pos.Compl.Det.width 5 5 5 0.2 0.2 0.2
- 10 Pos.Comp.Cancl.width 10 10 10 1.0 1.0 1.0
- 11 Ort.Spd.(rpm) 400 400 400 400 400 400
- 12 BCD resolution 1.0 1.0 1.0 1.0 1.0 1.0
- 13 Arb.Stop Posn.Offset 0 0 0 2.0 2.0 2.0
- 14 Ort.Spd.Chg.Ratio 0 0 0 0 0 0
- 15 Soft Start Time 0 0 0 0 0 0
- 16 Flux Level 60 60 60 60 60 60
- 17 Ort.Spd.Red.Coeff. 0 0 0 0 0 0
- 18 ----- 0 0 0 0 0 0
- 19 ----- 0 0 0 0 0 0
- 20 Sens.Sig.Std.Angle ----- ----- ----- 5.0 5.0 5.0
- 21 ----- 0 0 0 9.999 9.999 9.999
- 22 Select Signal 1 11010000 11010000 11010000 01010000........01010000.............01010000
- 23 Select Signal 2 00000000 00000000 00000000 00000000 00000000 00000000
- 24 Select Signal 3 10000000 10000000 10000000 10000000 10000000 10000000
-25 ----- Note 2 Note 2 Note 2 Note 2 Note 2 Note 2
-26 ----- Note 2 Note 2 Note 2 ----- ----- -----
D9
Note 2 - Leave at Factory Settings.
11


- 02 H gear Pos.Prop.Gain 15 15 9D8 09 09 09
- 03 M gear Pos.Prop.Gain 15 15 15 15 15 15
- 04 L gear Pos.Prop.Gain 15 15 15 15 15 15
- 05 H gear Spd.Prop.Gain 40 40 120D8 120 120 120
- 06 M gear Spd.Prop.Gain 100 100 100 100 100 100
- 07 L gear Spd.Prop.Gain 40 40 40 30 30 30
- 08 L gear Spd.Int.T.C. 100 100 100 100 100 100
- 09 Pos.Compl.Det.width 5 5 5 0.2 0.2 0.2
- 10 Pos.Comp.Cancl.width 10 10 10 1.0 1.0 1.0
- 11 Ort.Spd.(rpm) 400 400 400 400 400 400
- 12 BCD resolution 1.0 1.0 1.0 1.0 1.0 1.0
- 13 Arb.Stop Posn.Offset 0 0 0 2.0 2.0 2.0
- 16 Flux Level 60 60 60 60 60 60
- 18 ----- 0 0 0 0 0 0
- 19 ----- 0 0 0 0 0 0
- 21 ----- 0 0 0 9.999 9.999 9.999
- 22 Select Signal 1 11010000 11010000 11010000 (tune) (tune) (tune)
- 23 Select Signal 2 00000000 00000000 00000000 00000000 00000000 00000000
- 24 Select Signal 3 10000000 10000000 10000000 10000000 10000000 10000000
-26 ----- Note 2 Note 2 Note 2 ----- ----- -----
D9
11
757-4002-060 REV: F ECN #14012

R
14-Jul-97 CAD#D8433
40/50M, 50/50M.
M. J. Whittemore 6/9/95
2
D 13706 1)Added references to BMC 30/SSM, 2) Step RME 6/19/96 MFC 6/20/96
VII.A.5, added note, 3) Deleted step VII.B, 4)
Step VII.C.4, revised spindle speed tolerance,
5) Step VII.C.4, added note, 6) C1 Parameter
Table, Added column for 50/50/M with
4000rpm spindle, 7) C1 Parameter Table,
Changed settings for C1-25 thru 29 on 50/50
with 6000rpm spindle, 8) C2/C3 Parameter
Table, Changed C2-02 and -05 on 30HT, 9)
C2/C3 Parameter Table, Added note 2, 10)
Changed 30M C1-20 parameter, was 15.
E 14012 1) Page 6, section VII-C, Spindle RPM Range SAW 7/14/97 DEO 7/23/97
acceptability table was added.
F 14781 1) Page 7, step B3 was 11000000. 2) Page 7, DEO 9/1/99
step B10 was 11010000. 3) Page 11 was
(tune).
3
I. INTENT
II. APPLICABILITY
centers using software version 1.52 or later. This is the only procedure to be used within HURCO facilities
and should be used at customer installations to help achieve factory proven performance.
III. INDEX

Spindle parameters are loaded by default (WITH SOFTWARE VERSION 1.52). These parameters
must be checked to match the latest parameters published to date (757-4002-029 or 757-4002-048).
DSP parameters may be edited in the Tune Axis Parameter screen. Depress <ENTER> ,103,
<ENTER> while in the ATC Diagnostics screen of Manual machine mode.

BMC 30M 10 HP 402-6009- 08HHB11 8000 8000 1.00 27P50
092
BMC 30HT/M 15 HP 402-6009- 11HHBX1 8000 8000 1.00 20110
097
BMC 30/SSM D1 10 HP 402-6009- 08HHB11 8000 8000 1.00 27P50
092
BMC 40M 15 HP 402-6009- 11CZ1 6000 6000 1.00 20110-M*
030
BMC 40/50M 15 HP 402-6009- 11CZ1 6000 4000 0.67 20110-M*
030
4
BMC 50/50M 20 HP 402-6009- 15CZ1 6000 4000 0.67 20150-M*
018
jumper on the lowermost (EXT COM) of three 4-pin signal input selection blocks. On the 40M,
40/50M and 50/50M machines, the uppermost of the blocks (0V COM) should be used. In the case of
a magnetic sensor orient system, remove (or look up and behind) the Orient card to verify the connection.


desirable gap).
centering.
5
Do not adjust the VR potentiometers on the MX4 board! Leave them at their calibrated factory
settings. The range of adjustment available from the Yaskawa Spindle Amplifier is sufficient to
balance spindle offsets.

“down” arrow keys. Change the value until the spindle slows down, then changes direction. Now
slowly adjust C1-11 one digit at a time, until until the spindle stops rotating.
D2
B.D3
the machine. Note this commanded (desired) value .
3) Obtain a tachometer reading of Spindle RPM. Note this measured value .
6
RPM (±0.2%, max rpm * 0.002)D4. If the you can not get the spindle to run within the rated RPM
you may use the following formula to adjust the DAC voltage. Use the <ENTER>, 100,
Desired RPM
Measured RPM
D
calculate this new required Programmed RPM Acceptable RPM Range
voltage value (to two 80 (All) 79-81*
decimal places), and enter it 1000 (All) 999-1001
into Ultimax screen. 2000 (All) 1998-2002
4000 (All) 3996-4004
(Example: Spindle speed 6000 (BMC40) 5994-6006
= 4175 rpm, but 4000 rpm
8000 (BMC30’s) 7992-8008
is desired; DAC voltage on
Max3 screen is 9.5v. DAC voltage
value should be changed to 4000/4175*9.5 = 9.1v.)
VIII. ORIENT SETUP

7
3) F1 Set Spindle Drive parameter C3-22 = 01000000 (change Bit 4 to 0).
8
10) F2 Reset Spindle Drive parameter C3-22 = 01010000 (change Bit 4 back to 1).
<ENTER>.
9
D1
C1 - 01 H gear Prop.Gain 030 030 030 030 030 030 030
- 02 H gear Int.Time 0600 0600 0600 0600 0600 0600 0600
- 03 L gear Prop.Gain 030 030 030 030 030 030 030
- 04 L gear Int.Gain 0600 0600 0600 0600 0600 0600 0600
- 06 H gear Sv.Int.Time 0100 0100 0100 0100 0100 0100 0100
- 08 L gear Sv.Int.Time 0100 0100 0100 0100 0100 0100 0100
- 09 Tq.Filt TCnst. 1.0 1.0 1.0 1.0 1.0 1.0 1.0
- 10 Soft St.Time 000.1 000.1 000.1 000.1 000.1 000.1 000.1
- 13 Torque Offset 0 0 0 0 0 0 0
- 14 Torque Adj. 1.0 1.0 1.0 1.0 1.0 1.0 1.0
- 15 Speed Limiter 0 0 0 0 0 0 0
- 16 Spd.Meter Adj. 1.00 1.00 1.00 1.00 1.00 1.00 1.00
- 17 Load Meter Adj. 1.00 1.00 1.00 1.00 1.00 1.00 1.00
- 18 Loadmeter F.S. 200 200 200 200 200 200 200
- 19 Zero Spd.Det.Lvl. 30 30 30 30 30 30 30
- 21 Spd.Det.Lvl. 013 013 013 013 013 013 013
- 22 Spd.Det.Width 1.00 1.00 1.00 1.00 1.00 1.00 1.00
- 23 Torque Det.Level 30 30 030 30 30 30 30
- 24 Ext.Trq.Lim.Level 005 005 005 005 005 005 005
- 25 Motor Code 6A 6A 6b 34 34 35 35D7
- 27 H gear Ratio 1.00 1.00 1.00 1.00 0.67 0.83 1.25 D7
- 28 M gear Ratio 1.00 1.00 1.00 1.00 0.67 0.83 1.25 D7
- 29 L gear Ratio 1.00 1.00 1.00 1.00 0.67 0.83 1.25 D7
- 30 Mtr. Flux Low Lim. 030 030 030 030 030 030 030
- 31 SV Mode Flux Lev. 070 070 070 070 070 070 070
- 32 SV Md.H.gr Sp.Rat. 1.00 1.00 1.00 1.00 1.00 1.00 1.00
- 33 SV Md.Flux Lev. 070 070 070 070 070 070 070
- 34 SV Md.L.gr.Sp.Rat. 1.00 1.00 1.00 1.00 1.00 1.00 1.00
- 36 Sel .Signal 1 10001000 10001000 10001000 10001000 10001000 10001000 10001000
- 37 Sel.Signal 2 00001000 00001000 00001000 00001000 00001000 00001000 00001000
-38 Sel.Signal 3 00100000 00100000 00100000 00100000 00100000 00100000 00100000
- 39 Sel.Signal 4 00000000 00000000 00000000 00000001 00000001 00000001 00000001
- 40 Sel.Signal 5 00000000 00000000 00000000 00000000 00000000 00000000 00000000
11


- 02 H gear 15 15 9D8 09 09 09
Pos.Prop.Gain
- 03 M gear 15 15 15 15 15 15
Pos.Prop.Gain
- 04 L gear 15 15 15 15 15 15
Pos.Prop.Gain
- 05 H gear 40 40 120D8 120 120 120
Spd.Prop.Gain
- 06 M gear 100 100 100 100 100 100
Spd.Prop.Gain
- 07 L gear 40 40 40 30 30 30
Spd.Prop.Gain
- 08 L gear Spd.Int.T.C. 100 100 100 100 100 100
- 09 Pos.Compl.Det.widt 5 5 5 0.2 0.2 0.2
h
- 10 Pos.Comp.Cancl.wid 10 10 10 1.0 1.0 1.0
th
- 11 Ort.Spd.(rpm) 400 400 400 400 400 400
- 12 BCD resolution 1.0 1.0 1.0 1.0 1.0 1.0
- 13 Arb.Stop 0 0 0 2.0 2.0 2.0
Posn.Offset
- 16 Flux Level 60 60 60 60 60 60
- 18 ----- 0 0 0 0 0 0
- 19 ----- 0 0 0 0 0 0
- 21 ----- 0 0 0 9.999 9.999 9.999
- 22 Select Signal 1 11010000 11010000 11010000 01010000 F3 01010000 F3 01010000 F3
- 23 Select Signal 2 00000000 00000000 00000000 00000000 00000000 00000000
12
- 24 Select Signal 3 10000000 10000000 10000000 10000000 10000000 10000000
-26 ----- Note 2 Note 2 Note 2 ----- ----- -----
D9
13
R
757-4005-015 CAD #DP0015
SUBJECT: Installation Procedures and Parameter

Settings for Machines, with Yaskawa Sigma
and ULTIMAX 4 ISA Software V2.X.
Dan Ornelas 8/18/98

Originator Date Mgr. Control Integration Engineering Date
RECORD OF CHANGES
Engineering Document 757-4005-015 CAD

#DP0015
Revision ECN # Revision Description Rev Date Appd Date

By By
A 14364 Original Release DEO 8/18/98 DEO 8/19/98
B 14427 Page 8, Cn-04 for axes X & Y were 45 Hz DEO 10/20/98 DEO 10/21/9
8
C 14450 1) Page 3, Added BMC30’s & BMC4020. DEO 11/11/98 DEO 11/12/9
2) Page 4, BMC2416 axes parameter files 8
where no revision, now revision “A”.
3) Page 9, Added new Cn-03 values for
10mm ballscrew configuration machine.
4) Page 9, Added new Cn-04 Z-axis value
for10mm ballscrew configuration
machine.
D 14532 1) Page 4, Revised parameter file table, 4I. DEO 1/28/99 DEO 2/3/99
2) Pages 5-6, Clarified step 3I for speed
adj.
3) Pages 8, 11, 14, 17, 20, was 0880H.
4) Pages 8, 11, 14, 17, 20, was 0.
E 14660 1) Page 3, Added BMC6434-50T. 2) Page 4, DEO 6/7/99 DEO 6/10/99
All machine model servo files “.sgb” have
been revised to next level. 3) Pages 9, 12,
15, 18, 21, Was 800. 4) Pages 12,15, Was 35.
5) Page 22, Was 40.
F 14781 1) Page 4, was 2416zb.sgb. 2) Page 5-6, step DEO 9/2/99
3H was 01. Also included CH A and CH B
descriptions. 3) Z-axis Cn-04 was 40.
Procedures and Parameter Settings for Machines w/Yaskawa Sigma 757-4005-015 Rev. F Page 2 of 25
I. INTENT
To provide a standardized method to configure Yaskawa Sigma series servo drive parameters on
Ultimax 4 ISA V2.X type machining centers.
II. APPLICABILITY
Specific to all BMC2416, BMC30’s, BMC4020, and BMC6434 Ultimax type machining centers using
software version 2.11 or later. This is the only procedure to be used within Hurco facilities and should
be used at customer installations to help achieve factory proven performance.
III. REFERENCE DOCUMENTS
1. Yaskawa Sigma Series Users Manual (TSE-S800-16D) Reference

2. Yaskawa Digital Operator Instruction (TOE-S800-15.4)
IV. INDEX
Page 3-5 Parameter Setup Procedure, SVMON Software

Page 5-7 Parameter Setup Procedure, Digital Operator Keypad
Page 8-10 User Constant Parameters, BMC2416
Page 11-13 User Constant Parameters, BMC30 C1
Page 14-16 User Constant Parameters, BMC30HT/M C1
Page 17-19 User Constant Parameters, BMC4020 C1
Page 20-22 User Constant Parameters, BMC6434
Page 23-25 User Constant Parameters, BMC6434-50T E1
V. PARAMETER SETUP PROCEDURE
There are two methods of initializing or changing parameters using Yaskawa Sigma series servo drives.
They involve a software program, SVMON, or a Digital Operator keypad for manual data entry. Both
the software and manual keypad operations are described below:
SVMON, Software
1. The SERVOPACK parameters may be configured using personal computer and SVMON
software.
2. Cable harness, RS232 (See Below)
3. Communication Port (COM1) Properties

• Bits per second = 9600
• Data bits = 7
• Parity = Even
• Stop bits = 1
• Flow control = None
4. Download Parameter Files

A. Ensure drive and PC power is turned ON.
B. Connect RS232 cable harness from PC to desired axis SERVOPACK.
C. Select and start-up SVMON software from PC menu or icon.
D. Once communications is established select SERVOPACK Type SGDB-**AD
Series. Select OK.
E. Four separate windows will appear and dynamically display data for the specific
SERVOPACK selected.
• Status Monitor
• Monitor
• SERVOPACK
• I/O Signal Monitor
F. Select “Constants” from main menu.
G. Select “Constants Number” and User Constants Table will appear.
H. Select “Disk to PC”.
I. Load specific SERVOPACK file from table below for desired machine and axis.
Axis BMC2416 BMC30 BMC30HT/M BMC4020 Files BMC6434 Files BMC6434-50T
Files Files Files Files
X 2416xc.sgb E2 30xb.sgb E2 30htxb.sgb E2 4020xb.sgb E2
6434xb.sgb E2
64345x.sgb E1
Y 2416yc.sgb E2 30yb.sgb E2 30htyb.sgb E2 4020yb.sgb E2 6434yb.sgb E2 64345y.sgb E1
Z 2416zc.sgb F1 30za.sgb E2 30htza.sgb E2 4020za.sgb E2 6434za.sgb E2 64345z.sgb E1
J. To download parameter set select “PC to Drive”.

K. To commence download transmission, select “Start”. Once window closes
transmission is complete
L. If you wish to confirm download select “Verify” then “Start”. If compare agrees the
following message will appear: “The setup in the user constants list and internal
SERVOPACK settings all agree with other. Select OK.
M. To close open windows hit ESC (Escape).
N. To quit SVMON at main menu display press ALT-X.
O. (NOTE: Whenever a Memory Switch parameter is changed power to the drive
must be cycled for the change to take effect).
Digital Operator, Keypad
1. User constant (Memory Switch) setup and checks for CN-01 and CN-02.
A. With the UP or DOWN key, enter the setup Memory Switch bit number at the far right
end of the panel.
B. With the MODE/SET key, set the Memory Switch to ON or OFF. The panel
indication comes on when the switch is ON, and goes off when the switch is OFF.
C. Repeat steps A and B as needed.
D. Retain the data with the DATA key.
E. With the DATA key, return to the item number display state.
F. Using the MODE/SET key, switch from the setting mode to the monitor mode.
G. (NOTE: Whenever a Memory Switch parameter is changed power to the drive
must be cycled for the change to take effect).
2. User constant (Data) setup and checks for CN-03 thru CN-23.
A. Set up the item number with the UP or DOWN key. While the key is held down, the
numerical value increases or decreases successively by one.
B. With the DATA key, display the data related to the selected item number.
C. With the UP or DOWN key, set up the data. While the key is held down, the numerical
value increases or decreases successively by one.
D. Retain the data with the MODE/SET key.
E. Repeat steps A thru D as needed.
F. With the DATA key, return to the item number display state.
G. Using the MODE/SET key, switch from the setting mode to the monitor mode.
3. Speed Reference Offset Adjust D2, F2
A. Enter Integration Support Services on Hurco controller - AUX, 100, Enter, 100.
B. Enter Machine Setup and Test – F3.
C. Enter Axis Balance Adjustment – F3.
D. Select Axis to Adjust and press – Cycle Start.
E. When test cycles to Current Command Volts = 0V press – Motion Hold.
F. From the Digital Operator select item number Cn-00 with the UP and DOWN key.
G. With the DATA key, display the data related to the selected item number.
H. With the UP and DOWN key, select the number 03. Press the MODE/SET key, the
value in Channel A is displayed. Note: Leave Channel B at default.
I. Press the UP and DOWN key to adjust speed reference until counter DRO on the Axis
Balance screen no longer increments or decrements (nulled).
J. Press the MODE/SET key to, make speed reference offset adjustment and return to
the user constant Cn-00 data display state.
K. With the DATA key, return to the item number display state.
L. Using the MODE/SET key, switch from the setting mode to the monitor mode.
4. Monitor Mode
A. In the Monitor Mode speed reference, torque reference, and other data can be
observed on the digital operator.
B. Select Monitor Mode Indication by selecting UN-XX. See table below for various
monitor modes. ((*)Bit Indication of Monitor Mode UN-05 Internal Status Display)
C. Monitor Number Data Monitored
UN-00 Feedback Speed (r/min)
UN-01 Speed Reference (r/min)
UN-02 Torque Reference (%)
UN-03 No. of Pulses from Pulse edge (Phase-U)
UN-04 Electrical Angle (deg)
UN-05* Internal Status Bit Display
13 10 7 4 1
14 11 8 5 2
15 12 9 6 3
16 . 17 . 18 . 19 . 20 .
Bit Number Description

1 Servo Alarm
2 Dynamic Brake
3 Reverse Run Mode
4 Motor Running
5 Speed Agree
6 Mode Switch ON
7 Forward Current Limit
8 Reverse Current Limit
16 Servo ON
18 Forward Running Prohibit Input (P-OT)
19 Reverse Running Prohibit Input (N-OT)
5. Error Display Mode
A. In the error or abnormal trackback mode you can display the data for a particular error
as indicated by 0-A.XX. See table below for typical abnormal data.
Bit Number Description

A.02 Parameter Breakdown
A.04 Parameter Setting Error
A.10 Overcurrent
A.40 Overvoltage
A.51 Feedback Overspeed
A.52 Overspeed Reference Input
A.71 Momentary Overload
A.72 Continuous Overload
A.B1 Reference Input Read Error
A.C3 Phase A, B Disconnection
A.C4 Phase C Disconnection
Sigma Series Servo Drive Parameters
P No. User Constants for BMC2416 DIMENSION X-AXIS Y-AXIS Z-AXIS

Cn-00 Special Mode Selector - N/A N/A N/A
Cn-01 Memory Switch Settings, 1 - 0980H D3 0980H D3 0B80H
Bit 0 External S-ON signal used Binary 0 0 0
Bit 1 External SEN signal used Binary 0 0 0
Bit 2 Uses forward rotation prohibit (P-OT) Binary 0 0 0
Bit 3 Uses negative rotation prohibit (N-OT) Binary 0 0 0
Bit 4 Reserved Binary 0 0 0
Bit 5 Operation performed at recovery from power loss Binary 0 0 0
Bit 6 Sequence selection at alarm condition Binary 0 0 0
Bit 8 Sequence selection at alarm condition Binary 1 D4 1 D4 1
Bit A Process selection for Servo OFF Binary 0 0 0
Bit B Mode switch selection Binary 1 1 1
Bit C Mode switch selection Binary 0 0 0
Bit D Mode switch selection Binary 0 0 0
Bit E Encoder selection (Incremental) Binary 0 0 0
Bit F Reserved Binary 0 0 0
Cn-02 Memory switch Settings, 2 - 0000H 0000H 0000H
Bit 0 Rotation direction (CCW = Forward) Binary 0 0 0
Bit 1 Home position error processing selection Binary 0 0 0
Bit 2 Analog speed limit function Binary 0 0 0
Bit 3 Reference pulse form Binary 0 0 0
Bit 6 Output Torque to TRQ-M Binary 0 0 0
Bit 7 Output Speed to VTG-M Binary 0 0 0
Bit 8 Analog current limit function Binary 0 0 0
Bit 9 Torque feedforward function Binary 0 0 0
Procedures and Parameter Settings for machines w/Yaskawa Sigma 757-4005-015 Rev. F Page 8 of 25

Bit A Clear signal Binary 0 0 0
Bit B Reserved Binary 0 0 0
Bit C Torque Filter Binary 0 0 0
Bit D Reference pulse form Binary 0 0 0
Bit E Position error monitor Binary 0 0 0
Bit F Reference pulse filter Binary 0 0 0
Cn-03 Speed reference adjustment gain (*12mm ballscrew*) RPM/V 211 211 131
Cn-03 Speed reference adjustment gain (*10mm ballscrew*) RPM/V 252 C3 252 C3 158 C3
Cn-04 Speed loop gain (*12mm ballscrew*) Hz 30 B1 30 B1 70
Cn-04 Speed loop gain (*10mm ballscrew*) Hz 30 30 50 C4,F3
Cn-05 Speed loop integration time constant 0.01 ms 550 550 2000
Cn-06 Emergency stop torque % 125 E3 125 E3 125 E3
Cn-07 Soft start acceleration ms 0 0 0
Cn-08 Forward rotation torque limit % 800 800 800
Cn-09 Reverse rotation torque limit % 800 800 800
Cn-0A PG dividing ratio P/R 4800 4800 4800
Cn-0B Zero-speed level RPM 20 20 20
Cn-0C Mode switch torque reference % 200 200 200
Cn-0D Mode switch speed reference RPM 0 0 0
Cn-0E Mode switch acceleration 10 RPM/s 0 0 0
Cn-0F Mode switch error pulse Ref. unit 0 0 0
Cn-10 Jog speed RPM 500 500 500
Cn-11 Number of encoder pulses P/R 8192 8192 8192
Cn-12 Time delay from brake reference until servo OFF 10 ms 0 0 50
Cn-13 Torque reference gain 0.1V 30 30 30
Cn-14 Speed limit for torque control RPM 10000 10000 10000
Cn-15 Speed level for brake ref output during motor operation RPM 100 100 1250
Cn-16 Output timing of brake ref during motor operation 10 ms 50 50 10
Cn-17 Torque reference filter time constant 0.1 ms 4 4 5

Cn-18 Forward external current limit % 100 100 100
Cn-19 Reverse external current limit % 100 100 100
Cn-1A Position loop gain 1/s 40 40 50
Cn-1B Positioning completion range Ref. unit 7 7 7
Cn-1C Bias RPM 0 0 0
Cn-1D Feed-forward % 0 0 0
Cn-1E Overflow 256 Ref. unit 1024 1024 1024
Cn-1F 1st speed (contact input speed control) RPM 100 100 100
Cn-20 2nd speed (contact input speed control) RPM 200 200 200
Cn-21 3rd speed (contact input speed control) RPM 300 300 300
Cn-22 Speed coincidence signal output range RPM 10 10 10
Cn-23 Soft start deceleration range ms 0 0 0
Cn-24 Electronic gear ratio (numerator) - 4 4 4
Cn-25 Electronic gear ratio (denominator) - 1 1 1
Cn-26 Position reference acceleration/deceleration 0.1 ms 0 0 0
Cn-27 Feed-forward filter 0.1 ms 0 0 0
Cn-28 Speed loop compensation constant - 0 0 0
Cn-29 Zero clamp level RPM 10 10 10
Cn-2A Motor selection (Z=SGMG-13A) - 143 143 144
Cn-2B Control method selection - 0 0 0
Cn-2C PG power supply voltage change - 52500 52500 52500
Cn-2D Output signal selection - 210 210 214


Cn-03 Speed reference adjustment gain RPM/V 263 263 140
Cn-04 Speed loop gain Hz 50 E4 50 E4 50

P No. User Constants for BMC30HT/M DIMENSION X-AXIS Y-AXIS Z-AXIS


Cn-04 Speed loop gain Hz 50 E4 50 E4 50



Cn-04 Speed loop gain Hz 40 40 50




Cn-1A Position loop gain 1/s 40 40 45 E5
P No. User Constants for BMC6434 50-Taper DIMENSION X-AXIS Y-AXIS Z-AXIS
Cn-01 Memory Switch Settings, 1 - 0980H 0980H 0B80H
Cn-06 Emergency stop torque % 125 125 125
757-4002-182 CAD#D8597
R
SUBJECT: Yaskawa Digital Spindle Drive Setup Procedure with Ultimax 4

Software V2.X. Applicable Machining Centers: BMC2416, BMC30’s,
BMC4020, and BMC6434.
Dan Ornelas 10/12/98
Originator Date Mgr. Control Integration Engineering Date
Yaskawa Digital Spindle Drive Setup Procedure 757-4002-182 Rev. D Page 2 of 10

A 14407 Original Release DEO 10/12/98 DEO 10/13/98
B 14450 1) Pgs. 7-8, Added BMC30’s & BMC4020 to DEO 11/11/98 DEO 11/20/98
Table of Yaskawa parameter settings, 2) Pg 8,
was 15, 3) Pg. 8, was 09, 4) Pg 8, was 60.
C 14660 1) Pgs. 7-8, Added BMC6434 50 Taper to SAW 6/18/99 DEO 6/19/99
Table of Yaskawa parameter settings, 2) Pg 8,
Control Constant C2-05 was 120.
D 14781 1) Pg. 4 step B4, Added note, use C1-12 to DEO 9/1/99
adjust DAC offset instead of calculating new max.
DAC voltage.

I. INTENT
digital spindle drives used on Ultimax 4 ISA type machining centers.
II. APPLICABILITY
Specific to all BMC2416, BMC30, BMC4020, and BMC6434 Ultimax 4 type machining centers using
software version 2.x or later. This is the only procedure to be used within HURCO facilities and should be
used at customer installations to help achieve factory proven performance.
III. INDEX
Page 3 - Ultimax 4 Control Paramters

Page 5 - Orient Spindle and Tool Change Height Setup
Spindle parameters are loaded from the latest Engineering Document published (757-4005-013 or
757-4005-014) per machine.

BMC2416 10 HP 402-6009- 08HHB11 8000 8000 1.00 27P50
092
BMC30’s 15 HP 402-6009- 11HHB11 8000 8000 1.00 20110
097
BMC4020 20HP 402-6009- 15HHB12 8000 8000 1.00 20150
116
BMC6434 20HP 402-6009- 15HHB12 8000 8000 1.00 20150
116
BMC6434C50 25HP 402-6009- 19HHB11 6000 6000 1.00 20180
145
A. Prior to powering up machines, verify that there is a shunt jumper on the lowermost (EXT COM) of
three 4-pin signal input selection blocks.

B. Using the Yaskawa Digital Spindle Drive operator keypad, verify (and set, where necessary) the
User Control Constants for the appropriate BMC system per the Settings Tables on pages “X” of
this document. The C1-xx constants alter the operation of the spindle motor itself, while the C2-xx
constants affect the performance of the Motor Encoder Orient operation.

ISSUED OR THE SPINDLE IS IN ORIENT POSITION.
factory settings. The range of adjustment available from the Yaskawa Spindle Amplifier is sufficient
to balance spindle offsets.
1) Enter Integration Support Services on the Hurco controller – AUX,Enter,100,Enter.

2) Enter Machine Setup and Test – F3.
3) Enter Axis Balance Adjustment – F3.
4) Select Axis “Spindle” to Adjust and press – Cycle Start.
5) When test cycles to Current Command Volts = 0V press – Motion Hold.
button until the C1-XX screen is visible. Move the cursor to the XX position by toggling the
“Reset” (“ > “) button. Now advance from C1-XX to C1-11 by toggling the “up” or
“down” arrow keys. Change the value until the spindle slows down then changes direction.
Now slowly adjust C1-11 one digit at a time, until the spindle stops rotating. Verify the
quality of null by observing no change in the counts being displayed in the Following
Error column.
B. D1 To calibrate the Maximum Spindle Speed parameter (ensuring that the Ultimax Control reflects true
Spindle speed), proceed as follows:
1) In Manual Mode select “Manual Function Setup”- F2. Then set the Manual Spindle. Speed
value to the maximum spindle speed of the machine. Note this commanded (desired)
value.
2) Obtain a tachometer reading of Spindle RPM. Note this measured value .
3) It is likely that there will be a discrepancy between the commanded and the measured spindle
speeds. To correct this situation, adjust C1-12 until the spindle is running the rated RPM
(±0.2%, max rpm (0.002)).
4) NOTE: Do not use the formula below for machines with rigid tap.

5) Only after you have adjusted C1-12 and can not get the spindle to run within the rated RPM
may you use the following formula to adjust DAC voltage.
7) Enter CNC Configuration Parameters – F1.
8) Enter “Spindle” – F4.
9) Change Physical Spindle Parameter - Maximum DAC Volts.
Desired RPM
Measured RPM
Calculate this new required voltage value

(to four decimal places), and enter it into Programmed RPM Acceptable RPM Range
Ultimax screen. 80 (All) 79-81*
1000 (All) 999-1001
(Example: Spindle speed = 4175 rpm, but 2000 (All) 1998-2002
4000 rpm is desired; DAC voltage on 4000 (All) 3996-4004
Max3 screen is 9.5v. DAC voltage value 6000 (All) 5994-6006
should be changed to 4000/4175*9.5 = 8000 (All) 7992-8008
9.1018v.) (*) Rounded to whole number
VIII. ORIENT SPINDLE AND TOOL HEIGHT SETUP
Having modified C2 (Encoder Orient) Parameters per appropriate Machine type perform a Spindle Self-
Orient (using the Yaskawa Spindle Drive Keypad) as follows:
1) Calibrate machine, both axes and tool changer.

3) Enter “Machine Setup and Test” – F3.
4) Enter “Tool Changer Diagnostics” – F4.
5) Move Z-axis in positive direction until it stops at the software limit.
6) From the ATC Diagnostics screen command the ATC “Load Arm 60°” – F3.
7) From the ATC Diagnostics screen carefully and slowly jog Z-axis down (negative) until the
spindle nose is approximately 1.0” from top of ATC load arm.
8) Press the “Spindle OFF” button on console. Rotate the spindle by hand until the spindle key
is aligned with the ATC gripper key slot.
9) Record spindle motor position (counts) ________ from spindle drive display U2-03 (V2-03).
11) Push “Emergency Stop” on the control.
23) Orient is now set, and may be commanded by Ultimax 4 control.
B. Tool Change Height

2) Enter “Machine Setup and Test” – F3.
3) Enter “Tool Changer Diagnostics” – F4.
4) From the ATC Diagnostics screen press – MORE – F7 twice.
5) From the ATC Diagnostics screen select move “Move Z to Tool Change Height” – F2.
Note: This will be approx. 1.0” above final Tool Change Height position based on step
VIII-A-4.
6) From the ATC diagnostics screen press – MORE - F7.
7) From the ATC Diagnostics screen command the ATC “Tool Pocket Down” – F2.
9) Using the remote jog handwheel carefully and slowly jog Z-axis down until the spindle nose is
0.5” from the “V” centerline on the ATC gripper arm. Physically measure this distance.
11) Press the “Spindle Unclamp” button located on the spindle head.
12) Put an empty Tool Holder in Spindle.
13) Press the “Spindle Clamp” button located on the spindle head.
14) From the ATC diagnostics screen press – MORE - F7.
15) From the ATC Diagnostics screen command “Orient Spindle” – F3.
18) If necessary using the remote jog handwheel carefully adjust Z-axis up or down until the ATC
gripper arm completely seats into the Tool Holder.
20) Record the machines new tool changer height position _________ . Enter this value into the
control by selecting “Set Tool Changer Height” – F3.

21) Reverse the sequence from the ATC Diagnostics screen to place the ATC back to the
“Home” position. This completes tool change height setup procedure.

Machine BMC2416 BMC30’sB1 BMC4020B1 BMC6434 BMC6434C50 C1
Motor 08HHB11 11HHB11 15HHB12 15HHB12 15HHB12

COM Jmpr. EXT COM EXT COM EXT COM EXT COM EXT COM
Control Function Values Values Values Values Values
Constant
C1 - 01 H gear Prop.Gain 030 030 030 030 030
- 02 H gear Int.Time 0600 0600 0600 0600 0600
- 03 L gear Prop.Gain 030 030 030 030 030
- 04 L gear Int.Gain 0600 0600 0600 0600 0600
- 06 H gear Sv.Int.Time 0100 0100 0100 0100 0100
- 08 L gear Sv.Int.Time 0100 0100 0100 0100 0100
- 09 Tq.Filt TCnst. 1.0 1.0 1.0 1.0 1.0
- 10 Soft St.Time 000.1 000.1 000.1 000.1 000.1
- 14 Torque Adj. 1.0 1.0 1.0 1.0 1.0
- 16 Spd.Meter Adj. 1.00 1.00 1.00 1.00 1.00
- 17 Load Meter Adj. 1.00 1.00 1.00 1.00 1.00
- 18 Loadmeter F.S. 200 200 200 200 200
- 19 Zero Spd.Det.Lvl. 30 30 30 30 30
- 21 Spd.Det.Lvl. 013 013 013 013 013
- 22 Spd.Det.Width 1.00 1.00 1.00 1.00 1.00
- 23 Torque Det.Level 30 30 30 30 30
- 24 Ext.Trq.Lim.Level 005 005 005 005 005
- 25 Motor Code 6A 6B 3C 3C 80
- 27 H gear Ratio 1.00 1.00 1.00 1.00 1.00
- 28 M gear Ratio 1.00 1.00 1.00 1.00 1.00
- 29 L gear Ratio 1.00 1.00 1.00 1.00 1.00
- 30 Mtr. Flux Low Lim. 030 030 030 030 030
- 31 SV Mode Flux Lev. 070 070 070 070 070
- 32 SV Md.H.gr Sp.Rat. 1.00 1.00 1.00 1.00 1.00
- 33 SV Md.Flux Lev. 070 070 070 070 070
- 34 SV Md.L.gr.Sp.Rat. 1.00 1.00 1.00 1.00 1.00
- 36 Sel .Signal 1 10001000 10001000 10001000 10001000 10001000
- 37 Sel.Signal 2 00001000 00001000 00001000 00001000 00001000
- 38 Sel.Signal 3 00100000 00100000 00100000 00100000 00100000
- 39 Sel.Signal 4 00000000 00000000 00000000 00000000 00000000
- 40 Sel.Signal 5 00000000 00000000 00000000 00000000 00000000

Motor Encoder Orient
(C2 constants)
Control Function Value Value Value Value Value

Constant BMC2416 BMC30’sB1 BMC4020B1 BMC6434 BMC6434C50 C1
- 01 Pos’n origin (deg.) Note 1 Note 1 Note 1 Note 1 Note 1

- 02 H gear Pos.Prop.Gain 25 B2 25 25 25 B3 25
- 03 M gear 25 B2 25 25 25 B2 25
Pos.Prop.Gain
- 05 H gear Spd.Prop.Gain 40 40 C2 40 C2 40 C2 40
- 08 L gear Spd.Int.T.C. 100 100 100 100 100
- 09 Pos.Compl.Det.width 5 5 5 5 5
- 10 Pos.Comp.Cancl.widt 10 10 10 10 10
h
- 11 Ort.Spd.(rpm) 300 300 300 300 300
- 12 BCD resolution 1.0 1.0 1.0 1.0 1.0
- 13 Arb.Stop Posn.Offset 0 0 0 0 0
- 16 Flux Level 80 B4 80 80 80 B4 80
- 18 ----- 0 0 0 0 0
- 19 ----- 0 0 0 0 0
- 20 Sens.Sig.Std.Angle ----- ----- ----- ----- -----
- 21 ----- 0 0 0 0 0
- 22 Select Signal 1 11010000 11010000 11010000 11010000 11010000
- 23 Select Signal 2 00000000 00000000 00000000 00000000 00000000
- 24 Select Signal 3 10000000 10000000 10000000 10000000 10000000
-25 ----- Note 2 Note 2 Note 2 Note 2 Note 2
-26 ----- Note 2 Note 2 Note 2 Note 2 Note 2

R
704-0020-035 Rev E CAD #D8613
SUBJECT: Yaskawa Sigma Servo Pack Drive Parameter Diskette
Barry A. Van Paris 12/10/98 Dan Ornelas

Originator: B. Van Paris Date Mgr, Machine Integrations – ICP Date
RECORD OF CHANGES
Engineering Document: 704-0020-035 CAD #D8613

By By
A 14494 Original Release BVP 12/10/98 DEO 12/11/98
B 14547 Added description of revision B of the BVP 2/18/99 DEO 2/21/99
parameter disk.
C 14660 Updated all machine model servo DEO 6/25/99 DEO 6/27/99
parameters. Added BMC6434-50T.
D 14781 Update Section VI, page 4, file for DEO 9/23/99 DEO 9/25/99
BMC2416 Z-axis was 2416ZB.SGB
E 15154 Added parameters for Sigma II RMN 12/12/00
drives/machine models
Yaskawa Sigma Servo Pack Drive Parameter Diskette

704-0020-035 Rev. E Page 2 of 2
INTENT
The purpose of this document is to describe the functionality and to provide a revision history for the 007-4000-002
S/W, YASK SIGMA SERVO PACK CONFIGURATON DISK.
I. SCOPE
This document will provide the following:
• Description of the Yaskawa Sigma servo drive parameter diskette

• Where the parameter diskette can be obtained
• Revision history of the parameter diskette
• Diskette contents (filenames)
II. PARAMETER DISKETTE DESCRIPTION

The 007-4000-002 Yaskawa Sigma servo drive parameter diskette will provide files containing parameters that can be
downloaded into the Sigma drives using a PC and serial cable. A comparison of the drive’s internal parameters to
the released parameters on the diskette can also be made to assure proper drive set up. These parameters are
used in conjunction with the Yaskawa Sigma drive SVMON (DOS) or SigmaWin (Windows) software.
Refer to engineering document 757-4005-015 (CAD #: D0015) for detailed instructions for using these parameter
files. This document should be part of the Ultimax Field Installation Kit 007-4123-009 (notebook).
IV. PARAMETER DISKETTE AVAILABILITY

The Ultimax Field Installation Kit (notebook) will contain the 007-4000-002 parameter diskette. If this diskette is not
present or another is needed, the 007-4000-002 parameter diskette can be ordered directly from Hurco stock.
This diskette is available for Hurco engineering, production, field service and distributors and is not available for sale
to customers.

704-0020-035 Rev. E Page 3 of 3
V. PARAMETER DISKETTE REVISION HISTORY
Revision ECN # Revision Description

A 14494 Original Release for BMC2416 machines
B 14547 Added the drive parameter files for BMC30, BMC30HT, BMC4020 and
BMC6434. Also, put new files 2416XB.SGB and 2416YB.SGB to replace
2416XA.SGB and 2416YA.SGB respectively. The parameter change
causes the machine to decelerate with torque at overtravel. This new
behavior inhibits the "bumping" effects once observed on axes X and
Y with the previous parameter settings.
C 14660 All machine models servo files have been revised. Emg. stop torque
was reduced to 125% to soften limit switch behavior. Added drive
parameter files for BMC6434-50T.
D 14781 BMC2416 Z-axis speed loop gain parameter was 40, now 50 to improve
rigid tap performance.
E 15154 Added Yaskawa Sigma II drive parameters for VMX24, VMX30, VMX40,
VMX50, VMX64, and VMX64-50T

704-0020-035 Rev. E Page 4 of 4
VI. DISKETTE CONTENTS E1
The files contained on this parameter disk are:
Files
2416XC.SGB
2416YC.SGB
2416ZC.SGB
30HTXB.SGB
30HTYB.SGB
30HTZA.SGB
30XB.SGB
30YB.SGB
30ZA.SGB
4020XB.SGB
4020YB.SGB
4020ZA.SGB
6434XB.SGB
6434YB.SGB
6434ZA.SGB
64345X.SGB
64345Y.SGB
64345Z.SGB
VMX24XA.YPM
VMX24YA.YPM
VMX24ZA.YPM
VMX30XA.YPM
VMX30YA.YPM
VMX30ZA.YPM
VMX40XA.YPM
VMX40YA.YPM
VMX40ZA.YPM
VMX50XA.YPM
VMX50YA.YPM
VMX50ZA.YPM
VMX64XA.YPM
VMX64YA.YPM
VMX64ZA.YPM
VMX65XA.YPM
VMX65YA.YPM
VMX65ZA.YPM

704-0020-035 Rev. E Page 5 of 5
Sigma II Series Servo System
User’s Manual
Safety Information
The following conventions are used to indicate precautions in this manual. Failure to heed
precautions provided in this manual can result in serious or possibly even fatal injury or
damage to the products or to related equipment and systems.
! WARNING
• WARNING: Indicates precautions that, if not heeded, could possibly result in loss of life or serious injury.
! CAUTION
• CAUTION: Indicates precautions that, if not heeded, could result in relatively serious or minor injury,
damage to the product, or faulty operation.
•
PROHIBITED
• PROHIBITED: Indicates actions that must never be taken.
©Yaskawa,1999
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any
form, or by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior permission
of Yaskawa. No patent liability is assumed with respect to the use of the information contained herein. Moreover,
because Yaskawa is constantly striving to improve its high-quality products, the information contained in this man-
ual is subject to change without notice. Every precaution has been taken in the preparation of this manual. Never-
theless, Yaskawa assumes no responsibility for errors or omissions. Neither is any liability assumed for damages
resulting from the use of the information contained in this publication.
Sigma II User’s Manual Chapter 2: Installation
Overview....................................................................................................................... viii
Using This Manual.......................................................................................................... ix
Safety Precautions.............................................................................................................x
1: Checking Product and Part Names ...................................................................... 1-1
1.1 Checking the Sigma II Series Products on Deliver.............................................. 1-2
1.1.1 Servomotors ................................................................................................ 1-2
1.1.2 Servo Amplifiers......................................................................................... 1-4
1.2 Product Part Names ............................................................................................. 1-5
1.2.1 Servomotors ................................................................................................ 1-5
2 Installation ........................................................................................................... 2-1
2.1 Servomotors ......................................................................................................... 2-2
2.1.1 Storage Temperature ................................................................................... 2-2
2.1.2 Installation Site ........................................................................................... 2-2
2.1.3 Alignment ................................................................................................... 2-3
2.1.4 Orientation .................................................................................................. 2-3
2.1.5 Allowable Shaft Loads................................................................................ 2-4
2.1.6 Handling Oil and Water .............................................................................. 2-5
2.1.7 Cable Stress................................................................................................. 2-5
2.2 Servo Amplifiers.................................................................................................. 2-6
2.2.1 Storage Conditions...................................................................................... 2-6
2.2.3 Orientation .................................................................................................. 2-7
2.2.4 Installation .................................................................................................. 2-7
3 Wiring .................................................................................................................. 3-1
3.1 Connecting to Peripheral Devices....................................................................... 3-2
3.1.1 Single-Phase (100V or 200V) Main Circuit Specifications....................... 3-3
3.1.2 Three-Phase (200V) Main Circuit Specifications....................................... 3-4
3.2 Servo Amplifier Internal Block Diagrams.......................................................... 3-5
3.2.1 30 to 400W 200V and 30 to 200W 100V Models ...................................... 3-5
3.2.2 0.5kW to 1.5kW 200V Models ................................................................... 3-6
3.2.3 2.0kW and 3.0kW 200V Models ................................................................ 3-6
i
3.3 Main Circuit Wiring............................................................................................. 3-7

3.3.1 Names and Descriptions of Main Circuit Terminals................................... 3-8
3.3.2 Typical Main Circuit Wiring Example........................................................ 3-9
3.3.3 Cable Specifications and Peripheral Devices ............................................. 3-9
3.3.4 Servo Amplifier Power Losses ................................................................. 3-10
3.3.5 Wiring Main Circuit Terminal Blocks ...................................................... 3-11
3.4 I/O Signals ......................................................................................................... 3-12
3.4.1 Examples of I/O Signal Connections........................................................ 3-13
3.4.2 List of CN1 Terminals .............................................................................. 3-14
3.4.3 I/O Signal Names and Functions .............................................................. 3-15
3.4.4 Interface Circuits....................................................................................... 3-17
3.5 Wiring Encoders ................................................................................................ 3-20
3.5.1 Connecting an Encoder (CN2) and Output Signals from the
Servo Amplifier (CN1) ............................................................................. 3-20
3.5.2 CN2 Encoder Connector Terminal Layout and Types.............................. 3-21
3.6 Examples of Standard Connections .................................................................. 3-22
3.6.1 Single-Phase Power Supply Specifications .............................................. 3-23
3.6.2 Three-Phase Power Supply Specifications ............................................... 3-24
3.6.3 Position Control Mode.............................................................................. 3-25
3.6.4 Speed Control Mode ................................................................................. 3-26
3.6.5 Torque Control Mode................................................................................ 3-27
4 Trial Operation..................................................................................................... 4-1
4.1 Two-Step Trial Operation .................................................................................... 4-2
4.1.1 Step 1: Trial Operation for Servomotor without Load................................ 4-3
4.1.2 Step 2: Trial Operation with the Servomotor Connected to the Machine.. 4-9
4.2 Supplementary Information on Trial Operation................................................ 4-10
4.2.1 Servomotors with Brakes.......................................................................... 4-10
4.2.2 Position Control by Host Controller ......................................................... 4-11
4.3 Minimum Parameters and Input Signals........................................................... 4-11
4.3.1 Parameters................................................................................................. 4-11
4.3.2 Input Signals ............................................................................................. 4-12
ii
5: Parameter Settings and Functions........................................................................ 5-1

5.1 Settings According to Device Characteristics .................................................... 5-4
5.1.1 Switching Servomotor Rotation Direction ................................................. 5-4
5.1.2 Setting the Overtravel Limit Function ........................................................ 5-5
5.1.3 Limiting Torques......................................................................................... 5-9
5.2 Settings According to Host Controller.............................................................. 5-14
5.2.1 Speed Reference ....................................................................................... 5-14
5.2.2 Position Reference .................................................................................... 5-16
5.2.3 Using the Encoder Signal Output ............................................................. 5-22
5.2.4 Sequence I/O Signals ................................................................................ 5-25
5.2.5 Using the Electronic Gear Function.......................................................... 5-28
5.2.6 Contact Input Speed Control..................................................................... 5-32
5.2.7 Using Torque Control ............................................................................... 5-38
5.2.8 Torque Feed–forward Function................................................................. 5-44
5.2.9 Torque Limiting by Analog Voltage Reference ........................................ 5-46
5.2.10 Reference Pulse Inhibit Function (INHIBIT) ........................................... 5-48
5.3 Setting Up the Servo Amplifier ......................................................................... 5-49
5.3.1 Parameters................................................................................................. 5-49
5.3.2 JOG Speed ................................................................................................ 5-49
5.3.3 Input Circuit Signal Allocation................................................................. 5-50
5.3.4 Output Circuit Signal Allocation .............................................................. 5-54
5.3.5 Control Mode Selection ............................................................................ 5-57
5.4 Setting Stop Functions ....................................................................................... 5-60
5.4.1 Adjusting Offset........................................................................................ 5-60
5.4.2 Using the Dynamic Brake......................................................................... 5-61
5.4.3 Using the Zero Clamp Function................................................................ 5-62
5.4.4 Using the Holding Brake .......................................................................... 5-64
5.5 Forming a Protective Sequence ........................................................................ 5-69
5.5.1 Using Servo Alarm and Alarm Code Outputs .......................................... 5-69
5.5.2 Using the Servo ON Input Signal ............................................................. 5-71
5.5.3 Using the Positioning Completed Output Signal...................................... 5-72
iii
5.5.4 Speed Coincidence Output........................................................................ 5-74

5.5.5 Using the Running Output Signal ............................................................. 5-75
5.5.6 Using the Servo Ready Output Signal ...................................................... 5-76
5.5.7 Using the Warning Output Signal ............................................................. 5-77
5.5.8 Using the Near Output Signal ................................................................... 5-79
5.5.9 Handling Power Loss................................................................................ 5-80
5.6 Selecting a Regenerative Resistor..................................................................... 5-82
5.6.1 External Regenerative Resistor................................................................. 5-84
5.6.2 Calculating the Required Capacity of Regenerative Resistors ................. 5-86
5.7 Absolute Encoders ............................................................................................. 5-90
5.7.1 Interface Circuit ........................................................................................ 5-90
5.7.2 Selecting an Absolute Encoder ................................................................. 5-91
5.7.3 Handling Batteries .................................................................................... 5-92
5.7.4 Absolute Encoder Setup............................................................................ 5-93
5.7.5 Absolute Encoder Reception Sequence .................................................... 5-97
5.8 Special Wiring.................................................................................................. 5-102
5.8.1 Wiring Precautions.................................................................................. 5-102
5.8.2 Wiring for Noise Control ........................................................................ 5-104
5.8.3 Using More Than One Servodrive.......................................................... 5-109
5.8.4 Extending Encoder Cables...................................................................... 5-110
5.8.5 400V Power Supply Voltage................................................................... 5-112
5.8.6 Reactor for Harmonic Suppression......................................................... 5-113
5.9 Reserved Parameters........................................................................................ 5-114
6 Servo Adjustment ................................................................................................ 6-1
6.1 Smooth Operation ................................................................................................ 6-2
6.1.1 Using the Soft Start Function...................................................................... 6-2
6.1.2 Smoothing................................................................................................... 6-3
6.1.3 Adjusting Gain ............................................................................................ 6-4
6.1.4 Adjusting Offset.......................................................................................... 6-5
6.1.5 Setting the Torque Reference Filter Time Constant.................................... 6-5
6.1.6 Notch Filter ................................................................................................. 6-6
iv
6.2 High-speed Positioning........................................................................................ 6-7

6.2.1 Setting Servo Gain ...................................................................................... 6-7
6.2.2 Using Feed-Forward Control ...................................................................... 6-9
6.2.3 Using Proportional Control......................................................................... 6-9
6.2.4 Setting Speed Bias .................................................................................... 6-10
6.2.5 Using Mode Switch .................................................................................. 6-11
6.2.6 Speed Feedback Compensation ................................................................ 6-14
6.3 Auto-Tuning....................................................................................................... 6-17
6.3.1 Online Auto-Tuning.................................................................................. 6-17
6.3.2 Mechanical Rigidity Settings for Online Auto-Tuning............................. 6-20
6.3.3 Saving Results of Online Auto-Tuning..................................................... 6-22
6.3.4 Parameters Related to Online Auto-Tuning.............................................. 6-24
6.4 Servo Gain Adjustments .................................................................................... 6-26
6.4.1 Servo Gain Parameters.............................................................................. 6-26
6.4.2 Basic Rules of Gain Adjustment............................................................... 6-26
6.4.3 Making Manual Adjustments.................................................................... 6-28
6.4.4 Gain Setting Reference Values ................................................................. 6-33
6.5 Analog Monitor.................................................................................................. 6-35
7. Using the Digital Operator................................................................................... 7-1
7.1 Basic Operation.................................................................................................... 7-2
7.1.1 Connecting the Digital Operator................................................................. 7-2
7.1.2 Functions..................................................................................................... 7-3
7.1.3 Resetting Servo Alarms .............................................................................. 7-4
7.1.4 Basic Mode Selection ................................................................................. 7-5
7.1.5 Status Display Mode ................................................................................... 7-5
7.1.6 Operation in Parameter Setting Mode ........................................................ 7-8
7.1.7 Operation in Monitor Mode ...................................................................... 7-16
7.2 Applied Operation.............................................................................................. 7-21
7.2.1 Operation in Alarm Traceback Mode ....................................................... 7-22
7.2.2 Operation Using the Digital Operator....................................................... 7-23
7.2.3 Automatic Adjustment of the Speed and Torque Reference Offset.......... 7-26
v
7.2.4 Manual Adjustment of the Speed and Torque Reference Offset .............. 7-29
7.2.5 Clearing Alarm Traceback Data ............................................................... 7-34
7.2.6 Checking the Motor Model....................................................................... 7-36
7.2.7 Checking the Software Version................................................................. 7-39
7.2.8 Origin Search Mode.................................................................................. 7-40
7.2.9 Initializing Parameter Settings.................................................................. 7-42
7.2.10 Manual Zero Adjustment and Gain Adjustment of
Analog Monitor Output ............................................................................ 7-44
7.2.11 Adjusting the Motor Current Detection Offset ......................................... 7-49
7.2.12 Write Protected Setting)............................................................................ 7-53
8 Ratings and Characteristics.................................................................................. 8-1
8.1 Servomotors ......................................................................................................... 8-2
8.1.1 Ratings, Specifications, and Dimensional Drawings.................................. 8-2
8.2 Servo Amplifiers................................................................................................ 8-17
8.2.1 Combined Specifications .......................................................................... 8-17
8.2.2 Ratings and Specifications........................................................................ 8-21
8.2.3 Dimensional Drawings ............................................................................. 8-24
9: Inspection, Maintenance, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Servodrive Inspection and Maintenance............................................................. 9-2
9.1.1 Servomotor Inspection ................................................................................ 9-2
9.1.2 Servo Amplifier Inspection......................................................................... 9-3
9.1.3 Replacing Battery for Absolute Encoder .................................................... 9-4
9.2 Troubleshooting ................................................................................................... 9-5
9.2.1 Troubleshooting Problems with Alarm Displays........................................ 9-5
9.2.2 Troubleshooting Problems with No Alarm Display ................................. 9-35
9.2.3 Alarm Display Table ................................................................................. 9-37
9.2.4 Warning Displays...................................................................................... 9-39
A: Host Controller Connection Examples ............................................................... A-1
A.1 Connecting the GL-series MC20 Motion Module.............................................. A-2
A.2 Connecting the CP-9200SH Servo Controller Module (SVA) ........................... A-3
A.3 Connecting the GL-series B2813 Positioning Module ...................................... A-4
A.4 Connecting OMRON's C500-NC221 Position Control Unit.............................. A-5
vi
A.5 Connecting OMRON's C500-NC112 Position Control Unit .............................. A-6

A.6 Connecting MITSUBISHI's AD72 Positioning Unit.......................................... A-7
B: List of Parameters ................................................................................................B-1
B.1 Parameters............................................................................................................B-2
B.2 Switches ...............................................................................................................B-5
B.3 Input Signal Selections ........................................................................................B-9
B.4 Output Signal Selections....................................................................................B-11
B.6 Monitor Modes ..................................................................................................B-12
vii
Overview
n Manual Outline
This manual provides the following information for the Sigma II Series SGMoH/SGDH
servodrives.
• Procedures for installing and wiring the servomotor and servo amplifier.
• Procedures for trial operation of the servodrive.
• Procedures for using functions and adjusting the servodrives.
• Procedures for using the built-in panel operator and the hand-held digital operator.
• Ratings and specifications for standard models.
• Procedures for maintenance and inspection.
n Related Manuals
Refer to the following manuals as required.
Read this manual carefully to ensure the proper use of Sigma II Series servodrives. Also,
keep this manual in a safe place so that it can be referred to whenever necessary.
Manual Name Manual Number Contents

Sigma II Series Servo System
Catalog Supplement Describes the procedure used to select
G-MIAZ#99001 Sigma II Series servodrives and capaci-
Servo Selection and Data ties.
Sheets
Describes the applications and operation
Sigma Win Software SIA–S800–1.0 of software for the Sigma servodrive
Operation Manual monitoring devices for use on personal
computers.
Sigma II Series SGMoH/
SGDH Provides detailed information on the
TOE–S800–34 operation of the JUSP–OP02A–1
Digital Operator digital operator, which is an optional
product.
Operation Manual
viii
Sigma II User’s Manual Table of Contents/Preface
Using This Manual

n Intended Audience
This manual is intended for the following users.
• Those designing Sigma IΙ Series servodrive systems.
• Those installing or wiring Sigma IΙ Series servodrives.
• Those performing trial operation or adjustments of Sigma IΙ Series servodrives.
• Those maintaining or inspecting Sigma IΙ Series servodrives.
n Description of Technical Terms

In this manual, the following terms are defined as follows:
• Servomotor = Sigma IΙ Series SGMAH/SGMPH/SGMGH/SGMSH servomotor.
• Servo Amplifier = Sigma IΙ Series SGDH servo amplifier.
• Servodrive = A set including a servomotor and servo amplifier.
• Servo System = A servo control system that includes the combination of a servodrive
with a host computer and peripheral devices.
n Indication of Reverse Signals

In this manual, the names of reverse signals (ones that are valid when low) are written
with a forward slash (/) before the signal name, as shown in the following equations:
• /S–ON = S–ON
• /P–CON = P–CON
ix
Safety Precautions
The following precautions are for checking products upon delivery, installation, wiring,
operation, maintenance and inspections.
n Checking Products upon Delivery
! CAUTION
• Always use the servomotor and servo amplifier in one of the specified combinations.
Not doing so may cause fire or malfunction.
n Installation
! CAUTION
• Never use the products in an environment subject to water, corrosive gases, inflammable gases, or
combustibles.
Doing so may result in electric shock or fire.
n Wiring
! WARNING
• Connect the ground terminal to a class 3 ground (100Ω Ω or less).
Improper grounding may result in electric shock or fire.
• Required for 7.5kW amplifiers: use of Yaskawa kit Number XXX for wiring the power input and
output terminals, or equivalent UL listed closed-loop ring terminals designed to accept 4 AWG wires.
! CAUTION
• Do not connect a three-phase power supply to the U, V, or W output terminals.
Doing so may result in injury or fire.
• Securely fasten the power supply terminal screws and motor output terminal screws.
Not doing so may result in fire.
x
n Operation
! CAUTION
• Never touch any rotating motor parts while the motor is running.
Doing so may result in injury
! CAUTION
• Conduct trial operation on the servomotor alone with the motor shaft disconnected from machine to
avoid any unexpected accidents.
Not doing so may result in injury.
• Before starting operation with a machine connected, change the settings to match the parameters of
the machine.
Starting operation without matching the proper settings may cause the machine to run out of control or mal-
function.
• Before starting operation with a machine connected, make sure that an emergency stop can be applied
at any time.
Not doing so may result in injury.
• Do not touch the heat sinks during operation.
Not doing so may result in burns due to high temperatures.
n Maintenance and Inspection
! WARNING
• Do not remove the panel cover while the power is ON.
Doing so carries a risk of electric shock.
• Do not touch terminals for five minutes after the power has been turned OFF.
Residual voltage may cause electric shock.
• Never touch the inside of the servo amplifier.
Doing so may result in electric shock.
xi
! CAUTION
• Do not disassemble the servomotor.
Doing so may result in electric shock or injury
• Do not attempt to change wiring while the power is ON.
Doing so may result in electric shock or injury
n General Precautions
Note the following to ensure safe application:

• The drawings presented in this manual are sometimes shown without covers or protective guards. Always
replace the cover or protective guard as specified first, and then operate the products in accordance with the
manual.
• The drawings presented in this manual are typical examples and may not match the product you received.
• This manual is subject to change due to product improvement, specification modification, and manual
improvement. When this manual is revised, the manual code is updated and the new manual is published as
a next edition. The edition number appears on the front and back covers.
• If the manual must be ordered due to loss or damage, inform your nearest Yaskawa representative or one of
the offices listed on the back of this manual.
• Yaskawa will not take responsibility for the results of unauthorized modifications of this product. Yaskawa
shall not be liable for any damages or troubles resulting from unauthorized modification.
xii
Sigma II User’s Manual Chapter 1: Checking Products and Part Names
1 Checking Product and Part Names
This chapter describes the procedure for checking products

upon delivery as well as names for product parts.
1.1 Checking the Sigma II Series Products on Deliver.............................................. 1-2

1.1.1 Servomotors ................................................................................................ 1-2
1.2 Product Part Names ............................................................................................. 1-5
1.2.1 Servomotors ................................................................................................ 1-5
1-1
1.1 Checking the Sigma II Series Products on Delivery

The following procedure is suggested to check Sigma II series products upon delivery.
Use the following checklist when Sigma II series products are delivered.
Initial Inspection Comments

Check the model numbers marked on
Are the delivered products the nameplates of the servomotor and
the ones that were ordered? servo amplifier. (Refer to the descrip-
tions of model numbers on following
pages)
The servomotor shaft is normal if it can
Does the servomotor shaft be turned smoothly by hand. Servomo-
rotate smoothly? tors with brakes, however, cannot be
turned manually.
Check the overall appearance, and
Is there any damage? check for damage or scratches that may
have occurred during shipping.
Are there any loose screws? Check screws for looseness using a
screwdriver.
If any of the above are faulty or incorrect, contact Yaskawa or an authorized distributor.
1.1.1 Servomotors
n External Appearance and Nameplate Example

Rated output
Servomotor model
Serial number
Manufacturing date
Rated motor speed
1-2
n Model Numbers
Standard Servomotors
SGMPH - 01 A A A 2 S
Sigma II Series Servomotor Name Brake and Oil Seal Specifications
SGMAH
SGMPH 1: With brake, no oil seal
SGMGH S: With oil seal
SGMSH C: With 24VDC brake
E: S+C
Servomotor Capacity (See Table 1l1) Shaft End Specifications

(See Table 1.3)
A: 200V Design Revision Order

B: 100V A SGMAH
*The only 100V servomotors are the 0.2kW or less SGMPH
SGMAH and SGMPH models. SGMGH (1500rpm)
SGMSH
E: SGMPH (IP67 waterproof specification)
Serial Encoder Specifications (See Table 1.2)
Table 1.1: Servomotor Capacity (kW)

SGMAH SGMPH SGMGH SGMSH SGMAH SGMPH SGMGH SGMSH
Symbol Symbol
3000rpm 3000rpm 1500rpm 3000rpm 3000rpm 3000rpm 1500rpm 3000rpm
A3 0.03 — — — 08 0.75 0.75 — —
A5 0.05 — — — 09 — — 0.85 —
01 0.1 0.1 — — 10 — — — 1.0
02 0.2 0.2 — — 12 — — — —
03 — — — — 13 — — 1.3 —
04 0.4 0.4 — — 15 — 1.5 — 1.5
05 — — 0.45 — 20 — — 1.8 2.0
06 — — — — 30 — — 2.9 3.0
Table 1.2: Serial Encoders

Code Specification SGMAH SGMPH SGMGH SGMSH
1 16–bit absolute encoder Standard Standard — —
2 17–bit absolute encoder — — Standard Standard
A 13–bit incremental encoder Standard Standard — —
B 16-bit incremental encoder Optional Optional — —
C 17–bit incremental encoder — — Standard Standard
Table 1.3: Axis End Specifications (Straight)

Code Specification SGMAH SGMPH SGMGH SGMSH
2 Straight without key Optional Optional Standard Standard
4 Straight with key Standard Standard — —
6 Straight with key and tap Optional Optional Optional Optional
8 Straight with tap Optional Optional — —
1-3
1.1.2 Servo Amplifiers
n External Appearance and Nameplate Examples
Servo amplifier model
YASKAWA
200V
SERVOPACK
SGDH-
MODE/SET DATA/
CHARGE POWER
L1 C
N
L2 3
L3
1
2
C
N
1
L1C
L2C
B1
B2
B3
C
U N
2
V
W
Serial number
Sigma II series SGDH Applicable capacity
servo amplifier Applicable
power supply
n Model Numbers
SGDH - 10 A E - o
Sigma II Series
SGDH Servo Amplifier
Maximum Applicable Servomotor Capacity

(See Table 1.9)
Supply Voltage
A: 200V
B: 100V*
*The only 100V servomotors are the 2.0kW or
or less SGMAH and SGMPH
Type
E: For torque, speed,. and position control
Options
R: Rack mounted
S: Single-Phase
1-4
Table 1.4: Maximum Applicable Servomotor Capacity
Maximum Applicable Servomotor Capacity

Symbol Capacity (kW) Symbol Capacity (kW)
A3 0.03 08 0.75
A5 0.05 10 1.0
01 0.10 15 1.5
02 0.20 20 2.0
04 0.40 30 3.0
05 0.50 — —-
1.2 Product Part Names

This section describes product part names.
1.2.1 Servomotors
The figure below shows part names for servomotors with or without brakes.
Encoder Frame Flange
Output shaft
1-5
1.2.2 Servo Amplifiers

The figure below shows the part names for servo amplifiers.
Battery Holder
Used to house the backup battery for an
absolute encoder.
CN5 Analog Monitor Connector

Used to monitor motor speed, torque refer-
ence, and other values through a special cable.
CN8 Battery Connector

Used to connect to the backup battery for an
absolute encoder.
Panel Display
Five-digit 7-segment display panel used to
show servo status, alarm status, and other
values when parameters are entered.
Panel Keys
Used to set parameters.
Power ON Indicator
Lights when the control power supply is ON.
Charge Indicator
Lights when the main circuit power supply is
ON and stays as long as that component’s
capacitor remains charged. Therefore, if this
indicator is ON, do not touch the servo
amplifier, even after the power supply is
turned OFF.
CN10 Connector for Option Unit

Connects option units for expanding the amplifier’s functions.
CN3 Connector to PC or Digital Operator

Used to communicate with a personal computer or to con-
nect to an optional digital operator.
CN1 I/O Signal Connector

Used for both reference input and sequence I/O signals.
Nameplate
Indicates the servo amplifier model and its specific ratings.
CN2 Encoder Connector

Connects to the encoder in the servomotor.
Ground Terminal
Must be connected to protect against electrical shock.
Main Circuit Power Supply Terminal

Used for the main circuit power supply input.
Control Power Supply Terminal

Connects to the control power supply and to externally
mounted regenerative resistor (where applicable).
Servomotor Terminal
Connects to the servomotor power line.
1-6
2 Installation
This chapter describes precautions for Sigma II Series servomotor

and servo amplifier installation.
2.1 Servomotors ......................................................................................................... 2-2

2.1.1 Storage Temperature ................................................................................... 2-2
2.1.3 Alignment ................................................................................................... 2-3
2.1.4 Orientation .................................................................................................. 2-3
2.1.5 Allowable Shaft Loads................................................................................ 2-4
2.1.6 Handling Oil and Water .............................................................................. 2-5
2.1.7 Cable Stress................................................................................................. 2-5
2.2 Servo Amplifiers.................................................................................................. 2-6
2.2.1 Storage Conditions...................................................................................... 2-6
2.2.3 Orientation .................................................................................................. 2-7
2.2.4 Installation .................................................................................................. 2-7
2-1
2.1 Servomotors
SGMoH servomotors can be installed either horizontally or vertically.

The service life of the servomotor can be shortened or unexpected problems might occur if
it is installed incorrectly or in an inappropriate location. Follow these installation instruc-
tions carefully.
! CAUTION
• Do not connect the servomotor directly

to a commercial power line. This will
damage the servomotor.
The servomotor cannot operate without the

proper servo amplifier.
Note: Prior to Installation:The end of the motor shaft is coated with anticorrosive paint. Before installing,
carefully remove all of the paint using a cloth moistened with paint thinner. Avoid getting thinner on
other parts of the Servomotor.
Anticorrosive paint
2.1.1 Storage Temperature

Store the servomotor within the following temperature range if it is stored with the
power cable disconnected.
-20 to 60°C
2.1.2 Installation Site

SGMooH Servomotors are designed for indoor use. Install the servomotor in envi-
ronments that satisfy the following conditions.
2-2
• Free of corrosive or explosive gases.

• Well-ventilated and free of dust and moisture.
• Ambient temperature of 0 to 40°C.
• Relative humidity (r.h.) of 20 to 80% with no condensation.
• Accessible for inspection and cleaning.
2.1.3 Alignment
Align the shaft of the servomotor with the shaft of the equipment, and then couple
the shafts. Install the servomotor so that alignment accuracy falls within the follow-
ing range.
Measure this distance at four different positions on the circumference. The difference between the
maximum and minimum measurements must be 0.0012in. (0.03mm) or less. (Rotate with the shafts coupled).
Measure this distance at four different positions on the circumference. The

difference between the maximum and minimum measurements must be
0.0012in. (0.03mm) or less. (Rotate with the shafts coupled).
Note:
• Vibration that will damage the bearings will occur if the shafts are not properly aligned.
• Prevent direct impact to the shafts when installing the coupling. The encoder mounted on the
opposite end of the shaft may be damaged.
2.1.4 Orientation
SGMoH servomotors can be installed either horizontally or vertically.
2-3
2.1.5 Allowable Shaft Loads

Design the mechanical system so thrust and radial loads applied to the servomotor
shaft end during operation falls within the ranges shown in Table 2.1.
Allowable radial load in the table is the maximum load allowed on the end of the
output shaft.
Table 2.1: Allowable Radial and Thrust Loads for the Servomotor
Allowable Allowable
Radial Load Thrust Load LR
Servomotor MODEL Fr Fs Reference Diagram
in (mm)
Lbf (N) Lbf (N)
A3 15.29 (68) 12.14 (54)
0.79
A5 15.29 (68) 12.14 (54) (20)
01 17.54 (78) 12.14 (54)
SGMAH 02 55.1 (245) 16.63 (74) 0.98
04 55.1 (245) 16.63 (74) (25)
1.39
08 88.1 (392) 33.0 (147) (35)
01 17.54 (78) 11.02 (49) 0.79

(20)
02 55.1 (245) 15.29 (68) 0.98 LR
SGMPH 04 55.1 (245) 15.29 (68) (25)
08 392 (88.1) 33.0 (147) Fr
1.39
15 110 (490) 33.0 (147) (35) Fs
05AoA 110 (490) 22.0 (98)
2.28
09AoA 110 (490) 22.0 (98) (58)
SGMGH 13AoA 154 (686) 77.1 (343)
20AoA 264.3 (1176) 110 (490) 3.11
30AoA 330.4 (1470) 110 (490) (79)
10A 154 (686) 44.1 (196)
15A 154 (686)) 44.1 (196) 1.77
(45)
SGMSH 20A 154 (686) 44.1 (196)
30A 220 (980) (88.1 (392) 2.48

(63)
Fr
Note: Thrust and radial loads:

Servomotor Fs
Thrust load (Fs): Shaft-end load applied parallel to the
centerline of the shaft. Shaft end
Radial load (Fs): Shaft-end load applied perpendicular

to the centerline of the shaft.
2-4
2.1.6 Handling Oil and Water

Install a protective cover over the servomotor if it is used in a location that is subject
to water or oil mist. Also use a servomotor with an oil seal when needed to seal the
through-shaft section.
Install the servomotor with the connector facing down.
Through shaft section
Note: Through sections of the shaft: This refers to the gap where the shaft protrudes from the end of the
motor
2.1.7 Cable Stress

Make sure there are no bends or tension on the power lines.
Be especially careful to wire signal line cables so that they are not subject to stress
because the core wires are very thin, at only 0.0079 to 0.012in. (0.2 to 0.3mm).
2-5
2.2 Servo Amplifiers

The SGDH servo amplifiers are base-mounted servoamps. Incorrect installation will
cause problems. Follow the installation instructions below.
2.2.1 Storage Conditions

Store the servo amplifier within the following temperature range, as long as it is
stored with the power cable disconnected.
-20 to 85°C
YASKAWA
200V
SERVOPACK
SGDH-
MODE/SET DATA/
CHARGE POWER
L1 C
N
L2 3
L3
1
2
C
N
1
L1C
L2C
B1
B2
B3
C
U N
2
V
Sigma II series servo amplifier
2.2.2 Installation Site

The following precautions apply to the installation site.
Situation Installation Precaution
Installation in a Control Design the control panel size, unit layout, and cooling
method so the temperature around the servo amplifier does
Panel not exceed 55°C.
Installation Near a Heat- Minimize heat radiated from the heating unit as well as any
temperature rise caused by natural convection so the tem-
ing Unit perature around the servo amplifier does not exceed 55°C.
Installation Near a Install a vibration isolator beneath the servo amplifier to
Source of Vibration avoid subjecting it to vibration.
Corrosive gas does not have an immediate effect on
Installation at a Site the servo amplifier, but will eventually cause elec-
Exposed to Corrosive tronic components and contactor–related devices to
Gas malfunction. Take appropriate action to avoid corro-
sive gas.
Do not install the servo amplifier in hot and humid
Other Situations locations or locations subject to excessive dust or iron
powder in the air.
2-6
2.2.3 Orientation
Install the servo amplifier perpendicular to the wall as shown in the figure. The
servo amplifier must be oriented this way because it is designed to be cooled by nat-
ural convection or cooling fan.
Secure the servo amplifier using the mounting holes. The number of holes varies
(from two to four) with the frame size of the servo amplifier.
Wall
Ventilation
2.2.4 Installation
Follow the procedure below to install multiple servo amplifiers side by side in a con-
trol panel.
1.97in. (50mm) minimum
1.97in. (50mm) minimum

1.18in. (30mm) 0.39in. (10mm)
minimum minimum
n Servo Amplifier Orientation

Install the servo amplifier perpendicular to the wall so the front panel containing
connectors faces outward.
n Cooling
2-7
As shown in the figure above, allow sufficient space around each servo amplifier for
cooling by cooling fans or natural convection.
n Side-by-side Installation
When installing servo amplifiers side by side as shown in the figure above, allow at
least 0.39in. (10mm) between and at least 1.97in. (50mm) above and below each
servo amplifier. Install cooling fans above the servo amplifiers to avoid excessive
temperature rise and to maintain even temperature inside the control panel.
n Environmental Conditions in the Control Panel
• Ambient Temperature: 0 to 55°C

• Humidity: 90% r.h., or less
• Vibration: 0.5 G (4.9 m/s2)

• Condensation and Freezing: None
• Ambient Temperature for Long-term Reliability: 45°C maximum
2-8
Sigma II User’s Manual Chapter 3: Wiring
3 Wiring
This chapter describes the procedure used to connect Sigma II
Series products to peripheral devices and gives typical examples
of main circuit wiring as well as I/O signal connections.
3.1 Connecting to Peripheral Devices....................................................................... 3-2

3.1.1 Single-Phase (100V or 200V) Main Circuit Specifications....................... 3-3
3.1.2 Three-Phase (200V) Main Circuit Specifications....................................... 3-4
3.2 Servo Amplifier Internal Block Diagrams.......................................................... 3-5
3.2.1 30 to 400W 200V and 30 to 200W 100V Models ...................................... 3-5
3.2.2 0.5kW to 1.5kW 200V Models ................................................................... 3-6
3.2.3 2.0kW and 3.0kW 200V Models ................................................................ 3-6
3.3 Main Circuit Wiring............................................................................................. 3-7
3.3.1 Names and Descriptions of Main Circuit Terminals................................... 3-8
3.3.2 Typical Main Circuit Wiring Example........................................................ 3-9
3.3.3 Cable Specifications and Peripheral Devices ............................................. 3-9
3.3.4 Servo Amplifier Power Losses ................................................................. 3-10
3.3.5 Wiring Main Circuit Terminal Blocks ...................................................... 3-11
3.4 I/O Signals ......................................................................................................... 3-12
3.4.1 Examples of I/O Signal Connections........................................................ 3-13
3.4.2 List of CN1 Terminals .............................................................................. 3-14
3.4.3 I/O Signal Names and Functions .............................................................. 3-15
3.4.4 Interface Circuits....................................................................................... 3-17
3.5 Wiring Encoders ................................................................................................ 3-20
3.5.1 Connecting an Encoder (CN2) and Output Signals from the
Servo Amplifier (CN1) ............................................................................. 3-20
3.5.2 CN2 Encoder Connector Terminal Layout and Types.............................. 3-21
3.6 Examples of Standard Connections .................................................................. 3-22
3.6.1 Single-Phase Power Supply Specifications .............................................. 3-23
3.6.2 Three-Phase Power Supply Specifications ............................................... 3-24
3.6.3 Position Control Mode.............................................................................. 3-25
3.6.4 Speed Control Mode ................................................................................. 3-26
3.6.5 Torque Control Mode................................................................................ 3-27
3-1
3.1 Connecting to Peripheral Devices

This section provides examples of standard Sigma II Series product connections to peripheral
devices.
It also briefly explains how to connect each peripheral device.
3-2
3.1.1 Single-Phase (100V or 200V) Main Circuit Specifications

Host Connect the SGDH servo amplifier
to a Yaskawa host controller or to
Controller one made by another company.
MEMOCON GL120, GL130

with a motion module.
Power supply
Molded-Case Circuit Three-phase 200VAC
Breaker (MCCB)
R S T
Protects the power
line by shutting
OFF the circuit Digital Operator
when overcurrent JUSP-OPO2A-1
is detected.
and JZSP-CMS00-1
(cable)
Allows the user to
set parameters or
MCCB operation references
and to display opera-
tion or alarm status.
Commumication
Noise Filter and control is also
Used to eliminate external possible with a
noise from the power line. personal computer.
Personal Computer
Noise filter
Cable model: YS-12
Magnetic Contactor
HI Series
Turns the servo
ON and OFF.
Install a surge
suppressor on
the magnetic
contactor. Magnetic
Magnetic
contactor contactor
Power
supply
ground Encoder
Brake Power Supply Cable
line
Used for a servomotor Encoder
with a brake. Brake Connector
power
supply
Regenerative
resistor
(optional)
Regenerative Resistor
Connect an external regenerative
resistor to terminals B1 and B2 if
the regenerative capacity is
insufficient.
3-3
3.1.2 Three-Phase (200V) Main Circuit Specifications
Host Connect the SGDH servo amplifier

to a Yaskawa host controller or to
Controller one made by another company.
MEMOCON GL120, GL130

with a motion module.
Power supply
Molded-Case Circuit Three-phase 200VAC
Breaker (MCCB)
R S T
Protects the power Digital Operator
line by shutting JUSP-OPO2A-1
OFF the circuit
when overcurrent and JZSP-CMS00-1
(cable)
is detected.
Allows the user to
set parameters or
operation references
and to display opera-
MCCB tion or alarm status.
Commumication
and control is also
possible with a
Noise Filter personal computer.
Used to eliminate external
noise from the power line. Personal Computer
Noise filter
Cable model: YS-12
Magnetic Contactor
HI Series
Turns the servo
ON and OFF.
Install a surge
suppressor on
the magnetic Magnetic
contactor. contactor Magnetic
contactor
Power
supply
Brake Power Supply ground Encoder
line Cable
Used for a servomotor Brake Encoder
with a brake. power Connector
supply
Regenerative
resistor
(optional)
Regenerative Resistor
Connect an external regenerative
resistor to terminals B1 and B2 if
the regenerative capacity is
insufficient.
3-4
3.2 Servo Amplifier Internal Block Diagrams

The following sections show internal block diagrams of the Servo Amplifiers.
3.2.1 30 to 400W (200V) and 30 to 200W (100V) Models

Single-phase
200 to 230 V +10%
-15%
(50/60Hz) B1 B2 THS1
RY1
PM1-1 D2 D3 D4
PM1-2
P1 P2 AC Servomotor
Noise filter
R7
CHARGE D1 U
FU1 U
R +
L1 C1 V
IMC XX1 V
-
R8 W
T TR1 W
L2
N1 N2
Gate drive over
Relay drive Voltage Gate drive current protector
Sensor
CN2 PG
Voltage
Sensor Interface
Current
L1C + +5V PWM ASIC Sensor For battery
~ + DC/DC generator CN8 connection
+15V
- con
L2C ~ - verter
- Digital cur PG signal
Divider
+5V rent amp processing
CN1
+12V Reference pulse PG output
processing
+5V
Power Power Reference pulse inpu
OFF ON Current
1MC reference A/D Speed/torque
Position
0V calculation control reference input
POWER
1MC Surge Monitor display
suppressor Speed
Analog voltage control
converter
I/O Sequence I/O
Open during servo Serial port CPU
(5RY) alarm CN5 CN3
Serial port
Connection Digital monitor

for optional Analog monitor personal computer
board output for
supervision
Note: The power supply voltage is 100 to 115V (+10% -15%) 50/60Hz) for the 30 to 200W 100V models.
3-5
3.2.2 0.5kW to 1.5kW (200V) Models

Three-phase
+10%
200 to 230 V
(50/60Hz) -15% B1 B2 B3 FAN1
RY1 R2
FU1 D2 D3 D4
+12V
P P AC Servomotor
Noise filter
CHARGE U
IMC
L1 + U
R
XX1 XX3 C1 V
L2 - V
S
L3 W
XX2 T W
N
N
Gate drive over THS1
Relay drive Voltage Gate drive current protector
Sensor
CN2 PG
Voltage
Sensor Interface
*0.5 to 1.0 kW 200-V
models
Current
L1C + +5V ASIC Sensor For battery
PWM
~ + DC/DC generator CN8 connection
+15V
- con
L2C ~ - - verter
Digital cur PG signal
processing Divider
+5V rent amp
+12V CN1
Reference pulse PG output
processing
Reference pulse input

Power Power
OFF ON Current Speed and torque ref
1MC reference Position A/D erence input
calculation control
0V
POWER
suppressor Speed
control
Analog voltage I/O Sequence I/O
converter
(5RY) alarm CN5 CN3
Serial port
Connection Analog monitor
for optional output for Digital monitor
board supervision personal computer
3.2.3 2.0 kW and 3.0kW (200V) Models

Single-phase
200 to 230 V +10%
-15%
(50/60Hz) B1 B2 B3
FAN1
FU1
P P AC Servomotor
Noise filter
+12V
CHARGE U
IMC U
L1
R +
XX1 C1 V
L2 XX3 V
S -
L3 W
XX2 W
T RY1
N
N DB
~~~
Gate drive over
Voltage current protector
Relay drive Gate drive - +
Sensor
CN2 PG
Voltage
Sensor Interface Gate drive
Current
L1C +5V Sensor For battery
~ + PWM ASIC
+ DC/DC generator CN8 connection
+15V
-con
L2C ~ - verter
- Digital cur PG signal Divider
+5V rent amp processing
+12V
CN1
Reference pulse PG output
processing
Reference pulse input

Power Power
OFF ON Current Speed and torque ref
1MC Position
A/D
reference erence input
0V calculation control
POWER
suppressor Speed
control
Analog voltage I/O Sequence I/O
converter
(5RY) alarm CN5 CN3
Serial port
Connection Analog monitor Digital monitor
for optional output for personal computer
board supervision
3-6
3.3 Main Circuit Wiring

This section shows typical examples of main circuit wiring for Sigma II Series servo products,
functions of main circuit terminals, and the power ON sequence.
Observe the following precautions when wiring.
! CAUTION
• Do not bundle or run power and signal lines together in the same duct. Keep power and signal lines
separated by at least 11.81in (30cm)
Not doing so may cause fire or malfunction.
• Use twisted-pair wires or multi-core shielded-pair wires for signal and encoder (PG) feedback
lines.out of control or malfunction.
The maximum length is 118.11in. (3m) for reference input lines and is (787.40in. (20m) out of control or
malfunction.
• Do not touch the power terminals for 5 minutes after turning power OFF because high voltage may
still remain in the servo amplifier.
still remain in the servo amplifier.
• Avoid frequently turning power ON and OFF. Do not turn power ON or OFF more than once per
minute.
Since the servo amplifier has a capacitor in the power supply, a high charging current flows for 0.2 seconds
when power is turned ON. Frequently turning power ON and OFF causes main power devices like capaci-
tors and fuses to deteriorate, resulting in unexpected problems.
• Suitable for use on a circuit capable of delivering not more than 5000ARMS (symmetrical), 240V max-
imum.
Must be used with UL listed fuses or circuit breakers, in accordance with the National Electrical Code.
3-7
3.3.1 Names and Descriptions of Main Circuit Terminals

The following table gives the names and a description of main circuit terminals.
Main Circuit Names and Description
Terminal
Name Description
Symbol
30 to 200W Single-phase 100 to 115V +10%, -15% (50/60Hz)
L1, L2 or L1, Main circuit AC
L2, L3 input terminal 30 to 400W Single-phase 200 to 230V +10%, -15% (50/60Hz)
0.5 to 3.0kW Three-phase 200 to 230V +10%, -15% (50/60Hz)
Servomotor con-
U, V, W nection terminal Connects to the Servomotor.
Control power 30 to 200W Single-phase 100 to 115V +10%, -15% (50/60Hz)

L1C, L2C
input terminal 30 to 3.0kW Single-phase 200 to 230V +10%, -15% (50/60Hz)
Ground terminal Connects to the power supply ground terminals and motor ground terminal.
Normally not connected.

Connect an external regenerative resistor (provided by cus-
30 to 400W tomer) between B1 and B2 if the regenerative capacity is
B1, B2 insufficient.
External regen- Note: No B3 terminal.
or erative resistor Normally short B2 and B3 (for an internal regenerative resis-
terminal tor).
B1, B2, B3 Remove the wire between B2 and B3 and connect an external
0.5 to 3.0kW
regenerative resistor (provided by customer) between B1 and
B2 if the capacity of the internal regenerative resistor is insuf-
ficient.
DC reactor ter-
minal connec-
tion for power Normally short ⊕1 and ⊕2.
⊕1, ⊕2 supply har- If a countermeasure against power supply harmonic waves is needed, con-
monic wave nect a DC reactor between ⊕1 and ⊕2.
countermeasure
Main circuit
Negative termi- Normally not connected.
nal
Main circuit Pos- Normally not connected.
itive terminal
3-8
3.3.2 Typical Main Circuit Wiring Example

The following figure shows a typical example of main circuit wiring.
R S T Servo Amplifier
1MCCB
SGDH-ooAE
A
U
B M
V
FIL C
W
D
L1C
L2C
PG
1MC
L1
L2
L3 CN1
+24V
(For servo alarm display) 31
1Ry ALM 1Ry
1PL
Main Main power supply 0V
power supply ON ALM-SG 32 1D
1Ry 1MC
OFF
1MC 1SUP
1MCCB: Molded–case circuit breaker (for the inverter) 1Ry: Relay

FIL: Noise filter 1PL: Indicator lamp
1MC: Contactor 1SUP: Surge suppressor
1D: Flywheel diode
n Designing a Power ON Sequence

Note the following points when designing the power ON sequence.
Design the power ON sequence so that power is turned OFF when a servo alarm signal is
output. (See the circuit figure above.)
• Hold the power ON button for at least two seconds. The servo amplifier will output a
servo alarm signal for two seconds or less when power is turned ON. This is required
in order to initialize the servo amplifier.
Power Supply
2.0s maximum
Servo alarm (ALM)

output signal
3.3.3 Cable Specifications and Peripheral Devices

Refer to the Sigma II Series Servo System Catalog Supplement (No. G-MI#99001).
3-9
3.3.4 Servo Amplifier Power Losses

The following table shows servo amplifier power losses at the rated output.
Servo Amplifier Power Losses at Rated Output
Maximum
Output Main Control
Applicable Regenerative Total
Main Current Circuit Circuit
Servomot Servo Resistor Power
Circuit (Effective Power Power
or Amplifier Power Loss Loss
Power Value) Loss Loss
Capacity Model
Supply
[W] [W]
[A] [W] [W]
[kW]
0.03 SGDH–A3BE 0.66 3.5 - 13 16.5
Single– 0.05 SGDH–A5BE 0.95 5.2 - 13 18.2
phase
100V 0.10 SGDH–01BE 2.4 12 - 13 25
0.20 SGDH–02BE 3.0 16.4 - 13 29.4
0.03 SGDH–A3AE 0.44 3.1 - 13 16.1
0.05 SGDH–A5AE 0.64 4.6 - 13 17.6
0.10 SGDH–01AE 0.91 6.7 - 13 19.7
Single–
phase 0.20 SGDH–02AE 2.1 13.3 - 13 26.3
200V
0.40 SGDH–04AE 2.8 20 - 13 33
0.75 SGDH–08AE-S 4.4 47 12 15 74
1.50 SGDH–15AE-S 7.5 60 14 15 89
0.50 SGDH–05AE 3.8 27 12 15 54
0.75 SGDH–08AE 5.7 41 12 15 68
Three– 1.0 SGDH–10AE 7.6 55 12 15 82
phase
200V 1.5 SGDH–15AE 11.6 123 14 15 152
2.0 SGDH–20AE 18.5 120 28 15 163
3.0 SGDH–30AE 24.8 155 28 15 198
Note Regenerative resistor power losses are allowable losses. Take the following action if this value is
exceeded:
• Disconnect the internal regenerative resistor in the servo amplifier by removing the wire
between terminals B2 and B3.
• Install an external regenerative resistor between terminals B1 and B2.
External regenerative resistors are optional. See 5.6 Selecting a Regenerative Resistor for more
details on the resistors.
3-10
3.3.5 Wiring Main Circuit Terminal Blocks
Observe the following precautions when wiring main circuit terminal blocks.
! CAUTION
• Remove the terminal block from the servo amplifier prior to wiring.
• Insert only one wire per terminal on the terminal block.
• Make sure that the core wire is not electrically shorted to adjacent core wires.
• Reconnect any wires that were accidentally pulled out.
Servo amplifiers with a capacity below 1.5kW will have connector-type terminal blocks
for main circuit terminals. Follow the procedure below when connecting to the terminal
block.
n Connection Procedure
• Strip the end of the wire, leaving the ends twisted together.
0.31 to 0.35in. (8 to 9mm)
• Open the wire insert opening of the terminal block (plug) with a tool using either of the
two procedures shown in Fig. A and Fig. B on the following page.
1. Fig. A: Use the provided lever to open the wire insert opening .
Fig. B: Using a commercially available 1/8in. (3.0 to 3.5mm) slotted

screwdriver, press down firmly on the screwdriver insert opening
to release the wire insert slot.
Fig. A Fig. B
2. Figs A and B: Insert the wire end into the opening and then clamp it tightly by
releasing either the lever or the screwdriver.
3-11
3.4 I/O Signals
This section describes I/O signals for the SGDH servo amplifier
3-12
3.4.1 Examples of I/O Signal Connections

The following shows a typical example of I/O signal connections.
V-REF 5 37
LPF* ALO1
P Alarm code maximum output:
SG 6 38
ALO2 Operating voltage: 30VDC
A/D
T-REF 9
LPF* 39 Operating current: 20mADC
ALO3
P 10
SG
PULS 150Ω
PULS 7
CW P ~
AØ /PULS 8
33
SIGN PAO
SIGN 11
CCW 34 /PAO
P ~
BØ /SIGN 12
35 PG dividing ratio output
Position CLR 15 PBO Applicable line receiver
reference CLR 36 SN75175 or MC3486
P /PBO
/CLR
~ manufactured by T/I or the
14 equivalent
19
+12V PCO
1kΩ 20
3 /PCO
Open-collector PL1
reference 13
PL2 48
power supply Used only PSO Amount of S-phase rotation
18
PL3 with an 49 Serial data output
absolute encoder /PSO Applicable line receiver
Backup battery 2.8 to 4.5V BAT (+) SN75175 or MC3486
(When using an absolure + 21 1
SG manufactured by T/I or the
P
encoder). - BAT (-) equivalent
22
SEN signal input SEN
4
(When using an absolure +5V P
encoder). SG 2
0V
3.3kΩ
+24VIN 47
+
+24V ~
Servo ON - /S-ON 40
(Servo ON when ON)
~
/P-CON 41
P control
(P control when ON) 25
/V-CMP+ Speed coincidence detection
~
N-OT 43 ~
26 (/COIN+) (ON when speed coincides)
Reverse run prohibited
(Prohibited when OFF) /V-CMP- Positioning completed (ON
~ (/COIN-) when positioning is completed)
P-OT 42
Forward run prohibited 27
(Prohibited when OFF) /TGON+ TGON output
~ ~
/ALM-RST 44 28 (ON at levels above the setting)
Alarm reset /TGON-
(Reset when ON) 29
/S-RDY+ Servo ready output
/N-CL 46
~ ~ (ON when ready)
30
Reverse current limit /S-RDY- Servo alarm output
(Limit when ON) 31
ALM+ (OFF for an alarm)
~ ~
/P-CL 45 32
Forward current limit ALM-
(Limit when ON) Photocoupler maximum output:
Connector shell
Operating voltage: 30VDC
FG Connect shield to
P: Indicates twisted wore pairs. connector shell. Operating current: 50mADC
*The time constant for the primary filter is 47µs
3-13
3.4.2 List of CN1 Terminals

The following diagram shows the layout and specifications of CN1 terminals.
CN1 Terminal Layout
Speed coin-
1 SG GND 26 /V-CMP- cidence
TGON sig- (/COIN-) detection
2 SG GND 27 /TGON+ output
nal output
Open-collec-
3 PL1 tor reference 28 /TGON TGON sig-
SEN signal /S- Servo ready nal output
4 SEN input power supply 29 RDY+ output
Reference Servo ready

5 V–REF speed input Servo alarm 30 /S-RDY output
6 SG GND 31 ALM+ output
Reference PG divided Servo alarm

Reference 7 PULS pulse input 32 ALM output
8 /PULS 33 PAO output
pulse input A-phase
PG divided
9 T–REF Torque refer- PG divided 34 /PAO output
10 SG GND ence input 35 PBO output A-phase
B–phase
Reference PG divided
Reference 11 SIGN sign input Alarm code 36 /PBO output
12 /SIGN symbol input 37 AL01 output B-phase
Open-collec- Alarm code
13 PL2 tor reference Open-collec- 38 AL02 output
14 /CLR Clear input power supply 39 AL03
tor output
15 CLR Clear input 40 /S-ON Servo ON

P operation input
16 — —- 41 P-CON input
Forward
Open-collec- 17 — — Reverse 42 P-OT overtravel
18 PL3 tor reference 43 N–OT overtravel input
power supply input
PG divided /ALM– Alarm reset
PG divided 19 PCO output Forward cur- 44
20 /PCO output 45 /P–CL rent limit ON RST input
C-phase
C-phase input
Reverse
21 BAT (+) Battery (+) External 46 /N–CL current limit
22 BAT (-) Battery (-) 47 +24V input power
-IN ON input
supply
S-phase
23 — — S-phase sig- 48 PSO signal out-
24 — — 49 *PSO nal output put
/V-CMP+ Speed coinci-

25 (/COIN+) dence detec- 50 — —
tion output
Note 1. Do not use unused terminals for relays.

2. Connect the shield of the I/O signal cable to the connector shell.
Connect to the FG (frame ground) at the Servo Amplifier–end connector.
3-14
n CN1 Specifications
Specifications for Applicable Receptacles
Servo Amplifier
Connectors Solder Type Case Manufacturer
10250–52A2JL or
Equivalent 50–p 10150–3000VE 10350–52A0–008 Sumitomo 3M Co.
Right Angle Plug
3.4.3 I/O Signal Names and Functions

The following section describes Servo Amplifier I/O signal names and functions.
n Input Signals
Pin
Signal Name Function Reference
No.
Servo ON: Turns ON the servomotor when the gate block in the inverter is
/S–ON 40 released. 5.5.2
* Function selected via parameter. 5.2.1

5.2.7
Proportional opera- Switches the speed control loop from PI (proportional/ 5.2.1
tion reference integral) to P (proportional) control when ON.
With internal reference speed selected: Switches the
Direction reference direction of rotation. 5.2.6
Position ó Speed
/P–CON 41
Control mode switch- Speed ó Torque
ing
Torque ó Speed } Enables control mode switching 5.2.7
Zero–clamp refer- Speed control with zero–clamp function: Reference

ence speed is zero when ON. 5.4.3
Reference pulse Position control with reference pulse stop: Stops refer- 5.2.10
block ence pulse input when ON.
Common Forward Run prohib- Overtravel prohibited: Stops Servomotor when mov-
P–OT 42 ited able part travels beyond the allowable range of 5.1.2
N–OT 43 Reverse Run prohib- motion.
ited
* Function selected with a parameter. —
Forward current limit
/P–CL 45 ON Current limit function used when ON. 5.1.3
46 Reverse current limit
/N–CL ON
Internal speed switch- With internal reference speed selected: Switches the 5.2.6
ing internal speed settings.
/ALM 44 Alarm reset: Releases the servo alarm state. 5.5.1
–RST
+24VIN 47 Control power supply input for sequence signals: Users must provide the 5.2.4
+24–V power supply.
SEN 4 (2) Initial data request signal when using an absolute encoder. 5.2.3
BATT(+) 21 Connecting pin for the absolute encoder backup battery. 5.2.3
BATT(-) 22
Speed 5 (6) Speed reference input: ±2 to ±10V/rated motor speed (Input gain can be
Reference V–REF
5.2.1
modified with a parameter.)
Torque Torque reference input: ±1 to ±10V/rated motor speed (Input gain can be
Reference T–REF 9 (10) modified with a parameter.) 5.2.1
3-15
Pin
No.
PULS 7 Corresponds to refer- Input mode
/PULS 8 ence pulse input • Code + pulse string 5.2.1
SIGN 11 Line–driver • CCW/CW pulse
/SIGN 12 Open–collector
Position • Two–phase pulse (90° phase differential)
Reference CLR 15
/CLR 14 Error counter clear: Clears the error counter during position control. 5.2.1
PL1 3 +12V pull–up power supply when PULS, SIGN and CLR reference signals
PL2 13 are open–collector outputs (+12V power supply is built into the servo ampli- 5.2.1
PL3 18 fier).
Note 1. The functions allocated to /S–ON, /P–CON. P–OT, N–OT, /ALM–RST, /P–CL, and /N–CL input
signals can be changed with parameters. (See 5.3.3 Input Circuit Signal Allocation.)
2. Pin numbers in parenthesis ( ) indicate signal grounds.
3. The voltage input range for speed and torque references is a maximum of ±12V.
n Output Signals
Pin
Number
ALM+ 31 Servo alarm: Turns OFF when an error is detected. 5.5.1
ALM- 32
/TGON+ 27 Detection during servomotor rotation: Detects whether the servomotor is rotating at a
/TGON- 28 speed higher than the motor speed setting. Motor speed detection can be set via parame- 5.5.5
ter.
/S-RDY+ 29 Servo ready: ON if there is no servo alarm when the control/main circuit power supply is
/S-RDY- 30 turned ON. 5.5.6
PAO 33 (1)
/PAO 34 A phase signal
Common PBO 35 B phase signal Converted two-phase pulse (A and B phase) encoder output signal and
/PBO 36 C phase signal origin pulse (C phase) signal: RS-422 or the equivalent.
PCO 19 5.2.3
/PCO 20
PSO 48 S phase signal With an absolute encoder: Outputs serial data corresponding to the
/PSO 49 number of revolutions (RS-422 or equivalent).
ALO1 37
ALO2 38 Alarm code output: Outputs 3-bit alarm codes.
ALO3 39 (1) Open–collector: 30V and 20mA rating maximum.
5.5.1
FG Shell Connected to frame ground if the shield wire of the I/O signal cable is connected to the
connector shell.
Speed /V-CMP+ 25 Speed coincidence (output in Speed Control Mode): Detects whether the motor speed is 5.5.4
/V-CMP- 26 within the setting range and if it matches the reference speed value.
Positioning completed (output in Position Control Mode): Turns ON when the number of
Position /COIN+ 25 error pulses reaches the value set. The setting is the number of error pulses set in refer- 5.5.3
/COIN- 26 ence units (input pulse units defined by the electronic gear).
16
17 These terminals are not used.
Not used. 23 Do not connect relays to these terminals. —
24
50
Note 1. Pin numbers in parenthesis () indicate signal grounds.
2. The functions allocated to /TGON, /S-RDY, and /V-CMP (/COIN) can be changed via parame-
ters. Functions /CLT, /VCT, /BK, /WARN, and /NEAR signals can also be changed. (See 5.3.4 Out-
put Circuit Signal Allocation).
3-16
3.4.4 Interface Circuits

This section shows examples of servo amplifier I/O signal connection to the host control-
ler.
n Interface for Reference Input Circuits
Analog Input Circuit

Analog signals are either speed or torque reference signals at the impedance below.
• Speed reference input: About 14kΩ
• Torque reference input: About 14kΩ
The maximum allowable voltage for input signals is ±12V.
Servo Amplifier
1.8kΩ (½W) minimum
3 V-REF or
25-HP-10B 2 T-REF
12V
2kΩ
1
About 14kΩ
1000:1 SG
0V
Reference Position Input Circuit

An output circuit for the reference pulse and error counter clear signal at the host control-
ler can be either line-driver or open-collector outputs. These are shown below by type.
Line-driver Output Example:

Host controller end Servo amplifier end
150Ω 4.7kΩ
Applicable line-driver
SN75174 manufactured by
TI, or the equivalent 2.8V ≤ (High level) - (Low level) ≤ 3.7V
• Open–collector Output, Example 1: External power supply

Host
controller end Servo amplifier end
R1
i 150Ω 4.7kΩ
Tr1 VF = 1.5 to 1.8V
3-17
The following examples show how to select the pull-up resistor R1 so the input cur-
rent, I, falls between 7 and 15mA.
Application Examples
R1 = 2.2kΩ with R1 = 1kΩ with R1 = 180Ω with
VCC = 24V ±5% VCC = 12V ±5% VCC = 5V ±5%
• Open-Collector Output, Example 2: Using a servo amplifier with an internal

12V power supply
This circuit uses the 12V power supply built into the servo amplifier. The input
is not isolated in this case. 150Ω 3.3kΩ
Host Servo amplifier end

controller end
PL1, PL2, PL3 terminals
1.0kΩ
150Ω
About
9mA
1.5V maximum V
when ON
n Sequence Input Circuit Interface

The sequence input circuit interface connects through a relay or open-collector tran-
sistor circuit. Select a low-current relay otherwise a faulty contact will result.
Servo amplifier Servo amplifier
24VDC 24VDC
50mA minimum 24VIN 3.3kΩ 50mA minimum 24VIN 3.3kΩ
/S-ON, etc. /S-ON, etc.
n Output Circuit Interfaces

Any of the following three types of servo amplifier output circuits can be used. Con-
nect an input circuit at the host controller following one of these types.
• Connecting to a Line-driver Output Circuit
Encoder serial data converted to two-phase (A and B phase) pulse output signals
(PAO, /PAO, PBO, /PBO), origin pulse signals (PCO, /PCO) and S phase rota-
tion signals (PCO, /PCO) are output via line-driver output circuits that normally
comprise the position control system at the host controller. Connect the line-
driver output circuit through a line receiver circuit at the host controller.
3-18
See 3.5 Wiring to an Encoder for connection circuit examples.

• Connecting to an Open-Collector Output Circuit
Alarm code signals are output from open-collector transistor output circuits.
Connect an open-collector output circuit through a photocoupler, relay, or line receiver
circuit.
5 to 12VDC
Photocoupler 5 to 12VDC
Relay
Servo amplifier Servo amplifier
end end
0V 0V
0V
5 to 12VDC
Servo amplifier
end
P
0V 0V
Note: The maximum allowable voltage and current capacities for open-collector circuits are:
• Voltage: 30VDC
• Current: 20mADC
• Connecting to a Photocoupler Output Circuit

Photocoupler output circuits are used for servo alarm, servo ready, and other sequence
output signal circuits.
Connect a photocoupler output circuit through a relay or line receiver circuit.
5 to 12VDC 5 to 12VDC
Relay
Servo amplifier end Servo amplifier end
0V
0V
Note: The maximum allowable capacities for photocoupler output circuits are:
• Voltage: 30VDC
• Current: 50mADC
3-19
3.5 Wiring Encoders

The following sections describe the procedure for wiring a Servo Amplifier to the encoder.
3.5.1 Connecting an Encoder (CN2) and Output Signals from the Servo
Amplifier (CN1)
The following diagrams show wiring for incremental and absolute encoders.
n Incremental Encoders
Servo amplifier
(Note)
CN1
1-33 P
A phase PAO
Incremental 1-34 /PAO
encoder (Note) P
B phase 1-35 PBO
1-36 /PBO
P CN2 P
C (5) Blue 2-5 C phase 1-19 PCO
D (6) White/blue 2-6 1-20 /PCO
Output line-driver
PG Applicable line
SN75ALS194 manufactured
receiver
by T/I, or the equivalent
SN75175
H (1) Red 2-1 manufactured
PG5V by T/I, or the
G (2) Black 2-2 PG0V equivalent
ov 1-1 SG
0.001in2 ov
(0.33mm2)
J Connector shell
(Shell) Shield wires Connector
shell
n Absolute Encoders
Servo amplifier (Note )
CN1 P
A phase 1-33 PAO
(Note) 1-34 /PAO
Absolute encoder B phase P
1-35 PBO
1-36 /PBO
CN2 P
C phase 1-19
C (5) Blue 2-5 PCO
D (6)White/blue P 2-6 1-20 /PCO
S phase 1-48 PSO
P
PG Output line-driver 1-49 /PSO
SN75ALS194 manufactured Applicable line
by T/I, or the equivalent receiver
SN75175
H (1) Red 2-1 manufactured
2-2 PG5V by T/I, or the
G (2) Black PG0V equivalent
P
1-4 SEN
+5V
0.001in 2
0.001in22 1-2 SG ov
(0.33mm
(33 mm2)) 1-1 SG
ov
P BAT (+)
T (3) Orange 2-3 1-21 +
S (4) White/ 2-4 1-22 BAT (-) P Battery
orange -
J Connector shell
Shield Connector
(Shell) shell
3-20
3.5.2 CN2 Encoder Connector Terminal Layout and Types

The following tables describe CN2 connector terminal layout and types.
n CN2 Connector Terminal Layout
Pin Signal Function Pin Signal Function

1 PG 5V PG power supply +5V 2 PG 0V PG power supply 0V
BAT Battery (+) Battery (-)
3 4 BAT (-)
(+) (For an absolute encoder) (For an absolute encoder)
5 PS PG serial signal input 6 /PS PG serial signal input
n CN2 Connector Models

Applicable Plug (or Socket)
Servo Amplifier Soldered Plug Soldered Plug
Connectors (Servo Amplifier (Servomotor Manufacturer
Connector) Connector)
55100–0600 54280–0600
53460–0611 (Yaskawa number: (Yaskawa number: Molex Japan Co., Ltd.
JZSP-CMP9-1) JZSP-CMP9-2)
Note: 1. FA1394 is the product number for the servo amplifier end plug and the servomotor end socket set from
Molex Japan Co., Ltd.
2.The servomotor-end relay socket connects to the encoder connector for the SGMAH and SGMPH servomo-
tor.
3. The following encoder connectors are for the SGMGH and SGMSH servomotor:
L-shaped plug: MS3108B20-29S

Straight: MS3106B20-29S
Cable clamp: MS3057-12A
Note: Encoder cables are available from Yaskawa. For more details on the cables, see Sigma II Series Servo System
Catalog Supplement (G-MI#99001).
3-21
3.6 Examples of Standard Connections

The following diagrams show examples of standard servo amplifier connections by speci-
fications and type of control.
3-22
3.6.1 Single-Phase Power Supply Specifications
Single-phase 200 to 230VAC or Single-phase 100 to 115VAC

(50/60Hz) (50/60 Hz)
1MCCB
Alarm
Noise filter Power Power processing
OFF ON
1MC
1MC Be sure to attach a surge suppressor to the excitation

SUP coil of the magnetic contactor and relay.
1MC B1 B2 A (1) Servomotor

U
L1 B (2)
V M
L2 W C (3)
D (4)
L1C
L2C Optical
encoder
⊕1
⊕2 CN2 PG
Be sure to
ground. Be sure to prepare the end of
CN1
the shielded wire properly.
V-REF 5 LPF*
Reference speed P
±2 to ±10V/rated motor speed SG 6
A/D 37
T-REF 9 LPF* ALO1 Alarm code maximum output:
Torque reference 38 Operating voltage: 30VDC
±1 to ±10V/rated motor torque P SG 10 ALO2 Operating current: 20mADC
39 ALO3
150Ω
PULS PULS 7
CW P ~
A phase /PULS 8
SIGN SIGN 11
CCW 33 PAO
B phase P ~
34
/SIGN 12 /PAO PG dividing ratio output
Position reference CLR CLR 15 Applicable line receiver
35 PBO
P/CLR 14 ~ SN75175 or MC3486 manufac
36 /PBO tured by T/I or the equivalent
1kΩ +12 V
Open-collector 3 19
reference PL1 PCO
13 20
power supply PL2 /PCO
18 Amount of S-phase rotation
PL3 Used only with 48 PSO Serial data output
an absolute encoder 49
Backup battery 2.8 to 4.5V BAT (+) /PSO Applicable line receiver
+ 21 1 SN75175 or MC3486
(When using an absolure encoder). P SG
- BAT (-) 22 manufactured by T/I or the
equivalent
SEN signal input +5V SEN 4
P
(When using an absolure encoder). SG 2
0V
3.3kΩ
+24V +2 V 47 Speed coincidence detection
25
1Ry Servo ON /V-CMP+ (ON when speed coincides)
/S-ON 40 ~
26 (/COIN+)
Servo ON with 1Ry ON
2Ry Proportional control /V-CMP- Positioning completed
/P-CON 41 (P control) (/COIN-) (ON when positioning is
P control with 2Ry ON
Forward run completed)
P-LS P-OT 42 prohibited 27
Forward run prohibited with /TGON+ TGON output
~
P-LS OPEN Reverse run 28
N-LS N-OT 43 prohibited /TGON- (ON at levels above the setting)
Reverse run prohibited with N-LS
OPEN 29
3Ry /ALM-RST 44 Alarm reset /S-RDY+ Servo ready output
~
Alarm reset with 3Ry ON 30
Forward current /S-RDY- (ON when ready)
6Ry /P-CL limit ON
Reverse current limit ON with 6Ry ON 45 31
Reverse current ALM+ Servo alarm output
7Ry ~
/N-CL 46 limit ON 32 ALM- (OFF with an alarm)
Forward current limit ON with 7Ry ON
Connector shell Photocoupler maximum output:

FG Operating current: 50mADC
*The time constant for the primary filter is 47µs P: Indicates twisted wore pairs.
3-23
3.6.2 Three-Phase Power Supply Specifications

Three-phase 200 to 230VAC
(50/60Hz)
R S T
1MCCB
Alarm
Noise filter Power Power processing
OFF ON
1MC
SUP Be sure to attach a surge suppressor to the excitation

1MC
coil of the magnetic contactor and relay.
1MC B1 B2 B3 Servomotor
U A (1)
L1 B (2)
V M
L2 C (3)
W
L3 D (4)
L1C
L2C Optical
encoder
⊕1
⊕2 CN2 PG
Be sure to
CN1 the shielded wire properly.
Reference speed: V-REF 5 LPF*
±2 to ±10V/rated motor speed (set by parameter) P SG 6
A/D 37
Ttorque reference: T-REF 9 LPF* ALO1 Alarm code maximum output:
±1 to ±10V/rated motor speed (set by parameter) P SG 38 ALO2 Operating voltage: 30VDC
10
39 Operating current: 20mADC
ALO3
150Ω
PULS PULS 7
CW P ~
A phase /PULS 8
SIGN SIGN 11 33
CCW P PAO
B phase /SIGN 12 ~ 34 /PAO PG dividing ratio output
Position reference CLR 15 Applicable line receiver
CLR 35
P ~
PBO SN75175 or MC3486 manufac
/CLR 14 36 /PBO tured by T/I or the equivalent
1kΩ +12 V
Open-collector 3 19
PL1 PCO
reference 20
power supply 13 /PCO
PL2
PL3 48
Used only with PSO Serial data output
49
an absolute encoder /PSO Applicable line receiver
Backup battery 2.8 to 4.5V BAT (+)
+ 21 1 SN75175 or MC3486
P SG
(When using an absolure encoder). - BAT (-) 22 manufactured by T/I or the
equivalent
P
0V
3.3kΩ Speed coincidence detection
+24V +24V 47 (ON when speed coincides)
25 /V-CMP+
1Ry Servo ON (/COIN+) Positioning completed
/S- 40 ~
26
Servo ON with 1Ry ON ON
2Ry /V-CMP- (ON when positioning is
/P-CON 41 Proportional control (P control) (/COIN-) completed)
Forward run
P-LS P-OT 27
Forward run prohibited with 42 prohibited /TGON+ TGON output
P-LS OPEN Reverse run ~
28 (ON at levels above the setting)
N-LS N-OT /TGON-
43 prohibited
OPEN 29 /S-RDY+ Servo ready output
3Ry /ALM-RST 44 Alarm reset
Alarm reset with 3Ry ON ~
30 (ON when ready)
Forward current /S-RDY-
6Ry P-CL limit ON
Reverse current limit ON with 6Ry ON 45 31 ALM+ Servo alarm output
7Ry Reverse current
N-CL 46 limit ON ~ 32 ALM- (OFF with an alarm)

Connect shield to connector shell.
3-24
3.6.3 Position Control Mode
(50/60Hz)
R S T
1MCCB
Power Power Alarm

Noise filter processing
OFF ON
1MC

1MC coil of the magnetic contactor and relay.
1MC B1 B2 B3
U A (1) Servomotor
L1 B (2)
V M
L2 C (3)
W
L3 D (4)
L1C
L2C SGDH Servo Amplifier Optical
⊕1 encoder
⊕2 CN2 PG
Be sure to
CN1
Ttorque reference: T-REF 9

LPF*
±1 to ±10V/rated motor speed (set by parameter) P SG 10 A/D
37
ALO1 Alarm code maximum output:
38 ALO2 Operating voltage: 30VDC
Operating current: 20mADC
39
ALO3
150Ω
PULS PULS 7
CW P ~
A phase /PULS 8
SIGN SIGN 11 33 PAO
CCW P ~
B phase /SIGN 12 34 /PAO
PG dividing ratio output
Position reference CLR CLR 15 Applicable line receiver
35 PBO
P ~ SN75175 or MC3486 manufac
/CLR 14 36 /PBO tured by T/I or the equivalent
*1. +12 V
Open-collector 3 1kΩ 19
reference PL1 PCO
13 20
power supply PL2 /PCO
PL3 48
Used only with PSO
49 Serial data output
BAT (+) 21 an absolute encoder /PSO
Backup battery 2.8 to 4.5V + Applicable line receiver
P 1 SN75175 or MC3486
(When using an absolure encoder). - BAT (-) 22 SG
manufactured by T/I or the
+5V SEN equivalent
SEN signal input 4
P
0V
+24 V 47 3.3kΩ
+24 V 25 Positioning completed
1Ry /COIN+
Servo ON (ON when positioning is
/S-ON 40 ~ 26
Servo ON with 1Ry ON /COIN- completed)
2Ry
/P-CON 41 Proportional control (P control)
P-LS Forward run 27
P-OT 42 prohibited /TGON+ TGON output
Forward run prohibited with ~ 28 (ON at levels above the setting)
P-LS OPEN N-LS Reverse run /TGON-
N-OT 43 prohibited
Reverse run prohibited with N-LS 29
OPEN 3Ry /S-RDY+ Servo ready output
/ALM-RST 44 Alarm reset
~ 30 (ON when ready)
Alarm reset with 3Ry ON /S-RDY-
6Ry Forward current
/P-CL 45 limit ON 31
Reverse current limit ON with 6Ry ON ALM+ Servo alarm output
7Ry Reverse current ~ 32 ALM- (OFF with an alarm)
/N-CL 46 limit ON
FG
Connect shield to connector shell. Operating current: 50mADC
3.6.4 Speed Control Mode

(50/60Hz)
R S T
1MCCB
Noise filter Power Power Alarm

OFF ON processing
1MC

1MC
1MC B1 B2 B3 U A (1) Servomotor

L1 B (2)
V M
L2 C (3)
W
L3 D (4)
L1C
L2C Optical
encoder
⊕1
⊕2 CN2 PG
Be sure to
ground.
CN1 Be sure to prepare the end of
Reference speed: V-REF 5
LPF*
±2 to ±10V/rated motor speed (set by parameter) P SG
6
A/D 37
Ttorque reference: T-REF 9 ALO1 Alarm code maximum output:
LPF*
P SG 38 ALO2 Operating voltage: 30VDC
±2 to ±10V/rated motor speed (set by parameter) 10 Operating current: 20mADC
39
ALO3
33 PAO
34 /PAO PG dividing ratio output
Applicable line receiver
35 PBO SN75175 or MC3486 manufac
36 /PBO tured by T/I or the equivalent
19
PCO
20
/PCO
Amount of S-phase rotation
48
Used only with PSO Serial data output
49
BAT (+) an absolute encoder /PSO Applicable line receiver
Backup battery 2.8 to 4.5V + 21 SN75175 or MC3486
P 1
(When using an absolure encoder). BAT (-) 22 SG manufactured by T/I or the
-
equivalent
P
0V
+24V +24V 47 3.3kΩ
25
1Ry /V-CMP+ Speed coincidence detection
/S-ON 40 Servo ON ~ 26 (ON when speed coincides)
Servo ON with 1Ry ON /V-CMP-
2Ry
/P-CON 41 Proportional control (P control)
P-LS Forward run 27
P-OT 42 prohibited /TGON+ TGON output
Forward run prohibited with
~ 28
P-LS OPEN
N-LS Reverse run /TGON- (ON at levels above the setting)
N-OT 43 prohibited
OPEN 29
3Ry Alarm reset /S-RDY+ Servo ready output
Alarm reset with 3Ry ON /ALM-RST 44 ~ 30 (ON when ready)
Forward current /S-RDY-
6Ry
Reverse current limit ON with 6Ry ON /P-CL 45 limit ON 31
ALM+ Servo alarm output
7Ry Reverse current ~ 32
/N-CL 46 limit ON ALM- (OFF with an alarm)

FG
Connect shield to connector shell. Operating current: 50mADC
3-26
3.6.5 Torque Control Mode

Three-phase 200 to 230 VAC
(50/60 Hz)
R S T
1MCCB
Power Power Alarm

Noise filter OFF ON processing
1MC

1MC
1MC B1 B2 B3
U A (1) Servomotor
L1 B (2)
V M
L2 C (3)
W
L3 D (4)
L1C
L2C Optical
⊕1 encoder
⊕2 CN2 PG
Be sure to
External speed control: ground.
CN1 Be sure to prepare the end of
±2 to ±10V/rated motor speed (set by parameter) the shielded wire properly.
V-REF 5 LPF*
P
SG 6
A/D 37
T-REF 9 ALO1 Alarm code maximum output:
External torque control: LPF*
P SG 38 ALO2 Operating voltage: 30VDC
±2 to ±10V/rated motor speed (set by parameter) 10
Operating current: 20mADC
39
ALO3
33 PAO
34 /PAO
PG dividing ratio output
35 PBO Applicable line receiver
36 SN75175 or MC3486 manufac
/PBO tured by T/I or the equivalent
19
PCO
20
/PCO
Used only with 48 Amount of S-phase rotation

PSO
49 Serial data output
Backup battery 2.8 to 4.5V BAT (+) an absolute encoder /PSO
+ 21 Applicable line receiver
P 1 SN75175 or MC3486
(When using an absolure encoder). - BAT (-) 22 SG
manufactured by T/I or the
SEN signal input +5V SEN 4 equivalent
P
0V
3.3kΩ
+24V +24V 47 25
/VLT+ Speed control output *6.
1Ry Servo ON ~ 26
/S-ON 40 /VLT- (ON during speed control)
Servo ON with 1Ry ON
2Ry /P-CON Proportional control
41 (P control)
Forward run 27
P-LS P-OT 42 /TGON+ TGON output
Forward run prohibited with prohibited ~ 28
P-LS OPEN (ON at levels above the setting)
Reverse run /TGON-
N-LS N-OT 43
Reverse run prohibited with N-LS prohibited 29
OPEN 3Ry /ALM-RST 44 /S-RDY+ Servo ready output
Alarm reset ~ 30 (ON when ready)
Alarm reset with 3Ry ON /S-RDY-
6Ry Forward current
/P-CL 45 limit ON 31
Reverse current limit ON with 6Ry ON ALM+ Servo alarm output
Reverse current ~ 32 (OFF with an alarm)
7Ry /N-CL 46 ALM-
Forward current limit ON with 7Ry ON limit ON
Connect shield to connector shell.
3-27
Sigma II User’s Manual Chapter 4: Trial Operation
4 Trial Operation
This chapter describes a two-step trial operation. Be sure to

complete step 1 before proceeding to step 2.
4.1 Two-Step Trial Operation .................................................................................... 4-2

4.1.1 Step 1: Trial Operation for Servomotor without Load................................ 4-3
4.1.2 Step 2: Trial Operation with the Servomotor Connected to the Machine.. 4-9
4.2 Supplementary Information on Trial Operation................................................ 4-10
4.2.1 Servomotors with Brakes.......................................................................... 4-10
4.2.2 Position Control by Host Controller ......................................................... 4-11
4.3 Minimum Parameters and Input Signals........................................................... 4-11
4.3.1 Parameters................................................................................................. 4-11
4.3.2 Input Signals ............................................................................................. 4-12
4-1
4.1 Two-Step Trial Operation

Make sure that all wiring is completed prior to starting trial operation.
Perform the trial operation in the order given below (step 1 and 2) for your safety. See
4.1.1 and 4.1.2 for more details on the trial operation.
Step 1: Trial Operation for Servomotor without Load
Make sure the servomotor is wired properly and then turn the
shaft prior to connecting the servomotor to the equipment.
YASKAWA 200V
SERVOPACK
SGDM-
MODE/SET DATA/
CHARGE POWER
L1 C
N
L2 3
C
L1C N
1
L2C
B1
B2
V
C
W N
2
Check wiring.
Do not connect to the equipment.
Step 2: Trial Operation with the Equipment and Servomotor Connected
Adjust the servomotor according to equipment characteristics.

Connect the servomotor to the equipment, and perform the trial
operation.
Adjust speed by autotuning.
SGMoH
SGDH servomotor
servo
amplifier
Connect to the equipment.
4-2
4.1.1 Step 1: Trial Operation for Servomotor without Load
! CAUTION
• Do not operate the servomotor while it is connected to the equipment.
To prevent accidents, initially perform step 1 where the trial operation is conducted under no-load conditions
(with all couplings and belts disconnected).
In step 1, make sure that the servomotor is wired properly as shown below. Incorrect
wiring is generally the reason why servomotors fail to operate properly during trial
operation.
• Check main power supply circuit wiring.
• Check servomotor wiring.
• Check CN1 I/O signal wiring.
Make sure the host controller and other adjustments are completed as much as possi-
ble in step 1 (prior to connecting the servomotor to equipment).
YASKAWA 200V
SERVOPACK
SGDH-
MODE/SET DATA/
CHARGE POWER
L1 C
N
L2 3
1
2
C
L1C N
L2C 1
B1
B2
V
C
W N
2
Check wiring.
Do not connect to the equipment.
Note Check the items on the following pages in the order given during the servomotor trial operation.
See 4.2.1 Servomotors with Brakes, if you are using a servomotor with brakes.
4-3
1. Secure the servomotor.

Secure the mounting plate of the
servomotor to the equipment.
Do not connect anything to the sha

(no-load conditions).
Secure the servomotor mounting plate to the equipment in order to prevent the
servomotor from moving during operation.
2. Check the wiring.
YASKAWA 200V
SERVOPACK
SGDH
-
MODE/SET DATA/
CHARGE POWER
L1 C
N
L2
3
L3
1
2
C
N
1
L1C
L2C
B1
B2
B3
C
U N
2
V
Disconnect the CN1

connector.
Disconnect the CN1 connector and check servomotor wiring in the power supply
circuit. The CN1 I/O signals are not used, so leave the connector disconnected.
3. Turn ON power.
Normal display
Alternate display
Example of Alarm Display
Turn ON servo amplifier power. If the servo amplifier has turned ON normally,
the LED display on the front panel of the servo amplifier will appear as shown
above. Power is not supplied to the servomotor because the servo is OFF.
If an alarm display appears on the LED indicator as shown above, the power sup-
ply circuit, servomotor wiring, or encoder wiring is incorrect. In this case, turn
OFF power and take appropriate action. See 9.2 Troubleshooting.
Note If an absolute encoder is used, it must be set up. Refer to 5.7.4 Absolute Encoder Setup.
4-4
4. Operate with the Panel Operator.

YASKAWA 200V
SERVOPACK
SGDH-
Panel operator
MODE/SET DATA/
CHARGE POWER
Operate the servomotor using the Panel Operator. Check to see if the servomotor runs
normally.
See 7.2.2 Operation Using the Digital Operator for more details on the procedure.
5. Connect the signal lines.
YASKAWA
200V
SERVOPACK
SGDH-
MODE/SET DATA/
CHARGE POWER
L1 C
N
L2 3
L3
1
2
C
N
1
L1C
L2C
B1
B2
B3
C
U N
2
V
Connect the
CN1 connector.
Use the following procedure to connect the CN1 connector.

a) Turn OFF power.
b) Connect the CN1 connector.
c) Turn ON power again.
6. Check the input signals.
Check input signal wiring in Monitor Mode using the panel operator. See 7.1.7 Opera-
tion in Monitor Mode for more details on the procedure.
Turn ON and OFF each signal line to see if the LED monitor bit display on the panel
changes as shown below.
Input signal LED display
P-OT /P-CON
N-OT /S-ON
Top lights: ON = high level
Bottom lights: ON = low level
/ALM-RST
/P-CL
/N-CL
SEN
4-5
Input Signal Status LED Display

OFF (high level) Top LED indicators light.
ON (low level) Bottom LED indicators light.
Note: The servomotor will not operate properly if the following signal lines are not wired correctly. Always
wire them correctly. Short the signal lines if they will be unused. The input signal selections (param-
eters Pn50A to Pn50D) can be used to eliminate the need for external short circuiting.
Signal Connector Pin

Description
Symbol No.
The servomotor can rotate in the forward
P-OT CN1-42
direction when this signal line is low (0V).
The servomotor can rotate in the reverse
N-OT CN1-43
direction when this signal line is low (0V).
The servomotor is turned ON when this signal
/S-ON CN1-40
line is low (0V). Leave the servomotor OFF.
Control power supply terminal for sequence
+24VIN CN1-47
signals.
Note: IF an absolute encoder is being used, the servo will not turn ON when the servo ON signal (/S-ON) is
input unless the SEN signal is also ON.
When the SEN signal is checked in monitor mode, the top of the LED will light because the SEN sig-
nal is high when ON.
7. Turn ON the servo.

Servo amplifier
Servomotor
/S-ON
CN1-40
0V
Turns ON the servo.
Turn ON the servo using the following procedure.

a. Make sure there are no reference signals input.
• Set V-REF (CN1-5) and T-REF (CN1-9) to 0V for speed and torque
control.
• Set PULS (CN1-7) and SIGN (CN1-11) to low for position control.
4-6
b. Turn ON the servo ON signal.

Display with the servo ON.
Set /S-ON (CN1-40) to 0V. If normal, the servomotor will turn ON and the LED
indicator on the front panel will display as shown above. If an alarm display
appears, take appropriate action as described in 9.2 Troubleshooting.
Note: If there is noise in the reference voltage for speed control, the “-” on the left of the 7-segment LED may flash.
n Operating Using Reference Input

The operating procedure here depends on the parameter settings (control mode selection at
memory switch Pn000.1). Use the following procedure for operations with speed and posi-
tion control.
Operating Procedure in Speed Control Mode: Set Pn000.1 to 0

Standard speed control setting is described here.
Servopack
Servomotor
V-REF
(CN1-5)
SG
(CN1-6)
Servomotor rotates at a speed proportiona
to the reference voltage.
1. Gradually increase the reference speed input (V-REF, CN1-5) voltage. The servomotor
will rotate.
2. Check the following items in Monitor Mode. See 7.1.7 Operation in Monitor Mode.
Un000 Actual motor speed

Un001 Reference speed
• Has the reference speed been input?

• Is the motor speed as designed?
• Does the reference speed coincide with the actual motor speed?
• Does the servomotor stop when the speed reference is 0?
3. If the servomotor rotates at extremely slow speed with 0V specified for the reference
voltage, correct the reference offset value as described in 7.2.3 Automatic Adjustment of
Speed and Torque Reference Offset or 7.2.4 Manual Adjustment of Speed and Torque
Reference Offset.
4-7
4. Reset the following parameters to change the motor speed or direction of rota-
tion.
Sets the reference speed input gain
Pn300
See 5.2.1 Speed Reference.
Selects the rotation direction.
Pn000.0 See 5.1.1 Switching Servomotor Rota-
tion Direction.
Operating Procedure in Position Control Mode: Set Pn000.1 to 1

1. Set the parameter Pn200.0 so the reference pulse form is the same as the host
controller output form.
Selecting the reference pulse form: See 5.2.2 Position Reference.
2. Input a slow speed pulse from the host controller and execute low-speed opera-
tion.
Host controller Servo amplifier
Servomotor
PULS (CN1-7)
Reference
pulse /PULS (CN1-8)
SIGN
(CN1-11)
/SIGN
(CN1-12)
3. Check the following data in Monitor Mode. See 7.1.7 Operation in Monitor
Mode.
Un000 Actual motor speed
Un007 Reference pulse speed display
Un008 Position offset
• Has the reference pulse been input?
• Is the motor speed as designed?
• Does the reference speed coincide with the actual motor speed?
• Does the servomotor stop when the speed reference is 0?
4. Reset the parameters shown below to change the motor speed or direction of
rotation.
Electronic gear ratio

Pn202, Pn203
See 5.2.5 Using the Electronic Gear Function.
Selects the direction of rotation.
Pn000.0
See 5.1.1 Switching Servomotor Rotation Direction.
If an alarm occurs or the servomotor fails to operate during the above operation,
CN1 connector wiring is incorrect or parameter settings do not match the host
controller specifications. Check the wiring and review the parameter settings,
then repeat step 1.
Note: References
4-8
• List of Alarms: See 9.2.3 Alarm Display Table.

• List of Parameters: See Appendix B List of Parameters.
4.1.2 Step 2: Trial Operation with the Servomotor Connected to the Machine
! WARNING
Follow the procedure below for step 2 operation precisely as given.
Malfunctions that occur after the servomotor is connected to the equipment not only damage the equipment,
but may also cause an accident resulting in death or injury.
Before proceeding to step 2, repeat step 1 (servomotor trial operation without a load) until
all concerns including parameters and wiring have fully satisfied expectations.
After step 1 has been completed, proceed to step 2 for trial operation with the servomotor
connected to the equipment. The servo amplifier is now adjusted in the following ways to
meet the specific equipment’s characteristics.
• Using autotuning to match the servo amplifier to the equipment’s characteristics.
• Matching the direction of rotation and speed to the equipment’s specifications.
• Checking the final control form.
SGDH Servomotor
servo
amplifier
Connect to the machine.
Follow the procedures below to perform the trial operation.

1. Make sure power is OFF.
2. Connect the servomotor to the equipment.
See 2.1 Servomotors for more details on connecting the servomotor.
3. Use autotuning to match the servo amplifier to equipment characteristics.
See 6.3 Autotuning.
4. Operate the servomotor by reference input.
As in step 1 (Servomotor trial operation with no–load), execute operation by reference
input as described in 4.1.1 Step 1: Servomotor Trial Operation. Tune to match the host
controller at this time, as well.
5. Set and record user settings.
Set parameters as required and record all settings for use later in maintenance.
Note: The servomotor will not be broken in completely during the trial operation. Therefore, let the system run for a
sufficient amount of time after the trial operation has been completed to ensure that it is properly broken in.
4-9
4.2 Supplementary Information on Trial Operation

Always refer to this information before starting trial operation in the following instances:
4.2.1 Servomotor with Brakes
4.2.2 Position Control by Host Controller
4.2.1 Servomotors with Brakes

Use servomotors with brakes for vertical shaft applications or when external force
must be applied to the shaft to prevent rotation due to gravity or external force dur-
ing a power loss.
The servo amplifier uses the brake interlock output (/BK) signal to control the hold-
ing brake operation when using servomotors with brakes.
•Vertical shaft •Shaft with external force applied
Servomotor
Holding brake External Servomotor

force
Prevents the
servomotor from
rotating due to gravity.
Note: To prevent faulty operation due to gravity or external force, first make sure that both the servomotor
and holding brake work properly when . When assured that each operates properly, connect the ser-
vomotor to the rest of the equipment to start the trial operation.
The following figure shows wiring for a servomotor with brakes. See 5.4.4 Using
the Holding Brake for details on wiring.
Power supply Servomotor with brakes

Three-phase 200V SGDH Encoder
L1,L2,L3 Servo
amplifier U,V,W
M PG
CN2
Magnetic contactor
Single-phase
200V 90VDC
Brake control relay Brake power supply
4-10
4.2.2 Position Control by Host Controller

If position control from the host controller has not been confirmed, disconnect the servomo-
tor from the equipment and perform a trial operation, otherwise the servomotor may run out
of control.
Reference
speed
SGDH
Host servo M
controller amplifier
Trial operation for
Speed control servomotor without loa
Position control
Check servomotor operation as described in the following table.
Controller
Check Procedure Description
Reference
JOG Operation Check motor speed as follows:

• Use the speed monitor (Un000) on the Panel
(Constant Operator. Check the parameter setting
Reference Speed Motor speed • Run the servomotor at low speed. Input a ref- at Pn300 to see if the refer-
Input from Host Con- erence speed of 60rpm, for example, to see if ence speed gain is correct.
troller) the servomotor makes one revolution per sec-
ond.
Input a reference equivalent to one servomotor Check the parameter setting
Simple Number of motor rotation and visually check to see if the shaft at Pn201 to see if the number
Positioning rotations makes one revolution. of dividing pulses is correct.
Overtravel Whether the servomotor stops Check to see if the servomotor stops when P-OT Review P-OT and N-OT wiring
(P-OT and rotating when P-OT and N-OT and N-OT signals are input during continuous ser- if the servomotor does not
N-OT Used) signals are applied vomotor operation. stop.
Overtravel Whether the servomotor stops Check to see if the servomotor stops when P-OT Review P-OT and N-OT wiring
(P-OT and rotating when P-OT and N-OT and N-OT signals are input during continuous ser- if the servomotor does not
N-OT Used) signals are applied vomotor operation. stop.
4.3 Minimum Parameters and Input Signals

This section describes the minimum parameters and input signals required for trial operation.
4.3.1 Parameters
See 7.1.6 Operation in parameter Setting Mode for more details on setting parameters.
Turn OFF power once after changing any parameter except Pn300. The change will be valid
when power is restored.
4-11
Basic Parameters
Pn000.1 Function Selection Basic Switches: Control Method Selection See 5.3.5
Speed Control
Pn300 Speed Reference Input Gain See 5.2.1
Pn201 PG Divider See 5.2.3
Position Control
Pn200.0 Reference Pulse Form See 5.2.2
Pn202 Electronic Gear Ratio (Numerator) See 5.2.5
Pn203 Electronic Gear Ratio (Denominator) See 5.2.5
Changing Servomotor Rotation Direction

The wiring may be incorrect if the specified direction of rotation differs from the
actual direction of rotation. Recheck the wiring and correct if necessary. Use the
following parameter to reverse the direction of rotation.
Pn000.0 Function Selection Basic Switches: Direction Selection See 5.1.1
4.3.2 Input Signals

Refer to the specified section of this manual for details on each input signal.
Input signal selection settings through parameters can be used to eliminate the need
for external short circuits.
Pin
Signal Name Description
Number
/S-ON Servo ON CN1-40 See 5.5.2 for more details on turning ON

and OFF the servomotor.
P-OT Forward run prohibited CN1-42 See 5.1.2 for more details on the overtravel
N-OT Reverse run prohibited CN1-43 limit switch.
4-12
Sigma II User’s Manual Chapter 5: Parameter Settings and Functions
5 Parameter Settings and Functions

This chapter describes the procedure for setting and applying
parameters.
5.1 Settings According to Device Characteristics .................................................... 5-4
5.1.1 Switching Servomotor Rotation Direction ................................................. 5-4
5.1.2 Setting the Overtravel Limit Function ........................................................ 5-5
5.1.3 Limiting Torques......................................................................................... 5-9
5.2 Settings According to Host Controller.............................................................. 5-14
5.2.1 Speed Reference ....................................................................................... 5-14
5.2.2 Position Reference .................................................................................... 5-16
5.2.3 Using the Encoder Signal Output ............................................................. 5-22
5.2.4 Sequence I/O Signals ................................................................................ 5-25
5.2.5 Using the Electronic Gear Function.......................................................... 5-28
5.2.6 Contact Input Speed Control..................................................................... 5-32
5.2.7 Using Torque Control ............................................................................... 5-38
5.2.8 Torque Feed–forward Function................................................................. 5-44
5.2.9 Torque Limiting by Analog Voltage Reference ........................................ 5-46
5.2.10 Reference Pulse Inhibit Function (INHIBIT) ........................................... 5-48
5.3 Setting Up the Servo Amplifier ......................................................................... 5-49
5.3.1 Parameters................................................................................................. 5-49
5.3.2 JOG Speed ................................................................................................ 5-49
5.3.3 Input Circuit Signal Allocation................................................................. 5-50
5.3.4 Output Circuit Signal Allocation .............................................................. 5-54
5.3.5 Control Mode Selection ............................................................................ 5-57
5.4 Setting Stop Functions ....................................................................................... 5-60
5.4.1 Adjusting Offset........................................................................................ 5-60
5.4.2 Using the Dynamic Brake......................................................................... 5-61
5.4.3 Using the Zero Clamp Function................................................................ 5-62
5.4.4 Using the Holding Brake .......................................................................... 5-64
5.5 Forming a Protective Sequence ........................................................................ 5-69
5.5.1 Using Servo Alarm and Alarm Code Outputs .......................................... 5-69
5-1
5.5.2 Using the Servo ON Input Signal ............................................................. 5-71

5.5.3 Using the Positioning Completed Output Signal...................................... 5-72
5.5.4 Speed Coincidence Output........................................................................ 5-74
5.5.5 Using the Running Output Signal ............................................................. 5-75
5.5.6 Using the Servo Ready Output Signal ...................................................... 5-76
5.5.7 Using the Warning Output Signal ............................................................. 5-77
5.5.8 Using the Near Output Signal ................................................................... 5-79
5.5.9 Handling Power Loss................................................................................ 5-80
5.6 Selecting a Regenerative Resistor..................................................................... 5-82
5.6.1 External Regenerative Resistor................................................................. 5-84
5.6.2 Calculating the Required Capacity of Regenerative Resistors ................. 5-86
5.7 Absolute Encoders ............................................................................................. 5-90
5.7.1 Interface Circuit ........................................................................................ 5-90
5.7.2 Selecting an Absolute Encoder ................................................................. 5-91
5.7.3 Handling Batteries .................................................................................... 5-92
5.7.4 Absolute Encoder Setup............................................................................ 5-93
5.7.5 Absolute Encoder Reception Sequence .................................................... 5-97
5.8 Special Wiring.................................................................................................. 5-102
5.8.1 Wiring Precautions.................................................................................. 5-102
5.8.2 Wiring for Noise Control ........................................................................ 5-104
5.8.3 Using More Than One Servodrive.......................................................... 5-109
5.8.4 Extending Encoder Cables...................................................................... 5-110
5.8.5 400V Power Supply Voltage................................................................... 5-112
5.8.6 Reactor for Harmonic Suppression......................................................... 5-113
5.9 Reserved Parameters........................................................................................ 5-114
5-2
n Before Reading this Chapter

This chapter describes the use of each CN1 connector I/O signals in the SGDH servo
amplifier as well as the procedure for setting the related parameters for the intended pur-
poses.
The following sections can be used as references for this chapter.
• List of CN1 I/O signals: See 3.4.3 I/O Signal Names and Functions.
• CN1 I/O signal terminal layout See 3.4.2 List of CN1 Terminals.
• List of parameters: Appendix Appendix B List of Parameters.
• Parameter setting procedure: 7.1.6 Operation in Parameter Setting Mode
The CN1 connector is used to exchange signals with the host controller and external cir-
cuits.
n Parameter Configurations
Parameters are comprised of the types shown in the following table. See Appendix B List
of Parameters.
Type Parameter Number Description

Select basic and application functions such as the
Function Selection Constants Pn000 to Pn003 type of control or the stop mode used when an alarm
occurs.
Servo Gain and Other Con- Pn100 to Pn123 Set numerical values such as speed and position
stants loop gains.
Set position control parameters such as the refer-
Position Control Constants Pn200 to Pn208 ence pulse input form and gear ratio.
Set speed control parameters such as speed refer-
Speed Control Constants Pn300 to Pn308 ence input gain and soft start deceleration time.
Torque Control Constants Pn400 to Pn409 Set torque control parameters such as the torque ref-
erence input gain and forward/reverse torque limits.
Set output conditions for all sequence signals and
Sequence Constants Pn500 to Pn512 changes I/O signal selections and allocations.
Specify the capacity for an external regenerative
Others Pn600 to Pn601 resistor and reserved constants.
Auxiliary Function Execution Fn000 to Fn013 Execute auxiliary functions such as JOG Mode oper-
ation.
Enable speed and torque reference monitoring, as
Monitor Modes Un000 to Un00D well as monitoring to check whether I/O signals are
ON or OFF.
5-3
5.1 Settings According to Device Characteristics

This section describes the procedure for setting parameters according to the dimensions
and performance of the equipment used.
5.1.1 Switching Servomotor Rotation Direction

The servo amplifier has a Reverse Rotation Mode that reverses the direction of ser-
vomotor rotation without rewiring. Forward rotation in the standard setting is
defined as counterclockwise as viewed from the load.
With the Reverse Rotation Mode, the direction of servomotor rotation can be
reversed without changing other parameters. Only the direction (+, −) of shaft
motion is reversed.
Standard Setting Reverse Rotation Mode
Encoder output from Encoder output from

servo amplifier servo amplifier
Forward Reference PAO (Phase A) PAO (Phase A)
PAO (Phase B) PAO (Phase B)
Encoder output from Encoder output from

servo amplifier servo amplifier
Reverse Reference PAO (Phase A) PAO (Phase A)
PAO (Phase B) PAO (Phase B)
n Setting Reverse Rotation Mode

Use the parameter Pn000.0.
Parameter Signal Setting Control Mode

Speed/Torque Control,
Pn000.0 Direction Selection Default Setting: 0 Position Control
Use the following settings to select the direction of servomotor rotation.
Setting Description
0 Forward rotation is defined as counterclockwise (Standard setting)

(CCW) rotation as viewed from the load.
Forward rotation is defined as clockwise (CW)
1 rotation as viewed from the load. (Reverse Rotation Mode)
5-4
5.1.2 Setting the Overtravel Limit Function

The overtravel limit function forces movable equipment parts to stop if they exceed
the allowable range of motion.
n Using the Overtravel Function

To use the overtravel function, connect the overtravel limit switch input signal termi-
nals shown below to the correct pins of the servo amplifier CN1 connector.
Forward Run Prohibited Speed/Torque Control,

Input ð P-OT CN1-42
(Forward Overtravel) Position Control
Reverse Run Prohibited Speed/Torque Control,
Input ð N-OT CN1-43
(Reverse Overtravel) Position Control
Connect limit switches as shown below to prevent damage to the devices during lin-
ear motion.
Reverse rotation end Forward rotation end
Servomotor
Limit Limit
switch switch
Servo Amplifier
P-OT
CN1-42
N-OT
CN1-43
Drive status with an input signal ON or OFF is shown in the following table.
Signal State Input Level Description
ON CN1-42: low Forward rotation allowed, (normal

operation status).
P-OT
OFF CN1-42: high Forward run prohibited (reverse rota-
tion allowed).
Reverse rotation allowed, (normal
ON CN1-43: low operation status).
N-OT
OFF CN1-43: high Reverse run prohibited (forward rota-
tion allowed).
5-5
n Enabling/Disabling Input Signals

Set the following parameters to specify whether input signals are used for overtravel
or not. The default setting is “used.”
Pn50A.3 P-OT Signal Mapping Default Setting: 2 Speed/Torque Control,

(Forward Run Prohibit Input Signal) Position Control
Pn50B.0 N-OT Signal Mapping Default Setting: 3 Speed/Torque Control,

(Reverse Run Prohibit Input Signal) Position Control
Servo Amplifier
CN1-42
(P-OT) The short-circuit wiring shown in the figure can be
omitted when P-OT and N-OT are not used.
CN-43
(N-OT)
0V
Parameter Signal Setting Description

Uses the P-OT input signal to prevent forward
rotation. (Forward rotation is prohibited when
Default Setting: 2 CN1-42 is open and is allowed when CN1-42 is
P-OT Signal Mapping at 0V).
Pn50A.3 (Forward Run Prohibit
Input Signal) Does not use the P-OT input signal to prevent
forward rotation. (Forward rotation is always
8 allowed and has the same effect as shorting
CN1-42 to 0V).
Uses the N-OT input signal to prevent reverse
Default Setting: 3 rotation. (Reverse rotation is prohibited when
CN1-43 is open and is allowed when CN1-43 is
N-OT Signal Mapping at 0V).
Pn50B.0 (Reverse Run Pro-
hibit Input Signal) Does not use the N-OT input signal to prevent
reverse rotation. (Reverse rotation is always
8 allowed and has the same effect as shorting
CN1-43 to 0V).
n Servomotor Stop Mode for P-OT and N-OT Input Signals

Set the following parameters to specify the Servomotor Stop Mode when P-OT and
N-OT input signals are used.
Specify the Servomotor Stop Mode when either of the following signals is input dur-
ing servomotor operation.
• Forward run prohibited input (P-OT,CN1-42)
• Reverse run prohibited input (N-OT,CN1-43)
5-6
Pn001.1 Overtravel Stop Mode Default Setting: 0 Speed/Torque Control,

Position Control
Overtravel Stop Mode After stopping Pn001.1

setting
Pn001.0 = 0, 1 Stop by dynamic
brake
Pn001.1 = 0 Coast 0
status
2 Coast to a stop
Zero clamp 1
Pn001.1 = 1 or 2
Decelerate to a
stop
Coast status 2
Note: For torque control, the servomotor will be placed in coast status after either decelerating or coasting
to a stop (according to the stop mode set in Pn001.0), regardless of the setting of Pn001.1.
0 Stops the servomotor the same way as turning the servo

OFF (according to Pn001.0).
Decelerates the servomotor to a stop at the preset torque,
1 and then locks the servomotor in Zero Clamp Mode.
Pn001.1 Overtravel Stop Mode Torque setting: Pn406 emergency stop torque
Decelerates the servomotor to a stop at the preset torque,
2 and puts the servomotor in coast status.
Torque setting: Pn406 emergency stop torque
Pn406 specifies the stop torque applied for overtravel when the input signal for pro-
hibiting forward or reverse rotation is used.
The torque limit is specified as a percentage of rated torque.
Setting
Parameter Signal Control Mode
(%)
Range: 0% to Maximum
Pn406 Emergency Stop Torque Torque Speed/Torque Control,
(Valid when Pn001.1 is 1 or 2) Default Setting: 800 Position Control
5-7
Stop Mode
Stop by dynamic brake
Forward run
prohibit input
P-OT (CN1-42) Coast to a stop
Reverse run Decelerate to a stop

prohibit input
N-OT (CN1-43)
Max. torque setting for an
emergency stop
Pn406
n Servo OFF Stop Mode Selection

The SGDH servo amplifier turns OFF under the following conditions:
• Servo ON input signal (/S-ON, CN1-40) is turned OFF.
• Servo alarm occurs.
• Power is turned OFF.
Specify the Stop Mode if any of these occurs during operation.

Servo OFF or Speed/Torque Control,
Pn001.0 Alarm Stop Mode Default Setting: 0 Position Control
Servo Stop Mode After stopping

OFF
0 Hold with
Pn001.0 = 0 dynamic brake
or 1
Stop by dynamic
brake The dynamic brake stops the servomotor
electrically by shorting the motor windings
1 Coast status and diverting the energy to a resistor.
Pn001.0 = 2 Coast to a stop Coast status

Uses the dynamic brake to stop the
Default Setting: 0 servomotor, and maintains dynamic
brake status after stopping.
Uses the dynamic brake to stop the
Servo OFF or servomotor, and cancels dynamic
Pn001.0 Alarm Stop Mode 1 brake status after stopping to go into
coast status.
Coasts the servomotor to a stop. The
2 servomotor is turned OFF and stops
due to equipment friction.
Note: If the Servomotor is stopped or rotating at extremely low speed when the items above are set at 0
(dynamic brake status after stopping with the dynamic brake), then braking power is not generated
and the servomotor will stop the same as in coast status.
5-8
5.1.3 Limiting Torques

The SGDH servo amplifier limits torques as follows:
• Level 1: Limits maximum output torque to protect the equipment or workpiece.
• Level 2: Limits torque after the servomotor moves the equipment to a specified
position (internal torque limit).
• Level 3: Always limits output torque rather than speed.
• Level 4: Switches between speed and torque limit.
Application of levels 1 and 2 in the torque limit function are described below.
n Setting Level 1: Internal Torque Limits

Maximum torque is limited to the values set in the following parameters.
Setting
(%)
Pn402 Forward Torque Limit Range: 0 to 800 Speed/Torque Control,

Default Setting: 800 Position Control
Pn403 Reverse Torque Limit Range: 0 to 800 Speed/Torque Control,

Sets the maximum torque limits for forward and reverse rotation.
Used when torque must be limited due to equipment conditions.
The torque limit function always monitors torque and outputs the signals
below when the limit is reached.
The following signals are output by the torque limit function.
Signal Description
/CLT Generated when Pn50F.0 allocates an output terminal from SO1 to SO3.
Monitor Mode (Un006) -
The torque limits are specified as a percentage of the rated torque.

Note: If torque limit is set higher than the maximum torque of the servomotor, the maximum torque of the
servomotor is the limit.
5-9
Application Example: Equipment Protection

Torque limit Too small a torque limit will result in a
insufficient torque during acceleration and
Motor deceleration.
speed
Torque
Using the /CLT Signal

The following section describes the use of the contact output signal /CLT as a torque
limit output signal.
I/O power supply
Servo Amplifier + 24V
Photocoupler output
Maximum operating voltage CN1-*1 CLT+
per output: 30VDC
Maximum operating current
per output: 50mADC
CN1-*2 CLT-
Output ð /CLT CN1-*1 Torque Limit Output
Position Control
This signal indicates whether servomotor output torque (current) is being limited.
Status Conditions Description

The circuit between CN1–*1 and *2 Servomotor output torque is being limited.
ON is closed. (Internal torque reference is greater than
the limit setting).
CN1–*1 is at low level.
The circuit between CN1–*1 and *2 Servomotor output torque is not being lim-
OFF is open. ited.
(Internal torque reference is less than the
CN1–*1 is at high level. limit setting).
Settings: Pn402 (Forward Torque Limit)

Pn403 (Reverse Torque Limit)
Pn404 (Forward External Torque Limit): /P-CL input only
Pn405 (Reverse External Torque Limit): /N-CL input only
When the /CLT signal is used, the following parameter must be used to select the
output signal.

Pn50F Output Signal Selections 2 Default Setting: 0000 Position Control
5-10
Pn50F.0 Output terminal

1
CLT CN1-25, 26 (SO1)
Torque limit 2
CN1-27, 28 (SO2)
detection 3 CN1-29, 30 (SO3)
Use the following table to select which terminal will output the /CLT signal.
Output Terminal (CN1–)

Parameter Setting
*1 *2
0 - -
1 25 26
Pn50F.0
2 27 28
3 29 30
Note: Multiple signals allocated to the same output circuit are output using OR logic. Set other output sig-
nals to a value other than that allocated to the /CLT signal in order to use just the /CLT output signal.
See 5.3.4 Output Circuit Signal Allocation.
n Setting Level 2: External Torque Limit

A contact input signal is used to enable the torque (current) limits previously set in
parameters. Torque limits can be set separately for forward and reverse rotation.
Servo Amplifier
Torque limit
Pn402
Reverse Rotation
P-CL rotation Speed
CN1-45 Torque limit

Pn402 or Pn404
Rotation (limited by whichever
Speed is smaller)
Torque limit
Rotation Pn403
Forward
rotation Speed
N-CL
CN1-46 Torque limit
Rotation Pn403 or Pn405
Speed (limited by whichever
is smaller)
ð Input P-CL CN1-45 Forward External Torque Limit Input Speed/Torque Control,
Position Control
ð Output N-CL CN1-46 Reverse External Torque Limit Input Position Control
5-11
This is the external torque (current) limit input for forward and reverse rotation.
Check input signal allocation status when using this function. (See 5.3.3
Input Circuit Signal Allocation). Default settings are given in the table on
the following page.
Parameter Signal Status Comments Description

CN1-45 at low level when ON Use forward torque limit. Limit: Pn404
/P–CL Do not use forward torque limit.
CN1-45 at high level when OFF —
Normal operation.
CN1-46 at low level when ON Use reverse torque limit. Limit: Pn405
/N–CL Do not use reverse torque limit.
CN1-46 at high level when OFF —
Normal operation.
The following output signals and monitor methods are used when torque is
being limited.
Signal Description
Generated when Pn50F.0 is allocated to an output terminal from SO1
/CLT to SO3.
Monitor Mode (Un006) —
• Un005: Numbers 6
and 7 (With Default Refer to 7.1.7 Operation in Monitor Mode.
Settings)
• Un006: Depending
on output signal
—
allocation condi-
tions.
Application Examples:
• Forced stop.
• Robot holding a workpiece.
Setting
(%)
Range: 0 to 800 Speed/Torque Control,
Pn404 Forward External Torque Limit
Pn405 Reverse External Torque Limit
5-12
Set the torque limits when the torque is limited by an external contact input.
Setting Description
/P-CL (CN1-45) Input Pn404 torque limit applied.
/N-CL (CN1-46) Input Pn405 torque limit applied.
See 5.2.9 Using Torque Limiting by Analog Voltage Reference.
Using /P-CL and /N-CL Signals

The procedure for using /P-CL and /N-CL as torque limit input signals is illustrated
below.
Servo Amplifier
I/O power supply
+24V
3.3kΩ Photocoupler
CN1-47
Host controller 5mA

/P-CL
CN1-45
/N-CL CN1-46
5-13
5.2 Settings According to Host Controller

This section describes the procedure for connecting a Sigma II Series servo to a host con-
troller, including the procedure for setting related parameters.
5.2.1 Speed Reference

Input the speed reference using the input signal Speed Reference Input. Since this
signal has various uses, set the optimum reference input for the system created.
Servo Amplifier
T-REF CN1-9
Torque reference input Torque
(analog voltage input) SG
P
CN1-10 reference
V-REF CN1-5
Speed reference input Speed
(analog voltage input) P
SG CN1-6 reference
P represents twisted pair wires
ð Input V-REF CN1-5 Speed Reference Input Speed Control

ð Input SG CN1-6 Signal Ground Speed Control
The above inputs are used for speed control (analog reference). (Pn000.1 = 0, 4, 7,
9, or A).
Always wire for normal speed control.
The motor speed is controlled in proportion
Refer to 7.1.7 Operation in Monitor Mode.
to the input voltage between V-REF and SG.
Rated motor speed

Factory setting
-12 -8 -4
4 8 12
Input voltage (V)
Rated motor speed
The slope is set in Pn300.
n Setting Examples
Pn300 = 600: This setting means that 6V is equivalent to the rated motor speed.
Speed SGMAH
Rotation Direction Motor Speed
Reference Input Servomotor
+6V Forward rotation Rated motor speed 3000rpm
+1V Forward rotation (1/6) rated motor speed 500rpm
–3V Reverse rotation (1/2) rated motor speed 1500rpm
5-14
Parameter Pn300 can be used to change the voltage input range.
n Input Circuit Example

470Ω, ½W minimum Servo Amplifier
VREF
+ 12V 2kΩ
CN1-5
P
SG CN1-6
• Always use twisted pair cable for noise control.

Recommended variable resistor: Model 25HP-10B manufactured by Sakae
Tsushin Kogyo Co., Ltd.
Connect V-REF and SG to the speed reference output terminals on the host control-
ler when using a host controller, such as a programmable controller, for position con-
trol.
Host controller Servo Amplifier
V-REF
Speed CN1-5
reference P SG
output CN1-6
terminals
PAO
Feedback P /PAO CN1-33
pulse input PBO CN1-34
terminals P /PBO CN1-35
CN1-36
Adjust Pn300 according to the output voltage specifications of the host controller.
Adjust the speed reference input adjustment factor at the following parameter.
Speed Reference Input Range: 150 to 3000 x (0.01V/

Pn300 Speed Control
Adjustment Factor rated motor speed)
Set the voltage range for the speed reference input V-REF at CN1-5 according to
host controller and external circuit output range.
Reference
speed (rpm) Set this slope.
Reference
voltage (V)
The default setting is adjusted so that a 6V input is equivalent to the rated motor
speed of all applicable servomotors.
Note: The maximum allowable voltage to the speed reference input (between CN1–5 and 6) is ± 12VDC.
5-15
Using the /P-CON Signal

Speed Control,
ð Input P-CON CN1-41 Proportional Control Reference
Position Control
The /P-CON input signal switches the Speed Control Mode from PI (proportional-
integral) to P (proportional) control.
Proportional control can be used in the following two ways:
• When operation is performed by sending speed references from the host control-
ler to the servo amplifier, the host controller can selectively use P control mode
for particular conditions only. This method can prevent the occurence of over-
shoot and also shorten settling time.
• If PI control mode is used when the speed reference has a reference offset, the
motor may rotate at a very slow speed and fail to stop even if 0 is specified as a
speed reference. In this case, use P control mode to stop the motor.
5.2.2 Position Reference

The reference pulse, reference code, and clear inputs are used for the position refer-
ence. Since this signal can be used in different ways, set the optimum reference
input for the system created.
n Reference by Pulse Input

Positioning is controlled by inputting a move reference pulse.
Servo Amplifier
Photocoupler
PULS CN1-7
Reference
pulse input /PULS P CN1-8
SIGN CN1-11
Reference /SIGN P CN1-12
code input
CLR CN1-15
Clear input /CLR P CN1-14
Any of the following forms can be used for the position reference:
• Line-driver output
• +12V open-collector output
• +5V open-collector output
Connection Example 1: Line-driver Output

Applicable line driver: SN75174 manufactured by Texas Instruments Inc., MC3487
5-16
or equivalent
Photocoupler
Line-driver PULS CN1-7
150Ω
P
/PULS CN1-8
SIGN CN1-11
P /SIGN CN1-12
CLR CN1-15
P /CLR CN1-14
Connection Example 2: Open-collector Output

Set limiting resistor R1 so that input current, I, falls within the following range:
Vcc Photocoupler
R1 i PULS CN1-7
150Ω
P
/PULS CN1-8
Tr1
R1 SIGN CN1-11
P /SIGN CN1-12
R1 CLR CN1-15
P /CLR CN1-14
The examples below show how to select the pull-up resistor R1 so the input current,
I, falls between 7 and 15mA.
Application Examples of V = IR
R1 = 1kΩ with VCC = 12V ±5% R1 = 180Ω with VCC = 5V ±5%
Note: The following table shows the signal logic for an open–collector output.
Tr1 Output Level Signal Logic

ON Equivalent to high–level input
OFF Equivalent to low–level input
This circuit uses the 12V power supply built into the servo amplifier. The input is
5-17
not isolated in this case.

Host controller Servo Amplifier
CN1-3 1kΩ +12V
PL1
CN1-7 Photocoupler
Approx. PULS
9mA 150Ω
/PULS CN1-8
Tr1
P
CN1-13
PL2 CN1-11
SIGN
ON: 1.5V maximum /SIGN CN1-12
P
CN1-18
PL3
CN1-15
CLR
/CLR CN1-14
P CN1-1
Note: The noise margin of the input signal will decrease if the reference pulse is provoded by an open-col-
lector output. Set parameter Pn200.3 to 1 if the position drifts due to noise.
n Selecting a Reference Pulse Form

Use the following parameters to select the reference pulse form used.
ð Input PULS CN1-7 Reference Pulse Input Position Control

ð Input /PULS CN1-8 Reference Pulse Input Position Control
ð Input SIGN CN1-11 Reference Code Input Position Control
ð Input /SIGN CN1-12 Reference Code Input Position Control
The servomotor only rotates at an angle proportional to the input pulse.
Parameter Signal Setting Range Control Mode

Pn200.0 Reference Pulse Form Default Setting: 0 Position Control
Set reference pulse form input to the servo amplifier from the host controller.
Host
controller Position
reference Servo Amplifier
pulse
PULS
CN1-7
CN1-11
SIGN
5-18
Since the reference pulse form can be selected from among those listed below, set
one according to host controller specifications.
Input
Parameter Reference Forward Rotation Reverse Rotation
Pulse Logic
Pn200.0 Pulse Form Reference Reference
Multiplier
PULS
0 Sign + pulse - (CN1-7)
PULS
(CN1-7)
train SIGN Low
High SIGN
(CN1-11) (CN1-11)
PULS Low
Positive PULS
CW pulse + (CN1-7)
1 CCW pulse - logic
(CN1-7)
SIGN Low
(CN1-11) SIGN
(CN1-11)
2 ×1
Two-phase
3 pulse train ×2 PULS 90° PULS 90°
(CN1-7) (CN1-7)
with 90° phase
SIGN SIGN
4 differential ×4 (CN1-11) (CN1-11)
Sign + pulse PULS PULS

5 train - (CN1-7) (CN1-7)
SIGN Low SIGN High
(CN1-11) (CN1-11)
CW pulse + PULS High PULS

6 - Negative (CN1-7) (CN1-7)
CCW pulse
logic SIGN SIGN High
(CN1-11) (CN1-11)
7 ×1
Two-phase
8 pulse train ×2 PULS
90° 90°
PULS
with 90° phase (CN1-7) (CN1-7)
9 differential ×4 SIGN SIGN
(CN1-11) (CN1-11)
Input Pulse Multiplier

Number of
servomotor ×4
move pulses
×2
×1
PULS Input reference pulse

(CN1-7)
SIGN
(CN1-11)
The input pulse multiplier function can be used if the reference pulse is a two-phase
pulse train with a 90° phase differential. The electronic gear function can also be
used to convert input pulses.
5-19
Example of I/O Signal Generation Timing
Servo ON
Release
t1 ≤ 30ms
Baseblock t2 ≤ 6ms
(when parameter
CN1-1 Pn506 is set to 0)
Sign+pulse 1 t3 ≥ 40ms
train CN1-
7
PAO t4, t5, t6 ≤ 2ms

t7 ≥ 20ms
PG pulse
PBO
t6
Note: 1. In order for the input pulse to register, the interval from the time the servo ON signal is turned
ON until a reference pulse is entered must be a minimum of 40ms.
2. The error counter clear signal must be on for at least 20µs.
Reference Pulse Input Signal Timing
Reference Pulse Form Electrical Specifications
Sign + pulse train input SIGN

t1 t2
t1, t2 ≤ 0.1µs
(SIGN + PULS signal) t3 t7 t3, t7 ≤ 0.1µs Sign (SIGN)
Maximum reference fre-
quency: 500kpps
PULS
t4
t4, t5, t6 > 3µs H = Forward reference
(200kpps open-collector τ t5 t6
τ ≥ 1.0µs L = Reverse reference
output) T
Forward Reverse
(τ/T) × 100 ≤ 50%
reference reference
t1
CW pulse and CCW
pulse
T
t1, t2 ≤ 0.1µs
Maximum reference fre- CCW τ t3 > 3µs
—
quency: 500kpps t2 τ ≥ 1.0µs
(200kpps open-collector CW
t3
(τ/T) × 100 ≤ 50%
output)
Forward Reverse
reference reference
Two–phase pulse train t2

t1
with 90°° phase differen-
tial (A phase + B phase)
Maximum reference fre- A phase
t1, t2 ≤ 0.1µs Parameter Pn200.0
quency × 1: 500kpps is used to switch the
B phase
τ τ ≥ 1.0µs
(200kpps open-collector input pulse multiplier
output) T (τ/T) × 100 = 50% mode.
×2: 400kpps Forward
reference
Reverse
reference
B phase leads
×4: 200kpps
B phase lags
A phase by 90° A phase by 90°
5-20
n Error Counter Clear Input

The procedure for clearing the error counter is described below.
ð Input CLR CN1-15 Clear Input Position Control

ð Input /CLR CN1-14 Clear Input Position Control
The following occur when the CLR signal is set to high level.
Servo Amplifier
CLR
Clear
Position loop
error counter
• The error counter inside the servo amplifier is set to 0.

• Position loop control is prohibited.
Use this signal to clear the error counter from the host controller or select the follow-
ing clear operation through parameter Pn200.1.
Parameter Signal Setting Range Control Mode

Pn200.1 Error Counter Clear Signal Form Default Setting: 0 Position Control
Select the pulse form for the error counter clear signal CLR (CN1-15).
Pn200.1
Description Clear Timing
Setting
Clears the error counter when the
CLR signal goes high. CLR High
0 (CN1-15)
Error pulses do not accumulate as Cleared state
long as the signal remains high.
Clears the error counter on the rising

edge of the CLR signal. CLR High
1 (CN1-15)
Clears the error counter only once on Cleared only once at this point
the rising edge of the CLR signal.
Clears the error counter when the

CLR signal goes low. CLR Low
2 (CN1-15)
Error pulses do not accumulate as
long as the signal remains low. Cleared state
Clears the error counter on the falling

edge of the CLR signal. CLR Low
3 (CN1-15)
Clears the error counter only once on Cleared only once at this point
the falling edge of the CLR signal.
5-21
5.2.3 Using the Encoder Signal Output

Encoder output signals divided inside the servo amplifier can be output externally.
These signals can be used to form a position control loop in the host controller.
Servo amplifier Host controller

(Servomotor)
CN2 CN1
Encoder
Serial data Phase A
PG Phase B
Phase C
The output circuit is for line-driver output. Connect each signal line according to the
following circuit diagram.
Servo amplifier Host controller

Line receiver
Phase A CN1-33 PAO R 2 3
Phase
P A
CN1-34 /PAO 1
Phase B CN1-35 PBO R 6 5

Phase
P B
CN1-36 /PBO 7
Phase C CN1-19 10
PCO R 11
Phase
P C
CN1-20 /PCO 9
Choke
8 C 16 coil
OV +5V
+5V
+
CN1-1 -
0V
Smoothing
OV capacitor
Connector shell Shield
P: Indicates twisted pair wires.
Note: Dividing means converting an input pulse train from the encoder mounted on the servomotor accord-
ing to the preset pulse density and outputting the converted pulse. The units are pulses per revolution
(ppr).
5-22
n I/O Signals
I/O signals are described below.
Output ð PAO CN1-33 Encoder Output Phase A Speed/Torque Control,

Position Control
Output ð /PAO CN1-34 Encoder Output Phase /A Speed/Torque Control,

Position Control
Output ð PBO CN1-35 Encoder Output Phase B Position Control
Output ð /PBO CN1-36 Encoder Output Phase /B Speed/Torque Control,

Position Control
Output ð PCO CN1-19 Encoder Output Phase C Speed/Torque Control,

Position Control
Output ð /PCO CN1-20 Encoder Output Phase /C Position Control
Divided encoder signals are output.

Always connect these signal terminals when a position loop is formed in the host
controller for position control.
Set a dividing ratio at the following parameter.
PG Dividing Ratio Pn201
The dividing ratio setting is not related to the gear ratio setting (Pn202 and 203) for
the servo amplifier electronic gear function during position control.
Output Phase Form
Forward 90° Reverse 90°

rotation rotation
Phase A Phase A
Phase B Phase B
Phase C Phase C
t t
5-23
ð Input SEN CN1-4 SEN Signal Input Speed/Torque Control

ðInput /SEN CN1-2 Signal Ground Speed/Torque Control
Output ð PSO CN1-48 Encoder Output Phase S Speed/Torque Control,

Position Control
Output ð /PSO CN1-49 Encoder Output Phase /S Position Control
ð Input BAT (+) CN1-21 Battery (+) Speed/Torque Control,

Position Control
ð Input /BAT (-) CN1-22 Battery (-) Speed/Torque Control,

Position Control
Use SEN to BAT (-) signals for absolute encoders. See 5.7 Absolute Encoder for
more details.
Output ð SG CN1-1 Signal ground Speed/Torque Control,

Position Control
SG: Connect to 0V on the host controller.
n Pulse Divider Setting

Set the pulse dividing ratio in the following parameter.
Setting
(p/rev)
Pn201 PG Divider Default Setting: 16384 Position Control
Set the number of pulses for PG output signals (PAO, /PAO, PBO, /PBO).
Output terminals: PAO (CN1-33)
/PAO (CN1-34)
Servo Amplifier PBO (CN1-35)
Servomotor /PBO (CN1-36)
encoder
Frequency Phase A
PG division Output
Phase B
Serial
data
Pulses from the servomotor encoder (PG) are divided by the preset number before
being output.
The number of output pulses per revolution is set at this parameter. Set the value
using the reference units of the equipment or the controller used.
5-24
The setting range varies with the encoder used.

Setting Preset value: 16
Example PAO
PBO
1 revolution
Servomotor Model Number of Encoder

Resolution
and Encoder Pulses Per Revolution Setting Range
(Bits)
Specifications (p/rev)
A 13 2048 16 to 2048
B, 1 16
16384 16 to 16384
C, 2 17
Note: 1. Turn OFF power once and turn ON again after changing the parameter.
2. A 13-bit encoder will run at 2048p/rev even if the setting at Pn201 is set higher than 2049.
5.2.4 Sequence I/O Signals

Sequence I/O signals are used to control servo amplifier operation. Connect these
signal terminals as required.
n Input Signal Connections

Connect the sequence input signals as shown below.
Servo Amplifier
I/O power
supply
+ 24V
+24VIN CN1-47
3.3kΩ Photocoupler
Host controller
/S-ON CN1-40
/P-CON CN1-41
P-OT CN1-42
N-OT CN1-43
/ALM-RST CN1-44
/P-CL CN1-45
/N-CL CN1-46
0V
5-25
Note: Provide a separate external I/O power supply; the servo amplifier does not have an internal 24V
power supply.
• External power supply specifications: 24V ±1 VDC, 50mA minimum.
Yaskawa recommends using the same type of external power supply as that used for output circuits.
The function allocation for sequence input signal circuits can be changed.
See 5.3.3 Input Circuit Signal Allocation for more details.
ð Input +24VIN CN1-47 Speed/Torque Control,

External I/O Power Supply Input Position Control
The external power supply input terminal is common to sequence input signals.
Servo Amplifier
I/O power supply
+ 24V
+ 24VIN
CN1-47
Connect an external I/O power supply.
Contact input signals: /S-ON (CN1-40)

/P-CON (CN1-41)
P-OT (CN1-42)
N-OT (CN1-43)
/ALM-RST (CN1-44)
/P-CL (CN1-45)
/N-CL (CN1-46)
5-26
n Output Signal Connections

Connect the sequence output signals as shown in the following figure.
Servo amplifier I/O power supply
+24V 0V
Photocoupler CN1
31 ALM+
~ 50mA max.
32 ALM-
Photocoupler output 25 V-CMP+
levels per output node: ~ 50mA max.
26 V-CMP-
• Maximum operating 27 TGON+
voltage: 30VDC
• Maximum output cur- ~
28 TGON-
rent: 50mADC 29 S-RDY+
~ 30 S-RDY-
CN1
37 ALO1
Open-collector output
20mA max.
levels per output node:
• Maximum operating 38 ALO2
voltage: 30VDC
• Maximum output cur-
rent: 20mADC 39 ALO3
1 SG Host controller
0V 0V
Note: Provide a separate external I/O power supply; the servo amplifier does not have an internal 24V
power supply. Yaskawa recommends using the same type of external power supply as that used for
input circuits.
Function allocation for some sequence output signal circuits can be changed.
See 5.3.4 Output Circuit Signal Allocation for more details.
5-27
5.2.5 Using the Electronic Gear Function

The electronic gear function enables the servomotor travel distance per input refer-
ence pulse to be set to any value. It allows the pulses generated by the host control-
ler to be used for control without having to consider the equipment gear ratio or the
number of encoder pulses.
When the Electronic Gear When the Electronic Gear
Function is Not Used Function is Used
Workpiece
Workpiece
Reference unit: 1µm
No. of encoder pulses: 2048

Ball screw pitch: 0.24in. (6mm) No. of encoder pulses: 2048 Ball screw pitch: 0.24in. (6mm)
To move a workpiece 0.39in. (10mm): To move a workpiece 0.39in. (10mm):
1 revolution = 6mm. Therefore,

Equipment conditions and reference
10 ÷ 6 = 1.6667 revolutions.
units must be defined for the electronic
(2048 × 4) pulses = 1 revolution. So,
gear function beforehand.
(1.6667 × 2048 × 4) = 13653 pulses
13563 pulses are input as the reference. Reference unit is 1µm. Therefore,
The equation must be calculated at the 10mm = 10000 pulses
host controller. 1µm
n Setting the Electronic Gear

Calculate the electronic gear ratio (B/A) using the following procedure, and set the
values in parameters Pn202 and 203.
1. Check equipment specifications related to the electronic gear:
• Deceleration ratio
• Ball screw pitch
• Pulley diameter
Ball screw pitch
Deceleration ratio
2. Check the number of encoder pulses for the SGMoH servomotor.
Servomotor Model
Number of Encoder Pulses
and Encoder Encoder Type
Per Revolution (p/rev)
Specifications
A 13–bit 2048
B Incremental encoder 16–bit 16384
C 17–bit 32768
1 16–bit 16384
Absolute encoder
2 17–bit 32768
5-28
Note: The number of bits representing the resolution of the applicable encoder is not the same as the num-
ber of encoder signal pulses (A and B phase) output from the servo amplifier.
3. Determine the reference unit used.

A reference unit is the minimum position data unit used to move a load. (Mini-
mum unit of reference from the host controller).
To move a table in 0.001mm units
Reference unit: 0.001mm
Determine the reference unit according to

equipment specifications and positioning accuracy.
Examples (in mm):

• Reference unit can be0.1in., or 0.01in., or 0.01mm, or 0.001mm, etc.
A reference unit of one pulse moves the load by one reference unit.
• When the reference unit is 1µm
If a reference of 50000 units is input, the load moves 50mm (1.97in.)
(50000 × 0.001mm = 50mm).
4. Determine the load travel distance per load shaft revolution in reference units.
Travel distance per load shaft revolution = Travel distance per load shaft revolution
Reference Unit
• When the ball screw pitch is 0.20in. (5mm) and the reference unit is
0.00004in. (0.001mm),
0.20
- = 5000(reference units)
------------------
0.00004
Ball Screw Disc Table Belt and Pulley
Load shaft P Load shaft π∆
D
P: Pitch
Load shaft D:D:Pulley
Pulley
P 360°
1 revolution = 1 revolution = πD
reference unit reference unit 1 revolution =
reference unit
5-29
B---
5. Electronic gear ratio is given as:  A
m
If the gear ratio of the motor and the load shaft is given as: ----
m
where m is the rotation of the motor and n is the rotation of the load shaft,
Number of encoder pulses × 4
 B
Electronic gear ratio  ---
A = Travel distance per load shaft revolution (reference unit)
× n-
---
m
Note: Make sure the electronic gear ratio satisfies the following condition:
 B
0.01 ≤ Electreconic gear ratio  ---
A ≤ 100
The servo amplifier will not work properly if the electronic gear ratio exceeds this range. In that case,
modify either the load configuration or the reference unit.
6. Set the parameters.

Reduce the electronic gear ratio to the lower terms so that both A and B are inte-
gers smaller than 65535, then set A and B in the respective parameters:
()
B
A
Pn202
Pn203
Electronic Gear Ratio (Numerator)
Electronic Gear Ratio (Denominator)
Pn202 Electronic Gear Ratio (Numerator) Range: 1 to 65535 Position Control

Default Setting: 4
Range: 1 to 65535
Pn203 Electronic Gear Ratio (Denominator) Default Setting: 1 Position Control
Set the electronic gear ratio according to equipment specifications.

SGDH Servo amplifier
Reference Electronic
input pulse gear
SGMoH
M servomotor
B---
Pn202
Electronic gear ratio =  A =
Pn203
• B = [(Number of encoder pulses) × 4] × [motor speed]
• A = [Reference units (travel distance per load shaft revolution)] × [load shaft
revolution speed]
5-30
n Electronic Gear Setting Examples

The following examples show electronic gear settings for different load mecha-
nisms.
Ball Screws
Reference unit: 0.001mm

Travel distance per load shaft revolution = 0.24in. = 6000
Load shaft 0.0004in.
2048 × 4 × 1
Electronic gear ratio =  ---
13-bit incremental Ball screw pitch: 0.24in. (6mm) B Pn202
encoder
A
= =
6000 Pn203
Preset Pn202 8192

Values Pn203 6000
Circular Tables
Reference unit: 0.1°

Travel distance per load shaft revolution = 360° = 3600
Deceleration
0.1°
ratio: 3:1
Load Shaft
2048 × 4 × 1 Pn202
13-bit Incremental encoder B
A
= =
3600 Pn203
Preset Pn202 24576

Values Pn203 3600
Belts and Pulleys

Reference unit: 0.0010in. (0.0254mm)
Load shaft
3.14 × 0.03937in.
Travel distance per load shaft revolution = = 12362
0.0010in.
1024 × 4 × 2.4 Pn202

Deceleration Pulley diameter Φ100mm B
ratio: 2.4:1
A
= =
12362 Pn203
Set a PG dividing ratio equivalent 9830.4 49152
to 1024p/rev for the absolute encoder = =
12362 61810
Preset Pn202 49152

Values Pn203 61810
5-31
n Control Block Diagram

The following diagram illustrates a control block for position control.
Servo Amplifier (position control)
Pn109 Pn202 Pn10A

Pn107
Differentiation Feed- Primary
forward gain lag filter Bias
Pn108
Pn203
Bias addition
Pn200.0 range
Pn204 Pn202
Reference X1 Pn102
pulse + + +
Servomotor
X2 Smoothing
Error + Speed Current
X4 counter Kp loop loop M
Pn203 -
PG
PG signal Pn201
Encoder
output
Frequency
dividing
5.2.6 Contact Input Speed Control

This function provides a method for easy speed control. It allows the user to initially
set three different motor speeds with parameters, and then select one of the speeds
externally using a contact input.
Servo amplifier
/P-CON (/SPD-D)
CN1-41
M
Contact /P-CL (/SPD-A)
CN1-45
input
Servomotor
/N-CL (/SPD-B)
CN1-46
Speed selection
SPEED 1 Pn301
The servomotor operates at
SPEED 2 Pn302 the speed set in the parameter.
External speed
SPEED 3 Pn303
setting devices and
pulse generators
are not required.
5-32
n Using Contact Input Speed Control

Follow steps 1 to 3 below to use the contact input speed control function.
1. Set contact input speed control as shown below.
Pn000.1 Control Mode Selection Default Setting: 0 Speed/Torque Control,

Position Control
The speed can be controlled via contact inputs.

Servo Amplifier
Servo operates
at the internally M
set speed.
Servomotor
Contact
input SPEED 1
SPEED 2
SPEED 3
Meanings for the following signals change when the contact input speed control
function is used.
Pn000.1
Description Input Signal
Setting
/P–CON (CN1–41) Used to switch between P and PI

control.
Contact input
0, 1, 2, 7, 8, speed control Used to switch between forward
9, A, B function not /P–CL (CN1–45) external torque limit ON and OFF.
used.
Used to switch between reverse
/N–CL (CN1–46) external torque limit ON and OFF.
/P–CON /P–CL /N–CL Speed setting
(/SPD–D) (/SPD–A) (/SPD–B)
0 reference,
0 0 etc.
Contact input SPEED 1
3, 4, 5, 6 speed control Direction of 0 1
rotation (Pn301)
function used.
0:Forward SPEED 2
1:Reverse 1 1
(Pn302)
SPEED 3
1 0 (Pn303)
Note: 1. 0: OFF (high level); 1: ON (low level)

2. /P-CON, /P-CL and /N-CL functions differ from those in the table above when Pn000.1 is set to 3, 4, 5, or
6. The function is switched automatically when Pn50A. 0 is set to 0.
3. The /SPD-D, /SPD-A, and /SPD–B signals can be used only when signals are allocated to the input circuits.
See 5.3.3 Input Circuit Signal Allocation.
5-33
2. Set the motor speeds with the following parameters.
Setting
(rpm)
Pn301 Speed 1 (SPEED 1) Range: 0 to 10000 Speed Control

(Contact Input Speed Control) Default Setting: 100
Speed 2 (SPEED 2) Range: 0 to 10000
Pn302 (Contact Input Speed Control) Default Setting: 200 Speed Control
Pn303 Speed 3 (SPEED 3) Range: 0 to 10000 Speed Control

(Contact Input Speed Control) Default Setting: 300
These parameters are used to set motor speeds when the contact input speed con-
trol function is selected. If the setting is higher than the maximum motor speed
of the servomotor, then the servomotor will rotate at its maximum speed.
Contact Input Speed Control
Servo Amplifier
Servo operates
at the internally M
set speed.
Servomotor
SPEED1
SPEED2
SPEED3
Speed selection input signals /P-CL(SPD-A)(CN1-45) and /N-CL (/SPD-B)

(CN1-46) and the rotation direction selection signal /P-CON (/SPD-D)(CN1-41)
enable the servomotor to run at the preset speeds.
3. Set the soft start time.
Setting
(ms)
Pn305 Soft Start Acceleration Time Setting Range: 0 to 10000 Speed Control
Default Setting: 0
Setting Range: 0 to 10000
Pn306 Soft Start Deceleration Time Default Setting: 0 Speed Control
The servo amplifier internal speed reference controls speed by applying this acceler-
5-34
ation setting.
Speed
reference
Soft start
Maximum speed
Servo amplifier
internal speed
reference
Pn305: Sets this time interval.
Maximum speed
Pn306: Sets this time interval.
Smooth speed control can be performed by entering a progressive speed refer-

ence or using contact input speed control. Set each constant to 0 for normal
speed control.
Set each parameter to the following time intervals.
• Pn305: Time interval from when the servomotor starts until it reaches max-
imum speed.
• Pn306: Time interval from when the servomotor maximum speed until it
stops.
n Operation by Contact Input Speed Control

The following describes operation by contact input speed control.
Start and Stop

The following input signals are used to start and stop the servomotor.
Speed Selection 1 Speed/Torque Control,

ð Input /P-CL CN1-45 (Forward External Torque Limit Input) Position Control
ð Input /N-CL CN1-46 Speed Selection 2 Speed/Torque Control,

(Reverse External Torque Limit Input) Position Control
5-35
Use the following table when contact input speed control is used.
Contact Signal Parameter

/P-CON /P-CL /N-CL Selected Speed
Pn000.1
(/SPD-D) (/SPD-A) (/SPD-B)
Stopped by an inter-
3 nal speed reference
of 0.
Analog speed refer-
4 ence (V-REF) input
- 0 0 Pulse reference
5 input (position con-
trol)
Analog torque refer-
6 ence input (torque
control)
Direction of 0 1 SPEED 1 (Pn301)
rotation 1 1 3, 4, 5, SPEED 2 (Pn302)
0: Forward 6Common
1: Reverse 1 0 SPEED 3 (Pn303)
Note: 1. 0: OFF (high level); 1: ON (low level)

2. Input signals indicated by the horizontal bar (-) are optional.
• When contact input speed control is not used, input signals are used as external
torque limit inputs.
Note: The contact input speed control function is used only when signals are allocated to /SPD-D, /SPD-A,
and /SPD–B.
Direction of Rotation Selection

The input signal /P-CON(/SPD-D) is used to specify the direction of servomotor
rotation.
ð Input /P-CON CN1-41 Proportional Control Reference, etc. Speed/Torque Control,

Position Control
• When contact input speed control is used, the input signal /P-CON (/SPD-D)
specifies the direction of Servomotor rotation.
/P-CON (/SPD-D)
Signal Logic
Input Level
0 Forward rotation
1 Reverse rotation
Note: 0: OFF (high level); 1: ON (low level)
• When contact input speed control is not used, the /P-CON signal is used for pro-
portional control, zero clamping, and torque/speed control switching.
5-36
n Example of Contact Input Speed Control Operation

The following example shows operation by contact input speed control. Using the
soft start function reduces physical shock when the speed is changed.
Motor speed
Speed 3
+SPEED 3
Set acceleration and
Speed 2 deceleration at Pn305 and
+SPEED 2 Pn306 (soft start times).
Speed 1
+SPEED 1
Stop Stop
0
Stop
-SPEED 1
Speed 1
-SPEED 2 Speed 2
-SPEED 3 Speed 3
/P-CL (/SPD-A)
OFF OFF ON ON OFF OFF ON ON OFF
/N-CL (/SPD-B)
OFF ON ON OFF OFF ON ON OFF OFF
ON ON ON OFF OFF OFF OFF OFF

/P-CON (/SPD-D)
Note: The soft start function is available only when contact input speed control is used with Pn000.1 set to
5, and is not available when a pulse reference input is used. If the Contact Input Speed Control Mode
is switched to Pulse Reference Input Mode while the servomotor is operating at speed 1, speed 2, or
speed 3, the servo amplifier will not receive a reference pulse until the positioning completed signal /
COIN is output. Always start pulse reference output from the host controller after a positioning com-
pleted signal is output from the servo amplifier.
Signal Generation Timing for Position Control
Motor Speed
0rpm
/COIN
Pulse
Reference
t1 t1
/P-CL (/SPD-A) OFF ON ON OFF OFF
/N-CL (/SPD-B) ON ON OFF OFF ON
Selected Speed Speed 1 Speed 2 Speed 3 Pulse reference Speed 1
t1 > 2ms
1. The above figure illustrates signal generation timing when the soft start function is used.
2. The value of t1 is not affected by the use of the soft start function. A maximum 2ms delay
occurs when the /PC-L(/SPD-A) or /N-CL(/SPD-B) signal is read. 1
5-37
5.2.7 Using Torque Control

The SGDH servo amplifier limits torque as shown below.
• Level 1: Limits maximum output torque to protect the equipment or workpiece.
• Level 2: Limits torque after the Servomotor moves the equipment to a specified
position (internal torque limit).
• Level 3: Always control torque rather than speed output.
• Level 4: Switches between speed and torque control.
The following describes uses for levels 3 and 4 in the torque control function.
n Torque Control Selection

Set in the following parameters to select level 3 or 4 torque control.

Pn000.1 Control Method Selection Default Setting: 0 Position Control
A torque reference is entered from the host controller to the servo amplifier in order
to control torque.
5-38
Application Examples
• Tension control
• Pressure control
Pn000.1 Control Mode
Torque Control
This is a dedicated Torque Control Mode. Servo amplifier
•A torque reference is input from T-REF (CN1-9).
•Speed reference input V-REF (CN1-5) cannot be Torque T-REF
reference Cn1-9
used for speed control if Pn002.1 is set to 1.
•Parameter Pn407 can be used for maximum speed Speed V-REF
Limit Cn1-5
control.
2
ApplicationExample Servomotor
Servo
Tension control amplifier
Tension
Torque Control <-> Speed Control (Analog Refer-

ence) Servo amplifier
Switches between torque and speed control
•V-REF (CN1-5) inputs a speed reference or speed Speed V-REF
limit. reference Cn1-5
•T-REF (CN1-9) inputs a torque reference, torque
Torque T-REF
feed–forward reference or torque limit depending reference Cn1-9
on the control mode.
•/P-CON (/C-SEL)(CN1-41) is used to switch /P-CON
Speed and
between torque and speed control. torque Cn1-41
(/C-SEL)
reference
switching
CN1-41
9 Selects
State
Open Torque Control
0V Speed Control
Torque Control: When /P-CON (/C-SEL) is OFF

•The T-REF reference controls torque.
•V-REF can be used to limit servomotor speed
when Pn002.1 is set to 1. V-REF voltage (+) limit
servomotor speed during forward and reverse rota-
tion.
•parameter Pn407 can be used to limit the maximum
servomotor speed.
5-39
Pn000.1 Control Method

Speed Control: When /P-CON (/C-SEL) is ON
Set the parameter Pn002.0 as shown below.
Parameter Speed Reference

Torque Reference Input
Pn002.0 Input Comments
(T-REF) (CN1-9,10)
State (V-REF) (CN1-5,6)
Speed Control
9 0
Speed Reference Cannot be used.
Torque limit speed control by analog voltage See 5.2.9 for more details
1 reference on torque limit speed
control by analog voltage
Speed Reference Torque Limit reference.
Speed control with torque feed-forward See 5.2.8 for more details
2 on torque feed-forward
Speed reference Torque feed-forward speed control.
Position Control ⇔ Torque Control

Can be used to switch between speed (contact reference) and torque control.
•/P–CON (/C–SEL)(CN1–41) is used to switch control.
8 CN1-41
Selects
State
Open Position Control
0V Torque Control
Speed Control (Contact Reference) ⇔ Torque Control

Can be used to switch between speed (contact reference) and torque control.
•/P-CON (/C-SEL)(CN1-45) and /N-CL(SPD-B)(CN1-46) are used to switch control.
Parameter Parameter
/P-CL (/SPD-A) /N-CL (/SPD-N)
CN1-45 CN1-46
6
State State
0 0 Torque Control
0 1
Speed Control
1 1 (Contact reference)
1 0
Note: Input signal /C-SEL can be used only when a signal is allocated to the input circuit. See 5.3.3 Input
Circuit Signal Allocation.
5-40
n Input Signals
Torque Reference Inputs

The following input signals are used for torque control.
Servo Amplifier
T-REF CN1-9
Torque reference input Torque
SG P CN1-10 reference
(Analog voltage input)
V-REF CN1-5
Speed reference input Speed
SG P CN1-6 reference
(Analog voltage input)
ð Input T-REF CN1-9 Torque Reference Input Speed/Torque Control

Signal Ground for the Torque
ð Input SG CN1-10 Reference Input Speed/Torque Control
These signals are used when torque control is selected.

Servomotor torque is controlled so that it is proportional to the input voltage
between T-REF and SG.
300
Reference torque (%)
200
100
-12 -8 -4
Default setting 0 4 8 12
Input voltage (V)
-100
-200
-300 The slope is set to Pn400.
n Default Settings
Parameter Pn400 establishes the voltage level that applies rated torque.
For example:
With Pn400 = 30
VIN (V) Resulting Applied Torque
+3 100% of rated torque in the forward direction
+9 300% of rated torque in the forward direction
-0.3 10% of rated torque in the reverse direction
5-41
n Example of an Input Circuit

Servo Amplifier
470Ω
1/2W minimum
+12V 2kΩ T-REF

CN1-9
P
SG
CN1-10
Note:
• Always use twisted pair cables for noise control.
• Recommended variable resistor: Model 25HP–10B manufactured by Sakae Tsushin Kogyo Co.,
Ltd.
Speed Reference Inputs

Refer to Section 5.2.1.
Using the /P–CON Signal
ð Input /P-CON CN1-41 Proportional Control Reference, etc. Speed/Torque Control,

Position Control
The function of the input signal /P-CON varies with the setting applied to Pn000.1.
Servo Amplifier
P and PI control switching
Zero clamp ON/OFF switching

P-CON
Inhibit ON/OFF switching
Control mode switching
Direction of rotation switching

(Pn000.1)
Pn000.1 Setting /P–CON Function

0, 1 Switches between P (proportional) and PI (proportional-integral) control.
2 Not used.
3, 4, 5, 6 Switches the direction of rotation in Contact Input Speed Control Mode.
7, 8, 9 Switches the control mode.
A Turns ON/OFF zero clamp.
B Turns inhibit ON/OFF.
Note: The /P-CON signal function switches automatically when Pn50A.0 is set to 0.
5-42
n Torque Control Parameter

The following parameter is used for torque control. Set the parameter according to
requirements of the servo system that is used.
Setting
(0.1V x rated torque)
Pn400 Torque Reference Input Gain Setting Range: 10 to 100 Speed/Torque Control
Default Setting: 30
This parameter sets the voltage range for torque reference input T-REF (CN1-9)
depending on the output range of the host controller or external circuit.
The default setting is 30, so the rated torque output is equal to 3V (30 × 0.1).
Reference torque
Rated torque
Reference
voltage (V)
This reference voltage is set.
Setting
(rpm)
Pn407 Speed Limit during Torque Control Default Setting: 10000 Speed/Torque Control
This parameter sets a motor speed limit when torque control is selected.
It is used to prevent excessive equipment speed during torque control.
Since the speed limit detection signal /VLT functions the same in torque control as
the /CLT signal, see 5.1.3 Limiting Torque, where the /CLT signal is described.
Torque Control Range
Motor speed
Speed limit
Torque
control
range
Torque
The maximum speed of the sservomotor will be used if Pn407 is set to a value higher
than the maximum speed of the servomotor.
Principle of Speed Limit:

When the control speed range is exceeded, torque, inversely proportional to the dif-
ference between the speed limit and the actual speed, is fed back in order to return
the system to a level within the control speed range. In effect, the actual motor speed
5-43
limit depends on the load condition.

Motor speed
Speed limit range

V-REF
Setting
(no units)
Speed Reference Input Adjust-
Pn300 ment Factor (SRF) Setting Range: 150 to 3000 Speed/Torque Control
(0.01V × SRF =Rated Speed) Default Setting: 600
This parameter sets the voltage range for speed reference input V-REF (CN1–5)
according to the output range of the host controller or external circuit.
When the default setting (600) is multiplied by 0.01V, the result (6V) corresponds to
the rated motor speed.
Reference This slope is set.
speed
(rpm)
Reference voltage (V)
5.2.8 Torque Feed-Forward Function

The torque feed-forward function is used only in speed control (analog reference).
This function is used to:
• Shorten positioning time.
• Differentiate a speed reference at the host controller to generate a torque feed-
forward reference.
• Input this reference together with the speed reference to the servo amplifier.
Too high a torque feed-forward value will result in overshooting or undershooting.
To prevent this, set the optimum value while closely observing the system response.
Connect a speed reference signal to V-REF (CN1-5 and 6) and a torque feed-forward
5-44
reference signal to T-REF (CN1-9 and 10).

Host controller SGDH Servo Amplifier
T-REF
+ Differ
ential
KFF Pn400 Servomotor
V-REF + + +
Kp Pn300 Pn100 Current loop M
- + +
- Integration
(Pn101)
Speed PG
calculation
Position
reference Encoder
Divider
n Using the Torque Feed-Forward Function

To use the torque feed-forward function, set the following parameter to 2.
Setting
(rpm)
Pn002.0 Speed Control Option Default Setting: 0 Speed/Torque Control

(T-REF Terminal Allocation)
This setting enables the torque feed-forward function.
Pn002.0 Setting T-REF Function

0 None.
1 T-REF terminal used for external torque limit input.
2 T-REF terminal used for torque feed-forward input.
The torque feed-forward function cannot be used with the torque limiting by analog
voltage reference function described in 5.2.9 Using Torque Limiting by Analog Volt-
age Reference.
n Setting
Torque feed-forward is set using parameter Pn400.
The default setting at Pn400 is 30. If, for example, the torque feed-forward value is
±3V, then torque is limited to ±100% of the rated torque.
Setting
(rpm)
Torque Reference Input Adjust- Setting Range: 0 to 100
Pn400 ment Factor Default Setting: 30 Speed/Torque Control
5-45
5.2.9 Torque Limiting 2 by Analog Voltage Reference

Torque limiting 2 by analog voltage reference limits torque by assigning a torque
analog voltage to the T-REF terminal (CN1-9 and 10). It cannot be used for torque
control because the torque reference input terminal T-REF is used as an input termi-
nal.
Torque is limited at the forward run side when the P-CL signal turns ON; and is lim-
ited at the reverse run side when the N-CL signal turns ON.
T-REF (/N-CL: ON) (/P-CL: ON)

Torque limit value Pn400
Pn402
Pn404
Speed loop (/P-CL: ON)
V-REF Pn300 + gain +
Speed reference Torque
- (Pn100) + reference
Integration
(Pn101)
Pn405 Pn403
Speed feedback (/N-CL: ON) Torque limit
n Using Torque Limiting 2 by Analog Voltage Reference

To use this function, set the following parameter to 3:
Setting
(rpm)
Speed Control Option Speed Control
Pn002.0 (T-REF Terminal Allocation) Default Setting: 0 Position Control
This parameter can be used to enable torque limiting 2 by analog voltage reference.
Pn002.0 Setting T-REF Function

0 None.
1 T-REF terminal used for external torque limit input.
2 T-REF terminal used for torque feed–forward input.
3 T-REF terminal used for external torque limit input when P-CL and N-CL are valid.
This function cannot be used with the torque feed-forward function described in
5.2.8 Torque Feed–forward Function.
To use this function, verify how input signals have been allocated. (Refer to section
5.3.3 Input Circuit Signal Allocation). The following table outlines factory default
5-46
settings.
Input
Signal Level Description Comments
Signal
CN1-45 is at “L” level when Torque is limited at forward Limit value: either Pn404 or
ON run side. T-REF input, whichever is
smaller.
/P-CL
Torque is not limited at for- —
CN1-45 is at “H” level ward run side.
whenOFF Normal Operation
CN1-46 is at “L” level when Torque is limited at reverse Limit value: either Pn405 or
ON run side. T-REF input, whichever is
smaller.
/N-CL
CN1-46 is at “H” level when Torque is not limited at for- —
OFF ward run side.
Normal operation.
n Setting
The torque limit is set at parameter Pn400.
The default setting at Pn400 is 30. If, for example, the torque limit is ±3V, then
torque is limited to 100% of the rated torque. (A torque value higher than 100%
torque is clamped at 100%.)
Setting
(rpm)
Pn400 Torque Reference Input Adjust- Setting Range: 0 to 100 Speed/Torque Control
ment Factor Default Setting: 30
When either the P-CL or the N-CL signal is turned ON, the following torque limits
become valid simultaneously.
Setting
(rpm)
Pn404 Forward Run Side External Torque Setting Range: 0 to 800 Speed/Torque Control,
Limit Default Setting: 100 Position Control
Reverse Run Side External Torque Setting Range: 0 to 800 Speed/Torque Control,
Pn405 Limit Default Setting: 100 Position Control
5-47
5.2.10 Reference Pulse Inhibit Function (INHIBIT)

This function inhibits the servo amplifier from counting input reference pulses dur-
ing position control. The servomotor remains locked (clamped) while the function is
in use. The /P-ON(/INHIBIT) signal is used to enable or disable the function.
Servo Amplifier
Pn000.1
1
+
Reference OFF
pulse Error
B
- counter
O
P-CON P-CON (INHIBIT) N
(INHIBIT)
Feedback pulse
n Using Reference Pulse Inhibit Function (INHIBIT)

To use the inhibit function, set the parameter as shown below.
Setting
(rpm)
The following settings enable the inhibit function.
Pn000.1 Setting Description
1 Enables the inhibit function.

Always counts reference pulses.
Enables the inhibit function. The /P-CON (/INHIBIT) signal is used to
enable or disable the inhibit function.
/P–CON (/INHIBIT) Description
B OFF Counts reference pulses.
Prohibits the servo amplifier from
ON counting reference pulses.
The servomotor remains locked.
Note: Parentheses ( ) around an /INHIBIT signal indicate that a signal has been allocated to the input circuit.
See 5.3.3 Input Circuit Signal Allocation for more details.
n Relationship between Inhibit Signal and Reference Pulses

/INHIBIT signal ON OFF ON
(/P-CON)
Reference
pulse
t1 t2
Input reference pulses t1, t2 ≥ 0.5ms

are not counted
during this period.
5-48
5.3 Setting Up the Servo Amplifier
This section describes the procedure for setting parameters to operate the SGDH
servo amplifier.
5.3.1 Parameters
The Sigma IΙ Series servo amplifier provides many functions and has parameters
that allow the user to specify functions and perform fine adjustments.
Servo amplifier
Parameters
A panel operator or
digital operator is used
to set parameterts.
Parameters are divided into the following three groups.
Parameter Function
Pn000 to Pn601 Specify servo amplifier functions, set servo gains, etc.
Fn000 to Fn012 Execute auxiliary functions such as JOG Mode operations

and origin searches.
Enable monitoring the motor speed and torque reference on
Un000 to Un00D the panel display.
Note: Appendix B shows a list of parameters provided for reference. See 7.1.6 Operation in Parameter Set-
ting Mode for more details on the procedure for setting parameters.
5.3.2 JOG Speed

Use the following parameter to set or modify motor speed when operating the servo-
motor from a panel or digital operator.
Setting
Parameter Signal Description
(rpm)
Pn304 Jog Speed Setting Range: 0 to 10000 Speed/Torque Control,

Use this parameter to set the motor speed when operating the servomotor from a
panel or digital operator. If the setting is higher than the maximum motor speed of
the servomotor, then the servomotor will rotate at its maximum speed.
5-49
SERVOPACK 200V
SGDH-
YASKAWA
MODE/SET DATA/
CHARGE POWER
5.3.3 Input Circuit Signal Allocation

The functions allocated to sequence input signal circuits can be changed. CN1 con-
nector input signals are allocated with the default settings as shown in the following
table.
CN1 Default Setting

Connector Input Terminal
Terminal Name Symbol Name
Numbers
40 SI0 /S-ON Servo ON
41 SI1 /P-CON (Proportional control refer-

ence) *
42 SI2 P-OT Forward run prohibit
43 SI3 N-OT Reverse run prohibit
44 SI4 /ALM-RST Alarm reset
45 SI5 /P-CL (Forward current limit) *
46 SI6 /N-CL (Reverse current limit) *
Note: * The functions of these input signals are automatically switched according to the setting at parameter Pn000.1
as long as Pn50A.0 is set to 0.
The following parameter is used to enable input signal allocation.

Input Signal Allocation Mode Speed/Torque Control,
Pn50A.0 Default Setting: 0 Position Control
Pn50A.0 Setting Description

Default setting for sequence input signal allocation.
0 This setting is the same as Yaskawa SGDB-oADo servo amplifiers.
1 Enables any sequence input signal settings.
Note: The default setting for parameter Pn50A.0 is 0. Functions and applications in this manual are gener-
5-50
ally described for the factory defaults.
n Input Signal Allocation

The following signal can be allocated when Pn50A.0 is set to 1.
Servo amplifier
/S-ON CN1
40 (SI0) CN1-40 is default set for
41 (SI1)
the /S-ON input signal.
Determines 42 (SI2)
terminal
allocation 43 (SI3) Any terminal from CN1-40 to
for input 44 (SI4) 46 can be allocated to the
signals. 45 (SI5) /S-ON signal through the
46 (SI6) Pn50A.1 parameter.
The following table shows the parameter default settings for input settings 1 to 4.
Setting
(ms)
Pn50A Input Signal Selections 1 Default Setting: 2100 Speed/Torque Control,

Position Control
Pn50B Input Signal Selections 2 Default Setting: 6543 Position Control
Pn50C Input Signal Selections 3 Default Setting: 8888 Speed/Torque Control,

Position Control
Pn50D Input Signal Selections 4 Default Setting: 8888 Speed/Torque Control,

Position Control
Select the input terminal on the CN1 connector that will be used for each input sig-
nal.
n Examples of Input Signal Allocation

The procedure used to allocate sequence input signals is described using the /S-ON
signal as a typical example.
Pn50A.
1 Description
Setting
0 Inputs the /S-ON signal from the SI0 (CN1-40) input terminal.
2 Inputs the /S-ON signal from the SI2 (CN1-42) input terminal. Signal polarity:
Normal.
3 Inputs the /S-ON signal from the SI3 (CN1-43) input terminal. Servo ON signal is
valid when low
4 Inputs the /S-ON signal from the SI4 (CN1-44) input terminal. (ON)
7 Sets /S-ON signal so that it is always valid.
8 Sets /S-ON signal so that it is always invalid.
5-51
Pn50A.
1 Description
Setting
9 Inputs the S-ON signal from the SI0 (CN1-40) input terminal.
A Inputs the/S-ON signal from the SI1 (CN1-41) input terminal.
B Inputs the S-ON signal from the SI2 (CN1-42) input terminal. Signal polarity:
Inversion.
C Inputs the S-ON signal from the SI3 (CN1-43) input terminal. Valid at OFF
(H level) with Servo
D Inputs the S-ON signal from the SI4 (CN1-44) input terminal. ON signal
E Inputs the S-ON signal from the SI5 (CN1-45) input terminal.
F Inputs the/S-ON signal from the SI6 (CN1-46) input terminal.
As shown in the table above, the /S-ON signal can be allocated to any input terminal
from SI0 to SI6. /S-ON is always input when Pn50A.1 is set to 7, and an external
signal line would therefore not be needed because the servo amplifier will determine
whether the servo is ON or OFF.
The /S-ON signal is not used when Pn50A.1 is set to 8. This setting is meaningful
only in the following instances.
When the factory set input signal are to be replaced by another input signal.
The signal must be left ON (low level) during normal operation to make the signal
valid when OFF (high level) when forward run prohibit (P-OT) and reverse run pro-
hibit (N-OT) are input. The input terminal signal line must be left ON even in sys-
tem configurations that do not require this signal, but unnecessary wiring can be
eliminated by setting Pn50A.1 to 8.
• By setting 9 to F, the signal polarity can be reversed.
Note: Several signals can be allocated to the same input circuit.
When the servo is ON, the forward run prohibit or reverse run prohibit signal is used.
At a setting with inverted polarity, the failed safe operation may not be possible in the case of signal
line disconnection.
5-52
n Allocating Other Input Signals

Input signal allocation can be changed as shown below.
Input Signal Parameter
Applicable Description
Name Number Setting
Logic
0 Inputs the signal on the left from SI0 (CN1-40).
Proportional Control Reference ON 7 Sets the signal on the left to always enabled.
(/P-CON) (low level) Pn50A.2
8 Sets the signal on the left to always disabled.
9 Inputs the inverse signal on the left from SI0 (CN1-40).
A Inputs the inverse signal on the left from SI1 (CN1-41).
B Inputs the inverse signal on the left from SI2 (CN1-42).
C Inputs the inverse signal on the left from SI3 (CN1-43).
D Inputs the inverse signal on the left from SI4 (CN1-44).
E Inputs the inverse signal on the left from SI5 (CN1-45).
F Inputs the inverse signal on the left from SI6 (CN1-46).
Forward Run Prohibit Pn50A.3
(P-OT) OFF
Reverse Run Prohibit (high level) Pn50B.0
(N-OT)
Alarm Reset Pn50B.1
(/ARM-RST)
Forward Current Limit ON Pn50B.2
(/P-CL) (low level)
Reverse Current Limit Pn50B.3
(/N-CL)
Contact Input Speed Control Selection Pn50C.0
(/SPD-D)
0 to F Same as above.*
Contact Input Speed Control Selection — Pn50C.1
(/SPD-A)
Contact Input Speed Control Selection Pn50C.2
(/SPD-B)
Control Mode Selection Pn50C.3
(/C-SEL)
Zero Clamp Pn50D.0
(/ZCLAMP) ON
Reference Pulse Inhibit (low level) Pn50D.1
(/INHIBIT)
Gain Switching Pn50D.2
(/G-SEL)
Note: *Same as above” means that input signals and terminals SI0 to SI6 are enabled or disabled through
parameter settings 0 to 8.
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5.3.4 Output Circuit Signal Allocation

Output signal functions can be allocated to the sequence signal output circuits shown
below.
CN1 Connector Default Setting

Output Terminal
Terminal Comments
Name Symbol Name
Numbers
25 /V–CMP+
(/COIN+) Speed coincidence The signal output
SO1 detection (positioning will vary depending
26 (SG) /V–CMP- completed) on the control mode.
(/COIN-)
27 /TGON+
SO2 Rotation detection
28 (SG) /TGON-
29 /S–RDY+
SO3 Servo ready
30 (SG) /S–RDY-
The output signal selection parameters and their default settings are shown below.
Setting
(ms)
Pn50E Output Signal Selections 1 Default Setting: 3211 Speed/Torque Control,

Position Control
Pn50F Output Signal Selections 2 Default Setting: 0000 Speed/Torque Control,

Position Control
Pn510 Output Signal Selections 3 Default Setting: 0000 Position Control
Select the CN1 connector terminals that will output the signals.
Pn50E.o to Pn510.o
1
SO1 (CN1-25, 26)
Output 2
signal SO2 (CN1-27, 28)
3
SO3 (CN1-29, 30)
5-54
Parameter
Output Signal Numbe Description
Setting
r
0 Disabled. (Not used for the output signal on

the left.)
1 Outputs the signal on the left from the SO1

Positioning Completed (CN1-25 and 26) output terminal.
(/COIN) Pn50E.0
Outputs the signal on the left from the SO2
2 (CN1-27 and 28) output terminal.
3 Outputs the signal on the left from the SO3

(CN1-29 and 30) output terminal.
Speed Coincidence
Detection Pn50E.1 0 to 3
(/V-CMP)
Rotation Detection
(/TGON) Pn50E.2 0 to 3
Servo Ready Pn50E.3 0 to 3

(/S-RDY)
Torque Limit Detection Pn50F.0 0 to 3
(/CLT) Same as above*
Speed Limit Detection
(/VLT) Pn50F.1 0 to 3
Brake Interlock Pn50F.2 0 to 3

(/BK)
Warning Pn50F.3 0 to 3
(/WARN)
Near
(/NEAR) Pn510.0 0 to 3
Not used. — — —
Note: *“Same as above” means output signals are disabled or allocated to output terminals SO1 to SO3
through parameter settings 0 to 3.
Note: Signals are output with OR logic when multiple signals are allocated to the same output circuit. Sig-
nals that are not detected are invalid. For example, the positioning completed signal /COIN is invalid
in Speed Control Mode.
The following parameters can be used to invert the signals on output terminals SO1
to SO3.
Setting
(ms)
Pn512 Output Signal Inverted Setting Default Setting: 0000 Speed/Torque Control,
Position Control
5-55
These settings specify which of the connector CN1 output signals are to be inverted:
Parameter
Output Terminal Description
Number Setting
SO1 0 Does not invert the signal.
Pn512.0
(CN1-25, 26) 1 Inverts the signal.
SO2 0 Does not invert the signal.
(CN1-27, 28) Pn512.1
1 Inverts the signal.
0 Does not invert the signal.
SO3(CN1-29, 30) Pn512.2
1 Inverts the signal.
Not used. Pn512.3 — —
5-56
5.3.5 Control Mode Selection

The SGDH servo amplifier offers speed control, position control, torque control, and
the other control modes shown in the following table.
The following parameter is used to set the control mode.
Setting
(ms)
Pn000.1 Control Mode Selection Default Setting: 0 Position Control
Pn000.1 Setting Control Mode

0 Speed Control (Analog Reference)
1 Position Control (Pulse Train Reference)
2 Torque Control (Analog Reference)
3 Contact Input Speed Control Selection (Contact Reference)
4 Contact Input Speed Control Selection (Contact Reference) ↔ Speed Control

(Analog Reference)
Contact Input Speed Control Selection (Contact Reference) ↔ Position Control
5 (Pulse Train Reference)
6 Contact Input Speed Control Selection (Contact Reference) ↔ Torque Control

(Analog Reference)
7 Position Control (Pulse Train Reference) ↔ Speed Control (Analog Reference)
8 Position Control (Pulse Train Reference) ↔ Torque Control (Analog Reference)
9 Torque Control (Analog Reference) ↔ Speed Control (Analog Reference)
A Speed Control (Analog Reference) ↔ Zero Clamp Control
B Position Control (Pulse Train Reference) ↔ Position Control (Inhibit)
n Description of Control Modes

The control modes are described below.
Speed Control (Analog Reference)

This mode controls speed using an analog voltage input reference. See 5.2.1 Speed
Reference.
Position Control (Pulse Train Reference)

This mode controls positioning using a pulse train input reference. See 5.2.2 Posi-
tion Reference.
Torque Control (Analog Reference)

This mode controls torque using an analog voltage input reference. See 5.2.7 Using
5-57
Torque Control.
Contact Input Speed Control Selection (Contact Reference)

This mode uses the /P-CON (/SPD-D), /P-CL (/SPD-A), and /N-CL (/SPD-B) input
signals to control speed as it switches among the three preset operating speeds in the
servo amplifier. See 5.2.6 Contact Input Speed Control.
Contact Input Speed Control Selection (Contact Reference) ↔

Speed Control (Analog Reference)
This mode controls speed by switching between contact reference and analog volt-
age reference speed control. Analog voltage reference speed control is enabled
when both /P-CL (/SPD-A) and /N-CL (/SPD-B) input signals are OFF (high level).
See 5.2.6 Contact Input Speed Control.
Contact Input Speed Control Selection (Contact Reference) ↔ Posi-

tion Control (Pulse Train Reference)
This mode switches between contact reference speed control and pulse train refer-
ence position control. Pulse train reference position control is enabled when both /P-
CL (/SPD-A) and /N-CL (/SPD-B) input signals are OFF (high level). See 5.2.6
Contact Input Speed Control.
Contact Input Speed Control Selection (Contact Reference) ↔

Torque Control (Analog Reference)
This mode switches between contact reference speed control and analog voltage ref-
erence torque control. Torque control using an analog voltage reference is enabled
when both /P-CL (/SPD–A) and /N-CL (/SPD-B) input signals are OFF (high level).
See 5.2.6 Contact Input Speed Control.
Position Control (Pulse Train Reference) ↔ Speed Control (Analog

Reference)
This mode switches between position and speed control through the /P-CON (/C-
SEL) signal.
Position Control (Pulse Train Reference) ↔ Torque Control (Ana-

log Reference)
This mode switches between position and torque control through the /P-CON (/C-
SEL) signal.
5-58
Torque Control (Analog Reference) ↔ Speed Control (Analog Ref-

erence)
This mode switches between torque and speed control through the /P-CON (/C-SEL)
signal. See 5.2.7 Using Torque Control.
Speed Control (Analog Reference) ↔ Zero Clamp

This speed control mode is used to set the zero clamp function when the servo ampli-
fier is stopped. Zero clamp operates when the /P-CON (/ZCLAMP) signal is ON
(low level). See 5.4.3 Using the Zero Clamp Function.
Position Control (Pulse Train Reference) ↔ Position Control

(Inhibit)
This mode controls positioning by inhibiting reference pulse input through the /P-
CON (/INHIBIT) signal. See 5.2.10 Using Reference Pulse Inhibit Function
(INHIBIT)
5-59
5.4 Setting Stop Functions

This section describes the procedure used to stop the servo amplifier properly.
5.4.1 Adjusting Offset
n When the Servomotor Will Not Stop

The servomotor may rotate at very low speed and not stop even when 0V is specified
as the reference voltage for servo amplifier speed and torque control (analog refer-
ence). This happens when the reference voltage from the host controller or external
circuit is slightly offset (in mV units). The servomotor will stop if this offset is prop-
erly adjusted to 0V.
Reference Reference
voltage Offset voltage
Offset
corrected by
the servo
amplifier
Reference Offset adjustment Reference

speed or speed or
torque torque
n Reference Offset Adjustment

The following methods can be used to adjust the reference offset to 0V.
Adjustment Method Result

Automatic Adjustment of Reference Offset The reference offset is automatically adjusted to 0V.
Manual Adjustment of Reference Offset The reference offset can be set to a specified value.
Note: Use manual rather than automatic adjustment if a position control loop is formed in the host control-
ler.
See the following sections in Chapter 7 Using the Digital Operator for more details
on adjustment procedures.
Adjustment Method Reference Source

Automatic Adjustment of Reference
Offset 7.2.3 Automatic Adjustment of the Speed and Torque Reference Offset
Manual Adjustment of Reference

Offset 7.2.4 Manual Adjustment of the Speed and Torque Reference Offset
5-60
5.4.2 Using the Dynamic Brake

To stop the servomotor by applying the dynamic brake (DB), set the desired mode in
the following parameter. The servomotor will stop due to equipment friction if the
dynamic brake is not applied.
Setting
(ms)
Pn001.0 Servo OFF or Alarm Stop Mode Default Setting: 0 Speed/Torque Control,
Position Control
The SGDH servo amplifier turns OFF under the following conditions:
• The Servo ON input signal (/S–ON, CN1–40) is turned OFF.
• A servo alarm occurs.
• Power is turned OFF.
Servo
OFF Stop mode After stopping
0
Pn001.0 = 0 Hold dynamic brake
or 1
Dynamic
brake stop
1
Coast status
Pn001.0
=2
Coast to a Coast status
stop
Specify the Stop Mode if any of these occurs during operation.
Pn001.0 Setting Result

Uses the dynamic brake to stop the servomotor.
0
Maintains dynamic brake after the servomotor stops.*
Uses the dynamic brake to stop the servomotor.
1 Releases dynamic brake after the servomotor stops, and the servomotor
coasts to a stop.
2 Coasts the servomotor to a stop.

The servomotor is turned OFF and motion stops due to equipment friction.
Note: * If the servomotor is stopped or moving at extremely low speed, it will coast to a stop.
Note: The dynamic brake is an emergency stop function. Do not repeatedly start and stop the servomotor
using the servo ON signal (/S–ON) or by repeatedly turning power ON and OFF.
Servo amplifier Servomotor
Note: Dynamic brake (DB) is a common way of quickly stopping

a servomotor by electrically shorting its electrical windings.
The DB circuit is incorporated into the servo amplifier.
5-61
5.4.3 Using the Zero Clamp Function
n Zero Clamp Function

The zero clamp function is used for systems where the host controller does not form
a position loop for the speed reference input. In other words, this function is used to
stop and lock the servomotor even when the input voltage of speed reference V-REF
is not 0V. An internal position loop is temporarily formed to clamp the servomotor
within one pulse when the zero clamp function is turned ON. Even if the servomotor
is forcibly rotated by external force, it will still return to the zero clamp position.
A speed reference lower than
the Pn501 setting is ignored. Stops
precisely.
Host controller Speed reference

V-REF
/P-CON
(/Z-CLAMP)
n Parameter Setting
Set the following parameter so that the input signal /P-CON (/ZCLAMP) can be
used to enable or disable the zero clamp function.
Setting
(ms)
Pn000.1 Control Method Selection Default Setting: 0 Speed Control
ð Input /P-CON CN1-41 Proportional Control, etc. Position Control
Note: The /ZCLAMP signal can be used when an input circuit signal is allocated. See 5.3.3 Input Circuit
Signal Allocation for more details.
5-62
Pn000.1 Setting Control Mode

Zero Clamp Control Mode
This mode allows the zero clamp
function to be set when the servomo-
tor stops. Servo amplifier
• The speed reference is input
from V-REF (CN1–5). Speed reference V-REF
• /P-CON (/ZCLAMP)(CN1–41) CN1-5
is used to turn the zero clamp
function ON and OFF. /P-CON
Zero clamp CN1-41
/ZCLAMP
A
CN1-41 is Turns the zero

open (OFF). clamp func- Zero clamp is performed when the fol-
tion OFF. lowing two conditions are satisfied:
Turns the zero • /P-CON (/ZCLAMP) is ON.
CN1-41 is 0V • Speed reference is below the
(ON). clamp func-
tion ON. setting designated at Pn501.
n Setting
Use the following parameter to set the motor speed level at which zero clamp is per-
formed.
Setting
(rpm)
Pn501 Zero Clamp Level Default Setting: 10 Speed Control
If zero clamp speed control is selected, set the motor speed at which zero clamp is to
be performed. The maximum speed will be used if the value of Pn501 is set higher
than the maximum speed of the servomotor.
Zero Clamp Conditions

Zero clamp is performed when all the following conditions are satisfied:
• Zero clamp speed control is selected (parameter Pn000.1 is set to A).
• /P-CON (/ZCLAMP)(CN1-41) is ON (0V).
5-63
• Speed reference drops below the setting level of Pn501.

V-REF speed reference
Speed
Preset value for zero clamping

Time
Closed
(ON)
/P-CON (/ZCLAMP) input Open (OFF)
Zero clamp is performed
Note: When the /ZCLAMP signal is allocated, the zero clamp operation will be used even for speed control
(Pn000.1 = 0).
5.4.4 Using the Holding Brake

The holding brake is used when a servodrive controls a vertical axis. In other words,
a servomotor with brake prevents the movable part from shifting due to the force of
gravity when system power goes OFF.
Servomotor
Holding brake
Prevents the movable part from

shifting due to gravity when
system power goes OFF.
Note: The brake built into the servomotor SGMoH with brakes is a de–energization brake, which is used
only to hold and cannot be used for braking. Use the holding brake only to hold a stopped motor.
Brake torque is at least 120% of the rated motor torque.
n Wiring Example
Use the servo amplifier contact output signal /BK and the brake power supply to
form a brake ON/OFF circuit. The following diagram shows a standard wiring
5-64
example.
Servomotor
Servo amplifier with brake
Power supply A (1)

L1 U
L2 B (2)
V
L3 W
C (3) M
L1C D (4)
L2C E (5)
BK-RY CN1-o* F (6) BK
(BK+)
+24V
CN2-o*
/BK-
CN2 PG
BK-RY Blue or
yellow Red
White AC DC Black
Brake power supplies are available
Brake Power Supply in 200V and 100V models.
*CN1-o and CN2-o are the output terminals allocated at parameter Pn510.0.
Output ð /BK Brake Interlock Output Position Control
This output signal controls the brake when using a servomotor with a brake and does
not have to be connected when using a servomotor without a brake.
State Status Result

ON: Closed or low level Releases the brake.
OFF: Open or high level Applies the brake.
Related Parameters
Parameter Description
Pn506 Time Delay from Brake Reference until Servo OFF
Pn507 Speed Level for Brake Reference Output during Motor Operation
Pn508 Timing for Brake Reference Output during Motor Operation
The following parameter must be selected to determine the location of the output
signal, when the /BK signal is used.

5-65
Pn50F.2 Input terminals

1
/BK CN1-25, 26 (SO1)
2
Brake interlock CN1-27, 28 (SO2)
output 3
CN1-29, 30 (SO3)
Select the /BK output terminal.
Output Terminal (CN1)

Parameter Setting
*1 *2
0 - -
1 25 26
Pn50F.2
2 27 28
3 29 30
Note: Signals are output with OR logic when multiple signals are allocated to the same output circuit. Set
other output signals to a value other than that allocated to the /BK signal in order to output the /BK
signal alone. See 5.3.4 Output Circuit Signal Allocation.
5-66
n Brake ON Timing
If the equipment moves slightly due to gravity when the brake is applied, set the fol-
lowing parameter to adjust brake ON timing.
Setting
(10ms)
Pn506 Brake Reference Servo OFF Setting Range: 0 to 50 Speed/Torque Control,

Delay Time Default Setting: 0 Position Control
This parameter is used to set the output time from the brake control signal /BK until
the servo OFF operation (servomotor output stop) when a servomotor with a brake is
used.
/S-ON input Servo ON
(CN1-40) Servo OFF
Release brake
Hold with brake
/BK output
Servomotor
Servo ON/OFF ON
Servomotor OFF
operation
(Servomotor
ON/OFF status)
Servo OFF
time delay
With the standard setting, the servo is turned OFF when the /BK signal (brake opera-
tion) is active. The equipment may move slightly due to gravity depending on
equipment configuration and brake characteristics. If this happens, use this parame-
ter to delay servo OFF timing.
This setting sets the brake ON timing when the servomotor is stopped. Use Pn507
and 508 for brake ON timing during operation.
Note: The servomotor will turn OFF immediately if an alarm occurs. The equipment may move due to grav-
ity in the time it takes for the brake to operate.
5-67
n Holding Brake Setting

Set the following parameters to adjust brake ON timing so the holding brake is
applied when the servomotor stops.
Pn507 Brake Reference Output Speed Setting Range: 0 to 10000rpm Speed/Torque Control,
Level Default Setting: 100rpm Position Control
Pn508 Timing for Brake Reference Out- Setting Range: 0 to 100 x 10ms Speed/Torque Control,
put during Motor Operation Default Setting: 50 x 10ms Position Control
Set the brake timing used when the servo is turned OFF by input signal /S-ON (CN1-
40) or when an alarm occurs during motor operation.
/S-ON input
Power OFF by Servo ON
/S-ON (CN1-40) Servo OFF
input or alarm
occurrence
Stop by dynamic brake

or coast to a stop.
Motor speed (Pn001.0)
(rpm)
Pn-507
Release
brake
/BK output Hold with brake
Pn508
Brake ON timing when the servomotor stops must be adjusted properly because ser-
vomotor brakes are designed as holding brakes. Adjust the parameter settings while
observing equipment operation.
/BK Signal Output Conditions During Servomotor Operation

The circuit is open under either of the following conditions:
• Motor speed drops below the setting at Pn507 after servo OFF.
• The time set at Pn508 has elapsed since servo OFF.
The actual speed used will be the maximum speed even if Pn507 is set higher than
the maximum speed.
5-68
5.5 Forming a Protective Sequence

This section describes the procedure for using I/O signals from the servo amplifier to
form a protective safety sequence.
5.5.1 Using Servo Alarm and Alarm Code Outputs

The basic procedure for connecting alarm output signals is described below.
I/O power supply
Servo amplifier
+24V 0V
Photocoupler output levels Photocoupler CN1-3 ALM+

per output node: 1
50mA max.
• Maximum operating
voltage: 30VDC CN1-32 ALM-
rent: 50mADC
CN1-37 ALO1
20mA max.
Open-collector output
CN1-38 ALO2
levels per output node:
voltage: 30VDC CN1-39 ALO3
rent: 20mADC CN1-1 SG
0V 0V
Host controller
A suitable external I/O power supply must be provided by the user separately
because there is no internal 24V power supply in the servo amplifier.
The use of the photocoupler output signals is described below.
Output ð ALM+ CN1-31 Servo Alarm Output Speed/Torque Control,

Position Control
Output ð ALM- CN1-32 Signal Ground for Servo Alarm Output Position Control
These alarms are output when a servo amplifier alarm is detected.

Servo amplifier
Alarm
detection ALM output
Turns power OFF.
Form an external circuit so this alarm output (ALM) turns the servo amplifier OFF.
State Status Result
ON Circuit between CN1-31 and 32 is closed, and Normal state.

CN1-31 is at low level.
Circuit between CN1-31 and 32 is open, and
OFF CN1-31 is at high level. Alarm state.
Alarm codes ALO1, ALO2 and ALO3 are output to indicate each alarm type.
5-69
The uses of open-collector output signals ALO1, ALO2 and ALO3 is described
below.
Output ð ALO1 CN1-37 Alarm Code Output Speed/Torque Control,

Position Control
Output ð ALO2 CN1-38 Alarm Code Output Speed/Torque Control,

Position Control
Output ð ALO3 CN1-39 Alarm Code Output Position Control
Output ð *SG CN1-1 Signal Ground for Alarm Code Output Speed/Torque Control,
Position Control
These signals output alarm codes to indicate the type of alarm detected by the servo
amplifier. Use these signals to display alarm codes at the host controller. See 9.2.3
Alarm Display Table for more on the relationship between alarm display and alarm
code output.
When a servo alarm (ALM) occurs, eliminate the cause of the alarm and set the fol-
lowing /ALM-RST input signal to high level (ON) to reset the alarm.
Input ð /ALM-RST CN1-44 Alarm Reset Speed/Torque Control,

Position Control
The alarm reset signal is used to reset a servo alarm.

Form an external circuit so the servo amplifier turns OFF when an alarm occurs.
Alarms are reset automatically when the control power supply is turned OFF.
Alarms can also be reset using a panel or digital operator.
Note: 1. Encoder alarms cannot always be reset by inputting the /ALM-RST signal. In that case, turn the
control power supply OFF to reset the alarm.
2. When an alarm occurs, always eliminate the cause before resetting the alarm. See 9.2.1 Trouble-
shooting Problems with Alarm Displays for more details on troubleshooting the system when an
alarm occurs.
5-70
5.5.2 Using the Servo ON Input Signal

The basic use and wiring procedure for the Servo ON (/S-ON) input signal
(sequence input signal) is described below. Use this signal to forcibly turn OFF the
servomotor from the host controller.
I/O power supply Servo amplifier
+24V +24VIN 3.3kΩ Photo
CN1-47 coupler
Host controller
/S-OUT CN1-40 7mA
0V
ð Input /S-ON CN1-40 Servo ON Position Control
This signal is used to turn the servomotor ON and OFF.
CN1-40
Status Result
State
Turns ON the servomotor: operates
ON Closed or low level according to signal input.
This is the default state.
Servomotor cannot operate.
OFF Open or high level Do not turn OFF the servomotor while it
is operating except in an emergency.
! CAUTION
• Do not use the Servo ON (/S-ON) signal to start or stop the motor. Always use an input reference sig-
nal, such as Speed Reference to start or stop the servomotor.
Doing so will shorten the life of the servo amplifier.
Set the following parameter to 7 if the /S-ON signal will not be used.

Pn50A.1 /S-ON Signal Mapping Default Setting: 0 Position Control
5-71
Servopack
CN1-40 The external short-circuit wiring shown

(/S-ON) in the figure can be omitted if the Serv
0V ON (/S-ON) input signal is not used.
Pn50A.1
Status Result
Setting
0 Enables the servo ON The servo is OFF when CN-40 is open, and is ON when
(/S-ON) input signal. CN1-40 is at 0V.
7 Disables the servo ON The servo is always ON, and has the same effect as
(/S-ON) input signal. shorting CN1-40 to 0V.
Note See 5.3.3 Input Circuit Signal Allocation for other Pn50A.1 settings.
5.5.3 Using the Positioning Completed Output Signal

The basic use and wiring procedure for the positioning completed (/COIN) output
signal (photocoupler output signal) is described below. The signal is output to indi-
cate that servomotor operation is completed.
I/O power supply
Servo amplifier +24V 0V
Photocoupler output levels

per output node: CN1-25 /COIN+
voltage: 30VDC CN1-26 /COIN-
rent: 50mADC
Positioning Completed Output

Output ð /COIN CN1-25 Signal Position Control
This signal indicates that servomotor movement has been completed during position
control. The host controller uses the signal as an interlock to confirm that position-
5-72
ing is completed.
Reference
Servomotor
Speed
Pn500
Error pulse
(Un008)
/COIN
(CN1-25)
/COIN
Status Result
State
ON Circuit between CN1–25 and 26 is Positioning is completed. (Position

closed, and CN1–25 is at low level. error is below the setting.)
Circuit between CN1–25 and 26 is Positioning is not completed. (Position
OFF open, and CN1–25 is at high level. error is above the setting.)
The following parameter is used to change the CN1 connector terminal that outputs
the /COIN signal.
Setting
(rpm)
Pn50E Output Signal Selections 1 Default Setting: 3211 Position Control
The parameter is factory set so the /COIN signal is output between CN1-25 and 26.
See 5.3.4 Output Circuit Signal Allocation for more details on parameter Pn50E.
The following parameter is used to set the number of error pulses and to adjust the
output timing of the positioning completed signal.
Setting
(reference units*)
Pn500 Positioning Completed Width Setting Range: 0 to 250 Position Control

Default Setting: 7
Note: *reference units for this parameter are the number of input pulses as defined using the electronic
gear function.
This parameter is used to set output timing for the positioning completed signal (/
COIN) when the position reference pulse is input and servomotor operation is com-
pleted.
Set the number of error pulses in reference units.
Too large a value set at this parameter may output only a small error during low-
speed operation that will cause the /COIN signal to be output continuously.
The positioning completed width setting has no effect on final positioning accuracy.
Note: /COIN is a position control signal.
With the default setting, this signal is used for the speed coincidence output /V-CMP for speed con-
5-73
trol, and it is always ON for torque control.
5.5.4 Speed Coincidence Output

The basic use and wiring procedures for the speed coincidence (/V-CMP) output sig-
nal (photocoupler output signal), used to indicate a match with the speed reference,
are described below. The host controller uses the signal as an interlock.
I/O power supply

per output node: CN1-25 /V-CMP+
voltage: 30VDC CN1-26 /V-CMP-
rent: 50mADC
Output ð /V-CMP CN1-25 Speed Coincidence Output Speed Control
This signal is output when the actual motor speed during speed control is the same as the
speed reference input.
/V-CMP
Status Result
State
Circuit between CN1-25 and 26 is Speed coincides. (Speed error is below
ON closed, and CN1–25 is at low level. the setting).
OFF Circuit between CN1-25 and 26 is Speed does not coincide. (Speed error
open, and CN1-25 is at high level. is above the setting).
Motor
speed
Pn503
Reference speed
/V-CMP is output in this range.
The following parameter setting is used to change the CN1 connector terminal that
outputs the /V-CMP signal.
Setting
(rpm)
The parameter is default set so the /V-CMP signal is output between CN1-25 and 26.
5-74
The following parameter is used to set conditions for speed coincidence output.
Setting
(rpm)
Pn503 Speed Coincidence Signal Out- Setting Range: 0 to 100 Speed Control
put Width Default Setting: 10
This parameter is used to set conditions for speed coincidence signal /TGON output.
The /V-CMP signal is output when the difference between the speed reference and
actual motor speed is below this setting.
Example:The /V-CMP signal turns ON at 1900 to 2100rpm if the parameter is set to 100 and the reference
speed is 2000rpm.
Note: /V-CMP is a speed control signal. With the default setting, this signal is used as the positioning com-
pleted signal /COIN for position control, and it is always ON for torque control.
5.5.5 Using the Running Output Signal

The basic use and wiring procedures for the running (/TGON) output signal (photo-
coupler output signal) are described below. The signal can be activated to indicate
that the servomotor is currently operating. It is used as an external interlock.
I/O power supply

per output node: CN1-27 /TGON+
voltage: 30VDC CN1-28 /TGON-
rent: 50mADC
Output ð /TGON CN1-27 Running Output Signal Position Control
/TGON
Status Result
State
Servomotor is operating. (Motor speed
ON Closed or low level. is above the setting level).
Servomotor is not operating. (Motor
OFF Open or high level. speed is below the setting level).
outputs the /TGON signal.
Setting
(rpm)
5-75
The parameter is default set so the /TGON signal is output between CN1-27 and 28.
This parameter is used to set output conditions for the operation detection output sig-
nal /TGON.
Pn502 (Running Output Level)
Motor speed
(Un000)
Pn502
/TGON
Setting
(rpm)
Setting Range: 1 to 10000 Speed/Torque Control,
Pn502 Rotation Detection Level Default Setting: 20 Position Control
This parameter is used to set the speed at which the servo amplifier determines that
the servomotor is running and then to output an appropriate signal. The following
signals are generated when motor speed exceeds the preset level.
Signals generated when servomotor operation is detected:
• /TGON
• Status Indication Mode
• Monitor Mode Un006
5.5.6 Using the Servo Ready Output Signal

The basic use and wiring procedures for the Servo Ready (/S-RDY) output signal
(photocoupler output signal) are described below.
Servo Ready means there are no servo alarms and the main circuit power supply is
turned ON. An added condition with absolute encoder specifications is that the SEN
signal is at high level and absolute data was output to the host controller.
I/O power supply

per output node: CN1-29 /S-RDY+
voltage: 30VDC CN1-30 /S-RDY-
rent: 50mADC
Output ð /S-RDY CN1-29 Servo Ready Output Signal Speed/Torque Control,

Position Control
5-76
This signal indicates that the servo amplifier has received the Servo ON signal and
has completed all preparations.
/S-RDY
Status Result
State
ON Closed or low level. Servomotor is ready.
OFF Open or high level. Servomotor is not ready.
outputs the /S-RDY signal.
Parameter Signal Setting) Description

The parameter is factory set so the /V-CMP signal is output between CN1-29 and 30.
5.5.7 Using the Warning Output Signal

The basic use and wiring procedure for the warning (/WARN) output signal (photo-
coupler output signal) are given below.
The signal consists of the following two output signals.
/WARN signals: Overload and regenerative overload

I/O power supply

per output node: CN1-o* /WARN+
voltage: 30VDC CN1-o* /WARN-
rent: 50mADC
Note: *CN1-o terminals are allocated using parameter Pn50F.3.
Output ð /WARN Warning Output Signal Position Control
This output signal indicates an overload or regenerative overload warning.
/WARN
Status Result
State
ON Closed or low level. Normal operation. No warning.
OFF Open or high level. Error warning.
5-77
outputs the /WARN signal.

Pn50F.3 is used to allocate the /WARN output signals above.
Pn50F.3 Output Terminal (CN1–)

State *1 *2
0 — —
1 25 26
2 27 28
3 29 30
nals to a value other than that allocated to the /WARN signal in order to use the /WARN output signal
alone. See 5.3.4 Output Circuit Signal Allocation.
Pn50F.3 Output terminals

1
CN1-25, 26 (SO1)
/WARN 2
Warning output CN1-27, 28 (SO2)
3
signal CN1-29, 30 (SO3)
The following parameter is used to output warning details with an alarm code.

Pn001.3 Warning CodeOutput Selection Default Setting: 0 Position Control
Pn001.3
Result
Setting
0 Outputs alarm codes alone for alarm codes

ALO1, ALO2 and ALO3.
Outputs both alarm and warning codes for
1 alarm codes ALO1, ALO2 and ALO3 and out-
puts an alarm code when an alarm occurs.
The following warning codes are output in 3 bits.
Warning Warning Code Output

Warning Description
Indication ALO1 ALO2 ALO3
ON signal OFF signal OFF signal
A.91 (low level) (high level) (high level) Overload
OFF signal ON signal OFF signal

A.92 (high level) (low level) (high level) Regenerative overload
5-78
5.5.8 Using the Near Output Signal

The basic use and wiring procedures for the near (/NEAR) output signal (photocou-
pler output signal) are described below. The signal is a sequence signal that is gener-
ally output together with the positioning completed signal (/COIN), and it is used to
indicate the servomotor is close to completing operation.
/NEAR signals: Near output signals

I/O power supply

per output node: CN1-o* /NEAR+
voltage: 30VDC CN1-o* /NEAR-
rent: 50mADC
Note: *CN1-o terminals are allocated using parameter Pn510.0.
Output ð /NEAR Near Output Signal Position Control
The host controller can use the /NEAR signal to prepare the next motion sequence
before receiving the positioning completed signal. This reduces the time required to
complete the desired motion profile.
/NEAR
Status Result
State
ON Closed or low level. The servomotor has nearly completed operation.

(Position error is below the near signal setting range.)
The servomotor is not close to completing operation.
OFF Open or high level. (Position error is above the near signal setting range.)
To use the /NEAR signal, an output terminal must be allocated with the parameter
below.

Pn510 Output Signal Selections 3 Default Setting: 0000 Position Control
Pn510.0 is used to allocate the /NEAR output signals above.
Pn510.0 Output Terminal (CN1–)

State *1 *2
0 — —
1 25 26
2 27 28
3 29 30
nals to a value other than that allocated to the /NEAR signal in order to use the /NEAR output signal
5-79
alone. See 5.3.4 Output Circuit Signal Allocation.
The following parameter is used to set the timing for /NEAR signal output.
Setting
(reference unit*)
Pn504 NEAR Signal Width Default Setting: 7 Position Control
*The number of input pulses defined using the electronic gear function.
Generally set the near signal width higher than the positioning completed width.
Also see 5.5.3 Using the Positioning Completed Output Signal.
Reference
Servomotor
Speed
Pn504 Pn500
Error pulse
/NEAR
/COIN
5.5.9 Handling Power Loss

The following parameter is used to specify whether to generate an alarm when
power loss occurs.
Setting
(ms)
Pn509 Momentary Hold Time Default Setting: 20 Position Control
The servo amplifier turns the servomotor OFF if it detects a voltage drop in the
power supply. The default setting of 20ms means that servomotor operation will
continue if power is lost for less than 20ms.
In the following instances, however, either a servo alarm is generated or control is
lost (equivalent to normal power OFF operation) regardless of the parameter setting.
• When an insufficient voltage alarm (A.41) occurs during power loss with a large
servomotor load.
• Loss of the control power supply is equivalent to normal power OFF operation,
thus control is lost.
5-80
In power loss detection, the status of the main circuit power supply is detected but
the OFF status is ignored. So servomotor operation will continuous if the servomo-
tor turns ON again within the time limit set at parameter Pn509.
Power supply Power loss

voltage
t OFF
Time
1. Pn509 setting > t OFF
2. Pn509 setting < t OFF
For 1.
Servo ON
For 2.
Servo ON Servo OFF
5-81
5.6 Selecting a Regenerative Resistor

When the servomotor is driven in generator mode, power is returned to the servo amplifier
side. This is called regenerative power. The regenerative power is absorbed by charging
the smoothing capacitor, but when the capacitor charging energy is exceeded, the regener-
ative power is further consumed by the regenerative resistor.
The servomotor is driven in regeneration (generator) mode in the following circum-
stances:
• While decelerating to a stop during acceleration/deceleration operation.
• With a load on the vertical axis.
• During continuous operation with the servomotor driven from the load side (negative
load).
The capacity of the servo amplifier’s built-in regenerative resistor is sufficient for short–
time operation only, such as for the deceleration stop period. Operation under a negative
load is not possible.
If the regenerative power exceeds the processing capacity of the servo amplifier, install an
external regenerative resistor. The following table shows the specifications of the servo
amplifier’s built–in resistor and the amount of regenerative power (average values) that it
can process.
Built-in Resistor Regenerative

Minimum
Specifications Power
Allowable
Applicable Servo Amplifiers Processed
Resistance Capacity Resistance
by Built-in
(Ω) (W) (Ω)
Resistor* (W)
100V SGDH–A3BE to –02BE — — — 40
SGDH–A3AE to –04AE — — —
40
SGDH–05AE to –10AE 50 60 12
200V SGDH–15AE 30 70 14 20
SGDH–20AE 25 140 28 12
SGDH–30AE 12.5 140 28 12
* The amount of regenerative power (average value) that can be processed is rated at 20% of the capac-
ity of the servo amplifier’s built-in regenerative resistor.
When installing an external regenerative resistor, make sure that the resistance is the same
as that of the servo amplifier’s built-in resistor. If combining multiple small-capacity
regenerative resistors to increase the regenerative resistor capacity (W), select resistors so
that the resistance value including error is at least as high as the minimum allowable resis-
tance shown in the above table.
5-82
5.6.1 External Regenerative Resistor
When installing an external regenerative resistor, a parameter setting must be changed as

shown below.
Setting
(x 10W)
Pn600 Regenerative Resistor Capacity Setting Range: 0 to maximum Speed/Torque Control,

The default setting of “0” in the above table is the set value when the servo amplifier’s
built-in resistor is used or when a servo amplifier without a built-in resistor is used.
When installing an external regenerative resistor, set the regenerative resistor’s capacity
(W).
Example: When the external regenerative resistor’s actual consumable capacity is 100W, set the parameter
to “10” (10 x 10W = 100W)
Note: 1. In general, when resistors for power are used at the rated load ratio, the resistor temperature
increases to between 200°C and 300°C. The resistors must be used at or below the rated values.
Check with the manufacturer for the resistor’s load characteristics. Use resistors at no more than
20% of the rated load ratio with natural convection cooling, and no more than 50% of the rated
load ratio with forced air cooling.
2. Use of resistors with thermo switches is recommended as a safety precaution.
n Connecting Regenerative Resistors

The method for connecting regenerative resistors is shown below.
Servo Amplifier Capacity of 400W or Less

Connect an external regenerative resistor between the servo amplifier’s B1 and B2
terminals.
Servo amplifier
Regenerative resistor*
B1
B2
*The user must provide the regenerative resistor.
Servo Amplifier Capacity of 500W or More

Disconnect the wire between the servo amplifier’s B2 and B3 terminals and connect
an external regenerative resistor between the B1 and B2 terminals.
5-83
Servo amplifier
Regenerative resistor
B1
B2
B3 Be sure to take out the lead wire

between the B2 and B3 terminals.
* The user must provide the regenerative resistor.
Note: Adequate cooling must be provided for regenerative resistors because they reach very high tempera-
tures. Also use heat-resistant, non-flammable wire and make sure that the wiring does not come into
contact with the resistors.
5.6.2 Calculating the Required Capacity of Regenerative Resistors
n By Means of a Simple Calculation

When driving a servomotor normally along the horizontal axis, check the external
regenerative resistor requirements using the calculation method shown below.
Servo Amplifiers with Capacity of 400W or Less

Servo amplifiers with a capacity of 400W or less do not have built-in regenerative
resistors. The energy that can be absorbed by capacitors is shown in the following
table. If the rotational energy in the servo system exceeds these values, then connect
a regenerative resistor externally.
Regenerative Energy that

Applicable Servo
Voltage Can be Processed Remarks
Amplifiers
(joules)
SGDH–A3BE 7.8 Value when input voltage is
100V 100VAC
SGDH–A5BE to –02BE 15.7
SGDH–A3AE,–A5AE 18.5 Value when input voltage is
200V 200VAC
SGDH–01AE to –04AE 37.1
Calculate the rotational energy in the servo system using the following equation:
J x (NM)2
ES =
182 (joules)
Where: J = JM + JL
JM: Servomotor rotor inertia (kg·m2) (oz·in·s2)

JL: Motor axis conversion load inertia (kg·m2) (oz·in·s2)
NM: Rotation speed of thee servomotor (rpm)
5-84
Servo Amplifier Capacity of 500W or More

Servomotors with a capacity of 500W or more have built-in regenerative resistors.
The allowable frequencies for just the servomotor during acceleration/deceleration
operation, in the run cycle from 0 à maximum rotation speed à 0, are summarized
in the following table.
Convert the data into the values obtained with actual rotation speed used and load
inertia to determine whether an external regenerative resistor is needed.
Series Allowable Frequencies in Regeneration Mode (times/min)

Capacity
03 05 06 08 09 10 12 13 15 20 30
Symbol
SGMAH — — — 89 — — — — — — —
SGMPH — — — 29 — — — — — — —
SGMGH-oAoA — 34 — — 13 — — 10 — 12 8
SGMGH-oAoB 96 — 39 — 22 — 15 — — 20 13
SGMSH — — — — — 39 — — 31 48 20
Operating Conditions for Allowable Regenerative Frequency Calculation

Load inertia = 0 (motor only)
Speed reference
0 t
Maximum rotation speed
Servomotor rotation speed 0 t

Regeneration mode
Maximum cycle
Servomotor-generated torque 0 t
Maximum cycle
T
(Operating cycle)
Allowable frequency = 1 Cycles
T Minute
Use the following equation to calculate the allowable frequency for regeneration
mode operation.
( )
2
Allowable frequency for servomotor only Max. rotation speed Cycles
Allowable frequency = ×
(1 + n) Rotation speed used Minute
Where: n = JL/JM
JM: Servomotor rotary inertia [oz·in·s2 (kg·m2)]
JL: Motor axis conversion load inertia [oz·in·s2 (kg·m2)]
5-85
n By Calculating the Regenerative Energy

This section shows the procedure for calculating the regenerative resistor capacity
when acceleration and deceleration operation is as shown in the following diagram.
NM: Motor rotation speed
Rotation speed
0
tD
TL: Load torque
Motor torque
Regenerative
torque
T
Calculation Procedure
The procedure for calculating the capacity is as follows:
Units
Step Procedure Equation
[in. (mm)]
(JL + JM) × ΝΜ2

ES = [Joules] = [J]= ES =
1
Find the rotational energy of the [ oz·in·s2 (kg·m2·s2)] 182
servo system (ES). JL = JM = J Where: NM = Motor speed
NM = rpm JL = Load Inertia
JM = Motor Inertia
(Ν )
τL = oz·in (N·m)
Find the energy consumed by π
2 load system loss (EL) during the EL = Joules = J EL = Μ × τL× tD
NM = rpm 60
deceleration period (tD).
tD = s Where: τL = Motor torque
Calculate the energy lost (EM) tD = s EM = Value from the “Servomotor

3 from servomotor winding resis- EM = Joules = J Winding Resistance Loss” graph
tance. below.
Calculate the servoamp energy EC = Value from the “Absorbable

4 (EC) that can be absorbed. EC = Joules = J Servo Amplifier Energy” graph
below.
5
Find the energy consumed by
the regenerative resistor (EK).
EK = ES =EL =EM = EC =
Joules = J
(
EK = ES — EL +EM + EC )
WK = W EK
Calculate the required regener- WK =
6 EK = Joules = J
ative resistor capacity (WK). 0.2 × T
T = s
Where: T = Time
Note: 1. The “0.2” in the equation for calculating WK is the value for when the regenerative resistor’s uti-
lized load ratio is 20%.
5-86
If the previous calculation determines that the amount of regenerative power (Wk)
that can be processed by the built-in resistor is not exceeded, then an external regen-
erative resistor is not required.
If the amount of regenerative power that can be processed by the built-in resistor is
exceeded, install an external regenerative resistor for the capacity obtained from the
above calculation.
If the energy consumed by load system loss (in step 2 above) is unknown, then per-
form the calculation using EL = 0.
When the operation period in regeneration mode is continuous, add the following
items to the above calculation procedure in order to find the required capacity (W)
for the regenerative resistor.
• Energy for continuous regeneration mode operation period: EG (joules)
• Energy consumed by regenerative resistor: EK = ES - (EL + EM + EC) + EG
• Required capacity of regenerative resistor: WK = EK/ (0.2 × T)

Here, EG = (2π/60) NMG × τG × tG
• τG:Servomotor’s generated torque [oz·in (N·m)] in continuous regeneration

mode operation period.
• NMG: Servomotor rotation speed (rpm) for same operation period as above.
• tG: Same operation period (s) as above.
Servomotor Winding Resistance Loss

The following diagrams show the relationship between the generated torque and the
winding resistance loss for each servomotor.
• SGMAH Servomotor, 200V • SGMAH Servomotor, 100V
300 200
SGMAH-
SGMAH- 180 01B
04A 02B
250
08A 160
Loss
Loss
140
200
120
(W) 01A, 02A (W) A5B
150 100
80 A3b
A5A
100
60
A3A
40
50
20
0 0
0 100 200 300 0 100 200 300
Torque (%) Torque (%)
5-87
• SGMPH Servomotor, 200V • SGMPH Servomotor, 100V
300 160
SGMPH-
15A
08A 140
250 SGMPH-
02B
120
Loss
Loss
01B
200
100
(W) 04A (W)
150 80
01A
60
100
02A 40
50
20
0 0
0 100 200 300 0 100 200 300
Torque (%) Torque (%)
• SGMGH Servomotor, 1500rpm
1600
1400
1200
Loss
SGMGH-
1000 30AoA
(W) 2oAoA
800 13AoA
600
09AoA
400
05AoA
200
0
0 100 200 300
Torque (%)
5-88
• SGMSH Servomotor •
1200
SGMSH-
1000 30A
20A
Loss
800
(W)
600 15A
10A
400
200
0
0 100 200 300
Torque (%)
Servo Amplifier’s Absorbable Energy

The following diagrams show the relationship between the servoamp’s input power
supply voltage and its absorbable energy.
• Servo Amplifier for 200V motor • Servo Amplifier for 100V motor
120 18
Servo amplifier
Servo amplifier AGDH
16 A5BE to 02BE
100 SGDH
Absorbable energy
Absorbable energy
20AE, 30AE 14
01AE to 04AE
80 05AE to 10AE 12
15AE
A3AE, A5AE 10
60
A3BE
8
40 6
(J)
(J)
4
20
2
0 0
180 200 220 240 260
90 100 110 120
AC input power supply voltage (Vrms)
AC input power supply voltage (Vrms)
5-89
5.7 Absolute Encoders

If a motor with an absolute encoder is used, a system to detect the absolute position can be
formed in the host controller. Consequently, automatic operation can be performed with-
out zero return operation immediately after the power is turned ON.
Motor SGMoH–ooo1o···With 16-bit absolute encoder

SGMoH–ooo2o···With 17-bit absolute encoder
Always detects Origin return operation

absolute position.
Absolute encoder
5.7.1 Interface Circuit

The following diagram shows the standard connections for an absolute encoder
mounted to a servomotor.
+5V SEN CN1 CN2 PG5V
4 1 H (1)
7406 OSEN P PG0V P G (2)
2 2
0V BAT 21 3 BAT (+) T (3)
+ P
Battery - BATO 22 4 BAT (-) P S (4)
Serial interface Line driver PAO
circuit
/PAO 33
R P 34
UP PA PBO PS C (5)
Up/down Edge 35 5 PG
counter detection R /PBO P /PS P D (6)
PB 36 6
DOWN PCO
/PCO 19
PC R P 20
Clear
Serial interface
PSO
R /PSO P 48
circuit 49
PS
SG
1
0V Connector shell
J
P: Indicates twisted pair wires Shielded wire (shell)
Applicable line drivers: SN75175 or MC3486 by TI.

Terminating resistance R: 220 to 470Ω
5-90
n SEN Signals
+5V SEN CN1-4 1000Ω
Approx. 1mA 4.7kΩ 1µF

7406 or at high level
equivalent
0V OSEN CN1-2 0V
• Wait at least three seconds after turning on the power before raising the SEN sig-
nal to high level.
• When the SEN signal is changed from low level to high level, the multi–turn data
and initial incremental pulses are transmitted.
• The motor cannot be operated until these operations are completed, regardless of
the status of the servo ON signal (/S–ON).
Note: If for some reason it is necessary to turn OFF a SEN signal that is already ON, and then to turn it back
ON again, maintain the high level for at least 1.3 seconds before turning it ON and OFF.
SEN signal OFF ON = high level OFF ON
1.3s minimum 15ms (minimum)
5.7.2 Configuring an Absolute Encoder

Select the absolute encoder’s application with the following parameter.

Setting Range: 0 or 1 Speed/Torque Control,
Pn002.2 Absolute Encoder Application Default Setting: 0 Position Control
Either “0” or “1” in the following table must be set in order to enable the absolute
encoder.

0 Uses the absolute encoder as an absolute encoder.
1 Uses the absolute encoder as an incremental encoder.
The following parameter is used to periodically clear the encoder’s counter (return
the setting to 0) after a designated ratio of motor to load axis revolutions. This func-
tion is called the multi-turn limit.
Note: The term Multi-turn Limit refers to the highest number of rotations the encoder’s counter will dis-
5-91
play before returning the counter to 0.
Pn205 Multi-turn Limit Setting Setting Range: 0 to 65535 Speed/Torque Control,

• When Pn205 is set to the default (65535), multi-turn data varies in the range of
−32768 to +32767.
• With any other Pn205 value entered, data varies from 0 to the set value.
Note: To activate reassignment of this value, the user must first enter the change to the parameter, and then
cycle (turn OFF and then turn ON) the power.
Since the encoder’s multi-turn limit value is set as default to 65535, the following
alarm occurs if the servo amplifier’s power supply is cycled (turned OFF and ON)
after changing parameter Pn205:
Alarm Code Output

Alarm Display Description
ALO1 ALO2 ALO3
A.CC O X O Encoder multi-turn limit value does not

match with that of the servo amplifier.
Note: O: ON (“L”) signal

X: OFF (“H”) signal
In order to set a multi-turn limit value to the encoder, perform the multi-term limit
setting operation (Fn-013).
This operation can be executed using the hand-held digital operator or the servo
amplifier panel operator.
Note: The multi-turn limit setting is enabled only during the multi-turn limit value mismatch alarm. Cycle
the power after performing this operation.
! WARNING
• Connect the ground terminal to a class–3 ground (100Ω Ω or less).
Improper grounding may result in electric shock or fire.
5.7.3 Handling Batteries

In order for the absolute encoder to retain position data when the power is turned
OFF, the data must be backed up by a battery.
n Installing the Battery at the Host Device

Lithium battery, by Toshiba: ER6VC3, 3.6V, 2000mAh
5-92
n Battery Provided for Servo Amplifier

Lithium battery: JZSP–BA01 (includes battery and connector)
Battery: Toshiba, ER3 V, 3.6V, 1000mAh
Battery carrying space
Batter connector (CN8)
! WARNING
• Install the battery at either the host controller or the servo amplifier, NEVER at both simultaneously.
Such a connection would create a circuit between the batteries, which could lead to electric shock, injury, or
equipment damage.
5.7.4 Absolute Encoder Setup

Perform the setup operation for the absolute encoder in the following circumstances:
• When starting the machine for the first time.
• When an encoder backup alarm is generated.
When the servo amplifier’s power supply is turned OFF and the encoder’s cable is
removed.
The setup operation can be performed by using the hand-held digital operator, the
servo amplifier’s panel operator, or with personal computer monitor software.
The setup operation procedure shown here uses the digital operator. For more
details, refer to Chapter 7: Using the Digital Operator.
n Setup Using the Hand-held Digital Operator

1. Press the DSPL/SET key to select the auxiliary function mode.
2. Select the user function Fn008. Press the Left Arrow or Right Arrow
key to select the digit to set, and then press the Up Arrow or Down Arrow
5-93
key to change the number.
3. Press the DATA/ENTER key. The following display will appear.
4. Pressing the Up Arrow key will change the display as shown below. Con-
tinue pressing the Up Arrow key until “PGCL5” is displayed. If an erroneous
key entry is made, “nO_OP” will flash for one second and the display will return
to the auxiliary function mode. In that case, go back to step 3 above and perform
the operation again.
When an erroneous key entry is made
Up Cursor Key
Flashes for one second.
Up Cursor Key
Returns to auxiliary function mode.
5. When “PGCL5” is displayed, press the DSPL/SET key. The display will change
as follows, and the absolute encoder’s multi–turn data will be cleared.
Flashes for
1 second.
6. Press the DATA/ENTER key to return to the auxiliary function mode.
This completes the absolute encoder’s setup operation. Cycle the power to the servo
amplifier.
n Setup Using the Built–in Panel Operator

5-94
2. Press the Up Arrow or Down Arrow key to select the parameter Fn008.
3. Press the DATA/SHIFT key, holding it down for at least one second. The fol-
lowing display will appear.
4. Press the Up Arrow key, holding it down until “PGCL5” is displayed. If an

erroneous key entry is made, “nO_OP” will flash for one second and the display
will return to the auxiliary function mode. In that case, go back to step 3 above
and perform the operation again.
When an erroneous key entry is made
Up Cursor Key
Flashes for one second.
Up Cursor Key
Returns to auxiliary function mode.
5. When “PGCL5” is displayed, press the MODE/SET key. The display will
change as follows, and the absolute encoder’s multi–turn data will be cleared .
Flashes for
1 second.
6. Press the DATA/SHIFT key to return to the auxiliary function mode.
This completes the absolute encoder’s setup operation. Cycle the power to the servo
amplifier.
Note: If the following absolute encoder alarms are displayed, the alarms must be cleared using the method
described above for the setup operation. They cannot be cleared by the servo amplifier’s alarm reset
(/ARM–RST) input signal.
• Encoder backup alarm (A.81)
• Encoder sum check alarm (A.82)
In addition, if a monitoring alarm is generated in the encoder, the alarm must be cleared by turning
OFF the power.
5-95
n Multi-turn Setup Using the Hand-held Digital Operator

2. Select the user function Fn013. Press the Left Arrow or Right Arrow
key to select the digit to set, and then press the Up Arrow or Down Arrow
key to change the number.
3. Press the DATA/ENTER key. The following display will appear.

Flashes for
1 second.
4. Press the DSPL/SET key. The display will change as follows, and the absolute
encoder’s multi–turn data will be cleared.
Flashes for
1 second.
This completes the absolute encoder’s multi-turn limit setting operation. Cycle the
power.
n Multi-turn Setup Using the Built-in Panel Operator

3. Press the DATA/SHIFT key. The following display will appear.

Flashes for
1 second.
5-96
4. Press the MODE/SET key. The display will change as follows, and the absolute
encoder’s multi–turn limit setting operation will be performed.
Flashes for
1 second.
This completes the absolute encoder’s multi-turn limit setting operation. Cycle the
power to the servo amplifier.
! WARNING
• The multi-turn limit value should be changed only for special applications.
Cahanging it inappropriately or unintentionally can be dangerous.
• If the Multi-turn Limit Value Disagreement Alarm occurs, check the setting of parameter Pn205 in
the servo amplifier to be sure that it is correct. If Fn013 is executed when an incorrect value is set in
Pn205, that same incorrect value will be set in the encoder. There will not be an additional alarm,
even if an incorrect value is set, but incorrect positions will be detected.
This results in a potentially dangerous situation where the machine will move to an unexpected position.
5.7.5 Absolute Encoder Reception Sequence

The sequence in which the servo amplifier receives data from the absolute encoder
and transmits them to the host device is shown below.
Be sure you understand this section when designing the host device.
n Outline of Absolute Signals

The absolute encoder’s outputs are PAO, PBO, PCO, and PSO signals as shown
below.
Servo amplifier
Dividing PAO
PG PS Serial data
circuit
pulse conversion PBO
(Pn201)
PCO
Data data PSO

conversion
5-97
Signal Status Contents
Initial State Serial data

PAO Initial incremental pulse
Normal State Incremental pulse
Initial State Initial incremental pulse
PBO
Incremental pulse
PCO Normal State Home position pulse
PSO Rotation count serial data
n Contents of Absolute Data
• Serial data: Indicates how many turns the motor shaft has made from the refer-
ence position (position specified at setup).
• Initial incremental pulse: Outputs pulses at the same pulse rate as when the
motor shaft rotates from the home position to the current position at approxi-
mately 2500rpm (for 16 bits when the dividing pulse is at the default setting).
Reference position (setup) Current position
-1 0 +1 +2 +3
Coordinate value
+0 +1 +2 +3
Value M
M×R PO
PE
PS PM
The final absolute data PM can be found by using the following formulae:
Forward rotation mode: PE = M × R + PO Reverse rotation mode: PE = − M × R + PO ( )
(Pn0000.0 = 1)
PM = PE − PS PM = PE − RS
Where: PE = The current value read by the encoder.
M = The multi-turn data (rotation count data).
PO = The number of initial incremental pulses.
PS = The number of initial incremental pulses read at setup.
(This is saved and controlled by the host controller).
PM = The current value required for the user’s system.
R = The number of pulses per encoder revolution.
(Pulse count after dividing by the value of Pn201)
n Absolute Encoder Transmission Sequence

1. Set the SEN signal at high level.
2. After 100ms, set the system to serial data reception-waiting-state. Clear the
5-98
incremental pulse up/down counter to zero.

3. Receive eight bytes of serial data.
4. The system enters a normal incremental operation state approximately 50ms
after the last serial data is received.
Rotation count Initial incremental pulses
SEN signal serial data
Incremental pulses
PAO Undefined
(Phase A) (Phase A)
Initial Incremental pulses
PBO Undefined incremental pulses
(Phase B) (Phase B)
10ms Rotation count serial data
PSO Undefined max. 60ms minimum
90ms typical 1 to 3ms
260ms maximum
50 ms 25ms maximum
Approx. 15ms
n Detailed Signal Specifications
PAO Serial Data Specifications

The number of revolutions is output in five digits.
Start–stop Synchronization
Data Transfer Method
(ASYNC)
Baud rate 9600bps
Start bits 1 bit
Stop bits 1 bit
Parity Even
Character code ASCII 7–bit code
Data format 8 characters, as shown below.
“P” “+” or “-” “0” to “9” “CR”
0 00 00 10 10 1
Data Stop bit

Start bit Even parity
Note: 1. Data is “P+00000” (CR) or “P-00000” (CR) when the number of revolutions is zero.
2. The revolution range is “+32767” to “-32768.” When this range is exceeded, the data changes
from “+32767” to “-32768” or from “-32768” to “+32767”
5-99
PSO Serial Data Specifications

The number of revolutions and the absolute position within one revolution are
always output in five and seven digits, respectively. The data output cycle is approx-
imately 40ms.
Start–stop Synchronization
Data Transfer Method
(ASYNC)
Baud rate 9600 bps
Start bits 1 bit
Stop bits 1 bit
Parity Even
Character code ASCII 7–bit code
Data format 13 characters, as shown below.
“P” “+” or “-” “0” to “9” “CR”
0 00 00 10 10 1
Data Stop bit

Start bit Even parity
Note: 1. The absolute position data within one revolution is the value before dividing.
2. Absolute position data increases during forward rotation. (Not valid in reverse rotation mode).
Incremental Pulses and Origin Pulses

Just as with normal incremental pulses, initial incremental pulses which provide
absolute data are first divided by the frequency divider inside the Servo Amplifier
and then output.
Forward rotation Reverse rotation
Phase A Phase A
Phase B Phase B
Phase C Phase C
t t
Setting the Pulse Dividing Ratio

Use the following parameter to set the pulse dividing ratio.
Setting
(p/rev)
Pn201 PG Divider Setting Range: 16 to 16384 Speed/Torque Control,

5-100
This parameter sets the number of output pulses for PG output signals (PAO, /PAO,
PBO, /PBO).
Pulses from the motor encoder (PG) are divided by the number of pulses set here
before being output.
The set value is the number of output pulses per revolution. Set this value according
to the reference unit of the machine or controller to be used.
The setting range varies according to the encoder used.
Servo amplifier
Servomotor
Encoder
PS
Output terminals:
PG PAO PAO (CN1-33)
Divider
PBO Output /PAO (CN1-34)
PBO (CN1-35)
Setting Example /PBO (CN1-36)
Set value: 16
Motor one revolution
n Transferring Alarm Contents

When an absolute encoder is used, SEN signals can be utilized to transfer the alarm
contents through PAO outputs to the host device as serial data.
Alarm Contents Output Example
SEN Signal High: Error detection Low
Absolute encoder
Digital Operator Display backup alarm
or
PAO Serial Data ALM81 CR
Incremental pulses
Note: Refer to 9.2.3 Alarm Display Table for a table of alarm contents.
5-101
5.8 Special Wiring
This section describes special wiring methods including the one for noise control. In addi-
tion to 5.8.1 Wiring Precautions and 5.8.2 Wiring for Noise Control, refer to other sections
as necessary.
5.8.1 Wiring Precautions

To ensure safe and stable operation, always observe the following wiring precau-
tions:
1. Always use the following cables for reference input and encoder wiring.
Yaskawa Maximum
Cable Type
Drawing Number Allowable Length
Reference Twisted–pair wires JZSP–CKI01 118in (3m)
Input
Multiconductor JZSP–CMP00 SGMAH, SGMPH
Encoder shielded twisted–
pair wire JZSP–CMP02 SGMGH, SGMSH
• Trim off the excess portion of the cable to minimize the cable length.
2. For a ground wire, use as large a wire as possible: AWG14( 2.0mm2) or larger.
• At least class-3 ground (100 Ω maximum) is recommended.

• Ground to one point only.
• If the motor is insulated from the machine, ground the motor directly.
3. Do not bend or apply tension to cables.
The conductor of a signal cable is very thin (0.0079 to 0.012in. (0.2 to 0.3mm)),
handle the cables with care.
4. Use a noise filter to prevent noise interference.
(For details, refer to 5.8.2 Wiring for Noise Control.)
• If the equipment is to be used near private houses or may receive noise interfer-
ence, install a noise filter on the input side of the power supply line.
• Since this servo amplifier is designed as an industrial device, it provides no
5-102
mechanism to prevent noise interference.
5. To prevent malfunction due to noise, take the following actions:

• Position the input reference device and noise filter as close to the servo amplifier
as possible.
• Always install a surge absorber circuit in the relay, solenoid and electromagnetic
contactor coils.
• The distance between a power line (such as a power supply line or motor cable)
and a signal line must be at least XXin. (30cm). Do not put the power and signal
lines in the same duct or bundle them together.
• Do not share the power supply with an electric welder or electrical discharge
machine. When the servo amplifier is placed near a high-frequency oscillator,
install a noise filter on the input side of the power supply line.
Note: 1. Since the servo amplifier uses high-speed switching elements, signal lines may receive noise.
To prevent this, always take the above precautions.
2. For details on grounding and noise filters, refer to 5.8.2 Wiring for Noise Control.
6. Use a UL listed molded-case circuit breaker (MCCB) or fuse in accordance with

the National Electrical Code (NEC) to protect the power supply line from high
voltage.
• This Servo Amplifier connects directly to a commercial power supply without a
transformer, so always use an MCCB or fuse to protect the servo system from
accidental high voltage.
• Select an appropriate MCCB or fuse according to the servo amplifier capacity
and the number of servo amplifiers to be used as shown in the following table.
5-103
n MCCB or Fuse According to Power Capacity

The following table shows the MCCB or fuse capacity for each power supply capac-
ity.
Servo Amplifier
Main Circuit Model Power Capacity per Current Capacity per
Power Applicable Motor Servo Amplifier MCCB or Fuse
Supply Capacity (kVA)* (Arms)* **
SGDH–
(kW)
0.03 A3BE SGMAH–A3B 0.15
0.05 A5BE SGMAH–A5B 0.25
4
Single–phase, SGMAH–01B
100V 0.10 01BE 0.40
SGMPH–01B
SGMAH–02B
0.20 02BE 0.60 6
SGMPH–02B
0.03 A3AE SGMAH–A3A 0.20
0.05 A5AE SGMAH–A5A 0.25
SGMAH–01A
0.10 01AE 0.40 4
Single–phase, SGMPH–01A
200V SGMAH–02A
0.20 02AE 0.75
SGMPH–02A
SGMAH–04A
0.40 04AE 1.2 8
SGMPH–04A
SGMGH–05AoA
0.50 05AE 1.4 4
SGMGH–03AoB
SGMAH–08A
0.75 08AE SGMPH–08A 1.9
SGMGH–06AoB
7
SGMGH–09AoA
1.0 10AE SGMGH–09AoB 2.3
SGMSH–10A
Three–phase, SGMPH–15A
200V SGMGH–13AoA
1.5 15AE 3.2 10
SGMGH–12AoB
SGMSH–15A
SGMGH–20AoA
2.0 20AE SGMGH–20AoB 4.3 13
SGMSH–20A
SGMGH–30AoA
3.0 30AE SGMGH–30AoB 5.9 17
SGMSH–30A
* This is the net value at the rated load. When actually selecting fuses, determine the capacity using the
prescribed derating.
** Operating characteristics (at 25°C): 2 seconds or more for 200%, 0.01 second or more for 700%
Note: A fast-operating fuse cannot be used because the Servo Amplifier power supply is a capacitor input
type. A fast-operating fuse may blow when the power is turned ON.
5-104
Note: SGDH servo amplifiers do not have built-in ground protection circuits. To configure a safer system,
install a ground fault interrupter with or without a circuit breaker for protection against overload and
short circuit conditions.
5.8.2 Wiring for Noise Control
n Wiring Example
This servo amplifier uses high-speed switching elements in the main circuit. It may
receive “switching noise” from these high-speed switching elements if wiring or
grounding around the servo amplifier is not appropriate. To prevent this, always
wire and ground the servo amplifier correctly.
This servo amplifier has a built-in microprocessor (CPU). To protect it from exter-
nal noise install a noise filter in the appropriate place.
The following is an example of wiring for noise control.
Noise filter*** Servo amplifier Servomotor
L1 U
M
AC200V 2LF L2 V (FG)
L3 W
0.005in.2
(3.5mm2) (Casing) L1C CN2 PG
minimum L2C CN1
0.003in.2
•Operation relay (2mm2)
sequence minimum
•Signal generation
circuit (provided
P by user)
0.005in.2
AVR
P 1LF* P (Ground) (3.5mm2)
minimum
0.003in.2 (2mm2) minimum**
2 2
(Casing) (Casing) (Casing) 0.005in. (3.5mm )minimum
2 2
Wires of 0.005in. (3.5mm )minimum
(Casing)
P: Indicates twisted pair wires

Notes: *When using a noise filter, follow the precautions in Using a Noise Filter on the following page.
**For ground wires connecting to the casing, use a wire with a thickness of at least 0.005in2
(3.5mm2), preferably a braided flat copper wire.
5-105
n Correct Grounding
Grounding the Motor Frame

Always connect servomotor frame terminal FG to the servo amplifier ground termi-
nal . Also be sure to ground the ground terminal .
If the servomotor is grounded via the machine, switching noise current will flow
from the servo amplifier power unit through motor stray capacitance. The ground-
ing of the motor frame is required to prevent the adverse effects of switching noise.
Noise on the Reference Input Line
If the reference input line is affected by noise, ground the 0V line (SG) of the refer-
ence input line. If the main circuit wiring for the motor is accommodated in a metal
conduit, ground the conduit and its junction box.
All grounds must be made to only one point in the system.
n Using Noise Filters

Use a noise suppression filter to prevent noise generated by the power supply line.
Install a noise filter on the power supply line for peripheral equipment as necessary.
The following table recommends noise filters for each servo amplifier model.
Recommended Noise Filter

Servo Amplifier Model
Model Manufacturer
SGDH–A3AE to –02AE
SGDH–A3BE to –01BE SUP–P5H–EPR
SGDH–02BE SUP–P8H–EPR Okaya Electric Company
SGDH–04AE SUP–P10H–EPR
SGDH–05AE to –20AE LF–3200
Tokin Corp.
SGDH–30AE LF–3300
Note: Filters manufactured by Tokin Corp. are available from Yaskawa. Please contact Yaskawa or an
authorized distributor.
5-106
Installation and Wiring a Noise Filter

Incorrect application of a noise filter significantly reduces its benefits. Follow these
instructions for the best results.
• Separate the input lines from the output lines.
Do not put the input and output lines in the same duct or bundle them together.
Filter Filter
Filter Filter
Separate these circuits.
• Isolate the noise filter ground wire from the output lines.
Do not put the noise filter ground wire, output lines and other signal lines in the
same duct or bundle them together.
Filter Filter
The ground wire

can be close to
input lines.
BOX BOX
5-107
• Connect the noise filter ground wire directly to the ground plate.
Do not connect the noise filter ground wire to other ground wires.
Filter Filter
Shielded Thick and

ground wire short
BOX BOX
• When grounding a noise filter inside an enclosure:

If a noise filter is located inside an enclosure, connect the noise filter ground wire
and the ground wires from other devices inside to the ground plate for the enclosure
first, then ground these wires.
Enclosure
Filter
Ground
BOX
5-108
5.8.3 Using More Than One Servodrive

The following diagram is an example of the wiring when more than one servodrive
is used.
Power Supply
R S T
Power
MCCB supply ON
Power supply OFF 1RY 1MC
Noise filter 1MC

SUP
Fuse
1MC Fuse
L1 SGDH
L2 Servo
L3 amplifier
L1C M
L2C
+24V CN1
1RY
31 ALM+
32 ALM-
Fuse
L1 SGDH
L2 Servo
L3 amplifier
L1C M
L2C
CN1
31 ALM+
32 ALM-
Fuse
L1 SGDH
L2 Servo
L3 amplifier
L1C
M
L2C
CN1
31 ALM+
32
ALM-
0V
Note: Wire the system to comply to National Electrical Code.
Connect the alarm output (ALM) terminals for the three servo amplifiers in series to
enable alarm detection relay 1RY to operate. The output transistor is turned OFF
when the ALM output signal enters an alarm state.
Multiple servos can share a single MCCB or noise filter. Always select an MCCB or
5-109
noise filter that has enough capacity for the total power capacity (load conditions) of
those servos. For details, refer to 5.8.1 Wiring Precautions.
5.8.4 Extending Encoder Cables

Standard encoder cables have a maximum length of 20m. If a longer cable is
required, prepare an extension cable as described below. The maximum allowable
cable length is 50m.
Preparing 50m (164.0ft) Encoder Cables

• Cable Model Number: UL2076-SB
Cables are ordered in units of meters. Specify the length,when ordering.
• Connectors or Connector Kits
Connector Type Model

Servo amplifier end Encoder connector (CN2) socket JZSP–CMP9–1
Encoder connector socket for
SGMAH and SGMPH servomotors JZSP–CMP9–2
Servomotor end Encoder connector plug and cable Plug

plug for SGMGH and SGMSH servo- L: MS3108B20–29S
motors Straight: MS3106B20–29S
Cable clamp: MS3057–12A
5-110
• Preparing Encoder Cables
• ïEncoder Connector • ïCable Line • ïEncoder Connector at Servomotor

at Servo Amplifier
For SGMAH and

SGMPH servomotors
For SGMGH and

SGMSH servomotors
Maximum length: 50 m (1968.50 in)
5-111
5.8.5 400V Power Supply Voltage
! CAUTION
• Do not connect the servo amplifier directly to any level other than 400V.
Doing so will destroy the servo amplifier.
There are three types of SGDH servo amplifiers, for the power supply voltages: sin-
gle-phase 100Vac, three-phase 200Vac, and single-phase 200Vac. For the three-phase
400Vac power supply, prepare the following voltage conversion transformers (sin-
gle-phase or three-phase).
Primary Voltage Secondary Voltage

400Vac or 440V 200Vac
400Vac or 440V 100Vac
Refer to the capacities shown in the following table when selecting a voltage conver-
sion transformer.
Servo Amplifier Voltage capacity per

Voltage
Model Servo Amplifier* kVA
SGDH–A3BE 0.15
Single–phase SGDH–A5BE 0.25
100V SGDH–01BE 0.40
SGDH–02BE 0.60
SGDH–A3AE 0.20
SGDH–A5AE 0.25
Single–phase
200V SGDH–01AE 0.40
SGDH–02AE 0.75
SGDH–04AE 1.2
SGDH–05AE 1.4
SGDH–08AE 1.9
Three–phase SGDH–10AE 2.3
200V SGDH–15AE 3.2
SGDH–20AE 4.3
SGDH–30AE 5.9
* This is the net value at the rated load.
When using a 400V class power supply, turn the power supply ON and OFF at the
primary side of the voltage conversion transformer.
Note: Transformer inductance will cause a surge voltage if the power is turned ON and OFF at the second-
ary, damaging the servo amplifier.
5-112
Single-phase Power Supply Connection Example

Transformer for SGDH Servo amplifier
voltage conversion
1MC 200VAC or 100V

U
L1
1MC
L2
V
1MC
W
Electromagnetic contactor for
power supply ON/OFF
5.8.6 Reactor for Harmonic Suppression

SGDH servo amplifiers have DC reactor connection terminals for power supply har-
monic suppression.
n Connecting a DC Reactor
The DC reactor is connected in series to the rectifier circuit’s output side. Refer to
3.2 Servo Amplifier Internal Block Diagrams.
Servo amplifier
DC reactor
⊕1
⊕2
At the time of shipping, the servo amplifier’s (+)1 and (+)2 are short-circuited.
Remove the lead wire between the two terminals and connect the DC reactor.
5-113
n DC Reactor Specifications
The following table shows the specifications for the DC reactors provided by
Yaskawa.
Reactor Specifications
Applicable Servo Amplifiers Inductance Rated current Reactor Model
(mH) (A)
SGDH–A3BE - - -
SGDH–A5BE - - -
100 V
SGDH–01BE 10.0 1.8 X5063
SGDH–02BE 4.7 3.5 X5062
SGDH–A3AE - - -
SGDH–A5AE - - -
SGDH–01AE 22.0 1.0 X5064
SGDH–02AE 10.0 1.8 X5063
SGDH–04AE 4.7 3.5 X5063
200 V SGDH–05AE
SGDH–08AE 2.0 4.8 X5061
SGDH–10AE
SGDH–15AE
1.5 8.8 X5060
SGDH–20AE
SGDH–30AE 1.0 14.0 X5059
5.9 Reserved Parameters

The following parameters are reserved.
Do not change any of them from the default setting.
Parameter Number Lower Limit Upper Limit Default Setting

Pn002.3 0 2 0
Pn004 — — 0000
Pn005 — — 0001
Pn110.3 0 3 0
Pn119 1 2000 60
Pn11A 1 2000 1000
Pn11B 1 150 50
Pn11C 1 150 70
Pn11D 0 150 100
Pn11E 0 150 100
Pn11F 0 2000 0
Pn120 0 51200 0
Pn206 513 32768 16384
Pn511 — — 8888
5-114
Sigma II User’s Manual Chapter 6: Servo Adjustment
6 Servo Adjustment
This chapter describes the functions required for servo adjustment.
Find the required information by selecting the section from the
following table of contents.
6.1 Smooth Operation ................................................................................................ 6-2
6.1.1 Using the Soft Start Function...................................................................... 6-2
6.1.2 Smoothing................................................................................................... 6-3
6.1.3 Adjusting Gain ............................................................................................ 6-4
6.1.4 Adjusting Offset......................................................................................... 6-5
6.1.5 Setting the Torque Reference Filter Time Constant.................................... 6-5
6.1.6 Notch Filter ................................................................................................. 6-6
6.2 High-speed Positioning........................................................................................ 6-7
6.2.1 Setting Servo Gain ...................................................................................... 6-7
6.2.2 Using Feed-Forward Control ...................................................................... 6-9
6.2.3 Using Proportional Control......................................................................... 6-9
6.2.4 Setting Speed Bias .................................................................................... 6-10
6.2.5 Using Mode Switch .................................................................................. 6-11
6.2.6 Speed Feedback Compensation ................................................................ 6-14
6.3 Auto-Tuning....................................................................................................... 6-17
6.3.1 Online Auto-Tuning.................................................................................. 6-17
6.3.2 Mechanical Rigidity Settings for Online Auto-Tuning............................. 6-20
6.3.3 Saving Results of Online Auto-Tuning..................................................... 6-22
6.3.4 Parameters Related to Online Auto-Tuning.............................................. 6-24
6.4 Servo Gain Adjustments .................................................................................... 6-26
6.4.1 Servo Gain Parameters.............................................................................. 6-26
6.4.2 Basic Rules of Gain Adjustment............................................................... 6-26
6.4.3 Making Manual Adjustments.................................................................... 6-28
6.4.4 Gain Setting Reference Values ................................................................. 6-33
6.5 Analog Monitor.................................................................................................. 6-35
6-1
6.1 Smooth Operation

This section provides technical information on the smooth operation of servomotors.
6.1.1 Using the Soft Start Function

The soft start function adjusts progressive speed reference input inside the servo
amplifier so that acceleration and deceleration can be as constant as possible. To use
this function, set the following parameters.
Setting
(ms)
Pn305 Soft Start Acceleration Time Default Setting: 0 Speed Control
Pn306 Soft Start Deceleration Time Setting Range: 0 to 10000 Speed Control
Default Setting: 0
In the servo amplifier, a speed reference is multiplied by the acceleration or deceler-

ation value set in Pn305 or Pn306 to provide speed control.
The soft start function enables smooth speed control when progressive speed refer-
ences are input or when contact input speed control is used. Set both Pn305 and
Pn306 to “0” for normal speed control.
Set these parameters as follows:
• Pn305: The time interval from the time the motor starts until the maximum
speed is reached.
• Pn306: The time interval from the time the motor is operating at the maximum
speed until it stops.
Speed reference Soft start
Maximum speed
Servo amplifier internal

speed reference
Pn305: Set this time interval.
Maximum speed
Pn306: Set this time interval.
6-2
6.1.2 Smoothing
The smoothing function applies a filter inside the servo amplifier to a constant-fre-
quency reference input so that acceleration and deceleration can be as constant as
possible. To use this function, set the following parameters.
Use the following parameter to set the type of filter to be applied.
Pn207.0 Position Reference Filter Selec- Default Setting: 0 Position Control

tion
Either an acceleration/deceleration or average movement filter can be selected.

0 Enables acceleration/deceleration filter.
1 Enables average movement filter.
The time constant and time for these filters are set in the following parameters.
Time constant for Acceleration/Deceleration Filter:
Setting
(x 0.01ms)
Position Reference Accel/Decel Setting Range: 0 to 6400
Pn204 Time Constant Default Setting: 0 Position Control
Averaging time for Average Movement Filter:
Setting
(x 0.01ms)
Position Reference Movement Setting Range: 0 to 6400
Pn208 Averaging Time Default Setting: 0 Position Control
This function provides smooth motor operating in the following cases:

• When the host device which outputs references cannot perform acceleration/
deceleration processing.
• When the reference pulse frequency is too low.
• When the reference electronic gear ratio is too high (i.e., 10 × or more).
6-3
This function does not affect the travel distance (i.e., the number of pulses).
Servo amplifier
Reference pulses Servomotor
Acceleration/Deceleration
Reference pulse
frequency
Filter Applied
Pn204 or Pn208
Reference pulse
frequency
6.1.3 Adjusting Gain

If speed loop gain or position loop gain exceeds the allowable limit for the servo sys-
tem (including the machine to be controlled), the system will tend to vibrate or
become too sensitive. Smooth operation is not possible under such conditions.
Reduce each loop gain value to an appropriate value.
Refer to 6.2.1 Setting Servo Gain for details regarding servo gain adjustment.
6-4
6.1.4 Adjusting Offset

The servo system does not operate smoothly if reference voltage from the host con-
troller or external equipment has a reference offset value close to 0V. In that case,
adjust the reference offset value to 0V.
n Reference Voltage Offset from Host Controller or External
Circuitry
Reference Offset Reference

voltage voltage Make offset
adjustment with the
servo amplifier
Reference speed Reference speed

or reference or reference
torque Offset adjustment torque
n Reference Offset Adjustment

The following two methods are provided to reset the reference offset value to 0V.
• Reference offset automatic adjustment
• Reference offset manual adjustment
If a position loop is formed in the host controller, be sure to make a manual offset
adjustment and do not make automatic reference offset adjustment.
Refer to the following sections in Chapter 7 Using the Digital Operator for a
detailed description of reference offset adjustment.
Adjustment Method Detailed Description

Automatic 7.2.3 Automatic Adjustment of the Speed and Torque Reference Offset
Manual 7.2.4 Manual Adjustment of the Speed and Torque Reference Offset
6.1.5 Setting the Torque Reference Filter Time Constant

If there is machine vibration which may be caused by the servodrive, try adjusting
the filter time constant in Pn401. This may stop the vibration.
Setting
Parameter Signal Application
(x 0.01ms)
Torque Reference Filter Time Setting Range: 0 to 65535 Speed/Torque Control,
Pn401 Constant Default Setting: 100 Position Control
The above constant is the filter time constant of the torque reference to be set in the
servo amplifier. The smaller the value, the faster the speed control response will be.
There is, however, a limit, depending on machine conditions.
6-5
6.1.6 Notch Filter

Vibration in the machine can sometimes be eliminated by using a notch filter for the
frequency at which the vibration is occurring.
Pn408.0 Notch Filter Selection Default Setting: 0 Speed/Torque Control,

Position Control
This parameter can be set to enable the notch filter.

0 None.
1 Enables notch filter for torque reference.
Use the following parameter to set the frequency at which the filter is effective.
Setting
(Hz)
Pn409 Position Reference Accel/Decel Setting Range: 50 to 2000 Speed/Torque Control,

Time Constant Default Setting: 2000 Position Control
6-6
6.2 High-Speed Positioning
This section provides technical information on high-speed positioning.
6.2.1 Setting Servo Gain

Use the servo gain setting function in the following cases.
• To check each servo gain value that is automatically set after auto-tuning.
• To directly set each of the above servo gain values in another servo amplifier.
• To further refine responsiveness after auto-tuning (either to increase responsive-
ness or to reduce it).
n Setting Speed Loop Gain

Set the following speed loop related parameters as required.
Parameter Signal Setting Application
Speed Loop Gain (Kv) Setting Range: 1 to 2000Hz Speed/Torque Control,

Pn100 Default Setting: 40Hz Position Control
Speed Loop Integral Setting Range: 15 to 51200 X 0.01ms Speed/Torque Control,
Pn101 Time Constant (Ti) Default Setting: 2000 x 0.01ms Position Control
The higher the speed loop gain, or the smaller the speed loop integral time constant
value, the faster the speed control response will be. There is, however, a certain
limit depending on machine characteristics.
Speed reference +
loop gain
(
KV 1+
1
TiS
)
-
Speed feedback
Speed loop gain Kv is adjusted in 1Hz increments provided that the following
parameter is set correctly.
Setting
(%)
Pn103 Inertia Ratio Default Setting: 100 Position Control
Motor load inertia (JL)

Inertia Ratio = × 100%
Servomotor rotor inertia (JM)
The load inertia of the servo amplifier reflected at the motor shaft is default set to the
rotor inertia of the servomotor. Therefore, obtain the inertia ratio from the above
formula and set parameter Pn103 properly.
The above parameters are automatically set by the auto-tuning operation.
6-7
n Setting Position Loop Gain

Set the following position loop-related parameter as required.
Setting
(s-1)
Position Loop Gain Setting Range: 0 to 2000 Speed/Torque Control,
Pn102 (KP) Default Setting: 40 Position Control
The above constant is the position loop gain for the servo amplifier.
The higher the position loop gain, the smaller the position control error will be.
There is, however, a certain limit depending on machine characteristics.
Position reference Position loop gain
Position feedback
This gain setting is also valid for zero clamp operation.

The above parameter is automatically set by the auto-tuning operation.
Setting
(256 reference units)
Pn505 Overflow Level Setting Range: 1 to 32767 Position Control

Default Setting: 1024
Set in this parameter the error pulse level at which a position error pulse overflow
alarm (A.d0) is detected.
Alarm (A.d0) Pn505
Normal control
Error pulse
Alarm (A.d0)
If the machine permits only a small position loop gain value to be set in Pn102, an
overflow alarm may arise during high speed operation. In this case, increase the
value set in this parameter to avoid unnecessary alarms.
6-8
6.2.2 Using Feed-Forward Control

The time required for positioning can be shortened with feed-forward control by set-
ting the following parameter.
Definition:Feed-forward control makes necessary corrections beforehand to prevent the control system
from receiving the effects of external disturbance. By increasing the effective servo gain, feed-for-
ward control improves the system’s response.
Setting
(%)
Pn109 Feed-forward Setting Range: 0 to 100 Speed Control,

Parameter Pn109 is set to apply feed-forward frequency compensation to position

control inside the servo amplifier. Use it to shorten positioning time. Too high a
value may cause machine vibration. For most applications, set Pn109 to 80% or
less.
Difference
Pn109
Reference pulse
Feedback pulse
6.2.3 Using Proportional Control

If parameter Pn000.1 is set to 0 or 1 as shown below, input signal /P-CON serves as
a PI/P control changeover switch.
• PI control: Proportional/integral control.
• P control: Proportional control.
Setting
(%)
Speed Control,
6-9
Pn000.1
Control Mode
Setting
Usual speed control or position con-

Speed trol is selected. Servo amplifier
0 Control Input signal /P-CON (CN1-41) is used
to select PI control or P control.
CN1-41 PI control P or PI
Position is open. control /P-CON
1 Control CN1-41
CN1-41 selection
is 0V P control
n Methods for Using Proportional Control

Proportional control can be used in the following two ways.
• When operation is performed by sending speed references from the host control-
ler to the servo amplifier, the host controller can selectively use P control mode
for particular conditions only. This method can suppress overshooting and
shorten setting time. Refer to 6.2.5 Using Mode Switch for particular conditions.
• If PI control mode is used when the speed reference has a reference offset, the
motor may rotate at a very slow speed and fail to stop even if 0 is specified as a
speed reference. In this case, use P control mode to stop the motor.
6.2.4 Setting Speed Bias

The settling time for positioning can be reduced by assigning bias to the speed refer-
ence block in the servo amplifier. To assign bias, use the following constants.
Parameter Signal Setting Application

Setting Range: 0 to 450rpm
Pn107 Bias Position Control
Default Setting: 0rpm
Pn108 Bias Addition Width Default Setting: 7 Position Control
Set the parameters to shorten the time required for positioning according to the
application.
The bias increment width (Pn108) is expressed as an error pulse width that deter-
mines the time in which bias input (Pn107) takes effect. The bias input is ON if the
error pulse width exceeds the value set in Pn108.
Internal speed reference
Pn107
Error pulse
Bias increment width

Pn108
6-10
6.2.5 Using Mode Switch

Use the mode switch function for the following purposes.
• To suppress overshoot during acceleration or deceleration (for speed control).
• To suppress undershoot during positioning and to shorten the setting time (for
position control).
No mode switch function With mode switch function

Overshoot
Motor Motor
speed speed
Undershoot
Time Time
The mode switch function makes it possible to automatically switch the servo ampli-
fier’s internal speed control mode from PI to P control mode and vice versa when
specified conditions are satisfied.
Definition:PI control means proportional/integral control, and P control means proportional control. In
effect, switching “from PI control to P control” reduces effective servo gain, thereby making the
servo system more stable.
IMPORTANT
• The mode switch is used to fully utilize performance of a servodrive to achieve very high-speed positioning.
The speed response waveform must be observed to adjust the mode switch.
• For normal use, the speed loop gain and position loop gain set by auto-tuning provide sufficient speed/posi-
tion control. Even if overshoot or undershoot occurs, it can be suppressed by setting either:
•The acceleration/deceleration time constant for the host device.
•The soft start time constants (Pn305, Pn306)
•The position reference acceleration/deceleration constant (Pn204) for the servo amplifier.
n Selecting Mode Switch Setting

The servo amplifier incorporates four mode switch settings (0 to 3). Select a mode
switch with the following parameter (Pn10B.0).
Parameter
Pn10B.0
Description Used to Set Setting Unit
Setting
Detection Point
Uses torque reference as the detection point. Percentage of rated
0 (Standard setting) Pn10C torque (%)
1 Uses speed reference input as the detection point. Pn10D Motor Speed (rpm)
2 Uses acceleration as the detection point. Pn10E × 10rpm/s
6-11
Parameter
Pn10B.0
Description Used to Set Setting Unit
Setting
Detection Point
3 Uses error pulse input as the detection point. Pn10F Reference unit
Torque Reference Input Used as Detection Point (Standard Setting)

With this setting, if the value of torque reference input exceeds the torque set in
parameter Pn10C, the speed loop switches to P control.
The servo amplifier is default set to this standard mode (Pn10C = 200).
Reference speed
Speed Motor speed
+Pn10C Internal torque reference
Torque 0
-Pn10C
PI control PI control PI control
P control P control
Operating Example
If the system is always in PI control without using the mode switch function, the
speed of the motor may overshoot or undershoot due to torque saturation during
motor acceleration or deceleration. The mode switch function suppresses torque sat-
uration and eliminates motor speed overshoot or undershoot.
No mode switch function With mode switch function
Overshoot
Motor Motor
speed speed
Undershoot
Time Time
Speed Reference Used as Detection Point

With this setting, if a speed reference exceeds the value set in parameter Pn10D, the
speed loop switches to P control.
Speed reference Motor speed
Speed
Pn10D Time
PI P control PI control
control
6-12
Operating Example
In this example, the mode switch is used to reduce setting time. Generally, speed
loop gain must be increased to reduce setting time. Using the mode switch sup-
presses the occurrence of overshoot and undershoot as speed loop gain is increased.
Without mode switch Without mode switch
Speed reference Motor speed Overshoot
Motor Increase speed loop gain. Motor

speed speed
Undershoot
Long setting time Time
With mode switch
Suppress overshooting
Motor and undershooting.
speed
Setting time
Acceleration Used as Detection Point

If motor acceleration exceeds the value set in parameter Pn10E, the speed loop
switches to P control.
Reference speed
Speed Motor speed
+Pn10E Motor acceleration
Acceleration 0
-Pn10E
PI control PI control PI control
P control P control
Operating Example
If the system is always in PI control without using the mode switch function, the
speed of the motor may overshoot or undershoot due to torque saturation at the time
of the acceleration or deceleration of the motor. The mode switch function sup-
presses torque saturation and eliminates motor speed overshoot or undershoot.
Without mode switch With mode switch
Overshoot
Motor Motor
speed speed
Undershoot
Time Time
6-13
Error Pulse Used as a Detection Point

This setting is enabled for position control operation only.
If an error pulse exceeds the value set in parameter Pn10F, the speed loop switches to
P control.
Reference Motor speed
Speed
Deviation Time
Pulse
Pn10F
PI control P control PI control
Operating Example
In this example, the mode switch is used to reduce setting time. Generally, speed
loop gain must be increased to reduce setting time. Using the mode switch sup-
presses the occurrence of overshoot and undershoot when speed loop gain is
increased.
Without mode switch Without mode switch
Speed reference Motor speed Overshoot
Motor Increase speed loop gain. Motor
speed speed Under
shooting
Long setting time Time
With mode switch function
Suppress overshoot
Motor and undershoot
speed
Setting time
6.2.6 Speed Feedback Compensation

Use this function to shorten the system’s setting time in positioning operation.
Integral control
(Pn101)
Error counter +
output Position loop gain + Speed loop gain + Torque reference Torque reference
(Pn102) (Pn100) filter (Pn401)
-
Speed feedback Speed feedback com Speed feedback

filter (Pn308) pensation (Pn111)
Speed feedback com

pensation function
selection (Pn110.1)
6-14
Note: This function is available provided that the inertia ratio set in Pn103 is correct. Therefore, perform
online auto-tuning to obtain and save the results as the parameters. Refer to 6.3 Auto-Tuning for
details. Otherwise, directly set the inertia ratio.
n Adjustment Procedure
When adding the value of speed feedback compensation, be sure to follow the proce-
dure described below and make servo gain adjustments while watching the analog
monitor to observe the position error and torque reference. Refer to 6.5 Analog
Monitor for details.
1. Set parameter Pn110 to “0002” so that the online auto-tuning function will be
disabled. Refer to 6.3.4 Parameters Related to Online Auto-Tuning and Appen-
dix B List of Parameters for details regarding Pn110.
2. First, make normal servo gain adjustments with no feedback compensation. In
this case, gradually increase the speed loop gain in Pn100 while reducing the
speed loop integral time constant Pn101, and finally set the speed loop gain in
Pn100 to the same value as that of the position loop gain in Pn102.
The relationship between the speed loop gain and integral time constant is as fol-
lows:
Take the value obtained from the following formula as a reference value for setting
the speed loop integral time constant in Pn101.
4
Speed loop integral time constant = (s)
2p x Speed loop gain
Unit of speed loop gain: [Hz]

Check the unit when setting the speed loop integral time constant in Pn101. Pn101
is set in 0.01ms increments.
The units for speed loop gain (Hz) and position loop gain (s-1) differ, nevetheless, set
these gains to the same numerical value.
3. Repeat step 2 to increase the speed loop gain while watching the position error of
the analog monitor to observe the setting time and the torque reference of the
analog monitor to observe any occurrence of vibration. If there is any oscillating
noise or noticeable vibration, gradually increase the time constant of the torque
reference filter in Pn401.
4. Gradually increase only the position loop gain. When it has been increased
about as far as possible, then decrease the speed feedback compensation in
Pn111 from 100% to 90%. Then repeat steps 2 and 3.
5. Decrease the speed feedback compensation to a value lower than 90%. Then
repeat steps 2 through 4 to shorten the setting time. If the speed feedback com-
6-15
pensation is too low, however, the response waveform will vibrate.

6. Find the condition in which the shortest setting time is obtainable within the
range where the position error or torque reference waveform observed through
the analog monitor is not vibrating or unstable.
7. The servo gain adjustment is completed when no further shortening of the posi-
tioning time is possible.
IMPORTANT
• Speed feedback compensation usually makes it possible to increase the speed loop gain and position loop gain. The
machinery may vibrate excessively if the compensation value greatly changes or Pn110.1 is set to “1” (i.e., speed feed-
back compensation disabled) after increasing the speed loop gain or position loop gain.
6-16
6.3 Auto-Tuning
If positioning is taking a long time, the speed loop gain or position loop gain of the servo
system may not be set properly. If the gain settings are wrong, set them properly in accor-
dance with the configuration and rigidity of the machinery.
Autotuning
The characteristics of the machinery
are checked automatically for optimum
tuning.
Load inertia
Servomotor Friction
Servo amplifier
The servo amplifier incorporates an online auto-tuning function, which checks the charac-
teristics of the machinery automatically and makes the necessary servo gain adjustments.
The function is easy to use and makes it possible for even beginners to perform servo gain
tuning and set all servo gains as parameters.
The following parameters can be set automatically by using the online auto-tuning func-
tion.
Parameter Description
Pn100 Speed loop gain
Pn101 Speed loop integral time constant
Pn102 Position loop gain
Pn401 Torque reference filter time constant
6.3.1 Online Auto-Tuning

Online auto-tuning is a control function which enables the servo amplifier to check
changes in the load inertia during operation in order to maintain the target value for
speed loop gain or position loop gain.
Online auto-tuning may not work well in the following cases.
• When the cycle for load inertia change is 200ms or shorter (when the load
changes rapidly).
• When the application has slow acceleration or deceleration using the soft start
function, and the speed error of the Servomotor being driven is small.
• When adjusting the servomotor manually and operating at low gain (a machine
rigidity of 1 or less).
6-17
Disable the online auto-tuning function if tuning is not possible. (See 6.4.3).
IMPORTANT
• Do not use online auto-tuning in the following cases:
• When using Torque Control Mode.

• When using IP control for the speed loop.
• When using the torque feed–forward function.
• When switching gain using /G–SEL.
6-18
n Setting Parameters for Online Auto-Tuning

The following flowchart shows the procedure for setting the parameters for online
auto-tuning.
Start
Operate with factory

settings of parameters
Operation
OK?
No
No Load
inertia changes?
Yes
Set to always perform tuning.

(Set Pn110.0 to 1)
Yes
Operation
OK?
No
Adjust the rigidity setting

(Set in Fn001)
Yes
Operation
OK?
No
Adjust the friction

compensation.
Set in Pn110.2.
Yes
Operation
OK?
No
Set so that online autotuning

is not performed. Save the results of autotuning
(Set Pn110.0 to 2) to parameters. From the next
time, execute autotuning using
the calculated value as the
initial value.
Make servo gain Set in Fn007
adjustments manually *
Before making manual servo gain adjustments, refer to

6.4 Servo Gain Adjustments or 6.2 High-Speed Positioning.
End
6-19
6.3.2 Mechanical Rigidity Settings for Online Auto-Tuning

For the mechanical rigidity settings at the time of online auto-tuning, select the target
values for speed loop gain and position loop gain of the servo system. Any of the
following ten levels of rigidity can be selected.
Position Loop Speed Loop Torque

Speed Loop
Fn001 Gain Integral Time Reference Filter
Gain
Rigidity Constant Time Constant
[s-1] [Hz]
[0.01ms] [0.01ms]
Setting
Pn102 Pn100 Pn101 Pn401
1 15 15 6000 250
2 20 20 4500 200
3 30 30 3000 130
4 40 40 2000 100
5 60 60 1500 70
6 85 85 1000 50
7 120 120 800 30
8 160 160 600 20
9 200 200 500 15
10 250 250 400 10
Note: The Rigidity value is default set to 4.
As the rigidity value is increased, the servo system loop gain increases and the time
required for positioning is shortened. If the rigidity is excessively high, however, it
may cause the machinery to vibrate. In that case, decrease the set value.
The rigidity value setting automatically changes the parameters in the above table.
Note: If parameters Pn102, Pn100, Pn101, and Pn401 are set manually with the online auto-tuning function
enabled, tuning is performed with the manually set values as target values.
n Changing the Rigidity Setting

Use parameter Fn001 in the auxiliary function mode to change the rigidity setting.
The procedure for changing the setting is as follows:
Using the Hand-held Digital Operator

1. Press the DSPL/SET key and select Fn001 in the auxiliary function mode.
2. Press the DATA/ENTER key. The following data will be displayed.
6-20
3. Press the Up Arrow or Down Arrow key to select the rigidity setting.
Up Cursor Key Down Cursor Key
4. Press the DSPL/SET key. The following display will flash for 1 second and
then the rigidity setting will be changed.
Flashes for
1s
This completes the procedure for changing the rigidity setting.
Using the Built-in Panel Operator

1. Press the MODE/SET key to select Fn007 in the auxiliary function mode.
2. Press the DATA/SHIFT key for a minimum of 1 second. The following data
will be displayed.
3. Press Up Arrow or Down Arrow key to select the rigidity setting.
Up Cursor Key Down Cursor Key
4. Press the MODE/SET key. The following display will flash for 1 second and
then the rigidity setting will be changed.
Flashes for
1s
5. Press the DATA/SHIFT key for a minimum of one second to return to the auxil-
iary function mode.
6-21
This completes the procedure for changing the rigidity setting.
6.3.3 Saving Results of Online Auto-Tuning

Online auto-tuning always processes the latest load inertia to renew data so that the
speed loop gain will reach the target value that has been set. When the servo ampli-
fier is turned off, all the processed data is lost. Therefore, when the servo amplifier
is turned on again, online auto-tuning is performed by processing the factory-set val-
ues in the servo amplifier.
To save the results of online auto-tuning and use them as the initial values set in the
servo amplifier when the servo amplifier is turned on again, it is necessary to use
constant Fn007 in the auxiliary function mode. In this case, the inertia value set in
parameter Pn103 will be changed.
On the basis of the rotor inertia of the servomotor, the inertia ratio is expressed in
percentage terms by the load inertia. The value set in Pn103 is used to calculate the
load inertia at the time of online auto-tuning.
Setting
(%)
Pn103 Inertia Ratio Setting Range: 0 to 10000 Speed/Torque Control,

Motor Load Inertia (JL)

Inertia Ratio = × 100%
Rotor Inertia (JM)
The inertia ratio is default set to 0%.
IMPORTANT
• Before making servo gain adjustments manually, be sure to set the inertia ratio in Pn103.
If the inertia ratio is incorrect, the speed loop gain (in 1–Hz increments) set in Pn100 will be wrong.
For details on setting Pn103, refer to 7.1.6 Operation in Parameter Setting Mode.
6-22
n Procedure for Saving Results of Online Auto-Tuning

The procedure for saving the results of online auto-tuning is as follows:
Using the Hand-held Digital Operator

1. Press the DSPL/SET key to select Fn007 in the auxiliary function mode.
2. Press the DATA/ENTER key. If the inertia ratio is 200%, for example, the fol-
lowing data will be displayed.
3. Press the DSPL/SET key. The following display will flash for 1 second and
then the inertia ratio will be saved.
Flashes for
1 s.
This completes the procedure for saving the results of online auto-tuning. When the
servo amplifier is turned on again, the inertia ratio set in Pn103 will be used as the
default value.

1. Press the MODE/SET key and select Fn007 in the auxiliary function mode.
2. Press the DATA/SHIFT key for a minimum of 1 second. If the inertia ratio is
200%, for example, the following data will be displayed.
3. Press the MODE/SET key. The following display will flash for 1 second and
then the inertia ratio will be saved.
Flashes for
1 s.
6-23
4. Press the DATA/SHIFT key for a minimum of 1 second to return to the auxiliary
function mode.
This completes the procedure for saving the results of online auto-tuning. When the
servo amplifier is turned on again, the inertia ratio set in Pn103 will be used as the
default value.
6.3.4 Parameters Related to Online Auto-Tuning

This section provides information on a variety of parameters related to online auto-
tuning.
n Online Auto-Tuning Method

The following parameter is used to set the auto-tuning conditions.
Setting
(%)
Pn110.0 Online Auto-Tuning Default Setting: 0 Speed control,

Method Position Control
0 Auto-Tuning is performed only when the system runs for the first time after the power
is turned ON. After the load inertia is calculated, the calculated data is not refreshed.
1 Auto-Tuning is continuously performed (inertia value calculation).
2 The online auto-tuning function is not used.
This parameter is default set to “0”. If the load inertia change is minimal or if the
application makes few changes, there is no need to continue calculating the inertia
while the system is in operation. Instead, continue to use the value that was calcu-
lated when the system was first started up.
Set this parameter to “1” if the load inertia always fluctuates due to the load condi-
tions. Then the response characteristics can be kept stable by continuously refresh-
ing the inertia calculation data is refreshed continuously and reflecting them in the
servo gain.
If the load inertia fluctuation results within 200 ms, the inertia calculation data may
not be refreshed properly. If that happens, set Pn110.0 to “0” or “2.”
Set Pn110.0 to “2” if auto-tuning is not available or if the online auto-tuning function
is not used because the load inertia is already known and the servo amplifier is man-
ually adjusted by setting the inertia ratio data in Pn103.
6-24
n Speed Feedback Compensation Selection

Use the following parameter to enable or disable speed feedback compensation.
Refer to 6.2.6 Speed Feedback Compensation.
This parameter can be left as it is if online auto-tuning is performed. If this parame-
ter is set manually, however, the setting is reflected to the operational setting made
during online auto-tuning.
Setting
(%)
Speed Feedback Compen- Speed control,
Pn110.1 sation Selection Default Setting: 1 Position Control

0 Speed Feedback Compensation enabled.
1 Speed Feedback Compensation disabled.
n Friction Compensation Selection

Use the following parameter to enable or disable friction compensation to determine
whether or not the friction of the servo system is to be taken into consideration for
the calculation of load inertia.
If this compensation function is enabled, select small or large friction compensation
according to the extent of friction in order to ensure highly precise load inertia calcu-
lation.
Setting
(%)
Pn110.2 Friction Compensation Default Setting: 1 Speed control,

Selection Position Control

0 Friction Compensation enabled
1 Friction Compensation: Small
2 Friction Compensation: Large
Note: 1. Do not set friction compensation for loads with low friction (10% rated torque/speed or less).
2. Auto-Tuning will be performed as if the load inertia is 30 times the motor inertia.
6-25
6.4 Servo Gain Adjustments

This section describes information on the basic rules of gain adjustments in the servo
amplifier, adjustment methods in a variety of cases, and reference set values.
6.4.1 Servo Gain Parameters

The following parameters must be set properly for servo gain adjustments.
• Pn100: Speed loop gain
• Pn101: Speed loop integral time constant
• Pn102: Position loop gain
• Pn401: Torque reference filter time constant
If the servo amplifier is used in the speed control mode with the analog voltage refer-
ence, the position loop is controlled by the host device. Therefore, position loop
gain is adjusted through the host device.
If the host is not available for adjustments of position loop gain, set the speed refer-
ence input gain in parameter Pn300. If the set value is improper, the servomotor
may not run at top speed.
6.4.2 Basic Rules of Gain Adjustment

The servo system consists of three feedback loops (i.e., position loop, speed loop,
and current loop). The innermost loop must have the highest response speed and the
middle loop must have higher response speed than the outermost. If this principle is
not followed, it will result in vibration or poor responsiveness.
The servo amplifier is designed to ensure that the current loop has good response
performance. The user needs only to adjust the position loop and speed loop gain.
The servo system block diagram consists of the position, speed, and current loops, as
shown below.
In case of position control In case of speed control
Pulse
Speed train
Speed pattern
Analog
+ Motor
+ KP voltage + Speed KV Power
Current SM
Error (D/A con- control - limit conver
- counter - block Ti block sion block
verter)
Time
Speed loop
PG
Position loop
Encoder
Host controller (prepared by the user) Servo amplifier

Speed control mode
Servo amplifier
Position control mode
Host controller
(prepared by the user) KP = Position loop gain
KV = Speed loop gain
Ti = Integral time constant
6-26
• Generally speaking, the responsiveness of the position loop cannot be higher

than that of the speed loop. Therefore, to increase the position loop gain, you
must first increase the speed loop gain. If only the position loop gain is
increased, oscillation will result in the speed reference and positioning time will
increase, not decrease.
Position loop gain can be increased only to the point where oscillation begins in
the mechanical system.
• If the position loop response is faster than the speed loop response, speed refer-
ence output from the position loop cannot follow the position loop response due
to the slower speed loop response. Therefore, the position loop will keep accu-
mulating errors, thus increasing the amount of speed reference output.
As a result, the motor speed will be excessive and the position loop will try to
decrease the amount of speed reference output. The speed loop responsiveness
degrades, and the motor will not be able to follow. The speed reference will
oscillate as shown in the following graph. If this happens, reduce the position
loop gain or increase the speed loop gain.
Speed
reference
Actual speed reference output from controller.
Speed reference as a result of calculation in controller.
Time
• The position loop gain must not exceed the natural frequency of the mechanical
system. For example, if the mechanical system is an articulated robot, the rigid-
ity of the machinery mechanism is very low because the mechanism incorporates
a harmonic gear reducer and the natural frequency of the mechanical system is
10 to 20Hz. In this case, the position loop gain can be set to 10 to 20(s-1).
If the mechanical system is a chip mounting machine, IC bonding machine, or
high-precision machining tool, the natural frequency of the system is 70Hz or
more. Therefore, the position loop gain can be set to 70(s-1) or higher.
When high responsiveness is required, it is not only important to ensure the
responsiveness of the servo system (the controller, servo amplifier, motor, and
encoder), but it is also necessary to ensure that the mechanical system have high
rigidity.
6-27
6.4.3 Making Manual Adjustments

The auto-tuning function uses a gain adjustment algorithm with a comparatively
large safety margin by considering a variety of mechanical systems to which the
servo amplifier is applied. Therefore, the servo amplifier may not satisfy the
response characteristics of some applications. The auto-tuning function is not avail-
able to machines with low rigidity or high fluctuation.
In such cases, observe the mechanical systems and make manual adjustments of
parameters.
n Speed Control
Required Parameters
The following parameters are used.
• Speed Loop Gain (Pn100)
This parameter is used for determining the responsiveness of the speed loop. For
the best response, set this parameter as high as possible, without exceeding the
point where the mechanical system vibrates. The value of speed loop gain is the
same as the set value of Pn100 if the inertia ratio set in Pn103 is correct.
Speed loop gain Kv = Set value of Pn100 (Hz)
Set Pn103 to the following value.
Motor load inertia (JL)
Pn103 Setting Value = × 100%
Note: In the case of manual adjustments of parameters, the user must set the value of parameter Pn103. The
inertia ratio can be obtained if the servo gain constant is written with parameter Fn007 after auto-tun-
ing has been performed. For details regarding Fn007, refer to 6.3 Auto-Tuning.
• Speed Loop Integral Time Constant (Pn101)

The speed loop has an integral element so that the speed loop can respond to
minute inputs. This integral element delays the operation of the servo system,
resulting in a longer positioning settling time. As the value of the time constant
increases, the response becomes slower. If the load inertia is large or the
mechanical system is likely to vibrate, make sure that the speed loop integral
time constant is large enough. Use the following formula to calculate the opti-
mum integral time constant.
1
Ti ≥ 2.3 ×
2π × Kv
Where: Ti = Integral time constant [s]
Kv = Speed loop gain (calculated from the above) [Hz]
6-28
• Torque Reference Filter Time Constant (Pn401)

If the mechanical system uses ball screws, torsional resonance may result. In
this case, the oscillation noise will be a high-pitched tone. The oscillation may
be minimized by increasing the time constant of the torque reference filter. Like
the integral time constant, this filter causes a delay in the operation of the servo
system. Therefore, this constant must not be set to an excessively large value.
• Speed Reference Input Gain (Pn300)
Changing the speed reference input gain set in Pn300 is equivalent to changing
the position loop gain. In other words, an increase in the speed reference input
gain set in Pn300 is equivalent to a decrease in the position loop gain and vice
versa. Use this parameter in the following cases.
• When the host controller does not have a function for adjusting the position
loop gain. (The host incorporates a D/A converter to change the number of
bits but cannot make fine adjustments of position loop gain.)
• When it is necessary to clamp the full range of the speed reference output of
the host device to a specified rotation speed.
In normal operation, the default setting can be used as is.
Note: If the servo amplifier is used for speed control, the position loop gain set in Pn102 is enabled in zero–
clamp mode only. In normal control operation, change the position loop gain through the host or
change the speed reference input gain in Pn300 in the servo amplifier. The position loop gain remains
the same if the setting in Pn102 is changed.
Adjustment Method
1. Set the position loop gain to a low value in the host controller. Then increase the
speed loop gain set in Pn100 to within a range where there is no noise or oscilla-
tion. If the position loop gain cannot be changed through the host controller,
increase the speed reference input gain set in Pn300 to a larger value.
2. Decrease the speed loop gain a little from the value set in step 1. Then increase
the position loop gain through the host controller to within a range where there is
no noise or oscillation. As in step 1, decrease the set value of Pn300 if the posi-
tion loop gain cannot be changed through the host controller.
3. Set the speed loop integral time constant in Pn101 while observing the position-
ing settling time and the vibration of the mechanical system. If the constant is
too large, positioning settling time will be long.
4. Set the torque reference filter to a small value in Pn401 if the mechanical system
has shaft torsional resonance If the mechanical system generates oscillation
noise in a high-pitched tone, shaft torsional resonance may be occurring. In that
case, set Pn401 to a larger value.
5. Finally, progressively make fine adjustments to parameters such as the position
loop gain, speed loop gain, and integral time constant to find the optimal points.
6-29
n Position Control
Parameters
The following parameters are used.
• Speed Loop Gain (Pn100)
This parameter is used for determining the response speed of the speed loop. For
the best response, set this parameter as high as possible, without exceeding the
point where the mechanical system vibrates. The value of speed loop gain is the
same as the set value of Pn100 if the inertia ratio set in Pn103 is correct.
Speed loop gain Kv = Set value of Pn100 (Hz)
Set Pn103 to the following value:
Motor shaft reflected load inertia (JL)
Pn103 Setting Value = × 100%
Note: In the case of manual adjustments of parameters, the user must set the value of parameter Pn103. The
inertia ratio can be obtained if the servo gain constant is written with parameter Fn007 after auto-tun-
ing has been performed. For details regarding Fn007, refer to 6.3 Auto-Tuning.
• Speed Loop Integral Time Constant (Pn101)

The speed loop has an integral element so that the speed loop can respond to
minute inputs. This integral element delays the operation of the servo system,
resulting in longer positioning settling time. As the value of the time constant
increases, the response becomes slower.
If the load inertia is large or the mechanical system is likely to vibrate, make sure
that the speed loop integral time constant is large enough. Use the following for-
mula to calculate the optimum time constant.
1
Ti ≥ 2.3 × 2π × K
v
Where: Ti = Integral time constant [s]
Kv = Speed loop gain (calculated from the above) [Hz]
• Torque Reference Filter Time Constant (Pn401)

If the mechanical system uses ball screws, torsional resonance may result. In
this case, the oscillation noise will be a high-pitched tone. The oscillation may
be minimized by increasing the time constant of the torque reference filter. Like
the integral time constant, this filter causes a delay in the operation of the servo
system. Therefore, this constant must not be set to an excessively large value.
• Position Loop Gain (Pn102)
The responsiveness of the servo system is determined by the position loop gain.
6-30
The response increases if the position loop gain is set to a high value, and the
time required for positioning will be shortened. In order to set the position loop
gain to a high value, the rigidity and natural frequency of the mechanical system
must be high.
The responsiveness of the whole servo system may become unstable if only the
position loop gain is increased. Because the speed reference, as output from the
position loop, is likely to become unstable. Increase the speed loop gain while
observing the response.
Adjustment Method
1. Set the position loop gain to a comparatively low value. Then increase the speed
loop gain set in Pn100 to within a range where there is no noise or oscillation.
2. Decrease the speed loop gain a little from the value set in step 1. Then increase
the position loop gain to within a range where there is no overshooting or oscilla-
tion.
3. Set the speed loop integral time constant in Pn101 while observing the position-
ing settling time and the vibration of the mechanical system. If the constant is
too large, the positioning settling time will be too long.
4. Set the torque reference filter to a small value in Pn401 if the mechanical system
has shaft torsional resonance. If the mechanical system generates oscillation
noise in a high-pitched tone, shaft torsional resonance may occur. In that case,
set Pn401 to a larger value.
5. Finally, progressively make fine adjustments to parameters such as the position
loop gain, speed loop gain, and integral time constant to find the optimal points.
n Function to Improve Response Characteristics

The mode switch, feed-forward, and bias functions can improve the response of the
servo system only if they are used properly. If they are used improperly, they will
worsen the response. Refer to the following instructions and make adjustments to
these functions while observing the change in the actual response.
Mode Switch
Use the mode switch function to improve the transient characteristics of the servo
system if there is torque reference saturation at the time of acceleration or decelera-
tion. The speed loop in PI (proportional and integral) control is switched over to P
(proportional) control when the operation speed exceeds the set value in this func-
tion.
6-31
Feed-forward Function
The responsiveness is increased by using the feed-forward function. This function is
not effective if the position loop gain is set to a high value. Adjust the feed-forward
set value of Pn109 as described below.
1. Adjust speed and position loops according to the method described on this page.
2. Gradually increase the set value of Pn109 so that the positioning completion sig-
nal (/COIN) will be output quickly.
Make sure that the positioning completion signal (/COIN) does not bounce (i.e.,
turned on and off repeatedly within a short period) and that speed overshoot does
not occur. These will likely to occur if the feed-forward value is too high.
It is possible to add a primary delay filter (to be set in Pn10A) to the feed-for-
ward function. The primary delay filter may prevent the positioning completion
signal from bouncing and the system speed from overshooting.
Bias Function
This function adds the bias set in Pn107 to the output (i.e., speed reference) of the
error counter if the number of accumulated pulses of the error counter exceeds the
bias increment width set in Pn108. The bias will not be added if the output is within
the bias increment width. As a result, the number of accumulated pulses of the error
counter decreases and the time required for positioning can be shortened.
If the bias set value of Pn107 is too large, the motor speed will be unstable. The
optimum bias value varies with the load, gain, and bias increment width. Make bias
adjustments while observing the response. When not using this function, set Pn107
to 0.
Speed
Motor speed without bias function
Speed Motor speed with bias function
reference
Time
Bias increment width
Bias (Accumulated pulse setting)
Pn107 OFF ON OFF
Pn108
6-32
6.4.4 Gain Setting Reference Values

This section describes servo gain reference values.
Refer to the following for optimal gain adjustments according to the rigidity of the
mechanical system. Refer to these values and use the previously mentioned methods
to make gain adjustments. These values are for reference only and do not mean that
the mechanical system has good response characteristics or is free from oscillation in
the specified ranges.
Observe the response by monitoring the response waveform and make the optimum
gain adjustments. If the rigidity of the machinery is high, gain increments exceeding
the described ranges are possible.
n Machines with High Rigidity
These machines are directly connected to ball screws.
Examples: Chip mounting machine, bonding machine, high-precision machine tool
Speed Loop Integral Time Constant

Position Loop Gain (Pn102) Speed Loop Gain (Pn100)
(Pn101)
50 to 70s-1 50 to 70Hz 5 to 20ms
n Machines with Medium Rigidity

These machines are driven by ball screws through speed reducers or long-length
machines directly driven by screws.
Examples: General machine tool, transverse robot, conveyor
Speed Loop Gain Speed Loop Integral Time Constant

Position Loop Gain (Pn102)
(Pn100) (Pn101)
30 to 50s-1 30 to 50Hz 10 to 40ms
6-33
n Machines with Low Rigidity

These machines are driven by timing belts, chains, or machines with harmonic gear
reducers.
Examples: Conveyor, articulated robot
Speed Loop Integral Time Constant

Position Loop Gain (Pn102) Speed Loop Gain (Pn100)
(Pn101)
10 to 20s-1 10 to 20Hz 50 to 120ms
IMPORTANT
• When the inertia ratio is larger than 10, start gain adjustments with the position and speed
loop gains slightly below the ranges given above and the speed loop integral constant
slightly over the range.
• When the inertia ratio is much larger, start the gain adjustments with the position and
speed loop gains set to the smallest values and the speed loop integral constant to the
large value in the ranges given above.
In speed control operation, the position loop gain is set through the host controller.
If that is not possible, adjust the position loop gain with the speed reference input
gain in Pn300 in the servo amplifier. In speed control operation, the position loop
gain set in Pn102 is enabled in zero-clamp mode only. Position loop gain Kp is
obtainable from the following formula.
V
Kp ≥ s
ε
Where: Kp (s-1): Position Loop Gain

Vs (pps): Constant Speed Reference
ε (Pulse): Constant error: The number of accumulated pulses of
the error counter at the above constant speed.
6-34
6.5 Analog Monitor

The analog monitor can be used to observe a variety of analog voltage signals.
Analog monitor signals must be observed through the CN5 connector using the
DE9404559 cable.
White Red
CN5
Black Black
Cable Color Signal Name Description

White Analog monitor 1 Torque reference: 1V/100% rated torque
Red Analog monitor 2 motor speed:1 V/1000rpm
Black (two wires) GND (0V) —
Analog monitor signals can be selected with parameters Pn003.0 and Pn003.1.
Pn003.0 Analog Monitor 1 Default Setting: 2 Speed/Torque Control,

Position Control
Pn003.1 Analog Monitor 2 Default Setting: 0 Position Control
The following monitor signals can be observed.
Settings in Pn003.0 Description

and Pn003.1 Monitor signal Observation gain
0 Motor speed 1V/1000rpm
1 Speed reference 1V/1000rpm
2 Torque reference 1V/100% rated torque
3 Position error 0.05 V/1 reference unit
4 Position error 0.05 V/100 reference unit
5 Reference pulse frequency (converted to rpm) 1V/1000rpm
8 Reserved monitor signal —
9 — —
A — —
Note: 1. In the case of torque or speed control mode, the position error monitor signal has no meaning.
2. The output voltage range of the analog monitor is ±8V maximum. The polarity of the output voltage
will be changed if ±8V is exceeded.
6-35
Sigma II User’s Manual Chapter 7: Using the Digital Operator
7 Using the Digital Operator

This chapter describes the basic operation of the digital operator
and the features it offers. All parameter settings and motor
operations can be executed by simple, convenient operations.
Operate the digital operator as you read through this chapter.
7.1 Basic Operation.................................................................................................... 7-2
7.1.1 Connecting the Digital Operator................................................................. 7-2
7.1.2 Functions..................................................................................................... 7-3
7.1.3 Resetting Servo Alarms .............................................................................. 7-4
7.1.4 Basic Mode Selection ................................................................................. 7-5
7.1.5 Status Display Mode ................................................................................... 7-5
7.1.6 Operation in Parameter Setting Mode ........................................................ 7-8
7.1.7 Operation in Monitor Mode...................................................................... 7-16
7.2 Applied Operation.............................................................................................. 7-21
7.2.1 Operation in Alarm Traceback Mode ....................................................... 7-22
7.2.2 Operation Using the Digital Operator....................................................... 7-23
7.2.3 Automatic Adjustment of the Speed and Torque Reference Offset.......... 7-26
7.2.4 Manual Adjustment of the Speed and Torque Reference Offset .............. 7-29
7.2.5 Clearing Alarm Traceback Data ............................................................... 7-34
7.2.6 Checking the Motor Model....................................................................... 7-36
7.2.7 Checking the Software Version................................................................. 7-39
7.2.8 Origin Search Mode.................................................................................. 7-40
7.2.9 Initializing Parameter Settings.................................................................. 7-42
Analog Monitor Output ............................................................................ 7-44
7.2.11 Adjusting the Motor Current Detection Offset ......................................... 7-49
7.2.12 Write Protected Setting)............................................................................ 7-53
7-1
7.1 Basic Operation

This section provides information on the basic operation of the digital operator for setting
operating conditions.
7.1.1 Connecting the Digital Operator

There are two types of digital operator. One is a built-in operator incorporating a
panel indicator and switches located on the front panel of the servo amplifier. This
type of digital operator is also called a panel operator. The other one is a hand-held
operator (i.e., the JUSP-OP02A-1 digital operator), which can be connected to the
servo amplifier through connector CN3 of the servo amplifier.
There is no need to turn OFF the servo amplifier to connect this hand-held operator
to the servo amplifier. Refer to the following illustrations to connect the hand-held
digital operator to the servo amplifier.
Hand-held Digital Operator

JUSP-OP02-A Built-in Panel Operator
YASKAWA 200V
SERVOPACK
SGDH
MODE/SET DATA/
CN3
A dedicated cable is Servo amplifier

used to connect the
digital operator to the
servo amplifier.
Note: If the hand-held digital operator is connected to the servo amplifier, the built-in panel operator does
not display anything.
7-2
7.1.2 Functions
The digital operator can be used for parameter settings, operating references, and
status displays.
This section provides information on the keys and their functions available from the
initial displays.
Key Name Function
RESET Key Press this key to reset the servo

alarm
• Press this key to select the sta-

tus display mode, auxiliary
function mode, parameter set-
DSPL/SET Key
ting mode, or monitor mode.
• This key is used for data selec-
tion in parameter setting mode
Press this key to set each param-

DATA/ENTER Key eter or display the set value of
each parameter.
Value Press this key to increase the set

Change/ Up Arrow Key value. This key is used as a forward
JOG Key start key in JOG operation.
Press this key to decrease the set

Down Arrow Key value. This key is used as a reverse
start key in JOG operation.
• Press this key to select the digit

Digit
Select Right Arrow Key to be changed. The selected
Key digit flashes.
• Press the Right Arrow key to
shift to the next digit on the
right.
Left Arrow Key
• Press the Left Arrow key to
shift to the next digit on the left.
SVON Key Press this key to perform the JOG

operation with the digital operator.
7-3
Built-in Panel Operator

YASKAWA 200V
SERVOPACK
SGDM-
Key Name Function
• Press this key to set parame-
ters or display the set values of
MODE/SET DATA/ Up Arrow Key parameters.
• Press the Up Arrow key to
increase the set value.
• Press the Down Arrow key to
decrease the set value.
Down Arrow Key • Press the Up and Down Arrow
keys together to reset a servo
alarm.
Press this key to select the status
MODE/SET Key indicator mode, auxiliary function
mode, parameter setting mode, or
MODE/SET
monitor mode.
• Press this key to set each

parameter or display the set
value of each parameter.
DATA/SHIFT Key
DATA/
• This key is used for selecting
the editing (flashing) digit or
data setting.
7.1.3 Resetting Servo Alarms

Servo alarms can be reset using the digital operator.
Using the Hand-Held Digital Operator

Press the RESET key in status display mode.

Press the Up Arrow or Down Arrow keys together in status display mode.
The alarm can be reset with CN1-44, or /ALM-RST signal input. Refer to 5.5.1
Using Servo Alarm and Alarm Code Outputs.
The servo alarm will be reset if the control power supply is turned OFF.
IMPORTANT
• If an alarm is ON, reset the alarm after eliminating the cause of the alarm first. Refer to 9.2 Troubleshooting.
7-4
7.1.4 Basic Mode Selection

The basic mode selection of the digital operator is used for indicating the status of
the servo amplifier in operation and setting a variety of parameters and operation ref-
erences.
The status display, auxiliary function, parameter setting, and monitor modes are the
basic modes. As shown below, the mode is selected in the following order by press-
ing the key.
Hand-held Digital Operator Panel Operator
Press the DSPL/SET Key. Press the MODE/SET Key.

The basic mode changes. The basic mode changes.
Power ON
Status display mode (Refer to

7.1.5 Status Display Mode)
Auxiliary function mode (Refer

to 7.2 Applied Operation)
Parameter Setting Mode (Refer to 7.1.6

Operation in Parameter Setting Mode)
Monitor Mode (Refer to 7.1.7

Operation in Monitor Mode)
7.1.5 Status Display Mode

In status display mode, bit data and codes are displayed to indicate the status of the
servo amplifier.
Selecting Status Display Mode

The digital operator goes into status display mode when the digital operation is
turned ON.
Data in Status Display Mode

The screen contents in status display are different for speed, torque, and position
control modes.
7-5
Speed and Torque Control Mode

Bit Data Code
Speed Coincidence*
BaseBlock
Control Power ON
TGON
Speed Reference input Power Ready
* This indicator is always lit when the Servopack is in torque control mode.
The following tables list and explain the meanings of bit data and code displays in
Speed and Torque control modes.
Bit Data and Meanings in Speed and Torque Control Mode

Bit Datum Meaning
Control Power ON Lit when servo amplifier control power is ON.
Baseblock Lit for baseblock.

Not lit when servo is ON.
Lit when the difference between the motor speed and reference
Speed Coincidence speed is the same as or less than the value set in Pn503.
(The default value set in Pn503 is 10rpm).
Lit if motor speed exceeds preset value
/TGON Preset value: Set in Pn502. (Default setting is 20rpm).
Speed Reference Input Lit if input speed reference exceeds preset value.
Specified value: Set in Pn502. (Default setting is 20rpm)
Lit if input torque reference exceeds preset value.
Preset value: 10% rated torque is default setting
Lit when main power supply circuit is operating at normal level.
Power Ready
Not lit when power is OFF.
Codes and Meanings in Speed and Torque Control Mode

Code Meaning
Baseblock
Servo OFF (motor power OFF)
Run
Servo ON (motor power ON)
Forward Run Prohibited
CN1-42 (P-OT) is OFF. Refer to 5.1.2 Setting the Overtravel Linit
Setting.
Reverse Run Prohibited
CN1-43 (N-OT) is OFF. Refer to 5.1.2 Setting the Overtravel Linit
Setting.
Alarm Status
Displays the alarm number. Refer to 9.2 Troubleshooting.
7-6
Position Control Mode

Bit Data Code
Positioning Completed
Baseblock
Control Power ON
TGON
Reference Pulse Input Power Ready
Error Counter Clear Input
The following tables list and explain the meanings of bit data and code displays in
Speed and Torque control modes.
Bit Data and Meanings in Position Control Mode

Bit Datum Meaning
Control Power ON Lit when servo amplifier control power is ON.
Lit for baseblock.
Baseblock Not lit when servo is ON.
Lit if error between position reference and actual motor position
Positioning Completed is below preset value.
Preset value: Set in PN500. (Default setting is 7 pulses).
Lit if motor speed exceeds preset value.
/TGON
Preset value: Set in Pn502. (Default setting is 20rpm).
Reference Pulse Input Lit if reference pulse is input.
Error Counter Clear Input Lit when error counter clear signal is input.
Power Ready Lit when main power supply circuit is operating at normal level.
Not lit when power is OFF.
Codes and Meanings in Speed and Torque Control Mode

Code Meaning
Baseblock
Servo OFF (motor power OFF)
Run
Servo ON (motor power ON)
Forward Run Prohibited
CN1-42 (P-OT) is OFF. Refer to 5.1.2 Setting the Overtravel Linit
Setting.
Reverse Run Prohibited
CN1-43 (N-OT) is OFF. Refer to 5.1.2 Setting the Overtravel Linit
Setting.
Alarm Status
Displays the alarm number. Refer to 9.2 Troubleshooting.
7-7
7.1.6 Operation in Parameter Setting Mode

Functions can be selected or adjusted by setting parameters. There are two types of
parameters. One type requires value setting and the other requires function selec-
tion. These two types use different setting methods.
• With value setting, a parameter is set to a value within the specified range of the
parameter.
• With function selection, the functions allocated to each digit of the seven–seg-
ment LED panel indicator (five digits) can be selected.
Refer to Appendix B List of Parameters.
Changing Parameter Settings

The parameter settings can be used to change parameter data. Check the permitted
range of the parameters in Appendix B List of Parameters, before changing the data.
The example below shows how to change parameter Pn507 from 100 to 85.
1. Press the DSPL/SET key to select the parameter setting mode.
2. Select the parameter number to set. (Pn507 is selected in this example.)
Press the Left Arrow or Right Arrow key to select the digit. The selected
digit will flash.
Press the Up Arrow or Down Arrow key to change the value.

3. Press the DATA/ENTER key to display the current data for the parameter
selected at step 2.
4. Change the data as needed (to 85, in this example).
digit will flash.
Press the the Up Arrow or Down Arrow key to change the value. Con-
tinue pressing the key until “00085” is displayed.
7-8
5. Press the DATA/ENTER key to store the data. The display will flash.
6. Press the DATA/ENTER key again to return to the parameter number display.
This procedure has changed the setting of the parameter Pn507 from 100 to 85.
Repeat steps 2 to 6 to change the setting again.
Example Using the Panel Operator

YASKAWA 200V
SERVOPACK
SGDM-
1. Press the MODE/SET key to select the parameter setting mode.

MODE/SET DATA/
CHARGE POWER
2. Press the Up Arrow or Down Arrow key to select the parameter number
to set. (Pn507 is selected in this example.)
3. Press the DATA/SHIFT key for a minimum of one second to display the current
data for the parameter selected in step 2.
4. Press the the Up Arrow or Down Arrow key to change to the desired
value of “00085”.
As you keep pressing the Up Arrow or Down Arrow key, and the display
changes faster.
5. Press the DATA/SHIFT key for a minimum of one second to save the data. The
display will flash.
6. Press the DATA/SHIFT key once more for a minimum of one second to display
the parameter number again.
This has changed the setting of the parameter Pn507 from 100 to 85.
7-9
Repeat steps 2 to 6 to change the setting again.

Note: Parameter numbers that are not defined are skipped during Operator operations.
IMPORTANT
• Press the DATA/SHIFT Key for a maximum of one second to shift to a higher (left) digit.
7-10
Function Selection Parameters
Types of Function Selection Parameters

The following table shows the parameters for selecting servo amplifier functions.
Parameter Default Important

Category Name
No. Setting Note
Pn000 Function Selection Basic 0000 (See 1)

Switches
Function Selection Application
Pn001 0000 (See 1)
Function Selection Switches 1
Parameters Function Selection Application
Pn002 0000 (See 1)
Switches 2
Function Selection Application
Pn003 0002 —
Switches 3
Gain–related Application
Gain–related Param- Pn10B Switches 0000 (See 2)
eters
Pn110 Online Autotuning Switches 0010 (See 2)
Position Control– Position Control Reference
Pn200 0000 (See 1)
related Parameter Selection Switches
Pn50A Input Signal Selections 1 2100 (See 1)
Pn50B Input Signal Selections 2 6543 (See 1)
Pn50C Input Signal Selections 3 8888 (See 1)
Sequence–related
Pn50D Input Signal Selections 4 8888 (See 1)
Parameters
Pn50E Output Signal Selections 1 3211 (See 1)
Pn50F Output Signal Selections 2 0000 (See 1)
Pn510 Output Signal Selections 3 0000 (See 1)
IMPORTANT
• 1. After changing these parameters, turn OFF the main circuit and control power supplies and then turn them ON
again to enable the new settings.
• 2. Changing bits Pn10B.1 and Pn110.0 require the same sequence described in note 1 (above).
Parameter settings are displayed in two patterns as shown below.
Display Application Display Format
Function selection Hexadecimal display for each digit
Parameters setting Decimal display in five digits
Since each digit in the function selection parameters has a its own meaning, the
7-11
value can only be changed for each individual digit. Each digit can only display a
value within its own permitted range.
Definition of Display for Function Selection Parameters

Each digit of the function selection parameters has a unique meaning.
For example, the rightmost digit of parameter Pn000 is expressed as “Pn000.0”.
• Each digit of the function selection parameters is defined as shown below. The
parameter displayed below shows how the digits in the display are assigned.
0 digit
1st digit
2nd digit
3rd digit
Distribution of parameter digits

Designation Meaning
Pn000.0 Indicates the value entered at the 0 digit of parameter Pn000.
Pn000.1 Indicates the value entered at the 1st digit of parameter Pn000.
Pn000.2 Indicates the value entered at the 2nd digit of parameter Pn000.
Pn000.3 Indicates the value entered at the 3rd digit of parameter Pn000.
7-12
Changing Function Selection Parameter Settings
1. Press the DSPL/SET key to select the parameter setting mode.
2. Select the parameter number to be set.
digit will flash.
Press the Up Arrow or Down Arrow key to change the value. (Pn000 is
selected in this example.)
3. Press the DATA/ENTER key to display the current data of the parameter selected
in the above step 2.
Digit to be set
4. Press the Left Arrow or Right Arrow key to select the digit.
Digit to be set
5. Press the Up Arrow or Down Arrow key to select the value defined as a
function setting for the selected digit.
Digit to be set
Repeat the above steps 4 and 5 for changing the data as required.
6. Press the DATA/ENTER key to save the data. The display will flash.
7-13
7. Press the DATA/ENTER key once more to return to the parameter number dis-
play.
This has changed the 1st digit of parameter Pn000 to “1”.
Using the Panel Operator

YASKAWA 200V
SERVOPACK
SGDM-
1. Press the MODE/SET key to select the parameter setting mode.

MODE/SET DATA/
CHARGE POWER
2. Press the Up Arrow or Down Arrow key to select the parameter number
to be set. (Pn000 is selected in this example.)
3. Press the DATA/SHIFT key for a minimum of one second to display the current
data for the selected parameter.
Digit to be set
4. Press the DATA/SHIFT key to select the digit to be set.

Digit to be set
5. Press the Up Arrow or Down Arrow key to select the value defined as a
function setting for the selected digit.
Digit to be set
Repeat the above steps 4 and 5 for changing the data as required.
6. Press the DATA/SHIFT key for a minimum of one second to save the data. The
display will flash.
7-14
7. Press the DATA/SHIFT key once more for a minimum of one second to return to
the parameter number display.
This has changed the 1st digit of parameter Pn000 to “1”.
7-15
7.1.7 Operation in Monitor Mode

The monitor mode can be used for monitoring the reference values, I/O signal status,
and servo amplifier internal status.
The monitor mode can be set during motor operation.
Using the Monitor Mode

The example below shows how to display 1500, the contents of monitor number
Un000 when the Servomotor rotates at 1500rpm.
Example With the Hand-Held Digital Operator
1. Press the DSPL/SET key to select the monitor mode.
2. Press the Up Arrow or Down Arrow key to select the monitor number to
be displayed.
3. Press the DATA/ENTER key to display the monitor number selected in the
above step 2.
Data
4. Press the DATA/ENTER key once more to return to the monitor number dis-
play.
With the Panel Operator

YASKAWA 200V
SERVOPACK
SGDM-
MODE/SET DATA/
1. Press the MODE/SET key to select the monitor mode.
CHARGE POWER
2. Press the Up Arrow or Down Arrow key to select the monitor number to
be displayed.
3. Press the DATA/SHIFT key for a minimum of one second to display the monitor
7-16
number selected in the above step 2.

Data
the monitor number display.
This completes the example procedure for displaying 1500, the contents of mon-
itor number Un000.
Contents of Monitor Mode Display
The following table shows contents of the monitor mode display.
Monitor
Monitor Display Unit Comments
Number
Un000 Actual motor speed rpm
Un001 Input speed reference rpm (See note 3 below)
Un002 Internal torque reference % Value for rated torque
Un003 Rotation angle 1 pulses Number of pulses from the origin
Un004 Rotation angle 2 deg Angle (electrical angle) from the origin
Un005 Input signal monitor - (See note 1 below)
Un006 Output signal monitor - (See note 1 below)
Input reference pulse
Un007 rpm (See note 4 below)
speed
reference
Un008 Error counter value Positional error (See note 4 below)
unit
Accumulated load rate Value for the rated torque as 100%
Un009 %
Displays effective torque in 10s cycle.
Regenerative load rate Value for the processable regenerative power as
100%
Un00A %
Displays regenerative power consumption in 10s
cycle.
Power consumed by DB Value for the processable power when dynamic
Un00B resistance % brake is applied as 100%
Displays DB power consumption in 10s cycle.

Input reference pulse In hexadecimal (See notes 2 and 4)below
Un00C -
counter
Un00D Feedback pulse counter - In hexadecimal
Note: 1. Refer to Sequence I/O Signal Monitor on the next page.

2. Refer to Reference Pulse/Feedback Pulse Counter Monitor Display.
3. Displayed only in speed control mode.
7-17
4. Displayed only in position control mode.
7-18
Sequence I/O Signal Monitor Display

The following section describes the monitor display for sequence I/O signals.
Input Signal Monitor Display

Top: ON = High level
Bottom: ON = Low level
8 7 6 5 4 3 2 1 Number
LED Number Input Terminal Name Default Setting

1 SI0 (CN1–40) /S–ON
2 SI1 (CN1–41) /P–CON
3 SI2 (CN1–42) P–OT
4 SI3 (CN1–43) N–OT
5 SI4 (CN1–44) /ALM–RST
6 SI5 (CN1–45) /P–CL
7 SI6 (CN1–46) /N–CL
8 (CN1–4) SEN
Note Refer to 5.3.3 Input Circuit Signal Allocation for details on input terminals.
Input signals are allocated as shown above and displayed on the panel of the servo
amplifier or the digital operator. They are indicated by the ON/OFF status of the
vertical parts of seven-segment displays located in top and bottom rows. (The hori-
zontal segments are not used here). These turn ON or OFF relative to the state of the
corresponding input signals (ON for “L” level and OFF for “H” level).
Examples
• When /S-ON signal is ON (Servo ON at “L” signal)
The bottom segment

of number 1 is lit.
87 6 5 4 3 2 1
• When /S-ON signal is OFF

The top segment of
number 1 is lit.
87 6 5 4 3 2 1
• When P–OT signal operates (Operates at “H” signal)

The top segment of
number 3 is lit.
87 6 5 4 3 2 1
7-19
Output Signal Monitor Display

Top: ON = High level
Bottom: ON = Low level
7 6 5 4 3 2 1 Number
LED Number Output Terminal Name Default Setting

1 (CN1-31, -32) ALM
2 SO1 (CN1-25, -26) /COIN or /V-CMP
3 SO2 (CN1-27, -28) /TGON
4 SO3 (CN1-29, -30) /S-RDY
5 (CN1-37) AL01
6 (CN1-38) AL02
7 (CN1-39) AL03
Note: Refer to 5.3.4 Output Circuit Signal Allocation for details on output terminals.
Output signals are allocated as shown above and displayed on the panel of the servo
amplifier or the digital operator. They are indicated by the ON/OFF status of the
vertical parts of seven-segment displays located in top and bottom rows. (The hori-
zontal segments are not used here). These turn ON or OFF relative to the state of the
corresponding output signals (ON for “L” level and OFF for “H” level).
Example
• When ALM signal operates (alarm at “H”)

Only the top segment
of number 1 is lit.
7 6 5 4 3 2 1 Number
7-20
Reference Pulse/Feedback Pulse Counter Monitor Display
The monitor display of reference pulse counter and feedback pulse counter is
expressed in 32-bit hexadecimal.
The display procedure is as follows:
1. Press the DSPL/SET key to select the monitor mode.
2. Press the Up Arrow or Down Arrow key to select “Un00C” or “Un00D”.

3. Presss the DATA/ENTER key to display the data for the monitor number
selected in the above step.
4. Press the Up Arrow or Down Arrow key to alternately display the left-
most and the rightmost 16-bit data.
Leftmost 16-bit Data Rightmost 16-bit Data
5. Press both the Up Arrow or Down Arrow keys simultaneously to clear the
32-bit counter data.
6. Press the DATA/ENTER key once more to return to the monitor number dis-
play.

YASKAWA 200V
SERVOPACK
SGDM-
1. Press the MODE/SET key to select the monitor mode.

MODE/SET DATA/
CHARGE POWER
2. Press the Up Arrow or Down Arrow key to select “Un00C” or “Un00D”.

3. Press the DATA/SHIFT key for a minimum of one second to display the data for
the monitor number selected in the above step.
4. Press the Up Arrow or Down Arrow key to alternately display the left-
7-21
most 16-bit data and rightmost 16-bit data.
Leftmost 16-bit Data Rightmost 16-bit Data
5. Press both the Up Arrow or Down Arrow keys simultaneously to clear the
32-bit counter data.
the monitor number display.
7.2 Applied Operation

This section describes how to apply the basic operations using the digital operator to
run and adjust the motor. Read the basic operations described in section 7.1 before
proceeding to this section.
Parameters for applied operation can be set in the auxiliary function mode. The fol-
lowing table shows the parameters in the auxiliary function mode.
Parameter
Function Comments
Number
Fn000 Alarm traceback data display —
Fn001 Rigidity setting during online autotuning (See note).
Fn002 JOG mode operation
Fn003 Zero-point search mode —
Fn004 (Reserved parameter)
Fn005 Parameter settings initialization
Fn006 Alarm traceback data clear
Fn007 Writing to EEPROM the inertia ratio data obtained from online autotuning
Fn008 Absolute encoder multi–turn reset and encoder alarm reset.
Fn009 Automatic tuning of analog (speed, torque) reference offset
Fn00A Manual adjustment of speed reference offset (See note).
Fn00B Manual adjustment of torque reference offset
Fn00C Manual zero-adjustment of analog monitor output
Fn00D Manual gain-adjustment of analog monitor output
Fn00E Automatic offset-adjustment of motor current detection signal
Fn00F Manual offset-adjustment of motor current detection signal
Fn010 Password setting (protects from parameter changes)
Fn011 Motor models display —
Fn012 Software version display
Change Multi-Turn Limit Setting Value when a Multi-Turn Limit Disagreement
Fn013 (See note).
Alarm occurs
Note: These parameters and those indicated as Pn

are displayed as shown below if their write protect
is set (Fn010). These parameters cannot be changed.
Flashing for one second
7-22
7.2.1 Operation in Alarm Traceback Mode

The alarm traceback mode can display up to ten alarms that have occurred, thus
making it possible to check what kind of alarms have been generated.
The alarm traceback data is not cleared on alarm reset or when the servo amplifier
power is turned OFF.
The data can be cleared using the special “clear alarm traceback mode.” Refer to
Section 7.2.5 Clearing Alarm Traceback Data for details.
Alarm Code
See the table of
Alarm Sequence Number alarms.
The higher the number,
the older the alarm data.
Checking Alarms
Follow the procedure below to determine which alarms have been generated.
1. Press the DSPL/SET key to select the “Displaying alarm traceback data
(Fn000)” in the auxiliary function mode.
Alarm Traceback
Display
2. Press the DATA/ENTER key, and the alarm traceback data will be displayed.
3. Press the Up Arrow or Down Arrow key to scroll the alarm sequence
numbers up or down and display information on previous alarms.
The higher the leftmost digit (alarm sequence number), the older the alarm data.

YASKAWA 200V
SERVOPACK
SGDM-
1. Press the MODE/SET key to select the “Displaying alarm traceback data
MODE/SET
CHARGE
DATA/
POWER (Fn000)” in the auxiliary function mode.

Alarm Traceback
Display
2. Press the DATA/SHIFT key for a minimum of one second to display the alarm
traceback data.
7-23
3. Press the Up Arrow or Down Arrow key to scroll the alarm sequence
numbers up or down and display information on previous alarms.
The higher the leftmost digit (alarm sequence number), the older the alarm data.
For descriptions of each alarm code, refer to Section 9.2 Troubleshooting.
The following are operator-related alarms which are not recorded in the traceback
data.
Display Description
Digital operator transmission error 1
Digital operator transmission error 2
No error detected.
Note: Alarm traceback data is not updated when the same alarm occurs repeatedly.
7.2.2 Operation Using the Digital Operator
! CAUTION
• Forward run prohibited (P-OT) and reverse run prohibited (N-OT) signals are not effective during
jog operations using parameter Fn002.
Operation from the digital operator allows the servo amplifier to run the motor. This
allows rapid checking of motor’s rotation direction and speed setting during machine
setup and testing, without the trouble of connecting to a host controller.
7-24
For motor speed setting procedure, refer to 7.1.6 Operation in Parameter Setting
Mode and 5.3.2 Setting JOG Speed.
Panel YASKAWA
SERVOPaCK
200V Servo amplifier
Operator SGDH-
MODE/SET DATA/
CHARGE POWER
L1 C
N
L2 3
Power 1
2
C
L1C N
L2C 1
B1
B2
Servomotor
U
V
C
W N
2
Operation procedure using the digital operator is described on the following pages.
1. Press the DSPL/SET key to select Fn002 in the auxiliary function mode.
2. Press the DATA/ENTER key to select the digital operator operation mode.
Operation is now possible using the digital operator.
3. Press the SVON key to set to the servo ON state (with motor power turned ON).
4. Press the Up Arrow or Down Arrow key to operate the motor. The motor
keeps operating while the key is pressed.
Motor Forward Motor Reverse

Rotation Rotation
5. Press the DSPL/SET key, and the display will revert to Fn002. This sets to the
servo OFF state (with motor power turned OFF). Alternatively, press the SVON
Key to set to the servo OFF state.
This ends operation under digital operator control.
7-25

YASKAWA 200V
SERVOPACK
SGDM-
1. Press the MODE/SET key to select Fn002 in the auxiliary function mode.
MODE/SET DATA/
CHARGE POWER
2. Press the DATA/SHIFT key for a minimum of one second to select the Panel
Operator operation mode. Operation is now possible using the panel operator.
3. Press the MODE/SET key to set to the servo ON (with motor power turned
ON).
4. Press the Up Arrow or Down Arrow key to operate the motor. The motor
keeps operating while the key is pressed.
Motor Forward Motor Reverse

Rotation Rotation
5. Press the MODE/SET key to set to the servo OFF state (with motor power
turned OFF). Alternatively, press the DATA/SHIFT key for a minimum of one
second to set to the servo OFF state.
6. Press the DATA/SHIFT key for a minimum of one second, and the display will
revert to Fn002 in the auxiliary function mode.
This ends operation under panel operator control.

The motor speed for operation under digital operator control can be changed with a
parameter:
Setting
(rpm)
Pn304 Jog Speed Default Setting: 500 Speed Control
Note: The rotation direction of the servomotor depends on the setting of parameter Pn000.0 “Rotation
Direction.” The above example shows a case where Pn000.0 is set to “0” as a default setting.
7-26
7.2.3 Automatic Adjustment of the Speed and Torque Reference Offset

When speed and torque control are used, the motor may rotate slowly even when 0V
is specified as the analog reference voltage. This occurs when the host controller or
external circuit has a small offset (measured in mV) in the reference voltage.
The automatic reference offset adjustment mode automatically measures the offset
and adjusts the reference voltage. It adjusts both the speed and torque references.
The following diagram illustrates automatic adjustment of an offset in the reference
voltage by the servo amplifier.
Reference Offset Reference

voltage voltage Offset
automatically
adjusted in
Servo amplifier
Speed or Speed or
torque Automatic offset torque
reference adjustment reference
After completion of automatic offset adjustment, the amount of offset is stored in the
servo amplifier.
The amount of offset can be checked in the speed reference offset manual adjustment
mode. Refer to Section 7.2.4 Manual Adjustment of the Speed and Torque Reference
Offset for details.
The automatic reference offset adjustment mode cannot be used for setting the error
pulses to zero for a stopped servo amplifier when a position loop is formed with a
host controller. In such cases, use the manual reference offset adjustment mode.
Refer to Section 7.2.4 Manual Adjustment of the Speed and Torque Reference Offset
for details.
The zero-clamp speed control function is available to force the motor to stop while
the zero speed reference is given. Refer to Section 5.4.3 Using the Zero Clamp
Function.
IMPORTANT
• Automatic adjustment of the speed/torque reference offset must be performed under the servo OFF state .
Follow this procedure to automatically adjust the speed/torque reference offset.
7-27
1. Input the (intended) 0V reference voltage from the host controller or external cir-
cuit.
Servomotor
0V Speed or
Torque
Reference
Host
Controller
Servo OFF Slow Rotation
(Servo ON)
Servo amplifier
3. Select the parameter Fn009.
Press the Left Arrow or Right Arrow key to select the digit.

4. Press the DATA/ENTER key, and the display will be as shown below.
5. Press the DSPL/SET key, and the following display will flash for one second.
The reference offset will be automatically adjusted.
Flashing for
one second
6. Press the DATA/ENTER key to return to the auxiliary function mode display.
This completes the speed/torque reference offset automatic adjustment.
7-28

YASKAWA 200V
SERVOPACK
SGDM-
1. Input the (intended) 0V reference voltage from the host controller or external cir-
MODE/SET
CHARGE
DATA/
POWER
cuit.
Servomotor
0V Speed
or Torque
Host Reference
Controller
Servo OFF Slow Rotation
(Servo ON)
Servo amplifier
2. Press the MODE/SET key to select the auxiliary function mode.
be as shown below.
5. Press the MODE/SET key, and the following display will flash for one second.
The reference offset will be automatically adjusted.
Flashing for
one second
iary function mode display.
This completes the speed/torque reference offset automatic adjustment.
7-29
7.2.4 Manual Adjustment of the Speed and Torque Reference Offset

Manual speed/torque reference offset adjustment is useful in the following situa-
tions:
If a position loop is formed with a host controller and the error zeroed-out when the
motor was stopped in servo lock (zero reference).
• To deliberately set the offset to some value.
This mode can also be used to check the data set in the automatic reference offset
adjustment mode.
In principle, this mode operates in the same way as the automatic reference offset
adjustment mode, except that the amount of offset is directly input during the adjust-
ment. The offset amount can be set in the speed reference or torque reference.
The offset setting range and setting units are as follows:
Reference Speed or Reference Torque
Offset Setting
Range
Offset Units Analog Input Voltage
Offset Setting Range Offset Setting Range

Speed Reference: -0123 to +1023 Speed Reference: 0.46mV/LSB
Torque Reference: -128 to +127 Torque Reference: 1.47mV/LSB
Manual Adjustment of Speed Reference Offset

Follow the procedure below to manually adjust the speed reference offset.
2. Select the parameter Fn00A.
Press the Up Arrow or Down Arrow key to select the digit.
7-30
3. Press the DATA/ENTER key, and the display will be as shown below. The man-
ual adjustment mode for the speed reference offset will be entered.
4. Turn ON the Servo ON (/S-ON) signal. The display will be as shown below.
5. Press the Left Arrow or Right Arrow key, to display the speed reference
offset amount.
6. Press the Up Arrow or Down Arrow key to adjust the amount of offset
(adjustment of the speed reference offset).
7. Press the Right Cursor Key to return to the display shown in the above step 4.
This completes the speed reference offset manual adjustment.

YASKAWA 200V
SERVOPACK
SGDM-

MODE/SET DATA/
CHARGE POWER
2. Press the Up Arrow or Down Arrow key to select the parameter Fn00A.
be as shown below. The manual adjustment mode for the speed reference offset
will be entered.
4. Turn ON the Servo ON (/S-ON) signal. The display will be as shown below.
7-31
5. Press the DATA/SHIFT key for less than one second to display the speed refer-
ence offset amount.
6. Press the Up Arrow or Down Arrow key to adjust the amount of offset
(adjustment of the speed reference offset).
7. Press the DATA/SHIFT key for less than one second to return to the display
shown in the above step 4.
8. Press the DATA/SHIFT key to return to the auxiliary function mode display.
This completes the speed reference offset manual adjustment.
7-32
Manual Adjustment of Torque Reference Offset

Follow the procedure below to manually adjust the torque reference offset.
2. Select the parameter Fn00B.
3. Press the DATA/ENTER key, and the display will be as shown below. The man-
ual adjustment mode for the torque reference offset will be entered.
4. Turn ON the Servo ON (/S–ON) signal. The display will be as shown below.
5. Press the Left Arrow or Right Arrow key to display the torque reference
offset amount.
6. Press the Up Arrow or Down Arrow key to adjust the offset amount
(adjustment of torque reference offset).
7. Press the Left Arrow or Right Arrow key, and the display will be as
shown above in step 4.
This completes the torque reference offset manual adjustment.
7-33

YASKAWA 200V
SERVOPACK
SGDM-

MODE/SET DATA/
CHARGE POWER
2. Press the Up Arrow or Down Arrow key to select the parameter Fn00B.
3. Press the DSPL/SET key for a minimum of one second, and the display will be
as shown below. The manual adjustment mode for the torque reference offset
will be entered.
4. Turn ON the Servo ON (/S–ON) signal. The display will be as shown below.
5. Press the DATA/SHIFT key for less than one second, to display the torque refer-
ence offset amount.
6. Press the Up Arrow or Down Arrow key to adjust the offset amount,
(Adjustment of torque reference offset).
7. Press the DATA/SHIFT key for less than one second, and the display will be as
shown in the above step 4.
This completes the torque reference offset manual adjustment.
7-34
7.2.5 Clearing Alarm Traceback Data

This procedure clears the alarm history, which stores the alarms generated in the
servo amplifier. After clearing, each alarm in the alarm history is set to A.- -, which
is not an alarm code. Refer to Section 7.2.1 Operation in Alarm Traceback Mode for
details.
Follow the procedure below to clear the alarm traceback data.
4. Press the DSPL/SET key to clear the alarm traceback data. The following dis-
play will flash for one second, and, after the alarm traceback data is cleared, the
display will return to the one in the above step 3.
Flashing for
one second
5. Presss the DATA/ENTER key to return to the parameter code display.
This completes the alarm traceback data clearing procedure.
7-35

YASKAWA 200V
SERVOPACK
SGDM-

MODE/SET DATA/
CHARGE POWER
be as shown below.
4. Press the MODE/SET key to clear the alarm traceback data. The following dis-
play will flash for one second, and, after the alarm traceback data is cleared, the
display will return to the one shown above in step 3.
Flashing for
one second
5. Press the DATA/SHIFT key for a minimum of one second to return to the
parameter code display.
This completes the alarm traceback data clearing procedure.
7-36
7.2.6 Checking the Motor Model

Set the parameter Fn011 to select the motor model check mode. This mode is used
for motor maintenance, and can also be used to check the special (Y-specification)
codes of the servo amplifiers.
Follow the procedure below to check the motor model.
3. Press the DATA/ENTER key to display the servomotor model and voltage code.
Voltage Servomotor Mode
Voltage Servomotor Model

Code Voltage Code Servomotor Model
00 100VAC or 140VDC 00 SGMAH
01 200VAC or 280VDC 01 SGMPH
02 400VAC or 560VDC 02 SGMSH
03
SGMGH- A (1500rpm)
04 SGMGH-B (1000rpm)
05 SGMDH
06 SGMUH
4. Press the DSPL/SET key to display the Servomotor capacity.

Capacity: Displayed value y 10 (W)
In this example, the capacity is 100 W
7-37
5. Press the DSPL/SET key to display the encoder type and resolution code.
Encoder Type Encoder Resolution

Code Voltage Code Resolution
00 Incremental Encoder 13 13 bits
01 Absolute Encoder 16 16 bits
17 17 bits
20 Reserved
6. Press the DSPL/SET key to display the servo amplifier’s special (Y-specifica-
tion) code.
Capacity: Displayed value × 10W.
In this example, the capacity is 100W.
Pressing the DATA/ENTER key after the above displays in steps 3 to 5 will also
return to the auxiliary function mode display.
This ends checking motor type procedure.

YASKAWA 200V
SERVOPACK
SGDM-

MODE/SET DATA/
CHARGE POWER
3. Press the DATA/SHIFT key for a minimum of one second to display the Servo-
motor model and voltage code.
Voltage Servomotor Mode
7-38
Voltage Servomotor Model

Code Voltage Code Servomotor Model
00 100VAC or 140VDC 00 SGMAH
01 200VAC or 280VDC 01 SGMPH
02 400VAC or 560VDC 02 SGMSH
03
SGMGH- A (1500rpm)
04 SGMGH-B (1000rpm)
05 SAGMDH
06 SGMUH
4. Press the MODE/SET key to display the Servomotor capacity.

Capacity unit: Displayed value y 10 [W
This example shows 100 W.
5. Press the MODE/SET key, and the encoder type and resolution code will be dis-
played.

Code Voltage Code Resolution
00 Incremental Encoder 13 13 bits
01 Absolute Encoder 16 16 bits
17 17 bits
20 Reserved
6. Press the MODE/SET key to display the servo amplifier’s special (Y-specifica-
tion) code.
This example skows specification
code “Y10” (indicated in decimal).
7. Press the DATA/SHIFT key to return to the auxiliary function mode display.
Pressing the DATA/SHIFT key after the above displays in steps 3 to 5 will also
return to the auxiliary function mode display.
This completes the motor type checking procedure.
7-39
7.2.7 Checking the Software Version

Set Fn012 to select the software-version check mode.
This mode is used for motor maintenance.
Follow the procedure below to check the software version.
Using the Hand-Held Operator

2. Press the DATA/ENTER key, and the servo amplifier software version will be
displayed.
Software Version Display
Software
Version
3. Press the DSPL/SET key, and the software version of the encoder mounted on
the motor will be displayed.
Software Version Display
Software Version
4. Press the DATA/ENTER key to return to the parameter code display.
This completes the checking software version procedure.

YASKAWA 200V
SERVOPACK
SGDM-

MODE/SET DATA/
CHARGE POWER
2. Press the DATA/SHIFT key for a minimum of one second to display the servo
amplifier software version.
3. Press the MODE/SET key to display the encoder software version.
4. Press the DATA/SHIFT key for a minimum of one second to return to the
parameter code display.
7-40
7.2.8 Origin Search Mode
! CAUTION
• Forward run prohibited (P-OT) and reverse run prohibited (N-OT) signals are not effective during
jog operations using parameter Fn003.
The origin search mode is designed to position the origin pulse position of the
encoder and to clamp at the position. This mode is used when the motor shaft needs
to be aligned to the machine. Execute the origin search without connecting the cou-
plings.
The speed for executing the origin search is 60rpm.
For aligning the motor

shaft with the machine
Mechanical origin
The following conditions must be met to perform the origin search operation.
• If the Servo-ON input signal (/S-ON) is ON, turn it OFF.
• Release the Servo-ON signal mask if the parameter Pn50A.1 is set to 7, and the
servo has been set to be always ON.
Follow the procedure below to execute the origin search.
2.Select the parameter Fn003.

7-41
4. Press the SVON key, and the display will be as shown below. Now it is ready for
executing the origin search.
5. Hold down the Up Arrow or Down Arrow key to execute the origin
search.
When the parameter is set to Pn000.0 = 0 (default), pressing the Up Arrow

key will rotate the motor in the forward direction. Pressing the Down Arrow
key will rotate the motor in the reverse direction. When the parameter is set to
Pn000.0 = 1, the rotation of the motor is reversed.
Up: Forward Keeps flashing until
Down: Reverse search is completed
This completes the origin search operation.

YASKAWA 200V
SERVOPACK
SGDM-

MODE/SET DATA/
CHARGE POWER
be as shown below.
4. Press the MODE/SET key, and the display will change as shown below. Now it
is ready for executing the origin search mode.
5. Hold down the Up Arrow or Down Arrow key to execute the origin
search.
When the parameter is set to Pn000.0 = 0 (default), pressing the Up Arrow key
will rotate the motor in the forward direction. Pressing the Down Arrow key
7-42
will rotate the motor in the reverse direction. When the parameter is set to
Pn000.0 = 1, the rotation of the motor is reversed.
Keeps flashing unti
Up: Forward origin search is
Down: Reverse completed.
This completes the origin search operation.
7.2.9 Initializing Parameter Settings

This function is used to restore all the parameters to the default settings (standard
factory settings).
IMPORTANT
• Initialize the parameter settings with the servo OFF.
Follow the procedure below to initialize parameter settings.
4. Press the DSPL/SET key, and the display will be as shown below. The parame-
7-43
ters will be initialized.

Flashing during End
initialization
Flashing for
one second
This completes the initialization of parameter settings.

YASKAWA 200V
SERVOPACK
SGDM-

MODE/SET DATA/
CHARGE POWER
be as shown below.
4. Press the MODE/SET key, and the display will be as shown below. The param-
eters will be initialized.
Flashing during
initialization End
Flashing for
one second
This completes the initialization of parameter settings.

Note: Parameters will not be initialized by pressing the DSPL/SET or MODE/SET key with the
servo ON. Turn the power OFF and then back ON after initialization.
7-44

Analog Monitor Output
Motor speed, torque reference, and position error can be monitored through the ana-
log monitor output. Refer to Section 6.5 Analog Monitor.
Use the manual zero adjustment function to compensate for the output voltage drift
or the zero point drift caused by noise entering the monitor system. The gain adjust-
ment function can be changed to match the sensitivity of the measuring system.
Monitor Output Voltage
Gain Adjustment
Zero Adjustment
ÎÎ
Setting Unit
Zero Setting Range: ±2V 17mV/LSB
Gain Setting Range: 50 to 150% 0.4%/LSB
Note: The output voltage of the analog monitor is ±8V. The output voltage polarity will be reversed if ±8V
is exceeded.
Manual Zero Adjustment of Analog Monitor Output

Follow the procedure below to execute the manual zero adjustment of analog moni-
tor output.
7-45
2. Select the parameter Fn00C.
4. Press the DSPL/SET key. Each time the DSPL/SET key is pressed, the monitor
output will toggle between the displays for the two channels shown below.
DSPL/SET Key Data Display
Displayed
alternately
5. Press the Left Arrow or Right Arrow key to display the analog monitor
output data. Pressing the Left Arrow or Right Arrow key again will
return to the display shown in the above step 3 or 4.
LEFT Cursor Key
(RIGHT Cursor Key) Data Display
Displayed
alternately
6. Press the Up Arrow or Down Arrow key to perform zero adjustment of

the analog monitor output.
Data Setting Change
7. When zero adjustment has been completed for the two channels, press the
DATA/ENTER key to return to the auxiliary function mode display.
This completes the manual zero adjustment of the analog monitor output.
7-46

YASKAWA 200V
SERVOPACK
SGDM-

MODE/SET DATA/
CHARGE POWER
2. Press the Up Arrow or Down Arrow key to select the parameter Fn00C.
be as shown below.
4. Press the MODE/SET key. Each time the MODE/SET key is pressed, the mon-
itor output will toggle between the displays for the two channels shown below.
MODE/SET Key
Displayed
Alternately
5. Press the DATA/SHIFT key for less than one second, and the analog monitor
gain parameter will be displayed. Pressing the DATA/SHIFT key again for less
than one second will return to the display shown in the above steps 3 or 4.
Data Display
DATA/SHIFT Key
Displayed
Alternately
6. Press the Up Arrow or Down Arrow key to perform zero adjustment of

the analog monitor output.
Data Setting Change
7. When zero adjustment has been completed for the two channels, press the
DATA/SHIFT key for a minimum of one second to return to the auxiliary func-
tion mode display.
This completes the manual zero adjustment of the analog monitor output.
7-47
Manual Gain Adjustment of Analog Monitor Output

Follow the procedure below to execute the manual gain adjustment of analog moni-
tor output.
Using the Hand–held Digital Operator
2. Select the parameter Fn00D.

3. Press the DATA/SHIFT key, and the display will be as shown below.
4. Press the DSPL/SET key. Each time the DSPL/SET key is pressed, the monitor
output will toggle between the displays for the two channels shown below.
DSPL/SET Key
Displayed
Alternately
5. Press the Left Arrow or Right Arrow key to display the analog monitor
gain parameter. Pressing the Left Arrow or Right Arrow key again will
return to the display shown above in step 3 or 4.
Left Cursor Key
(Right Cursor Key) Data Display
Displayed
Alternately
6. Press the Up Arrow or Down Arrow key to adjust the gain for the analog
monitor output.
Data Setting Change
7. When the gain adjustment has been completed for the two channels, press the
DATA/ENTER key to return to the auxiliary function mode display.
This completes the manual gain adjustment of the analog monitor output.
7-48

YASKAWA 200V
SERVOPACK
SGDM-

MODE/SET DATA/
CHARGE POWER
2. Press the Left Arrow or Right Arrow key to select the parameter Fn00D.
be as shown below.
4. Press the MODE/SET key. Each time the MODE/SET key is pressed, the mon-
itor output will toggle between the displays for the two channels shown below.
MODE/SET Key
Displayed
Alternately
5. Press the DATA/SHIFT key for less than one second. The gain parameter for the
analog monitor will be displayed. Pressing the DATA/SHIFT key again for less
than one second will return to the display shown above in step 3 or 4.
Data Display
DATA/SHIFT Key
Displayed
Alternately
6. Press the Up Arrow or Down Arrow key to adjust the gain for the analog
monitor output.
Data Setting Change
7. When the gain adjustment has been completed for the two channels, press the
DATA/SHIFT key for a minimum of one second to return to the auxiliary func-
tion mode display.
This completes the manual gain adjustment of the analog monitor output.
7-49
7.2.11 Adjusting the Motor Current Detection Offset

Motor current detection offset adjustment is performed at Yaskawa before shipping.
Normally, the user does not need to perform this adjustment. Make this adjustment
only if highly accurate adjustment is required to reduce torque ripple caused by cur-
rent offset.
The following sections describe automatic and manual adjustment of the current
Note: If this function, particularly manual adjustment, is executed carelessly, it may degrade the perfor-
mance of the servo drive.
Automatic Adjustment of the Motor Current Detection Offset

Follow the procedure below to perform automatic adjustment of the current detec-
tion offset.
Note: Automatic adjustment is possible only with power supplied to the main circuits and with the servo
OFF.
2. Select the parameter Fn00E.
Press the Left Arrow or Right Arrow key to change the value.
4. Press the DSPL/SET key. The display will change as shown below and offset
will be automatically adjusted.
Flashing
for one
second
5. Press the DATA/ENTER key to return to the auxiliary function mode display .
This completes the automatic adjustment of the motor current detection offset.
7-50

YASKAWA 200V
SERVOPACK
SGDM-

MODE/SET DATA/
CHARGE POWER
2. Press the Up Arrow or Down Arrow key to select the parameter Fn00E.
be as shown below.
4. Press the MODE/SET key. The display will change as shown below and the off-
set will be automatically adjusted.
Flashing
for one
second
This completes the automatic adjustment of the motor current detection offset.
Manually Adjusting the Motor Current Detection Offset

Follow the procedure below to manually adjust the current detection offset.
IMPORTANT
• When making manual adjustments, run the motor at a speed of approximately 100rpm, and adjust
the Motor Current Detection Offset until the torque ripple, observed with the analog monitor, is mini-
mized. (Refer to Section 6.5 Analog Monitor.)
Adjust the U-phase and V-phase offsets alternately several times until these offsets are well balanced.
7-51
Hand-Held Digital Operator
2. Select the parameter Fn00F.
4. Press the DSPL/SET key to switch between the U-phase (Cu1_0) and V-phase
(Cu2_0) current detection offset adjustment mode
DSPL/SET Key
Displayed
Alternately
5. Press the Left Arrow or Right Arrow key to display the current detection
data. Pressing the Left Arrow or Right Arrow key again will return to the
display shown above in step 3 or 4.
Left Cursor Key
(Right Cursor Key)
Data Display
Displayed
Alternately
6. Press the Up Arrow or Down Arrow key to adjust the offset. Carefully
adjust the offset while monitoring the torque reference monitor signal.
Data Setting Change
7. When the current offset adjustment has been completed for the U-phase (Cu1_0)
and V-phase (Cu2_0), press the DATA/SHIFT key to return to the auxiliary
function mode display.
This completes the manual adjustment of the motor current detection offset.
7-52

YASKAWA 200V
SERVOPACK
SGDM-

MODE/SET DATA/
CHARGE POWER
2. Press the Up Arrow or Down Arrow key to select the parameter Fn00F.
be as shown below.
4. Press the MODE/SET key to switch between U-phase (Cu1_0) and V-phase
(Cu2_0) current detection offset adjustment mode.
MODE/SET Key
Displayed
Alternately
5. Press the DATA/SHIFT key for less than one second to display the current
detection data. Press the DATA/SHIFT key again for less than one second, and
the display will return to one shown above in step 3 or 4.
Data Display
DATA/SHIFT Key
Displayed
Alternately
6. Press the Up Arrow or Down Arrow key to adjust the offset. Carefully
adjust the offset while monitoring the torque reference monitor signal.
Data Setting Change
7. When the current offset adjustment has been completed for the U-phase (Cu1_0)
and V-phase (Cu2_0), press the DATA/SHIFT key to return to the auxiliary
function mode display
This completes the manual adjustment of the motor current detection offset.
7-53
7.2.12 Write Protected Setting

The write protect setting is used for preventing careless changes of the parameters.
Parameters Pn and some of Fn become write protected by setting the
parameter Fn010.
Password setting values are as follows:
• “0000”: Write enabled (Releases write prohibited mode.)
• “0001”: Write prohibited (parameters become write protected at the next power
ON.)
Follow the procedure below to set the password.
4. Input the value (0001) and press the DSPL/SET key. The display will change as
shown below and the write protect will be established.
Flashing
for one
second
This completes the write protect setting procedure. The new setting will be valid
after the next power OFF/ON cycle.
7-54

YASKAWA 200V
SERVOPACK
SGDM-

MODE/SET DATA/
CHARGE POWER
be as shown below.
4. Input the value (0001) and press the MODE/SET key. The display will change
to one shown below and the write protect will be established.
Flashing
for one
second
This completes the procedure for setting the write protect. The new setting pass-
word will be valid after the next power OFF/ON cycle.
7-55
Sigma II User’s Manual Chapter 8: Ratings and Characteristics
8 Ratings and Characteristics

This chapter provides the ratings, torque-speed characteristics
diagrams, and dimensional drawings of the Sigma II series
servo drives.
8.1 Servomotors ......................................................................................................... 8-2

8.1.1 Ratings, Specifications, and Dimensional Drawings.................................. 8-2
8.2 Servo Amplifiers................................................................................................ 8-17
8.2.1 Combined Specifications .......................................................................... 8-17
8.2.2 Ratings and Specifications........................................................................ 8-21
8.2.3 Dimensional Drawings ............................................................................. 8-24
8-1
8.1 Servomotors
This section describes ratings, specifications, and dimensional drawings of the servomo-
tors. Refer to this section for selecting an appropriate servo drive.
8.1.1 Ratings, Specifications, and Dimensional Drawings

The following sections provide the ratings specifications, and dimensional drawings
of the servomotors by model.
n SGMAH Servomotors
Ratings and Specifications for Standard Servomotors

• Time Rating: Continuous • Insulation Class: Class B
• Vibration Class: 15µm or below • Withstand Voltage: 1500VAC for one minute
• Insulation Resistance: 500VDC, • Enclosure: Totally enclosed, self–cooled,
10MΩ minimum IP55 (except for through-sections of the shaft)
• Ambient Temperature: 0 to 40°C • Ambient Humidity: 20% to 80% (with no
condensation)
• Excitation: Permanent magnet • Drive Method: Direct drive
• Mounting: Flange method
SGMAH Standard Servomotor Ratings and Specifications
Voltage 200V 100V

Servomotor Model
A3A A5A 01A 02A 04A 08A A3B A5B 01B 02B
SGMAH
Rated Output * kW 0.03 0.05 0.1 0.2 0.4 0.75 0.03 0.05 0.1 0.2
Rated oz·in 13.52 22.5 45.1 90.2 180 338 13.52 22.5 45.1 90.2
Torque*,** N·m 0.0955 0.159 0.318 0.637 1.27 2.39 0.0955 0.159 0.318 0.637
Instantaneous oz·in 40.6 67.6 135.2 270 541 1010 40.6 67.6 135.2 270
Peak Torque* N·m 0.286 0.477 0.955 1.91 3.82 7.16 0.286 0.477 0.955 1.91
Rated Current* Arms 0.44 0.64 0.91 2.1 2.8 4.4 0.66 0.95 2.4 3.0
Instantaneous
Maximum Arms 1.3 2.0 2.8 6.5 8.5 13.4 2.0 2.9 7.2 9.0
Current*
Rated Speed* rpm 3000
Maximum
rpm 5000
Speed*
oz·in/Arms 33.7 38.0 53.6 46.2 70.6 83.6 22.2 25.8 20.7 33.2
Torque Constant
N·m/Arms 0.238 0.268 0.378 0.327 0.498 0.590 0.157 0.182 0.146 0.234
Moment of oz·in·s2 x 10-3 0.235 0.312 0.515 1.501 2.45 9.52 0.235 0.312 0.515 1.501
Inertia
kg·m2 x 10-4 0.0166 0.0220 0.0364 0.106 0.173 0.672 0.0166 0.0220 0.0364 0.106
Rated Power
kW/s 5.49 11.5 27.8 38.2 93.7 84.8 5.49 11.5 27.8 38.2
Rating*
8-2
Voltage 200V 100V

Servomotor Model
A3A A5A 01A 02A 04A 08A A3B A5B 01B 02B
SGMAH
Rated Angular
Acceleration* rad/s2 57500 72300 87400 60100 73600 35500 57500 72300 87400 60100
Inertia ms 1.4 0.88 0.53 0.39 0.25 0.26 1.4 0.85 0.61 0.41
Time Constant
Inductive
Time Constant ms 1.0 1.1 1.2 4.6 5.4 8.7 1.0 1.1 1.1 4.4
Note: * These items and torque-motor speed characteristics quoted in combination with an SGDH servo
amplifier are at an armature winding temperature of 100°C. Other values quoted at 20°C. All
values are typical.
** Rated torques are continuous allowable torque values at 40°C with a 10 × 10 × 0.25in. ( 250 ×
250 × 6mm) heat sink attached.
8-3
SGMAH Servomotor Torque-Motor Speed Characteristics

The torque-motor speed characteristics are shown below for SGMAH servomotors.
• 200V Servomotors
SGMAH - A3 o SGMAH - A5 o
5000 5000
SPEED (rpm) 4000 4000
SPEED (rpm)
3000 3000
A B A B
2000 2000
1000 1000
0 0
0 0.1 0.2 0.3 0.4 0 0.15 0.3 0.45 0.6
TORQUE (N · m) TORQUE (N · m)
0 20 40 60 0 20 40 60 80 100
TORQUE (oz · in) TORQUE (oz · in)
SGMAH - 01 o SGMAH - 02 o
5000 5000
4000 4000
SPEED (rpm)
SPEED (rpm)
3000 3000
A B A B
2000 2000
1000 1000
0 0
0 0.25 0.5 0.75 1 0 0.5 1 1.5 2
TORQUE (N· m) TORQUE (N· m)
0 50 100 150 0 100 200 300
TORQUE (oz· in) TORQUE (oz· in)
5000
5000
SPEED (rpm)
4000
SPEED (rpm)
4000
3000
3000
2000
A B A B
2000
1000
1000
0
0
0 1 2 3 4 0 2 4 6 8
0 200 400 600 0 400 800 1200
8-4
SGMAH - A3 o SGMAH - A5 o
5000
5000
4000
SPEED (rpm)
4000
SPEED (rpm)
3000
3000
A B A B
2000
2000
1000
1000
0
00 0.1 0.2 0.3 0.4 0 0.15 0.3 0.45 0.6
0 20 40 60 0 20 40 60 80 100
TORQUE (lb · in) TORQUE (lb · in)
5000 5000
4000 4000
SPEED (rpm)
SPEED (rpm)
3000 3000
A B A B
2000 2000
1000 1000
0 0 0.25 0
0.5 0.75 1 0 0.5 1 1.5 2
0 50 100 150 0 100 200 300
8-5
SGMAH Dimensions in inches (mm)

Drawings that provide) SGMGH servomotor dimensions are shown below.
LL LR
LC
LG LE
LZ
LA
ΦLB
LC
ΦS
Mass
Model LL LC LA LZ LG ΦLB LE ΦS LR
kg (lb)
SGMAH–A3A (B) 2.74 0.661

(69.5) 0.24 (0.3)
3.03 1.57 1.81 0.17 0.20 1.19 0.098 (6) 0.98 0.882
SGMAH–A5A (B) (77.0) (40) (46) (4.3) (5) (30) (2.5) (25) (0.4)
SGMAH–01A (B) 3.72 0.32 1.10

(94.5) (8) (0.5)
SGMAH–02A (B) 3.80 2.43

(96.5) 2.36 2.76 0.22 0.24 1.98 0.56 1.18 (1.1)
4.90 (60) (70) (5.5) (6) (50) 0.12 (14) (30) 3.75
SGMAH–04A (124.5) (3) (1.7)
5.71 3.15 3.54 0.28 0.31 2.78 0.64 1.57 7.50
SGMAH–08A (145) (80) (90) (7) (8) (70) (16) (40) (3.4)
Specified Tolerances
Dimension ΦS ΦLB
Unit Diameter Tolerance Diameter Tolerance
0.24 1.19 +0.0000 -0.0008
0.31 1.98 +0.0000 -0.0010
in +0.0000-0.0004
0.56 2.78 +0.0000 -0.0012
0.64
6 30 +0.000 -0.021
+0.000 -0.009
8 50 +0.000 -0.025
mm
14 70 +0.000 -0.030
+0.000 -0.011
16
8-6
n SGMPH Servomotors
Ratings and Specifications for Standard Servomotors

• Time Rating: Continuous • Insulation Class: Class B
• Insulation Resistance: 500VDC, • Enclosure: Totally enclosed, self-cooled,
condensation)
SGMPH Standard Servomotor Ratings and Specifications
Voltage 200V 100V

Servomotor Model
01A 02A 04A 08A 15A 01B 02B
SGMPH-
Rated Output * kW 0.1 0.2 0.4 0.75 1.5 0.1 0.2
oz·in 45.1 90.2 180 338 676 45.1 90.2
Rated Torque* **
N·m 0.318 0.637 1.27 2.39 4.77 0.318 0.637
Instantaneous Peak oz·in 135 270 541 1010 2030 135.2 270
Torque* N·m 0.955 1.91 3.82 7.16 14.3 0.955 1.91
Rated Current* Arms 0.89 2.0 2.6 4.1 7.5 2.2 2.7
Instantaneous Max. Cur-
Arms 2.8 6.0 8.0 13.9 23.0 7.1 8.4
rent*
Max. Speed* rpm 5000
oz·in/Arms 55.6 49.4 75.8 91.0 97.4 22.8 36.5
Torque Constant
N·m/Arms 0.392 0.349 0.535 0.641 0.687 0.160 0.258
oz·in·s2 x 10-3 0.695 2.73 4.69 29.7 56.9 0.695 2.73
Moment of Inertia
kg·m2 x 10-4 0.0491 0.193 0.331 2.10 4.02 0.0491 0.193
Rated Power Rating* kW/s 20.6 21.0 49.0 27.1 56.7 20.6 21.0
Rated Angular Accelera-
tion* rad/s2 64800 33000 38500 11400 11900 64800 33000
Inertia Time Constant ms 0.53 0.54 0.36 0.66 0.46 0.56 0.64
Inductive Time Constant ms 3.7 7.4 8.6 18 22 3.6 6.3
Note: * These items and torque–motor speed characteristics quoted in combination with an SGDH servo
amplifier are at an armature winding temperature of 100°C. Other values quoted at 20°C. All val-
ues are typical.
** Rated torques are continuous allowable torque values at 40°C with a 10 × 10 × 0.25in. (250 ×
250 × 6mm) heat sink attached.
Heat sink dimensions
10 × 10 × 0.25in. (250 × 250 × 6mm): 0.1to 0.4kW
12 × 12 × 0.5in. (300 × 300 × 12mm): 0.75 to 1.5 kW
8-7
SGMPH Servomotor Torque-Motor Speed Characteristics

The torque-motor speed characteristics are shown below for SGMPH servomotors.
SGMPH - 01oo o
SGMPH - 02o
5000 5000
4000 4000
SPEED (rpm)
SPEED (rpm)
3000 3000
A B A B
2000 2000
1000 1000
0 0
0 0.25 0.5 0.75 1.0 0 0.5 1 1.5 2
0 50 100 150 0 100 200 300
o
SGMPH - 04o o
SGMPH - 08o
5000 5000
4000 4000
SPEED (rpm)
SPEED (rpm)
3000 3000
A B A B
2000 2000
1000 1000
0 0
0 1 2 3 4 0 2 4 6 8
0 200 400 600 0 400 800 1200

o
SGMPH - 15o
5000
4000
SPEED (rpm)
3000
A B
2000
1000
0
0 4 8 12 16
TORQUE (N · m)
0 800 1600 2400
TORQUE (oz · in)
8-8
o
SGMPH - 01o o
SGMPH - 02o
5000 5000
4000 4000
SPEED (rpm)
SPEED (rpm)
3000 3000
A B A B
2000 2000
1000 1000
0 0
0 0.25 0.5 0.75 1.0 0 0.5 1 1.5 2
0 50 100 150 0 100 200 300
8-9
SGMPH Dimensions in inches (mm)

Drawings that provide SGMPH servomotor dimensions are shown below.
LL LR
LC
LG LE
LZ
LA
ΦLB
LC
ΦS
Mass
Model LL LC LA LZ LG ΦLB LE ΦS LR
kg (lb)
SGMPH–01A (B) 2.44 2.36( 2.76 0.22 0.24 1.98 0.32 1.54
(62) 60) (70) (5.5) (6) (50) (8) (0.7)
2.64 0.12 0.98 3.09
SGMPH–02A (B) (67.0) (3) (25) (1.4)
3.15 3.54 0.28 0.31 2.76 0.56
3.43 (80) (90) (7) (8) (70) (14) 4.63
SGMPH–04A (B)
(87) (2.1)
SGMPH–08A (B) 3.410 0.64 9.26

(86.5) 4.72 5.71 0.39 0.39 4.37 0.14 (16) 1.18 (4.2)
4.51 (120) (145) (10) (10) (110) (3.5) 0.75 (30) 14.6
SGMPH–15A (114.5) (19) (6.6)
Dimension ΦS ΦLB
0.32 1.98 +0.0000 -0.0010
0.56 +0.0000-0.0004 2.78 +0.0000 -0.0012
in
0.64 4.37 +0.0000 -0.0014
0.75 +0.0000-0.0005
8 +0.000 -0.009 50 +0.000 -0.025
14 70 +0.000 -0.030
mm +0.000 -0.011
16 110 +0.000 -0.035
19 +0.000 -0.013
8-10
n SGMGH Servomotors for 1500rpm
Rating and Specifications for Standard Servomotors

• Time Rating: Continuous • Insulation Class: Class F
• Insulation Resistance: 50 VDC, • Enclosure: Totally enclosed, self–cooled,
condensation)
SGMGH Standard Servomotor Ratings and Specifications
Servomotor Model
05AoA 09AoA 13AoA 20AoA 30AoA
SGMGH-
Rated Output * kW 0.45 0.85 1.3 1.8 2.9
oz·in 402 763 1181 1628 2634
Rated Torque*
N·m 2.84 5.39 8.34 11.5 18.6
oz·in 1263 1954 3299 4064 6386
Instantaneous Peak Torque*
N·m 8.92 13.8 23.3 28.7 45.1
Rated Current* Arms 3.8 7.1 10.7 16.7 23.8
Instantaneous Max. Current* Arms 11 17 28 42 56
Maximum Speed* rpm 3000
oz·in/Arms 116.1 117.5 118.9 103.4 117.5
Torque Constant
N·m/Arms 0.82 0.83 0.84 0.73 0.83
oz·in·s2 x 10-3 102.5 196.8 290 449 651
Moment of Inertia
kg·m2 x 10-4 7.24 13.9 20.5 31.7 46.0
Rated Power Rating* kW/s 11.2 20.9 33.8 41.5 75.3
Rated Angular Acceleration* rad/s2 3930 3880 4060 3620 4050

Inertia Time Constant ms 5.0 3.1 2.8 2.2 1.9
Inductive Time Constant ms 5.1 5.3 6.3 12.8 12.5
Note: *These items and torque–motor speed characteristics quoted in combination with an SGDH servo
amplifier are at an armature winding temperature of 20°C.
Note: These characteristics have been calculated with the following heat sinks attached for cooling:
15.75 × 15.75 × 0.79in. (400 × 400 × 20mm): 05AoA to 13AoA
21.65 × 21.65 × 1.18in. (550 × 550 × 30mm): 20AoA to 30AoA
8-11
SGMGH Servomotor Torque-Motor Speed Characteristics

The following sections provide the torque-motor speed characteristics of the
SGMGH servomotors at 1500rpm
oA
SGMGH - 05Ao oA
SGMGH - 09Ao
3000 3000
SPEED (rpm)
SPEED (rpm)
2000 2000
A B A B
1000 1000
0 0
0 2 4 6 8 10 0 5 10 15 20
0 20 40 60 80 0 50 100 150
oA
SGMGH- 20Ao
oA
SGMGH - 13Ao
3000
3000
SPEED (rpm)
SPEED (rpm)
2000
2000
A B A B
1000
1000
0
0 0 10 20 30 40
0 10 20 30 TORQUE (N · m)
TORQUE (N · m)
0 100 200 300
0 20 40 60 80 TORQUE (lb · in)
TORQUE (lb · in)
oA
SGMGH - 30Ao
3000
SPEED (rpm)
2000
A B
1000
0
0 10 20 30 40 50
TORQUE (N · m)
0 100 200 300 400
TORQUE (lb · in)
8-12
SGMGH Dimensions in inches (mm)

Drawings that provide (1500rpm) SGMGH servomotor dimensions are shown
below.
ΦLB
ΦS
Mass
Model LL LC LA LZ LG ΦLB LE Q ΦS LR
lb (kg)
5.43 12.1
SGMGH–05AoA (138) (5.5)
0.75
6.34 5.12 5.71 0.35 0.47 4.33 0.24 1.57 (19) 2.28 16.8
SGMGH–09AoA (161) (130) (145) (9) (12) (110) (6) (40) (58) (7.6)
SGMGH–13AoA 7.28 0.87 21.2

(185) (22) (9.6)
6.54 30.9
SGMGH–20AoA (166) (14)
7.09 7.87 0.53 0.71 4.50 0.13 2.99 1.38 3.11
7.56 (180) (200) (13.5) (18) (114.3) (3.2) (76) (35) (79) 39.7
SGMGH–30AoA (192) (18)
Dimension ΦLB ΦS
4.33 +0.0000-0.0014 0.75
+0.0000-0.0005
in 4.50 +0.0000-0.0010 0.87
1.38 +0.0004-0.0000
110 +0.000 -0.035 19
+0.000 -0.013
mm 114.3 +0.000 -0.025 22
35 +0.01 -0.00
8-13
n SGMSH Servomotors
Rating and Specifications for Standard Servomotors
• Time Rating: Continuous • Insulation Class: Class F
• Insulation Resistance: 500VDC, • Enclosure: Totally enclosed, self–cooled,
condensation)
SGMSH Standard Servomotor Ratings and Specifications
Servomotor Model
10AoA 15AoA 20AoA 30AoA
SGMSH-
Rated Output * kW 1.0 1.5 2.0 3.0
oz·in 450 694 901 1388
Rated Torque*
N·m 3.18 4.9 6.36 9.8
oz·in 1351 2082 2705 4163
Instantaneous Peak Torque*
N·m 9.54 14.7 19.1 29.4
Rated Current* Arms 5.7 9.7 12.7 18.8
Instantaneous Max. Current* Arms 17 28 42 56
Max. Speed* rpm 5000
oz·in/Arms 90.1 79.4 77.0 81.1
Torque Constant
N·m/Arms 0.636 0.561 0.554 0.573
oz·in·s2 x 10-3 24.6 35.0 45.2 99.1
Moment of Inertia
kg·m2 x 10-4 1.74 2.47 3.19 7.00
Rated Power Rating* kW/s 57.9 97.2 127 137
Rated Angular Acceleration* rad/s2 18250 19840 19970 14000

Inertia Time Constant ms 0.87 0.74 0.62 0.74
Inductive Time Constant ms 7.1 7.7 8.3 13.0
Note: * These items and torque-motor speed characteristics quoted in combination with an SGDH servo
amplifier are at an armature winding temperature of 20°C.
Note: These characteristics have been calculated with the following heat sinks attached for cooling:
12 × 12 × 0.5in. (3400 × 300 × 12mm): 10AoA to 20AoA
18 × 18 × 0.8in. (400 × 400 × 20mm): 30AoA
8-14
SGMSH Servomotor Torque-Motor Speed Characteristics

The following sections provide the torque-motor speed characteristics of the SGMSH servomo-
tors.
200V Servomotors
oA
SGMSH - 10Ao oA
SGMSH - 15Ao
5000 5000
4000 4000
SPEED (rpm)
SPEED (rpm)
3000 3000
A B A B
2000 2000
1000 1000
0 0
0 2 4 6 8 10 0 5 10 15
TORQUE (N · m)
TORQUE (N · m)
0 20 40 60 80 0 50 100 150
oA
SGMSH - 20Ao oA
SGMSH - 30Ao
5000 5000
4000 4000
SPEED (rpm)
SPEED (rpm)
3000 3000
A B A B
2000 2000
1000 1000
0 0
0 5 10 15 20 0 10 20 30
0 50 100 150 0 100 200

TORQUE (lb · in)
8-15
SGMSH Dimensions in inches (mm)

Drawings that provide SGMSH servomotor dimensions are shown below.
ΦLB
ΦS
Mass
Model LL LC LA LZ LG ΦLB LE Q ΦS LR
lb (kg)
SGMSH–10AoA 5.87 10.1

(149) (4.6)
6.89 3.94 4.53 0.28 0.39 3.74 0.12 1.57 0.94 1.77 12.8
SGMSH–15AoA (175) (100) (115) (7) (10) (95) (3) (40) (24) (45) (5.8)
7.80 15.4
SGMSH–20AoA (198) (7.0)
SGMSH–30AoA 7.83 5.12 5.71 0.35 0.47 4.33 0.24 2.17 1.10 2.48 24.3
(199) (130) (145) (9) (12) (110) (6) (55) (28) (63) (11)
Dimension ΦLB ΦS
3.74 0.94
in +0.0000-0.0014 +0.0000-0.0005
4.33 1.10
95 24
mm +0.000 -0.035 +0.000 -0.013
110 28
8-16
8.2 Servo Amplifiers
This section presents tables of SGDH servo amplifier ratings and specifications.
8.2.1 Combined Specifications

The following table provides specifications of the SGDH servo amplifiers and
SGMAH, SGMPH, SGMGH, and SGMSH combinations.
Servo Amplifier and Servomotor Combination Specifications at 200V
Voltage Single-phase 200V Three-phase 200V

A3AE A5AE 01AE 02AE 04AE 05AE 08AE 10AE 15AE 20AE 30AE
SGDH–
Model
SGMAH– A3A A5A 01A 02A 04A — 08A — — — —
Appli-
cable Capacity 0.03 0.05 0.1 0.2 0.4 — 0.75 — — — —
Ser- (kW)
vomo-
tor Motor
Speed Rated 3000/maximum 5000
(rpm)
Applicable Encoder Standard: 13–bit incremental encoder
Continuous Output
SGMAH Current 0.44 0.64 0.91 2.1 2.8 — 4.4 — — — —
Series Arms
Maximum Output
Current 1..3 2.0 2.8 6.5 8.5 — 13.4 — — — —
Arms
Allowable Regener-
ative Energy 18.5 37.1 —
(Joules)
Allowable Regener-
ative Frequency** — — 89 —
(times/min)
8-17

SGDH–
Model — — 01A 02A 04A — 08A — 15A — —
SGMAH–
Appli-
cable Capacity — — 0.1 0.2 0.4 — 0.75 — 1.5 — —
Ser- (kW)
vomo-
tor Motor
(rpm)
Continuous Output
SGMAH Current — — 0.89 2.0 2.6 — 4.1 — 7.5 — —
Series Arms
Maximum Output
Current — — 2.8 6.0 8.0 — 13.9 — 23.0 — —
Arms
Allowable Regener-
ative Energy — 37.1 —
(Joules)
Allowable Regener-
ative Frequency** — — 29 — 17 —
(times/min) —
Model — — — — — 05A — 09A 13A 20A 30A

SGMGH– oA oA oA oA oA
Appli-
cable Capacity
— — — — — 0.45 — 0.85 1.3 1.8 2.9
Ser- (kW)
vomo-
tor Motor
(rpm)
SGMGH
Series Continuous Output
Current — — — — — 3.8 — 7.1 10.7 16.7 23.8
Arms
Maximum Output
Current — — — — — 11 — 17 28 42 56
Arms
Allowable Regener-
ative Energy — 34 — 13 10 12 8
(Joules)
8-18

SGDH–
Model — — — — — — — 10A 15A 20A 30A
SGMSH–
Appli-
cable Capacity — — — — — — — 1.0 1.5 2.0 3.0
Servo- (kW)
motor Motor
(rpm)
SGMSH
Series Continuous Output
Current — — — — — — — 5.7 9.7 12.7 18.8
Arms
Maximum Output
Current — — — — — — — 17 28 42 56
Arms
Allowable Regenera-
tive Frequency** — — 39 31 48 20
(times/min)
Note: * Allowable regenerative energy is the level when the AC input power supply voltage is 200Vrms. The allow-
able regenerative energy may vary with individaual power supply tolerance.
** Allowable regenerative frequency is the number of times the servomotor is allowed to accelerateand deceler-
ate through a 0rpm → maximum motor speed → 0rpm cycle in a minute.
8-19
Servo Amplifier and Servomotor Combination Specifications

at 100V
Voltage Single-phase 100V

A3BE A5BE 01BE 02BE
SGDH-
Model A3B A5B 01B 02B
SGMAH–
Applicable Capacity 0.03 0.05 0.1 0.2
Servomotor (kW)
Motor Speed
(rpm) Rated 3000/maximum 5000
SGMAH Applicable Encoder Standard: 13–bit incremental encoder
Series
Continuous Output Current
Arms 0.66 0.95 2.4 3.0
Maximum Output Current

Arms 2.0 2.9 7.2 9.0
Allowable Regenerative Frequency*

(times/min) 7.8 15.7
Model
SGMPH– — — 01B 02B
Applicable Capacity — — 0.1 0.2

Servo-motor (kW)
Motor Speed
(rpm) Rated 3000/maximum 5000
SGMPH Applicable Encoder Standard: 13–bit incremental encoder
Series
Continuous Output Current
Arms — — 2.2 2.7
Maximum Output Current

Arms — — 7.1 8.4
Allowable Regenerative Frequency* — 15.7

(times/min)
Note: * Allowable regenerative energy is the level when the AC input power supply voltage is 100Vrms.
The allowable regenerative energy may vary with the individaual power supply’s tolerance.
Note: Refer to Section 5.6 Selecting a Regeneration Resistor for more details on allowable regenerative
energy and frequency.
8-20
8.2.2 Ratings and Specifications

The following table shows ratings and specifications for the SGDH servo amplifier
to use in selecting the appropriate servo amplifier.
Servo Amplifier Ratings and Specifications

A3 A5 01 02 04 05 08 10 15 20 30
SGDH–
SGMAH-oA A3A A5A 01A 02A 04A — 08A — — — —
Applicable Servomotor
SGMPH-oA — — 01A 02A 04A — 08A — 15A — —

200V
SGMGH-oAoA (1500rpm) — — — — — 05 — 09 13 20 30
SGMSH-oA — — — — — — — 10 15 20 30
SGMAH-oB A3B A5B 01B 02B — — — — — — —
100V
SGMPH-oB — — 01B 02B — — — — — — —
Maximum Applicable Servomotor Capacity 0.03 0.05 0.1 0.2 0.4 0.5 0.75 1.0 1.5 2.0 3.0
[kW]
Continuous Output Current [Arms] 0.44 0.64 0.91 2.1 2.8 3.8 5.7 7.6 11.6 18.5 24.8
200V
Maximum Output Current [Arms] 1..3 2.0 2.8 6.5 8.5 11.0 13.9 17 28 42 56
Continuous Output Current [Arms] 0.66 0.95 2.4 3.0 — — — — — — —
100V
Maximum Output Current [Arms] 2.0 2.9 7.2 9.0 — — — — — — —
200 and 100V Servo Amplifier For Single-phase 200VAC For Three-phase 200VAC
Capacity Range For Single-phase100VAC —
Basic Specifications
Input
Power Three-phase (or single-phase) 200 to 230VAC +10 to -15%, 50/60Hz, or single-phase
Main Circuit*
Supply 100 to 115VAC +10 to -15%, 50/60Hz
Single-phase 200 to 230VAC +10 to -15%, 50/60Hz, or single-phase 100 to 115VAC +10
Control Circuit
or -15%, 50/60Hz
Control Method Single or three-phase full-wave rectification IGBT-PWM (sinewave driven)
Feedback Serial encoder: 13- (incremental only), 16-, or 17-bit (incremental/absolute).
Ambient/Storage Temperature** 0 to +55°C/-20 to +85°C
Ambient/Storage Humidity 90% relative humidity or less (with no condensation)
Vibration/Shock Resistance 4.9 m/s2/19.6 m/s2
Configuration Base mounted (Rack mounted optional).
For 200V 1.76 2.43 3.75 6.17 8.38

Approx. (0.8) (1.1) (1.7) (2.8) (3.8)
Mass
[lb (kg)} 1.76 2.43
For 100V (0.8) (1.1) —
Notes: * Supply voltage must not exceed 230V +10% (253V) or 115V + 10% (127V). A step-down transformer is
required if the voltage exceeds these values.
** Use the servo amplifier within the ambient temperature range. When enclosed, internal temperatures must
not exceed the specified range.
8-21

A3 A5 01 02 04 05 08 10 15 20 30
SGDH–
Speed Control Range 1:5000 (The lowest speed of the speed control range is the speed at which
the servomotor will not stop with a rated torque load.)
Load Regulation 0 to 100% load: 0.01% maximum (at rated speed)
Speed
Regulation* Voltage Regulation Rated Voltage ±10%: 0% (at rated speed)
Perfor-
mance Temperature Regulation 25 ± 25°C: ±0.1% max. (at rated speed)
Frequency Characteristics 400Hz (at JL = JM)
Speed and Torque Control Modes
Torque Control Tolerance (Repeatability) ±2%

Soft Start Time Setting 0 to 10s (Can be set individually for acceleration and deceleration)
±6VDC (Variable setting range: ±2 to ±10VDC) at rated torque (positive
Reference Voltage**
Speed torque reference with positive reference), input voltage: ±12V (maximum).
Reference
Input Input Impedance About 14kΩ
Circuit Time Constant —
±3VDC (Variable setting range: ±1 to ±10VDC) at rated torque (pos-
Reference Voltage**
Input Torque itive torque reference with positive reference), input volt
Signals Reference
Input Input Impedance About 14kΩ
Circuit Time Constant About 47µs
Rotation Direction Selec- With P control signal
tion
Contact Speed
Reference With forward/reverse current limit signal (speed 1 to 3 selection),
Speed Selection servomotor stops or another control method is used when both are
OFF.
Bias Setting 0 to 450rpm (setting resolution: 1rpm)
Perfor-
mance Feed Forward Compensation 0 to 100% (setting resolution: 1%)
Positioning Completed Width Setting 0 to 250 reference units (setting resolution: 1 reference unit)
Position Control Mode
Sign + pulse train, 90° phase difference 2-phase pulse (A phase + B

Type phase), or CCW + CW pulse train
Reference
Pulse Form Line driver (+5V level), open collector (+5V or +12V level)
Input
Signals Frequency 500/200kpps maximum (line driver/open collector).
Control Signal Clear Signal (input pulse form identical to reference pulse)
Built-in Open Collector Power Supply*** +12V (1kΩ built-in resistor)
Note: * Speed regulation is defined as follows:
The motor speed may change due to voltage variations or amplifier drift and changes in processing resistance
due to temperature variation. The ratio of speed changes to the rated speed represents speed regulation due to
voltage and temperature variations.
** Forward is clockwise viewed from the non-load side of the servomotor, (counterclockwise viewed from the
load and shaft end).
***The built-in open collector power supply is not electrically isolated from the control circuit in the servo
amplifier.
8-22

A3 A5 01 02 04 05 08 10 15 20 30
SGDH–
Form A-, B-, C-phase line driver

Position Output S-phase line driver (only with an absolute encoder)
Frequency Dividing Ratio Any
Servo ON, P control (or Control Mode switching, forward/reverse motor rotation by
I/O Signals
Sequence Input Signal allocation can be internal speed setting, zero clamping, reference pulse prohibited), forward run pro-
modified hibited (P-OT), reverse run prohibited (N-OT), alarm reset, forward current limit and
reverse current limit (or internal speed selection)
Fixed Output Servo alarm, 3-bit alarm codes
Sequence Output Positioning completed (speed coincidence), during servomotor rotation, servo
Signal allocation can be ready, during current limiting, during speed limiting, brake released, warning,
modified selecting three of the NEAR signals.
Dynamic Brake Operated at main power OFF, servo alarm, servo OFF, or overtravel.
Regeneration External regenerative resistor. Built-in.
Overtravel Stop Dynamic brake stop at P-OT or N-OT, deceleration to a stop, or free run to a stop.
Electronic Gear 0.01 <A/B < 100
Overcurrent, overvoltage, low voltage, overload, regeneration error, main circuit
Protection voltage error, heat sink overheated, no power supply, overflow, overspeed,
encoder error, overrun, CPU error, parameter error, etc.
LED Display Charge, Power, five 7-segment LEDs (built-in Digital Operator functions)
Internal Functions
Analog monitor connector built in for monitoring speed, torque and other reference
signals.
CN5 Analog Monitoring Speed: 1V/1000rpm
Torque: 1V/rated torque
Pulses remaining: 0.05V/reference units or 0.05V/100 reference units
Connected Devices Digital Operator (hand-held model), RS-422A port such as for a personal computer
(RS-232C ports under certain conditions)
1:N Communications Up to N = 14 for RS-422A ports
Communications Axis Address Setting Set with parameters.
Status display, user constant setting, monitor display, alarm trace-back display,
Functions JOG and auto-tuning operations, speed, torque reference signal and other drawing
functions.
Reverse rotation connection, origin search, automatic servomotor ID, DC reactor
Others connection terminal for high power supply frequency control
8-23
8.2.3 Base-Mounted Servo Amplifier Dimensional Drawings in inches

(mm)
n SGDH-A3AE to -02AE (Single-phase, 200V, 30 to 200W) and

SGDH-A3BE to -01BE (Single-phase, 100V, 30 to 100W)
0.315 (8)
SERVOPACK
SGDH
YASKAWA
Terminal 8 8 8 8 8
block
6.30 (160)
MODE/SET DATA/
(3 types)
CHARGE POWER
C
CN3
L1
N
3
L2
⊕1
⊕2
L1C
L2C
N
1 CN1
B1
0.24 (6)
B2
W
C
N
2
CN2
0.39
Ground terminal (10)
2 x M4 screws
0.24 (6) 2.95 (75) 5.12 (130)
2.17 (55)
0.22 (5.5)
Mounting Hole
Diagram
2 x M4 screw holes
5.89 (149.5) ±0.020 (0.5)
6.30 (160)
(Mounting pitch)
0.67 (17)
0.20 (5)
0.20 (5)
Approximate mass: 1.76lb (0.8kg)
2.17 (55)
The same Servo Amplifier connector is used for SGDH-A3AE (30W) to SGDH-30AE (3.0kW)
and SGDH-A3BE (30W) to SGDH-02BE (200W).
Connector Symbol Servo Amplifier Connector Model Manufacturer

CN1 101250-52A2JL Sumitomo 3M Co., Ltd.
CN2 53460-0611 Molex Japan Co., Ltd.
CN3 10214-52A2JL Sumitomo 3M Co., Ltd.
8-24
n SGDH-04AE (Single-phase, 200V, 400W) and

SGDH-02BE (Single-phase, 100V, 200W)
0.22 (5.5) 2-Φ0.20 (Φ5) holes

0.315 (8)
SERVOPACK
SGDH
YASKAWA
Terminal 88888
5.89 (149.5)
block
6.30 (160)
MODE/SET DATA/
(3 types) CHARGE POWER
C
CN3
L1
N
3
L2
⊕1
⊕2
L1C
C
N
1 CN1
L2C
B1
B2
0.20 (5)
W
C
N
CN2
2
0.24 (6)
0.39 (10)
Ground terminal 0.24 (6)
2 x M4 screws 2.95 (75) 5.12 (130)
0.20 (5) 2.48 (63)
0.47 (12)
2.95 (75)
Mounting Hole Diagram
0.22 (5.5) 2 x M4 screw holes

5.89 (149.5) ±0.020 (0.5)
0.67 (17)
(Mounting pitch)
6.30 (160)
0.20 (5)
0.47 (12)
2.95 (75)
8-25
n SGDH-05AE to-10AE (Three-phase, 200V, 0.5 to 1.0kW)
2-Φ0.20 (Φ5) holes

3.79 (96.2) Air flow
0.315 (8)
Terminal SERVO
SGDH
block YASKAWA
(3 types)
3.72 (94.4)
88888
6.30 (160)
MODE/SET DATA/
CHARGE
L1
POWER
C
CN3
N
3
L2
L3
⊕1
⊕2
C
N
1 CN1
Air flow L1C
L2C
B1
B2
0.24 (6)
B3
U C
N
2
CN2
V
Cooling fan
Air flow
0.59 (15) 0.39 (10) Ground
terminal
Mounting Hole Diagram 2.17 (55) 2.95 (75) 7.09 (180)
1.38 (35) 2 x M4
0.22 (5.5)
3.54 (90) screws
2 x M4
5.89 (149.5) ±0.020 (0.5)
screw holes
(Mounting pitch)
6.30 (160)
0.67 (17)
Air flow

0.20 (5)
1.06 (27)
3.54 (90)
8-26
n SGDH-15AE (Three-phase, 200V, 1.5kW)
2-Φ0.20 (Φ5) holes

Heat sink
Air flow 0.315 (8)

SGDH
YASKAWA
88888
CN3
6.30 (160)
MODE/SET DATA/
CHARGE POWER
L1 C
N
3
L2
⊕1
⊕2
CN1
C
N
L1C 1
L2C
B1
B2
W
C
N
CN2
2
Terminal
block
(3 types)
0.20 (5) Air flow Ground 0.16 (4)

terminal
4.33 (110) 2 x M4
2.95 (75) 7.09 (180)
screws

0.22 (5.5)
0.28 (7) 5.57 (141.5)

2 x M4 screw holes
5.89 (149.5) ±0.020 (0.5)
(Mounting pitch)
6.30 (160)
Cooling fan
0.20 (5)
0.20 3.94 (100) ±0.020 (0.5)

0.20 (5)
(5) (Mounting pitch)
4.33 (110)
8-27
n SGDH-20AE, 30AE (Three-phase 200V, 2.0kW,3.0kW)

2-Φ0.24 (Φ6) hole
Heat sink
0.24 (6)
Air flow
0.315 (8)
SERVOPACK
SGDH
YASKAWA
88888
MODE/SET
CHARGE
DATA/
POWER CN3
CN3
CN1
9.39 (238.5)
9.84 (250)
CN1
CN2
CN2
Β2
Β3
U
V
W
0.22 (5.5)
Ground
14-pin
terminal Air terminal
2 x M4 M4 mount-
screws flow ing screw
0.24 (6)
3.94 (100) 0.20 (5) 0.16 (4)
0.20 (5) 2.95 (75) 7.09 (180)
4.33 (110)
0.28 (7) 5.57 (141.5)

0.24 (6)
4 x M5 taps
9.39 (238.5) ±0.020 (0.5)
(100°)
(Mounting pitch)
9.84 (250)
Cooling fan
1.57 (40)
3.94 (100)
0.20 (5)
0.20 (5) ±0.020 (0.5) 0.20 (5)

(Mounting pitch) 1 (20)
4.33 (110) Approximate mass: 8.38lb (3.8kg)
8-28
Sigma II User’s Manual Chapter 9: Inspection, Maintenance, and Troubleshooting
9 Inspection, Maintenance, and Troubleshooting

This chapter describes the basic inspection and maintenance to be
carried out by the user. In addition, troubleshooting procedures
are described for problems which generate an alarm display and
for problems which result in no alarm display.
9.1 Servodrive Inspection and Maintenance............................................................. 9-2
9.1.1 Servomotor Inspection ................................................................................ 9-2
9.1.2 Servo Amplifier Inspection......................................................................... 9-3
9.1.3 Replacing Battery for Absolute Encoder .................................................... 9-4
9.2 Troubleshooting ................................................................................................... 9-5
9.2.1 Troubleshooting Problems with Alarm Displays........................................ 9-5
9.2.2 Troubleshooting Problems with No Alarm Display ................................. 9-35
9.2.3 Alarm Display Table ................................................................................. 9-37
9.2.4 Warning Displays...................................................................................... 9-39
9-1
9.1 Servodrive Inspection and Maintenance

This section describes the basic inspections and maintenance of servomotors and servo
amplifiers and the procedures for replacing the battery for absolute encoders.
9.1.1 Servomotor Inspection

For inspection and maintenance of servomotors, follow the simple, daily inspection
procedures in the following table.
The AC servomotors are brushless. Simple, daily inspection is sufficient under most
conditions. The inspection and maintenance frequencies in the table are only guide-
lines. Increase or decrease the frequency to suit the operating conditions and envi-
ronment.
IMPORTANT
• During inspection and maintenance, do not disassemble the servomotor.
If disassembly of the servomotor is required, contact Yaskawa.
Servomotor Inspections
Action or
Frequency Procedure Comments
Problem
Vibration and
Noise Daily Touch and listen. Levels higher than normal?
Exterior Dirt According to degree Clean with cloth or com- —

of contamination pressed air.
Disconnect servo amplifier
Insulation and test insulation resis- Contact Yaskawa if the insu-
Resistance At least every year tance at 500V. Must lation resistance is below
Measurement exceed 10MΩ.* 10MΩ.
Remove servomotor from

Oil Seal At least every 5000 machine and replace oil Applies only to motors with
Replacement hours seal. oil seals.
Servomotor At least every 20000 The user should not disas-

Overhaul hours or 5 years Contact Yaskawa. semble and clean the servo-
motor.
* Measure across the servomotor FG and the U-phase, V-phase, or W-phase power line
9-2
9.1.2 Servo Amplifier Inspection

For inspection and maintenance of the servo amplifier, follow the inspection proce-
dures in the following table. Perform inspection and maintenance at least once every
year. Other routine inspections are not required.
Servo Amplifier Inspections
Action or
Frequency Procedure Comments
Problem
Clean interior and At least every year Check for dust, dirt, and oil Clean with com-
circuit boards on the surfaces. pressed air.
Check for loose terminal Tighten any loose
Loose screws At least every year block and connector screws.
screws.
Defective parts in Check for discoloration,
unit or on circuit At least every year damage or discontinuities Contact Yaskawa.
boards due to heating.
n Part Replacement Schedule

The following parts are subject to mechanical wear or deterioration over time. To
avoid failure, replace these parts at the frequency indicated.
The parameters of any servo amplifiers overhauled by Yaskawa are reset to the
default (standard factory) settings before shipping. Be sure to confirm that the
parameters are set to the application’s requirements before starting operation.
Periodical Part Replacement
Standard
Part Replacement Method
Replacement Period
Cooling fan 4 to 5 years Replace with new part.
Smoothing capacitor 7 to 8 years Test. Replace with a new part, if necessary.
Relays — Test. Replace if necessary.
Fuse 10 years Replace with new part.
Aluminum electrolytic
capacitor on circuit 5 years Test. Replace with new circuit board, if nec-
board essary.
Operating Conditions:
Ambient Temperature: Annual average of 30°C
Load Factor: 80%, maximum.
Operation Rate: 20 hours/day, maximum.
9-3
9.1.3 Replacing Battery for Absolute Encoder

If the voltage of the battery for an absolute encoder drops to about 2.7V or less, an
Absolute Encoder Battery Alarm (A. 83) will occur in the servo amplifier. This
alarm occurs when the servo amplifier receives a signal from the absolute encoder
when the power to the servo amplifier is turned ON. Therefore, the servo amplifier
will not give an alarm when the battery voltage drops below the minimum voltage
level while the power is being supplied to the servo amplifier.
Refer to 5.7.3 Handling Batteries for the battery type recommended for absolute
encoders.
Replace the battery using the following procedure if the battery voltage drops below
the minimum required battery voltage.
n Battery Replacement Procedure
1. Replace the battery while the control power to the servo amplifier is ON.
2. After replacement, turn OFF the power to the servo amplifier in order to clear the
Absolute Encoder Battery Alarm (A. 83).
3. Turn ON the power to the servo amplifier again and confirm that it operates
properly.
Note: The absolute encoder data will be lost when the control power to the servo amplifier is turned OFF
and the encoder cable is disconnected from the battery. If the data is lost, refer to 5.7.4 Initializing the
Absolute Encoder and follow the procedure to initialize the absolute encoder.
9-4
9.2 Troubleshooting
This section describes causes and remedies for problems which generate an alarm display
and for problems which result in no alarm display.
9.2.1 Troubleshooting Problems with Alarm Displays

Problems that occur in the servodrives are displayed on the panel operator as
“A.oo” or “CPFoo”. Refer to the following sections to identify the cause of an
alarm and the action to be taken.
Note: “A.- -”, is not an alarm.
Contact Yaskawa if the problem has not been solved after following the described
procedures.
n A.02
A.02: Parameter Breakdown
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
OFF OFF OFF OFF
Note: OFF: Output transistor is OFF (alarm state).
Status and Remedy for Alarm
At power ON.
A, B
Cause of the Problem Solution
Power turned OFF during param- • Initialize parameters using

Fn005 and reinput user set-
A eter write. Alarm occurred at next tings.
power ON. • Replace servo amplifier.
B Circuit board (1PWB) defective. Replace servo amplifier.
9-5
n A.03
A.03: Main Circuit Encoder Error
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
OFF OFF OFF OFF

At power ON.
A, B
A Circuit board (1PWB or 2PWB) defec- Replace servo amplifier.

tive.
n A.04
A.04: Parameter Setting Error
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
OFF OFF OFF OFF
Note: OFF: Output transistor is OFF (alarm state)

At power ON. A, B
A An out–of–range parameter was pre- • Reset all parameters in range.

viously set or loaded. • Otherwise, reload correct parameter.
9-6
n A.05
A.05: Servomotor And Amplifier Combination Error
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
OFF OFF OFF OFF
At power ON.
A, B

The range of servomotor capacities Replace the servomotor so that an
A that can be combined has been acceptable balance is achieved.
exceeded.
Encoder parameters have not been
B written properly. Replace the servomotor.
9-7
n A.10
A.10: Overcurrent or Heat Sink Overheated
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
ON OFF OFF OFF

ON: Output transistor is ON.

During servomotor A, B, D, E, When Servo ON (S-ON)
operation. signal is turned ON. C, D
F, G, H
At power ON.
C
A Shorted wiring between servo ampli- Check and correct wiring.

fier and servomotor.
Shorted servomotor U, V, or W
B phase. Replace servomotor.
• Defective circuit board (1PWB) .

C • Defective power transistor. Replace servo amplifier.
Defective current feedback circuit,

D power transistor, DB circuit, or circuit Replace servo amplifier.
board.
Ambient temperature of the servo Alter conditions so that the ambient
E amplifier greater than 55°C. temperature is below 55°C.
Inadequate air flow around the heat Providing sufficient space as speci-
F sink. fied.
G Fan stopped. Replace servo amplifier.
Servo amplifier is operating under an
H overload. Reduce load.
Note: Problems E to H can occur using a servo amplifier with a capacity of 1.5 to 3kW.
9-8
n A.30
A.30: Regenerative Error Detected
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
ON ON OFF OFF


During servomotor When the control power
operation. A.B is turned ON. D
About 1s after main circuit

power is turned ON. A.B.C

A Malfunctioning regenerative transistor. Replace servo amplifier.
Replace servo amplifier or regenera-
B Regenerative resistor is open. tive resistor.
Disconnected regenerative unit Check the wiring of the external
C (for an external regenerative resistor). regenerative resistor.
D Defective servo amplifier. Replace servo amplifier.
9-9
n A.32
A.32: Regenerative Overload
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
ON ON OFF OFF
Note OFF: Output transistor is OFF (alarm state).

During servomotor operation.

A, B
Regenerative power exceeds the Use an external regenerative resistor

A limit. that matches the regenerative power
capacity.
Alarm occurs although an external
regenerative resistor is used and the
B temperature rise of the regenerative Correct parameter Pn600.
resistor is small.
9-10
n A.40
A.40: Main Circuit DC Voltage Error Detected: Overvoltage
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
OFF OFF ON OFF


During servomotor When control power
operation. A, B, C, D is turned ON. E
When main circuit

power is turned ON. A, D
A Power supply voltage is not within the Check power supply.

range of specifications.
Load exceeds capacity of the regenera- Check specifications of load inertia
B tive unit. and overhanging load.
C Malfunctioning regenerative transistor.
D Defective rectifying diode. Replace servo amplifier.
E Defective servo amplifier.
9-11
n A.41
A.41: Main Circuit Voltage Error Detected: Undervoltage
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
OFF OFF ON OFF


operation. A, B, C is turned ON. D
When main circuit

power is turned ON. A, B, C

A The power supply voltage exceeds Check power supply voltage.
specified range.
B Fuse blown.
C Defective rectifying diode. Replace servo amplifier.
D Defective servo amplifier.
9-12
n A.51
A.51: Overspeed
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
ON OFF ON OFF


When Servo ON (S-ON)
signal is turned ON. A At power ON. D
During high-speed
servomotor rotation
after a reference input. B, C
A Incorrect servomotor wiring. Check and correct wiring. (Check for

U-, V-, and W-phase wiring errors.)
Position or speed reference input is
B too large. Lower the reference input values.
Incorrect reference input gain set- Check and correct parameter set-
C tings. tings.
D Defective circuit board (1PWB). Replace servo amplifier.
9-13
n A.71
A.71: Overload: High Load
The alarm output, status, and remedy for A.71 are the same as for A.72.
n A.72
A.72: Overload: Low Load. (See the following page for details).
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
ON ON ON OFF


When Servo ON (S-ON)
At power ON.
signal is turned ON. A C
When speed reference

is entered.
No servomotor
rotation. B
During servomotor
operation. B

Incorrect or disconnected servomotor Check wiring and connectors at the
A wiring. servomotor.
Reduce load torque and inertia. Oth-
B Load greatly exceeds rated torque. erwise, replace with a larger capacity
servomotor.
C Defective circuit board (1PWB). Replace servo amplifier.
9-14
Overload Characteristics
Servo amplifiers have a built-in overload protection function that protects the servo
amplifiers and servo motors from overload. Allowable power for the servo amplifi-
ers is limited by the overload protective function, as shown in the figure below.
The overload detection level is set under hot start conditions at a servomotor ambient
temperature of 40°C.
10,000
Low Overload
Region (A.72)
1,000
Operating Time (s)
100
High Overload
Region (A.71)
A
10
5
1
Rated torque + Maximum torque
Approx.
2
Rated torque Maximum Torque
Motor Torque
Note: The overload protection characteristics of A and B in the figure are applicable when the servo ampli-
fier is combined with one of the following servomotors:
A: SGMAH or SGMPH servomotor with a maximum capacity of 400W.

B: Other servomotors similar to the SGMAH, SGMPH, SGMGH, and SGMSH.
9-15
n A.73
A.73: Dynamic Brake Overload
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
ON ON ON OFF


When the Servo OFF (/S-ON)
signal is turned ON. At power ON.
A B

The product of the square of rotational motor
speed, the combined inertia of the motor, and • Reduce the rotational speed.
A load (rotation energy) exceeds the capacity of the • Decrease the load inertia.
dynamic brake resistor built into servo amplifier. • Minimize use of the dynamic brake.
B Defective circuit board (1PWB). Replace servo amplifier.
9-16
n A.74
A.74: Overload of Surge Current Limit Resistor
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
ON ON ON OFF


When main circuit power
is turned ON or OFF. At power ON.
A B

Frequently turning the main circuit Do not repeatedly turn ON/OFF the
A power ON/OFF. main circuit power.
B Defective circuit board (1PWB). Replace servo amplifier.
9-17
n A.7A
A.7A: Heat Sink Overheated
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
ON ON ON OFF


operation. A, B, is turned ON. E
C, D

The ambient temperature of the servo Alter conditions so that the ambient
A amplifier exceeds 55°C. temperature goes below 55°C.
B Inadequate air flow around the heat Provide sufficient space as specified.
sink .
C Fan stopped. Replace servo amplifier.
Servo amplifier is operating under
D overload. Reduce load.
E Defective servo amplifier. Replace servo amplifier.
Note: This alarm tends to occur only with a servo amplifier of 30 to 1000W.
9-18
n A.81
A.81: Absolute Encoder Backup Power Supply Error
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
OFF OFF OFF OFF
At power ON.
When parameter
Pn002.2 = 0 or 2 A, B, C
When parameter
Pn002.2 = 1 C

The following power supplies to the
A absolute encoder both failed: Follow absolute encoder setup proce-
• +5V supply dure.
• Battery power
B Absolute encoder malfunctioned. Replace servomotor.
C Circuit board (1PWB) defective. Replace servo amplifier.
9-19
n A.82
A.82: Encoder Checksum Error
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
OFF OFF OFF OFF

When the sensing (SEN)
At power ON. signal is ON and parameter
A, B Pn002.2 = 0 or 2. A
During servomotor
operation. A, B

• Follow absolute encoder setup pro-
A
Error during encoder memory cedure.
check. • Replace servomotor if error occurs
frequently.
9-20
n A.83
A.83: Absolute Encoder Battery Error
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
OFF OFF OFF OFF
At power ON.
When parameter
Pn002.2 = 0 or 2 A, B, C
When parameter
Pn002.2 = 1 C
A • Disconnected battery. Check and correct battery connec-

• Defective battery connection. tion.
Install a new battery while the control
Battery voltage below specified value. power to the servo amplifier is ON.
B Specified value: 2.7V. After replacement, cycle the power
OFF and ON again.
Note: No alarm will occur at the servo amplifier is the battery error occurs during operation.
9-21
n A.84
A.84: Absolute Encoder Data Error
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
OFF OFF OFF OFF
At power ON. During servomotor

A operation. B
A Malfunctioning absolute encoder. Replace servomotor if error occurs

frequently.
Check and correct wiring around the
Operational error in encoder caused encoder, (grounding of servomotor,
B by external noise separation of encoder and power
cables, insertion of rotoidal cores
onto cables to reduce noise, etc.)
9-22
n A.85
A.85: Absolute Encoder Overspeed
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
OFF OFF OFF OFF
Not: OFF: Output transistor is OFF (alarm state).
At power ON.
A, B
A Absolute encoder turned ON at motor Turn ON power supply with the servo-
speed exceeding 200rpm. motor stopped.
9-23
n A.86
A.86: Encoder Overheated
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
OFF OFF OFF OFF
During survomotor operation. When the control panel

A, B is turned ON. C, D
A The ambient temperature of the ser- Alter conditions so that the ambient
vomotor is high. temperature goes below 40°C
Servomotor is operating under over-
B load. Reduce load.
C Circuit board (1PWB) defective. Replace servo amplifier.

D Encoder defective. Replace servo amplifier.
9-24
n A.b1, A.b2
A.b1: Reference Speed Input Read Error
A.b2: Reference Torque Input Read Error
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
OFF OFF OFF OFF
During servomotor operation. At power ON.

A, B C

Error in reference read-in unit (A/D
A Converter, etc.). Reset alarm and restart operation.
Faulty reference read-in unit (A/D

B Converter, etc.). Replace servo amplifier.
9-25
n A.C1
A.C1: Servo Overrun
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
ON OFF ON OFF

At power ON. When Servo ON (S-ON)

signal is turned ON. A, B, C, D
When parameter
Pn50A.1 = 7. D
When the speed reference
is entered. A, B, C
Within 1 to 3s after
power is turned ON.
When parameter
Pn50A.1 ≠ 7. A, B, C, D

Incorrect or disconnected servomotor Check wiring and connectors at the
A wiring. servomotor.
B Incorrect or disconnected encoder Check wiring and connectors at the

wiring. encoder.
C Defective encoder. Replace servomotor.
D Defective circuit board (1PWB). Replace servo amplifier.
9-26
n A.C8
A.C8: Absolute Encoder Clear Error and Multi–turn Limit Setting Error
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
ON OFF ON OFF


When resetting the multi-turn
At power ON.
A, B clear encoder alarm. A, B

A Encoder defective. Replace servomotor.
B Servo amplifier defective. Replace servo amplifier.
9-27
n A.C9
A.C9: Encoder Communications Error
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
ON OFF ON OFF


A, B, C A, B, C

Incorrect or disconnected encoder Check wiring and connectors at the
A wiring. encoder.
B Defective encoder. Replace servomotor.
C Defective servo amplifier. Replace servo amplifier.
9-28
n A.CA
A.CA: Encoder Parameter Error
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
ON OFF ON OFF

At power ON.
A, B

A Defective encoder. Replace servomotor.
B Defective servo amplifier. Replace servo amplifier.
n A.Cb
A.Cb: Encoder Echoback Error
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
ON OFF ON OFF

9-29
At power ON.
A, B
A Incorrect or disconnected encoder Check wiring and connectors at

wiring. encoder.
B Defective encoder. Replace servomotor.
C Defective servo amplifier. Replace servo amplifier.
n A.CC
A.CC: Multi-Turn Limit Disagreement Alarm
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
ON OFF ON OFF

At power ON.
A, B

Incorrectly set Multi-Turn Limit Setting
A parameter (Pn205) in the servo Change the value in parameter
amplifier. Pn205.
First verify that the Multi-Turn Limit

Setting parameter (Pn205) is set cor-
No Multi-Turn Lmit value set in the rectly in the servo amplifier. While in
B encoder. the active alarm state, change the
setting in the encoder Multi-Turn Limit
Setting parameter (Pn205) using
function Fn013.
9-30
n A.d0
A.d0: Position Error Pulse Overflow
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
ON ON OFF OFF


E
During high speed

rotation. A
When a long reference

is entered during B, C, D
normal operation.
When a properly entered

reference pulse does not E
generate a feedback pulse.

Servomotor wiring incorrect or poor Check wiring and connectors at
A connection encoder.
B Servo amplifier was not correctly Increase speed loop gain (Pn100)
adjusted. and position loop gain (Pn102).
Reduce load torque or inertia. If prob-
C Motor load was excessive. lem persists, replace with a larger
capacity motor.
•Increase or decrease reference
Position reference pulse frequency pulse frequency.
D was too high. •Add smoothing function.
•Correct electronic gear ratio.
E Circuit board (1PWB) defective. Replace servo amplifier.
9-31
n A.F1
A.F1: Power Line Open Phase
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
OFF ON OFF OFF


When the main circuit’s When the control power
power supply is turned ON. A, B is turned ON. C

• Check power supply.
• Check wiring of the main circuit
A One phase (L1, L2, or L3) of the main power supply.
circuit power supply is disconnected. • Check MCCB, noise filter, mag-
netic contactor.
B There is one phase where the line Check power supply.

voltage is low.
C Servo amplifier defective. Replace servo amplifier.
Note: A and B tend to occur in a servo amplifier with a capacity of 500W or higher.
9-32
n CPF00
CPF00: Digital Operator Transmission Error 1
This alarm is not stored in the alarm history.
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
Not Applicable

When the digital operator
is connected before or after
the servo amplifier has been A, B,
turned ON. C, D

Cable defective or poor contact
A between digital operator and servo • Check connector connections.
amplifier. • Replace cable.
B Malfunction due to external noise. Separate digital operator and cable

from noise source.
C Digital operator defective. Replace digital operator.
D Servo amplifier defective. Replace servo amplifier.
9-33
n CPF01
CPF01: Digital Operator Transmission Error 2
This alarm is not stored in the alarm history.
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
Not Applicable

During servomotor
operation. A, B, C, D

Cable defective or poor contact
A between digital operator and servo • Check connector connections.
amplifier. • Replace cable.
Separate digital operator and cable

B Malfunction due to external noise from noise source.
n A.- -
A.- -: Normal Operation
This is not an alarm display.
Display and Outputs
Alarm Outputs
Alarm Code Output
ALM Output
ALO1 ALO2 ALO3
OFF OFF OFF ON

9-34
9.2.2Troubleshooting Problems with No Alarm Display

Use the tables below to identify the cause of a problem that causes no alarm display
and follow the described corrective procedure.
Turn OFF the servo system power supply before starting the shaded procedures.
Contact Yaskawa if the problem cannot be solved by carefully following the
described procedure.
Troubleshooting Table No Alarm Display
Symptom Cause Comment Solution
Power not connected Check voltage between power Correct the power circuit.
supply terminals.
Check terminals of connec-
Loose connection tors (CN1, CN2). Tighten any loose parts.
Connector (CN1) external Check connector (CN1) exter- Refer to connection diagram
wiring incorrect nal wiring and correct wiring.
Servomotor or encoder wir- ––– Reconnect wiring
ing disconnected.
Reduce load or replace with
Overloaded Run under no load. larger capacity servomotor.
No speed/position refer- Check reference input pins. Correctly input speed/position
ences input references.
Servomotor does /S–ON is turned OFF Check settings of parameters Turn /S-ON input ON.
not start Pn50A.0 and Pn50A.1.
Refer to section 5.3.5 and set
/P–CON input function set- Check parameter Pn000.1. parameters to match applica-
ting incorrect tion.
Reference pulse mode Correct setting of parameter
selection incorrect. Refer to section 5.2.2 Pn200.0.
Encoder type differs from Incremental or absolute Set parameter Pn002.2 to the
parameter setting. encoder? encoder type being used.
P-OT and N-OT inputs are Turn P-OT and N-OT input
turned OFF. Refer to section 5.1.2. signals ON.
Check status of error counter
CLR input is turned ON clear input. Turn CLR input OFF.
SEN input is turned OFF. When absolute encoder is Turn SEN input ON.
used.
Servomotor
moves suddenly, Servomotor or encoder wir- ––– Refer to chapter 3 and cor-
then stops ing incorrect. rect wiring.
Suddenly stops
during operation Alarm reset signal (/ALM- Remove cause of alarm. Turn
and will not RST) is turned ON because ––– alarm reset signal (ALM-
restart an alarm occurred RST) from ON to OFF.
Check the connections of the

Unstable servo- Defective wiring connection power lead (U-, V-, and W- Tighten any loose terminals
motor speed. to the motor. phases) and the encoder con- or connectors
nectors.
9-35
Symptom Cause Comment Solution

Speed loop gain value too ––– Reduce speed loop gain
high. (Pn100) preset value.
Minimize length of speed/
position reference input
Servomotor vibrates Speed/position reference ––– lwire, with impedance not
at approximately 200 input wire too long. exceeding several hundred
to 400Hz. ohms
Speed/position reference Separate reference input
inputwire is bundled with ––– wire at least 30cm from
power cables. power cables.
Reduce speed loop gain
Speed loop gain value too ––– (Pn100) preset value.
high. Increase integration time
High rotation speed constant (Pn101).
overshoot on starting Increase the value of
and stopping. Speed loop gain is too low parameter Pn100 (speed
compared to position loop ––– loop gain).
gain. Reduce the integration time
constant (Pn101).
Ambient temperature too Measure servomotor ambient Reduce ambient tempera-
high temperature. ture to 40°C maximum.
Servomotor over- Servomotor surface dirty Visual check Clean dust and oil from
heated motor surface.
Reduce load or replace with
Overloaded Run under no load. larger capacity servomotor.
Servomotor mounting screws Tighten mounting screws.
loose?
Incorrect mechanical
mounting Coupling not centered? Center coupling.
Coupling unbalanced? Balance coupling.
Abnormal noise
Check noise and vibration Consult your Yaskawa rep-
Bearing defective near bearing. resentative if defective.
Machine causing vibra- Foreign object intrusion, dam- Consult with machine man-
tions age, or deformation of sliding ufacturer.
parts of machine.
Speed Reference 0V Adjust reference offset.
but Servomotor Speed reference voltage ––– Refer to sections 7.2.4 and
Rotates. offset applied 7.2.5
9-36
9.2.3 Alarm Display Table

A summary of alarm displays and alarm code outiuts is given in the following table.
Alarm Display Table
Alarm Alarm Code Output ALM

Alarm Name Description
Display ALO1 ALO2 ALO3 Output
EEPROM data of servo amplifier is
A.02 Parameter Breakdown* abnormal.
A.03 Main Circuit Encoder Detection data for power circuit is

Error abnormal.
OFF OFF OFF OFF
Parameter Setting The parameter setting is outside the
A.04
Error* allowable setting range.
Servomotor and Ampli- Servo amplifier and servomotor
A.05 fier Combination Error capacities do no match each other.
An overcurrent flowed through the
Overcurrent or Heat IGBT.
A.10 ON OFF OFF OFF
Sink Overheated*2 Heat sink of servo amplifier was over-
heated.
A.30 Regeneration Error • Regenerative circuit is faulty

Detected • Regenerative resistor is faulty.
ON ON OFF OFF
Regenerative energy exceeds regen-
A.32 Regenerative Overload erative resistor capacity.
A.40 Overvoltage Main circuit DC voltage is excessively

high.
OFF OFF ON OFF
A.41 Undervoltage Main circuit DC voltage is excessively
low.
Rotational speed of the motor is
A.51 ON OFF ON OFF Overspeed excessively high.
The motor was operating for several
seconds to several tens of seconds
A.71 Overload: High Load under a torque largely exceeding rat-
ings.
The motor was operating continu-
A.72 Overload: Low Load ously under a torque largely exceed-
ing ratings
ON ON ON OFF When the dynamic brake was
Dynamic Brake Over- applied, rotational energy exceeded
A.73 load the capacity of dynamic brake resis-
tor.
Overload of Surge Cur- The main circuit power was frequently
A.74 rent Limit Resistor turned ON and OFF.
A.7A Heat Sink Overheated The heat sink of servo amplifier over-
** heated.
9-37
Alarm Alarm Code Output ALM

Alarm Name Description
Display ALO1 ALO2 ALO3 Output
Absolute Encoder All the power supplies for the abso-

A.81 lute encoder have failed and position
Backup Error* data was cleared.
Encoder Checksum The checksum results of encoder
A.82
Error* memory is abnormal.
Absolute Encoder Bat- Battery voltage for the absolute
A.83 tery Error encoder has dropped.
Absolute Encoder Data
A.84 Received absolute data is abnormal.
Error*
OFF OFF OFF OFF Absolute Encoder The encoder was rotating at high
A.85 Overspeed speed when the power was turned
ON.
The internal temperature of encoder
A.86 Encoder Overheated is too high.
A.b1 Reference Speed Input The A/D converter for reference

Read Error speed input is faulty.
A.b2 Reference Torque The A/D converter for reference

Input Read Error torque input is faulty.
A system error occurred in the servo
A.bF System Alarm* amplifier.
A.C1 Servo Overrun The servomotor ran out of control.

Detected
Absolute Encoder
Clear Error and Multi- The multi-turn for the absolute
A.C8 Turn Limit Setting encoder was not properly cleared or
set.
Error*
ON OFF ON OFF Encoder Communica- Communications between servo
A.C9
tions Error* amplifier and encoder is not possible.
Encoder Parameter
A.CA Encoder parameters are faulty.
Error*
Encoder Echoback Contents of communications with
A.Cb
Error* encoder is incorrect.
Different multi-turn limits have been
A.CC ON OFF ON OFF Multi-Turn Limit Dis- set in the encoder and servo ampli-
agreement fier.
Position Error Pulse Position error pulse exceeded param-
A.d0 ON ON OFF OFF Overflow eter (Pn505).
A.F1 OFF ON OFF OFF Power Line Open One phase is not connected in the
Phase main power supply
CPF00 Digital operator (JUSP-OP02A-2)
Not Specified Digital Operator Trans- fails to communicate with servo
CPF01 mission Error amplifier (e.g., CPU error).
A.-- OFF OFF OFF ON Not an error Normal operation status
Notes: 1. OFF:Output transistor is OFF.

ON:Output transistor is ON.
2. (*) These alarms are not reset for the alarm reset signal (/ALM-RST). Eliminate the cause of the
alarm and then turn OFF the power supply to reset the alarms.
3. (**) This alarm display appears only within the range of 30 to 1000W.
9-38
9.2.4 Warning Displays

The correlation between warning displays and warning code outputs is shown in the
following table.
Warning Displays and Outputs
Warning Warning Code Outputs Warning

Meaning of Warning
Display ALO1 ALO2 ALO3 Name
This warning occurs before either of
the overload alarms (A.71 or A.72)
A.91 ON OFF OFF Overload occurs. If the warning is ignored and
operation continues, a regenerative
overload alarm may result.
This warning occurs before the
regenerative overload alarm (A.32)
A.92 OFF ON OFF Regenerative occurs. If the warning is ignored and
Overload operation continues, a regenerative
overload alarm may result.
9-39
Sigma II User’s Manual Appendix A: Host Controller Connection Examples
A Host Controller Connection Examples

This appendix provides examples SGDH servo amplifiers con-
nected to typical host controllers. Refer to the manuals for the
host controller when actually connecting to them.
A.1 Connecting the GL-series MC20 Motion Module.............................................. A-2

A.2 Connecting the CP-9200SH Servo Controller Module (SVA) ........................... A-3
A.3 Connecting the GL-series B2813 Positioning Module ...................................... A-4
A.4 Connecting OMRON's C500-NC221 Position Control Unit.............................. A-5
A.5 Connecting OMRON's C500-NC112 Position Control Unit .............................. A-6
A-1
A.1 Connecting the GL-series MC20 Motion Module

The following diagram shows an example of connecting to the GL-series MC20 Motion
Module. In this example, the servo amplifier is used in Speed Control Mode.
Servopack
SGDM
L1C
L2C
L1
Servomotor
L2
Yaskawa's L3
MC20 *1 U
A (1)
MC Unit SV1 CN1 V M
B (2)
1 *2 33
PA PAO W
2 P 34 C (3)
*PA *PAO
3 35 D (4)
PB PBO
4 P 36
*PB *PBO
5 19
PC PCO PG
6 P 20
*PC *PCO
7 5
VREF VREF
8 P 6
SG SG CN2
9 21
BAT BAT (+)
10 P 22
BAT0 BAT (-)
19 47
+24V +24VIN
13 40
SVON SON
14 41
PCON PCON
11 4
SEN SEN
12 P 2
0SEN SG
15 44
ALMRST ALMRST
16 31
ALM ALM+
17 32
ALM0 ALM-
FG (connector frame)
*. These pin numbers are the same for SV2 to SV4.

*. P indicates twistedpair wires.
A-2
A.2 Connecting the CP-9200SH Servo Controller Module (SVA)

The following diagram shows an example of connecting to the CP-9200SH servo control-
ler Module (SVA). In this example, the servo amplifier is used in Speed Control Mode.
Servopack
Servomotor
SGDM
L1C
L2C U
Yaskawa's A (1)
L1 M
CP9200SH SVA V
L2 B (2)
L3 W
C (3)
D (4)
CN CN1
17 47
+24V +24VIN PG
22 40
DO0 SON
47 41
DO1 PCON
23 43
DO2 NOT CN2
48 42
DO3 POT
24 44
DO4 ALMRST
19 27
DI2 TGON+
28
TGON-
43 25
DI1 VCMP+
26
VCMP-
18 29
DI0 SRDY+
30
SRDT-
44 31
DI3 ALM+
45 32
024V ALM-
21
BAT (+)
P 22
BAT (-)
1 * 4
SENS SEN
26 P 2
SENSG SG
3 5
INA VREF
4 P 6
0V SG
7 9
TLIMP TREF
8 P 10
TLIMPG SG
10 33
PA PAO
11 P 34
PAL *PAO
12 35
PB P PBO
13 36
PBL *PBO
14 19
PC P
PCO
15 20
PCL *PCO
9 1
PG0V SG
Connector shell
* P indicates twistedpair wires.
A-3
A.3 Connecting the GL-series B2813 Positioning Module

The following diagram shows an example of connecting to the GL-series B2813 Position-
ing Module. In this example, the servo amplifier is used in Position Control Mode.
Servopack
SGDM *2
L1C
L2C
L1 Servomotor
024 V +24 V Yaskawa's
CN2 L2 A (1)
JAMSCB2813 U
1 L3
B (2)
V M
33
1Ry C (3)
CN2 CN1 W
20 SERVO 24 D (4)
7
NORMAL PULSE PULSE
23 P 8
35 DECELERA *PULSE *PULSE
TION LS 22 *4 11
3 SIGN SIGN
START 21 P
*SIGN 12 *SIGN
2 38
P
STOP 15
CLR CLR
P G
45 5 14
*CLR *CLR
46 6 2 CN2
0V SG
+12 V 47
CN1 *3 Connector shell
16 33 +24 V 024 V
PA PAO CN1
17 P 34
*PA *PAO 47
18 35 +24VIN
PB PBO 40
19 P 36 SON
*PB *PBO 3Ry
42
14 19 POT
PC PCO 4Ry
15 P 20 43
48 *PC *PCO NOT
49 1 1 SG
0V 1Ry
+5 V 50 2 *1
0V 31
ALM+
0V 3
10
20 32
11 ALM-
FG 2Ry
0V CN2 +12 V
12
ERROR
36
* . The ALM signal is output for approximately two seconds when the power is turned ON. Take this into consid
eration when designing the power ON sequence. The ALM signal actuates the alarm detection relay 1Ry to stop
main circuit power supply to the Servopack.
* . Set user constant Pn200.0 to 1".
* . Connect the shield wire to the connector shell.
* . P indicates twistedpair wires.
A-4
A.4 Connecting OMRON's C500-NC221 Position Control Unit

The following diagram shows an example of connecting to an OMRON C500-NC221
Position Con trol Unit. In this example, the servo amplifier is used in Speed Control
Mode.
Servopack
SGDM
Servomotor
L1C
L2C U A (1)
I/O Power Supply
+24 V B (2)
C500NC221 L1 V M
+24V +
-
(Made by OMRON) 024 V L2 C (3)
W
X axis (Y axis) L3 D (4)
EXT IN
8 ON when
+24V 9 positioning is
3Ry canceled. PG
2 (12)
CCWLX
3 (13) ON when
STPX proximity is
4 (14) detected. CN2
ORGX
5 (15)
EMGX CN1
6 (16) 4Ry 1Ry
CWLX *1
31 CN1
1 ALM+
DC GND
11 32 42
DC GND ALM- POT
M/D 47 3Ry
11 +24VIN
+24V 12 43
NOT 024 V
4RY
3 (19) 40
OUT1X SON
XOUT 9 (25) 5 (9) VREF (TREF)
8 (24) 6 (10)
XAG SG
7 (23) 33 PAO
XA
6 (22) *3 P 34
XA *PAO
XB 5 (21) 35 PBO
XB 4 (20) P 36 *PBO
16 (14) 19
XC PCO
XC 15 (13) P 20 *PCO
1 (17) 1 SG
0V
*2 Connec
tor shell
*. The ALM signal is output for approximately two seconds when the power is turned ON. Take this into consider
ation when designing the power ON sequence. The ALM signal actuates the alarm detection relay 1Ry to stop
main circuit power supply to the Servopack.
* . Connect the shield wire of the I/O cable to the connector shell.
*. P indicates twistedpair wires.
Note Only signals applicable to OMRON's C500NC221 Position Control Unit and Yaskawa's SGDM Servopack
are shown here.
A-5
A.5 Connecting OMRON's C500-NC112 Position Control Unit

The following diagram shows an example of connecting to the OMRON C500-NC112
Position Con trol Unit. In this example, the servo amplifier is used in the position control
mode.
Servopack
*2
Servomotor
SGDM
L1C U
A (1) M
L2C V
W B (2)
I/O Power Supply L1 C (3)
C500NC112
L2 D (4)
(Made by OMRON) +
L3
+12V - 012 V
PG
1A
+12V 1B
4Ry CN2
CW LIMIT 2A
2B 3Ry
CCW LIMIT CN1
*3
EMERGENCY STOP 3A CN1 47 External
6 LRX01/A2 +24VIN
EXTERNAL 3B 10 19 PC 40 power
SON
INTERRUPT
4A O 3Ry +24 V supply
ORIGIN 9 20 POT 42
*PCO +24 V
ORIGIN PROXIMITY 4B *4 12V 0V NOT 43 4Ry
*
LOCAL 5A 8 7 1Ry
1 31 ALM+ 012 V
1Ry +24V 32
READY 5B ALM-
8A +5 V
+5V 8B
9A 7 PULSE
PULSE OUTPUT 9B 8 *PULSE
10A 11 SIGN
10B 12 *SIGN
15 CLR
14 *CLR
main circuit power supply to Servopack.
* . Set user constant Pn200.0 to 1".
* . Manufactured by Yaskawa Controls Co.
Note Only signals applicable to OMRON's C500NC112 Position Control Unit and Yaskawa's SGDM Servopack
are shown here.
A-6
A.6 Connecting MITSUBISHI's AD72 Positioning Unit

The following diagram shows an example of connecting to the MITSUBISHI AD72 Posi-
tioning Unit. In this example, the servo amplifier is used in Speed Control Mode.
Servopack
Servomotor
SGDM
I/O Power Supply L1C A (1)
+24 V L2C U
B (2) M
+ L1 V
AD 72 +24V - 024 V L2
C (3)
W D (4)
(Made by MITSUBISHI) *2 L3
CONT
1 ON when
2 positioning is PG
STOP canceled.
DOG 3 ON when CN1
proximity is
CN2
SERVO detected. 47 +24VIN
1 40 SON
SVON 2
3 *1 31 CN1
1Ry ALM+
READY 42
1Ry POT
4 32 ALM-
5 5 (9) 43
SPEED VREF (TREF) NOT 024 V
6 P 6 (10)
REFERENCE SG
ENCO
4 35 PBO
PULSE A 5 *4 P 36 *PBO
7 33 PAO
PULSE B 8 P 34 *PAO
10 19 PCO
PULSE C 11 P 20 *PCO
3 1 SG
0V
6
0V
9 *3 Connector
0V
shell
* . Pin numbers are the same both for X axis and Y axis.
* . Connect the connector wire of the cable to the connector shell.
* . P indicates twistedpair wires.
Note Only signals applicable to Mitsubishi's AD72 Positioning Unit and Yaskawa's SGDM Servopack are shown
here.
A-7
A.7 Connecting MITSUBISHI's AD75 Positioning Unit

The following diagram shows an example of connecting to the MITSUBISHI AD75 Posi-
tioning Unit. In this example, the servo amplifier is used in Position Control Mode.
Servopack
Servomotor
SGDM
U
A (1)
L1C
V M
L2C B (2)
L1 W
C (3)
L2
I/O Power Supply D (4)
L3
+24 V
+
AD75 -
(Made by Mitsubishi) +24v 024 V
P
G
X axis
(Y axis) CN2
26
1Ry
READY 7
CN1
ON when
14 positioning is 47 +24 V
STOP
canceled.
40
CN1 SON
11 ON when
DOG proximity is 42
POT
detected.
43
24 19 PCO NOT 024 V
PGO 25 20 *PCO
* 31 ALM+
1Ry
32 ALM-
3 7 PULSE
PULSE 21 8
*PULSE
4 11 SIGN
SIGN 22 12 *SIGN
2.2KW
15 CLR
5 14
*CLR
CLEAR 23
* The ALM signal is output for approximately two seconds when the power is turned ON. Take this into consider
Note Only signals applicable to MITSUBISHI's AD75 Positioning Unit and Yaskawa's SGDM Servopack are
shown here.
A-8
Sigma II User’s Manual Appendix B: List of Parameters
B List of Parameters
This appendix lists the parameters, switches, input signal
selections, out put signal selections, auxiliary functions, and
monitor modes for SGDH servo amplifiers.
B.1 Parameters............................................................................................................B-2
B.2 Switches ...............................................................................................................B-5
B.3 Input Signal Selections ........................................................................................B-9
B.4 Output Signal Selections....................................................................................B-11
B.6 Monitor Modes ..................................................................................................B-12
B-1
B.1 Parameters
The following list shows parameters and their settings.
Parameter Setting Default

Category Name Unit Reference
Number Range Setting
Pn000 Function Selection Basic Switches (See — — 0000 5.1.1,

note 3). 5.3.5
Function Selection Application Switches 1 5.1.2,

Function Pn001 (See notes 1 and 3). — — 0000 5.4.2,
Selection 5.5.7
Parameters 5.2.8,
Pn002 Function Selection Application Switches 2 — — 0000 5.2.9,
(See note 3). 5.7.2
Pn003 Function Selection Application Switches 3 — — 0002 6.5
Pn100 Speed Loop Gain Hz 1 to 2000 40 6.2.1
Pn101 Speed Loop Integral Time Constant 0.01ms 15 to 51200 2000 6.2.1
Pn102 Position Loop Gain s-1 1 to 2000 40 6.2.1
Pn103 Inertia Ratio % 0 to 10000 0 6.2.1,

6.3.3
Pn104 2nd Speed Loop Gain Hz 1 to 2000 40 —
Pn105 2nd Speed Loop Integral Time Constant 0.01ms 15 to 51200 2000 —
Pn106 2nd Position Loop Gain s-1 1 to 2000 40 —
Pn107 Bias rpm 0 to 450 0 6.2.4
Pn108 Bias Width Addition ref. units 0 to 250 7 6.2.4
Pn109 Feed-forward % 0 to 100 0 6.2.2
Pn10A Feed-forward Filter Time Constant 0.01ms 0 to 6400 0 5.2.5
Gain-related Application Switches (See
Pn10B note 3). — — 0000 6.2.5
Pn10C Mode Switch Torque Reference % 0 to 800 200 6.2.5

Pn10D Mode Switch Speed Reference rpm 0 to 10000 0 6.2.5
Gain Pn10E Mode Switch Acceleration 10rpm/s 0 to 3000 0 6.2.5
Parameters Pn10F Mode Switch Error Pulse ref. units 0 to 10000 0 6.2.5
Pn110 Online Autotuning Switches (See note 3.) — — 0010 6.3.4
Speed Feedback Compensation (See
Pn111 note 2). % 1 to 100 100 6.2.6
Pn112 % 0 to 1000 100 —

Pn113 — 0 to 10000 1000 —
Pn114 — 0 to 400 200 —
Pn115 — 0 to 1000 32 —
Pn116 — 0 to 1000 16 —
Pn117 % 20 to 100 100 —
Pn118 Reserved parameters (Do not change.) % 20 to 100 100 —
Pn119 s-1 1 to 2000 50 —
Pn11A 0.1% 1 to 2000 1000 —
Pn11B Hz 1 to 150 50 —
Pn11C Hz 1 to 150 70 —
Pn11D % 1 to 150 100 —
Pn11E % 1 to 150 100 —
B-2

Pn11F ms 1 to 2000 0 —
Pn120 0.01ms 1 to 51200 0 —
Gain Pn121 Reserved parameters (Do not change). Hz 10 to 250 50 —
Parameters
Pn122 Hz 0 to 250 0 —
Pn123 % 0 to100 0 —
Position Control Reference Selection
Pn200 Switches (See note 3). — — 0000 5.2.2
Pn201 PG Divider (See note 3). p/r 16 to 16384 16384 5.2.3
Pn202 Electronic Gear Ratio (Numerator) (See — 1 to 65535 4 5.2.5

note 3).
Electronic Gear Ratio (Denominator) (See
Pn203 note 3). — 1 to 65535 1 5.2.5
Position Pn204 Position Reference Accel/Decel Parame- 0.01ms 0 to 6400 0 6.1.2

Parameters ter
Pn205 Multi-turn Limit Setting (See notes 1 and rev 0 to 65535 65535 5.7.2
3).
513 to
Pn206 Reserved parameter (Do not change). P/rev 65535 16384 —
Pn207 Position Control Function Switches (See — — 0000 5.2.9

note 3). 6.1.2
Pn208 Position Reference Movement Averaging 0.01ms 6 to 6400 0 6.1.2

Time (See note 3).
0.01V/ rated
Pn300 Speed Reference Input Gain speed 150 to 3000 600 5.2.1
Pn301 Speed 1 rpm 0 to 10000 100 5.2.6

Pn302 Speed 2 rpm 0 to 10000 200 5.2.6
Pn303 Speed 3 rpm 0 to 10000 300 5.2.6
Speed Pn304 Jog Speed rpm 0 to 10000 500 5.3.2
Parameters
Pn305 Soft Start Acceleration Time ms 0 to 10000 0 6.1.1
Pn306 Soft Start Deceleration Time ms 0 to 10000 0 6.1.1
Pn307 Speed Reference Filter Time Constant 0.01ms 0 to 65535 40 —
Pn308 Speed Feed-Forward Filter Time Con- 0.01ms 0 to 65535 0 6.2.6

stant
0.1V/rated
Pn400 Torque Reference Input Gain torque 10 to 100 30 5.2.7
Pn401 Torque Reference Filter Time Constant 0.01ms 0 to 65535 100 6.1.5
Pn402 Forward Torque Limit % 0 to 800 800 5.1.3
Pn403 Reverse Torque Limit % 0 to 800 800 5.1.3
Torque Pn404 Forward External Torque Limit % 0 to 800 100 5.1.3
Parameters
Pn405 Reverse External Torque Limit % 0 to 800 100 5.1.3
Pn406 Emergency Stop Torque % 0 to 800 800 5.1.2
Pn407 Speed Limit during Torque Control rpm 0 to 10000 10000 5.2.7
Pn408 Torque Function Switches — — 0000 6.1.6
Pn409 Notch Filter Frequency Hz 50 to 2000 2000 6.1.6
B-3

Pn500 Positioning Completed Width ref. units 0 to 250 7 5.5.3
Pn501 Zero Clamp Level rpm 0 to 10000 10 5.4.3
Pn502 Rotation Detection Level rpm 1 to 10000 20 5.5.5
Sequence Pn503 Speed Coincidence Signal Output Width rpm 0 to 100 10 5.5.4
Parameters Pn504 NEAR Signal Width ref. units 1 to 250 7 5.5.8
Pn505 Overflow Level 256 ref. units 1 to 32767 1024 6.2.1
Pn506 Brake Reference Servo OFF Delay Time 10ms 0 to 50 0 5.4.4
Pn507 Brake Reference Output Speed Level rpm 0 to 10000 100 5.4.4
Timing for Brake Reference Output dur
Pn508 ing Motor Operation 10ms 10 to 100 50 5.4.4
Pn509 Momentary Hold Time ms 20 to 1000 20 5.5.9

Pn50A Input Signal Selections 1 (See note 3). — — 2100 5.3.3
Pn50B Input Signal Selections 2 (See note 3). — — 6543 5.3.3
Pn50C Input Signal Selections 3 (See note 3). — — 8888 5.3.3
Sequence
Parameters Pn50D Input Signal Selections 4 (See note 3). — — 8888 5.3.3
Pn50E Output Signal Selectionss 1 (See note 3). — — 3211 5.3.4
Pn50F Output Signal Selections 2 (See note 3). — — 0000 5.3.4
Pn510 Output Signal Selections 3 (See note 3). — — 0000 5.3.4
Pn511 Reserved parameter (Do not change). — — 8888 —
Pn512 Output Signal Reversal Settings (See — — 0000 5.3.4

note 3).
Pn600 Regenerative Resistor Capacity 10 W 0 to capacity 0 5.6.1

Other (See note 4). (See note 5).
Parameters 0 to capacity
Pn601 Reserved parameter (Do not change.) — (See note 5). 0 —
Notes: 1. The multi-turn limit is valid only when parameter Pn002.2 Absolute Encoder Usage is set to "2".
The value will be processed in the range of "+32767 to -32768" for other settings even if the
value is changed.
• There is no need to change the multi-turn limit except for in special cases. Be careful not to
change the setting unless necessary.
2. The setting of parameter Pn111 is valid only when parameter Pn110.1 is set to 0.
3. After changing these parameters, cycle the main circuit and control power supplies to enable the
new settings.
4. Normally set to "0". When using an external regenerative resistor, set the capacity (W) of the
regenerative resistor.
5. The upper limit is the maximum output capacity (W) of the servo amplifier.
B-4
B.2 Switches
The following list shows the switches and their default settings.
Digit Default
Parameter Name Setting Description
Place Setting
Direction 0 Sets CCW as forward direction.
0 Selection 0
1 Sets CW as forward direction (reverse rotation mode).
0 Speed control (analog reference).
1 Position control (pulse train reference).
2 Torque control (analog reference).
3 Internal set speed control (contact reference).
4 Internal set speed control (contact reference)/Speed control

(analog reference).
Internal set speed control (contact reference)/Position con-
5 trol (pulse train reference).
Pn000
Function Internal set speed control (contact reference)/Torque control
Selection 1 Control Method 6 0
Selection (analog reference).
Basic
Switches 7 Position control (pulse train reference)/Speed control (ana-
log reference).
Position control (pulse train reference)/Torque control (ana-
8 log reference).
9 Torque control (analog reference)/Speed control (analog

reference).
A Speed control (analog reference)/Zero clamp.
Position control (pulse tra.in reference)/Position control
B (Inhibit)
2 Axis Address 0 to F Sets servo amplifier axis address. 0
3 Reserved — 0
0 Stops the motor by applying dynamic brake (DB). 0
Stops the motor by applying dynamic brake (DB) and then
0 Servo OFF or Alarm 1 releases DB.
Stop Mode
2 Makes the motor coast to a stop state without using the
dynamic brake (DB).
Same setting as Pn001.0 (Stops the motor by applying DB
0 or by coasting.)
Pn001 Overtravel Stop Sets the torque of Pn406 to the maximum value, decelerates
1 Mode 1 the motor to a stop, and then sets it to servo lock state. 0
Function
Selection Sets the torque of Pn406 to the maximum value, decelerates
Application 2
the motor to a stop, and then sets it to coasting state.
Switches
Not applicable to DC power input: Input AC power supply
0 through L1, L2, and (L3) terminals.
AC/DC Power Input
2 Selection 0
Applicable to DC power input: Input DC power supply
1 through (+)1 and (-) terminals.
0 ALO1, ALO2, and ALO3 output only alarm codes.
3 Warning Code Out- ALO1, ALO2, and ALO3 output both alarm codes and warn- 0
put Selection 1 ing codes. While warning codes are output, ALM signal out-
put remains ON (normal state).
B-5
Digit Default
Place Setting
0 None.
Speed Control
0 Option (T-REF Ter- 1 Uses T-REF as an external torque limit input. 0
minal Allocation)
2 Uses T-REF as a torque feed-forward input.
Pn002 Torque Control 0 None.
Function 1 Option (V-REF Ter- 0
Selection minal Allocation) 1 Uses V-REF as an external speed limit input.
Application 0 Uses absolute encoder as an absolute encoder.
Switches
2 Absolute Encoder 1 Uses absolute encoder as an incremental encoder. 0
Usage
2 Uses absolute encoder as an absolute encoder.
Uses multi-turn limit.
3 Not used. 0 — 0
0 Motor speed: 1V/1000rpm. 2
1 Speed reference: 1V/1000rpm.
2 Torque reference: 1V/100%.
3 Position error: 0.05V/1 reference units.
4 Position error: 0.05V/100 reference units.
Reference pulse frequency (converted to rpm): 1V/
Analog Monitor 1 5 1000rpm.
0 Torque Reference
Monitor 6 Motor speed × 4: 1V/250rpm.
Pn003 7 Motor speed × 8: 1V/125rpm.
Function 0
Selection Analog Monitor 2 8
1
Application Speed Reference 9
Switches Monitor
A
B
Reserved parameter (Do not change.).
C
D
E
F
2 Not used. — — 0
Uses internal torque reference as the condition (Level set-
0 ting: Pn10C).
1 Uses speed reference as the condition (Level setting:

Mode Switch Selec- Pn10D).
0 0
tion 2 Uses acceleration as the condition (Level setting: Pn10E).
Pn10B 3 Uses error pulse as the condition (Level setting: Pn10F).
Gain Applica-
tion Switches 4 No mode switch function available.
Speed Loop Con- 0 PI control.
1 trol Method 0
1 IP control.
2 Not used. 0 — 0
3 Reserved 0 to 2 Reserved parameter. (Do not change). 0
B-6
Digit Default
Place Setting
0 Tunes only at the beginning of operation.
0 Online Autotuning 1 Always tunes. 0
Method
2 Does not perform autotuning.
Pn110 Speed Feedback 0 Enabled.
Online Auto- 1 Compensation 1
tuning Selection 1 Disabled.
Switches 0 Friction compensation: Disabled.
Friction Compensa-
2 tion Selection 1 Friction compensation: Small. 0
2 Friction compensation: Large.
3 Reserved 0-3 Reserved parameter (Do not change). 0
0 Sign + pulse, positive logic.
1 CW + CCW, positive logic.
2 A phase + B phase (x1), positive logic.
3 A phase + B phase (x2), positive logic.
Reference Pulse 4 A phase + B phase (x4), positive logic.
0 Form 0
5 Sign + pulse, negative logic.
6 CW + CCW, negative logic.
7 A phase + B phase (x1), negative logic.
Pn200 8 A phase + B phase (x2), negative logic.
Position Con-
trol Refer- 9 A phase + B phase (x4), negative logic.
ences
Selection 0 Clears error counter when the signal goes high.
Switches Error Counter Clear 1 Clears error counter at the rising edge of the signal.
1 Signal Form 0
2 Clears error counter when the signal goes low.
3 Clears error counter at the falling edge of the signal.
0 Clears error counter at the baseblock.
Does not clear error counter. (Possible to clear error counter
2 Clear Operation 1 only with CLR signal). 0
2 Clears error counter when an alarm occurs.

0 Reference input filter for line driver signals.
3 Filter Selection 0
1 Reference input filter for open collector signals.
Position Reference 0 Acceleration/deceleration filter.
0
Filter Selection 1 Average movement filter.
Pn207
Position Con- Position Control Disabled.
1 0
trol Function Option Uses V-REF as a speed feed-forward input.
Switches
2 —
3 —
Notch Filter Selec- 0 Disabled.
0
Pn408 tion 1 Uses a notch filter for torque reference.
Torque Control 1 0
Function
Switches 2 Not used. — —
3
B-7
B.3 Input Signal Selections

The following list shows input signal selections and their default settings.
Digit Default
Place Setting
0 Sets the input signal allocation for the sequence

0 Input Signal Allocation Mode to the same one as for the SGDH servo amplifier. 0
1 Possible to freely allocate the input signals.
0 Inputs from the SI0 (CN1-40) input terminal.
7 Sets signal ON.
8 Sets signal OFF.
9 Inputs the reverse signal from the SI0 (CN1-40)

1 /S-ON Signal Mapping (Servo input terminal. 0: SI0
Pn50A ON when low.)
A Inputs the reverse signal from the SI1 (CN1-41)
input terminal.
Inputs the reverse signal from the SI2 (CN1-42)
B input terminal.
C Inputs the reverse signal from the SI3 (CN1-43)

input terminal.
D Input the reverse signals from the SI4 (CN1-44)

input terminal.
E input terminal.
F input terminal.
2 /P-CON Signal Mapping 0 to F Same as above. 1: SI1

(Pcontrol when low.)
P-OT Signal Mapping
3 (Ovetravel when high.) 0 to F Same as above. 2: SI2
N-OT Signal Mapping (Over-

0 travel when high.) 0 to F Same as above. 3: SI3
1 /ALM-RST Signal Mapping 0 to F Same as above. 4: SI4

(Alarm reset when low.)
Pn50B
/P-CL Signal Mapping
2 (Torque control when low.) 0 to F Same as above. 5: SI5
/N-CL Signal Mapping

3 (Torque control when low.) 0 to 8 Same as above. 6: SI6
B-8
Digit Default
Place Setting
/SPD-D Signal Mapping
0 (Internal Set Speed Selec- 0 to F Same as above. 8: OFF
tion)
/SPD-A Signal Mapping
1 (Internal Set Speed Selec- 0 to F Same as above. 8: OFF
Pn50C tion)
/SPD-B Signal Mapping
2 (Internal Set Speed Selec- 0 toF Same as above. 8: OFF
tion)
3 /C-SEL Signal Mapping (Con- 0 to F Same as above. 8: OFF

trol Mode Switching)
/ZCLAMP Signal Mapping
0 (Zero Clamping) 0 to F Same as above. 8: OFF
1 /INHIBIT Signal Mapping 0 to F Same as above. 8: OFF

Pn50D (Disab ling Reference Pulse)
2 /G-SEL Signal Mapping (Gain 0 to F Same as above. 8: OFF

Switching)
3 (Reserved) 0 to F Same as above. 8: OFF
Note: * When Pn50A.0 is set to 0 for the SGDH servo amplifier, only the following modes are compatible:
Pn50A.1=7, Pn50A.3=8, and Pn50B.0=8.
B-9
B.4 Output Signal Selections

The following list shows output signal selections and their default settings.
Digit Default
Place Setting
0 Disabled.
/COIN Signal Map- 1 Outputs from the SO1 (CN1-25, 26) output terminal.
0 ping 1: SO1
2 Outputs from the SO2 (CN1-27, 28) output terminal.
3 Outputs from the SO3 (CN1-29, 30) output terminal.
Pn50E /V-CMP Signal
1 Mapping 0 to 3 Same as above 1: SO1
2 /TGON Signal Map- 0 to 3 Same as above 2: SO2

ping
3 /S-RDY Signal Map- 0 to 3 Same as above 3: SO3

ping
/CLT Signal Map-
0 ping 0 to 3 Same as above
1 /VLT Signal Map- 0 to 3 Same as above

ping
Pn50F
2 /BK Signal Map 0 to 3 Same as above
ping 0: Not
used
/WARN Signal Map-
3 ping 0 to 3 Same as above
0 /NEAR Signal Map- 0 to 3 Same as above

ping
Pn510 1 Reserved 0 to 3 Same as above
2 Not used. 0 — 0
3 Not used. 0 — 0
Output Signal 0 Output signal is not reversed.
0 Reversal for SO1
(CN-25 and 26) 1 Output signal is reversed.
1 Reversal for SO1 0: Not
Pn512 (CN-25 and 26) 1 Output signal is reversed. reversed

2 Reversal for SO1
(CN-25 and 26) 1 Output signal is reversed.
Note 1. When more than one signal is allocated to the same output circuit, data is output using OR logic.
2. Depending on the control mode, undetected signals are treated as OFF. For example, in the speed
control mode, the /COIN signal is treated as OFF.
3. Types of /WARN signals: Overload and regenerative overload.
B-10
B.5 Auxiliary Functions

The following list shows the available auxiliary functions.
Parameter Function
Fn000 Alarm traceback data display.
Fn001 Rigidity setting during online autotuning.
Fn002 JOG mode operation.
Fn003 Zero-point search mode.
Fn004 (Reserved parameter).
Fn005 Parameter settings initialization.
Fn006 Alarm traceback data clear.
Fn007 Writing to EEPROM inertia ratio data obtained from online autotuning.
Fn008 Absolute encoder multi-turn reset and encoder alarm reset.
Fn009 Automatic tuning of analog (speed, torque) reference offset.
Fn00A Manual adjustment of speed reference offset.
Fn00B Manual adjustment of torque reference offset.
Fn00C Manual zero-adjustment of analog monitor output.
Fn00D Manual gain-adjustment of analog monitor output.
Fn00E Automatic offset-adjustment of motor current detection signal.
Fn00F Manual offset-adjustment of motor current detection signal.
Fn010 Password setting (protects parameters from being changed).
Fn011 Motor models display.
Fn012 Software version display.
Multi-Turn Limit Setting: Change when a Multi-Turn Limit Disagreement Alarm
Fn013 (A.CC) occurs.
B-11
B.6 Monitor Modes

The following list shows monitor modes available.
Parameter Content of Display Unit Remarks

Un000 Actual motor speed rpm —
Un001 Input speed reference rpm —
Un002 Internal torque reference % Value for rated torque
Un003 Rotation angle 1 pulse Number of pulses from the origin
Un004 Rotation angle 2 degree Angle from the origin (electrical angle)
Un005 Input signal monitor — —
Un006 Output signal monitor — —
Un007 Input reference pulse speed rpm —
Un008 Error counter value reference Amount of position error

units
Un009 Accumulated load rate % Value for the rated torque as 100%
Value for the processable regenerative
Un00A Regenerative load rate % power as 100%
Value for the processable power when
Un00B Power consumed by DB resistance % dynamic brake is applied as 100%
Un00C Input reference pulse counter — Displayed in hexadecimal.
Un00D Feedback pulse counter — Displayed in hexadecimal.
B-12
YASKAWA ELECTRIC AMERICA, INC.
Chicago-Corporate Headquarters 2121 Norman Drive South, Waukegan, IL 60085, U.S.A.
Phone: (847) 887-7000 Fax: (847) 887-7310 Internet: http://www.yaskawa.com
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Phone: (937) 847-6200 Fax: (937) 847-6277
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Phone: 49-6196-569-300 Fax: 49-6196-888-301 Internet: http://www.yaskawa.de
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Phone: 46-486-48800 Fax: 46-486-41410
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Kammerfeldstraβe 1, 85391 Allershausen, Germany
Phone: 49-8166-900 Fax: 49-8166-9039
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Phone: 44-12-3673-5000 Fax: 44-12-3645-8182
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Phone: 86-10-6232-9943 Fax: 86-10-6234-5002
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Beijing 100076 China
Phone: 86-10-6788-0551 Fax: 86-10-6788-2878
Yaskawa Electric America, Inc., May 1999 YEA-SIA-S800-32.2 Printed In U.S.A.

Sigma Win for Sigma Servo Systems Software Manual
Table of Contents
Preface .....................................................................................................................4
Cautions And Warnings.....................................................................................4

Incorrect Use Can Cause Damage .........................................................4
Operator Panel for Sigma II...................................................................5
Welcome To Sigma Win....................................................................................6
Features Of Sigma Win......................................................................................6
Supported Devices .............................................................................................6
Installing Sigma Win .........................................................................................8

Software Requirements..........................................................................8
System Requirements ............................................................................8
Program Setup........................................................................................8
Technical Support ............................................................................................11
Availability And Rules For Use And Distribution ..........................................12
Starting Sigma Win................................................................................................13
Navigating Sigma Win.....................................................................................13

Menus Options .....................................................................................14
Main Setup Toolbar .............................................................................14
Servo Setup Toolbar ............................................................................15
Starting Sigma Win..........................................................................................18

Servo Amplifier Selection ...................................................................20
Configuring An Application Using Sigma Win.....................................................21
STEP 1 - Motor And Encoder Setup ...............................................................21
STEP 2 - Select Servo Control Mode ..............................................................22
STEP 3 - Jog Test ............................................................................................23
STEP 4 - Reference Offset Adjustments .........................................................25
STEP 5 - Autotuning The Application ............................................................26
STEP 6 - Save User Settings............................................................................26
1
Application Monitoring .........................................................................................27
Monitoring .......................................................................................................27
Overview..............................................................................................27
Servo Monitoring.................................................................................27
Mapping I/O Monitors .........................................................................28
Alarms..............................................................................................................30
Overview..............................................................................................30
Viewing and Clearing Alarms .............................................................30
Alarm History ......................................................................................31
Advanced Topics....................................................................................................32
Parameters........................................................................................................32
Overview..............................................................................................32
Reading and Writing Parameters .........................................................35
Loading and Saving Parameters ..........................................................35
Printing Parameters..............................................................................35
Restoring Default Parameters ..............................................................35
Software Reset .....................................................................................36
Autotuning .......................................................................................................37
Offline Autotuning...............................................................................37
Online Autotuning ...............................................................................40
Advanced (High Precision) Autotuning ..............................................41
Tuning ..............................................................................................................45
Overview..............................................................................................45
Manual Tuning.....................................................................................45
Special Adjustments ............................................................................48
Data Tracing ....................................................................................................51

Overview..............................................................................................51
Standard (Static Data Tracing) ............................................................51
Cyclic Data Tracing .............................................................................55
Setup ....................................................................................................56
Viewing Trace Graphs .........................................................................57
Start/stop Sequences ........................................................................................58
Origin Search ...................................................................................................60
Working Offline...............................................................................................62
User Options ....................................................................................................63

Skill Level Setting ...............................................................................63
Startup Tab Setting ..............................................................................63
2
Servo Scanning Setting........................................................................63
Communication Settings..................................................................................64
Working with Multiple Servo Amplifiers............................................64
Appendix A - Troubleshooting ..............................................................................66
Alarm Troubleshooting....................................................................................66
SGDA-***S / SGDA-***P............................................................ 66
SGDB-***D................................................................................... 87
SGDC-***SA .............................................................................. 109
DR2-*** / DR2-****-F ............................................................... 130
SGDE-***S / SGDL-***S .......................................................... 151
SDGE-****P / SDGL-****P ...................................................... 163
SGDF-***S / SGDF-***S ........................................................... 176
SGDM-***D / SGDM-***DA / SGDH-***E ............................ 187
Appendix B - Pc To Servo Cables .......................................................................211
Sigma Series Cables.......................................................................................211

RS-232C Single-Axis Connection .....................................................211
RS-422A Multi-Axis Connection ......................................................212
Sigma Ii Series Cables ...................................................................................212

RS-232C Single-Axis Connection .....................................................213
RS-422A Multi-Axis Connection ......................................................213
Appendix C - Autotuning Rigidity Levels...........................................................214
Suggested Rigidity Levels For Sigma Series Amplifiers ..............................214
Appendix D - Sigma Win Uninstall.....................................................................215
Uninstall Information.....................................................................................215
List of Installed Files .........................................................................215
Uninstalling Sigma Win.....................................................................216
3
PREFACE
CAUTIONS AND WARNINGS
Incorrect Use Can Cause Damage
! CAUTION
Sigma Win is an application used to operate servo systems ranging in

power from 10W to 30kW. To avoid damage to machines or personal
injury, please read this manual carefully. Follow all safety procedures
noted in this manual and in the operations manual of the servo
amplifiers and servo motors.
Please refer to the following manuals for detailed information on correct operation
of the servo amplifiers.
Manual Name Manual Number

Sigma Series SGM/SGDA User’s Manual TSE-S800-15
Sigma Series SGM*/SGDB User’s Manual TSE-S800-16
Sigma Series SGM*/DR2 User’s Manual TSE-S800-17
Sigma Series SGM*/SGDC User’s Manual TSE-S800-22
Sigma Series SGME/SGDE User’s Manual (for TSE-S800-15.10
position control)
Sigma Series SGME/SGDE User’s Manual (for TSE-S800-15.11
speed/torque control)
Sigma Series SGME/SGDL User’s Manual (for TSE-S800-??.??
position control)
Sigma Series SGME/SGDL User’s Manual (for TSE-S800-??.??
speed/torque control)
Sigma Series SGMM/SGDF User’s Manual SIE-S800-27
Sigma II Series SGM*H/SGDM User’s Manual SIE-S800-32.1
Servo Selection and Datasheets
4
Manual Name Manual Number

Sigma II Series SGM*H/SGDM User’s Manual SIE-S800-32.2
Design and Maintenance
Operator Panel for Sigma II
The Sigma II can communicate with either the Built-in Operator Panel or Sigma
Win. When Sigma Win is running, the Operator Panel is disabled (all the panel
LEDs are OFF and all the switches are inactive).
The Operator Panel is enabled when properly exiting Sigma Win. In case of an
improper termination of Sigma Win, the Operator Panel is enabled after three
minutes.
5
WELCOME TO SIGMA WIN
Welcome to Sigma Win, a software tool to help set up servo applications for the
Sigma Series servo amplifiers. Sigma Win provides a set of tools to simplify the
setup and operation of applications, for both experienced users of Sigma servo
products and novices alike.
Sigma Win provides a user-friendly graphical user interface for setup, control,
monitoring, and testing of Sigma servo systems. All user functions are easy to
access and complete online help is available in a single keystroke.
FEATURES OF SIGMA WIN
Sigma Win enables full setup, monitoring, and control of any Sigma servo system
through:
• Real-time monitoring of servo system data (I/O, alarms, internal registers, etc.)
• Context sensitive help on parameters and alarms.
• Graphical manual and autotuning of servo loop parameters
• Graphical dynamic and static oscilloscope for graphic view of servo system response
• Real-time monitoring of all analog and digital I/O.
• Context sensitive help on all screens, accessible via the F1 key.
SUPPORTED DEVICES
Sigma Win supports the following Sigma series servo amplifiers::

Sigma Series Servo Amplifiers
Servo Amplifier Name Description
DR2-**** DR2 Sigma servo amplifier for speed, torque and position control
DR2-****-F DR2 Sigma servo amplifier with full closed loop control
SGDA-***S SGDA Sigma servo amplifier for speed and torque control
SGDA-***P SGDA Sigma servo amplifier for position control
SGDB-***D SGDB Sigma servo amplifier for speed, torque and position control
SGDC-***SA SGDC Sigma servo amplifier for speed, torque and position control
SGDE-**S Low-cost SGDA-***S
SGDE-**P Low-cost SGDA-***P
SGDF-**CS Sigma Mini servo amplifier for speed control
SGDF-**CP Sigma Mini servo amplifier for position control
SGDL-***S Alternative low-cost SGDA-***S
SGDL-***P Alternative low-cost SGDA-***P
6
Sigma II Series Servo Amplifiers

Servo Amplifier Name Description
SGDM-***D Sigma II servo amplifier for speed torque and position control
SGDM-***DA Sigma II servo amplifier for speed torque and position control
SGDH-***E Sigma II servo amplifier for speed torque and position control
Note: Some servo amplifiers do not support all Sigma Win functions. Therefore, any features not
supported by the amplifier will be noted in this manual.
7
INSTALLING SIGMA WIN

Software Requirements
The Sigma Win software includes the following:
1. One CD-ROM labeled "Sigma Win ver. 1.00."
System Requirements
Sigma Win requires the following minimum configuration:
• An IBM-compatible computer with a Pentium class microprocessor

• 16 megabytes of RAM (32 megabytes recommended)
• VGA monitor and graphics adapter with a resolution of at least 800 by 600 pixels
• CD-ROM Drive
• An asynchronous adapter (RS-232, RS-422) on the computer
• Sigma Servo motors and amplifiers as required
• Communication cable (YS-11 or YS-12) for servo amplifier connection to personal computer
• Windows 95, Windows 98, or Windows NT version 4.0 or higher
Note: If Microsoft Internet Explorer version 3.02 or higher is not installed, the
Help files will not display correctly. No other user functions will be
affected.
Program Setup
Run the Sigma Win Setup program to set up Sigma Win. The Sigma Win Setup
program decompresses the Sigma Win program and its associated files, and copies
them onto your hard drive.
Exit all other programs as a precaution against program conflicts that may occur
during software installation and testing.
To run the setup program:
1. Insert the CD-ROM in the CD-ROM drive (e.g., F:).
8
2. Select the Run option from the Start menu; type F:\SETUP. Click on OK. If
AutoPlay is enabled, the setup program will automatically load when the CD-
ROM is inserted. The dialog below will appear.
Select the desired language and press OK.
3. Or, explore the contents of the CD using Windows Explorer. Double-click on

the F:\ SETUP.EXE file.
4. The following screen displays as the setup program begins.
9
5. The informational screen shown below appears. Read the information. Press
Next to proceed.
6. The screen shown below appears. Select the directory in which to copy the
Sigma Win files. Press Next to proceed.
10
7. The installation program begins to copy the files from the CD-ROM onto the
hard drive. The progress bar shown below depicts the progress of the file copy
function.
Note: If Sigma Win requires a newer version of a support file located on the
computer, a prompt appears inquiring whether to overwrite the current
version or cancel the install process. If the new version of the support file is
not installed, Sigma Win may not work properly.
9. The screen below appears when the installation process is finished.
TECHNICAL SUPPORT
Yaskawa Electric America and its distributors are committed to customer

satisfaction. Technical support is provided to all registered users subject to the
terms and conditions in this document. Follow the steps below for questions
regarding the installation or use of Sigma Win.
1. First, refer to this manual or the help file.
11
2. If further assistance is required, note the type of computer in use, and the
following characteristics: operating system version, available memory and other
programs running.
3. Note when the error, if applicable, occurred. Include the exact wording of any
error messages.
AVAILABILITY AND RULES FOR USE AND DISTRIBUTION
Distribution of Sigma Win without Yaskawa’s permission is not permitted. For

additional copies, contact Yaskawa or an authorized distributor.
This software product is copyrighted, and all rights are reserved by Yaskawa
Electric America. Users are licensed to install and use this software in a single
computer. The software may be copied as needed to facilitate the user’s own use;
however, making copies of the software to be used for any other purpose is a
violation of United States copyright laws. Contact Yaskawa or an authorized
distributor for assistance.
12
STARTING SIGMA WIN

Navigating Sigma Win
This section describes how to quickly connect Sigma Win to the servo system. It
guides the user through the minimal functions needed to set up Sigma Win and the
servo amplifier.
A typical view of the Sigma Win main screen is shown below.
Figure 1: Main Window of Sigma Win
The main window of Sigma Win has four sections, the Menu and Toolbar section,
the Monitor Panel Section, the Servo Data section, and the Status Bar
The Menu and Toolbar section is used to access all the functions of the application.
The user can control the location and visibility of the toolbars and menus. If a servo
amplifier does not support a function, the corresponding control is disabled.
13
Sigma Win offers two toolbars: the Main toolbar and the Servo Setup toolbar. The
Main toolbar is used for file operations and program control, and for operations
between the servo amplifier and the computer such as upload, download, amplifier
scan, etc. The Servo Setup toolbar is used to set up, configure, and test run the
servo amplifier. The menu is shown in Figure 2; the toolbars are shown in Figures
3 and 4 on the following pages.
Menus Options
Figure 2: Sigma Win Menus Bar
Main Setup Toolbar
Figure 3: Sigma Win Main Toolbar
14
This toolbar button… Does this…

Creates new parameter table (offline only)
Opens/Imports existing parameter table
Saves parameter table to file
Prints parameter table
Selects Monitor and Parameters mode
Selects Tuning and Data Tracing mode
Scans for servo amplifiers (offline only)
Goes offline (online only)
Closes servo amplifier
Sends a selected parameter to servo (online only)
Sends all parameters to servo (online only)
Gets a selected parameter from servo (online only)
Gets all parameters from servo (online only)
Jogs the servomotor
Origin search
Servo Setup Toolbar
Figure 4: Sigma Win Servo Setup Toolbar
This toolbar button… Does this…

Sets up servo control mode
Set up start/stop sequences
Sets up motors and encoders
Sets up I/O
15
The Monitor Panel shown below displays essential status information of the
connected servo amplifier. The user selects which monitor to update, and controls
the location and visibility of this section
Figure 5: The Monitor Panel
The Servo Data section (shown below) is used to monitor servo operations and
adjust servo performance.
Figure 6: The Servo Data Section
16
This section has two modes of operation: Monitors and Parameters, and Tuning
and Data Tracing. Switch between the two modes using the buttons on the
toolbar. Click on the button to select the Monitors and Parameters mode.
Click on the button to select the Tuning and Data Tracing mode.
The Monitor and Parameter mode has five tabs as follows:
• Servo Status tab - monitors status registers in the amplifier

• I/O tab - monitors amplifier inputs and outputs
• Alarms tab - monitors and controls alarms
• Encoders tab - monitors encoder related registers
• Parameter tab - displays and allows editing of User Parameters on the servo amplifier.
The Tuning and Data Tracing mode has four tabs as follows:
• Autotuning tab - provides autotuning of the amplifier

• Manual Tuning tab - provides manual adjustment of tuning parameters
• Adjustments tab - provides control on zero adjustment tuning values
• Data Tracing tab - provides graphical display of servo performance (data and
I/O)
The Status Bar, shown below, is used by Sigma Win to display the current status of
the application and of the amplifier.
Figure 7: The Status Bar
The Status Bar contains seven sections or panes.
Beginning on the left, the first pane is the application message area. This pane is
used to display the status of the application (e.g. "Ready," "Jogging Reverse," etc.).
This pane also displays a brief description of each toolbar button function when the
mouse pointer is over the button.
The second pane shows the model of the connected servo amplifier.
The third pane shows the software version of the connected servo amplifier.
The fourth pane shows the unit number (i.e., axis address) of the connected servo
amplifier.
The fifth pane shows the current communication settings.
The sixth pane shows whether the amplifier is in a Servo ON or Servo OFF state.
The seventh pane shows the current user level (Advanced/Basic). The user level
can be changed in the User Options Dialog (see page 63 for details).
17
STARTING SIGMA WIN
From the Start Menu
To start Sigma Win from the Start menu:
1. Click on the Start button on the Windows taskbar. The Start menu opens.
2. Choose Programs. The Programs folder opens.
3. Choose Yaskawa. The Yaskawa folder opens.
4. Click on Sigma Win.
From My Computer or the Windows Explorer
To start Sigma Win from My Computer or the Windows Explorer, navigate the
Sigma Win folder and double-click SIGMAWIN.EXE. The SIGMAWIN.EXE file
is located in the drive and folder that specified during installation. If the default
setup was used, SIGMAWIN.EXE is in C:\PROGRAM
FILES\YASKAWA\SIGMAWIN.
The screen shown below appears while the application loads. The name and
version of the application and copyright information appear on the screen.
Figure 8: The opening Screen of Sigma Win
18
The first time Sigma Win runs, the Communication Setting dialog, shown below,
appears. This screen is used to define the settings needed for Sigma Win to connect
to the servo amplifier through the serial port.
Figure 9: First Time Communication Setup Screen
Select the port to which the amplifier is connected to the computer. Once selected,
Sigma Win uses this as its default.
Select the protocol (RS-232/RS-422) that matches the type of communications port
on the computer.
Note: Use an RS-422 interface card if more than one servo amplifier is desired to
be connected to one serial port. (See Page 64 for details on how to connect
multiple devices, and Appendix B for cable layouts).
When all communication parameters are set, click on OK.
Sigma Win then attempts to connect to the amplifier.
Following a successful connection, Sigma Win lists the attached amplifier(s).
19
Servo Amplifier Selection
After Sigma Win starts, the application scans the serial port for connected servo
amplifiers. If any servo amplifiers are detected, the Servo Selection Dialog box
shows the results of the scan.
Figure 10: Servo Selection Screen
Note: If using RS-232, only one device can be shown.
At this point, click on the device selected for connection then click OK, or double-
click on the device.
Press Rescan to rescan the serial port.
Press Cancel to dismiss the dialog. The application reverts to a disconnected state.
After the user selects the servo amplifier, Sigma Win obtains all the user parameters
from the servo amplifier and displays them in the Parameter tab.
20
CONFIGURING AN APPLICATION
USING SIGMA WIN
After Sigma Win has established communications and connected to the amplifier,
the user can set up and test an application in a few simple steps.
During this process, an alarm status may occur on the servo amplifier (noted by the
red alarm LED on the amplifier being ON). To investigate the cause of the alarm
(incorrect encoder settings, cables not attached correctly, etc.), see page 30 and
Appendix A for information on how to view and clear alarms, and for
troubleshooting alarms.
STEP 1 - MOTOR AND ENCODER SETUP
After the parameters from the servo amplifier have been downloaded to the
application, the user must verify that the amplifier is set up correctly for the
connected motor and encoder.
To set or view the current motor and encoder settings, click on the button in
the Servo Setup Toolbar or select Motors and Encoder from the Servo Setup
menu.
The Motor and Encoder Setup dialog appears.
Figure 11: Motor and Encoder Setup Screen
The application displays the present settings for motor and encoder.
Verify that the information matches the attached hardware.
21
If the amplifier is not configured correctly, or if the user desires to change the
motor, take the following steps:
1. Click the down arrow on the Model selection box. A list of motors that can be
attached to the current servo amplifier is displayed. Click on a motor to select
it. While scrolling through the list, the Power and Voltage rating of each motor
are displayed.
2. Click on the appropriate Encoder type selection (Incremental/Absolute).
3. In the Encoder Resolution box, type in the PPR (pulses per revolution) of the
selected motor. (See the manual that was included with the motor for this data.)
4. If desired, enter a value in the Output Dividing Ratio box. This value scales the
encoder count that is seen by a high level controller. One output pulse =
Resolution / Output Dividing Ratio
5. Select the default direction of rotation (clockwise or counter-clockwise).
Note: For Sigma II, items 2 - 4 are automatically set and are, therefore, read only.
Note: This direction is as seen when looking at the motor from the shaft side.
STEP 2 - SELECT SERVO CONTROL MODE
Sigma Series servo amplifiers can be controlled in several methods (e.g., torque
control, speed control, position control, etc.). Each servo amplifier has a matching
Servo Control Mode that allows the servo amplifier to be controlled in an
appropriate control loop.
To select the current Servo Control Mode, click on the button in the Servo
Setup Toolbar or select Control Mode from the Servo Setup menu.
22
The dialog shown below appears:
Figure 12: Servo Control Mode Setup Screen
To change the mode of operation of the servo amplifier:
1. Click on the Servo Control Mode box and select the desired control mode from
the list shown.
2. Verify the values of the Control Mode Parameters. Adjust the values as needed
(the parameters change per control mode). The value of these parameters can be
edited in the same manner as the Parameter Table tab (see page 32).
3. If needed, disable the over-travel signals (P-OT, N-OT), /S-ON signal or the
SEN (absolute encoder only) signal by selecting the matching checkbox.
4. Click OK to accept the values, or Cancel to dismiss the dialog and return to the
main screen without any changes.
STEP 3 - JOG TEST
After all the previous steps have been executed, perform a no-load test run of the
servo amplifier, using the Servo Jog function. The Servo Jog function tests the
direction of rotation and speed settings without the need to connect to a host
controller.
23
The Jog Test must be done before coupling the motor to the application.
! CAUTION
The Jog function rotates the motor at speeds up to 5000 RPM. Make
sure all personnel and all equipment are away from the motor before
turning the servo ON.
The jog function is accessed either from the Operations menu or by clicking the
button on the Servo Setup toolbar. The following screen appears after calling the
jog function:
Figure 13: Servo Jog Screen
Note: For Sigma II models, the jog screen cannot be accessed if an external /S-ON
signal is applied or if the /S-ON signal is masked on.
24
To jog the servo amplifier:
1. Set the jog speed in the Jog Speed box (in some models the jog speed is fixed at
500 RPM and the Speed field is disabled)
2. Make sure the motor is clear from all obstructions. Click the Servo button to
turn the servo on. When the servo signal is activated, a graphic of an LED turns
green.
3. Note: If the servo signal is controlled by an external /S-ON signal applied, or the
user parameter switch for masking /S-ON signal is ON, the Servo button will
not be able to control the servo ON/OFF status.
4. To jog the motor clockwise, click on the button and hold the left mouse
button down. To jog counter-clockwise, click on and hold the left mouse
button down. When the mouse button is released, the motor stops rotating
within 1-2 seconds.
Click on Close or press the ESC key to return to the main Sigma Win window.
Note: The servo is turned off when the window is dismissed.
STEP 4 - REFERENCE OFFSET ADJUSTMENTS
If the motor drifts (rotates at a very slow speed) while at zero speed, the reference
offset must be adjusted
This adjustment is executed from the Adjustment tab.
25
To access the Adjustment functions, switch to the Monitors and Parameters mode
by clicking on the button and select the Adjustments tab. The dialog shown
below appears.
Figure 14: Adjustments Tab
Adjust the Speed and Torque References by clicking on the Automatic button,
located next to the Speed and Torque Reference values.
STEP 5 - AUTOTUNING THE APPLICATION
After a successful Jog Test, connect the motor to the application. Autotune the
servo amplifier to maximize the performance of the application. To autotune Sigma
Series amplifiers, see the offline autotuning function. To autotune Sigma II series
amplifiers, see the online autotuning function.
STEP 6 - SAVE USER SETTINGS
When the servo amplifier is set up and ready to perform in the application, the
parameter table for this application must be saved to a file for maintenance
purposes.
To save the parameter table to the disk, use the Save item from the File menu or
click on the button. To save the parameters with other than the current file
name, use the Save As item.
26
APPLICATION MONITORING
MONITORING
Overview
Monitors are used to monitor the status of the servo amplifier. The monitors show
values such as speed, torque or I/O status. There are two types of monitors:
Numerical monitors and Bit Status monitors. Numerical monitors are used to
monitor numerical values such as speed, torque and position error. Bit Status
monitors are used to determine the OFF/ON status of individual I/O points such as
/S-ON or /P-CON.
Servo Monitoring
All of the monitors for the servo amplifier are displayed in three groups located on
three corresponding tabs:
1. Servo Status - These monitors show the overall state of the amplifier such as
motor speed, position error, Servo On status, Alarm status, etc.
2. I/O - These monitors display the ON/OFF status of amplifier inputs and outputs
(internal and external).
3. Encoders - These monitors show the current state of the encoder phases and of
the encoder position.
In addition to the three tabs, the most important monitors are also displayed on the
Monitor Panel. The monitor panel can be positioned anywhere on the screen or can
be left floating. To move the panel; locate the mouse pointer over the panel, hold
down the left mouse button and drag the mouse. Release the button when the panel
is in the desired location.
De-select the Monitor panel from the View menu, if desired, to discontinue viewing
the Monitor panel.
In order for Sigma Win to update a particular monitor in real-time, the monitor must
be selected using the checkbox located next to the desired monitor.
Note: The overall update time of the monitors depends on the total number of
monitors that are selected to update.
Note: During sending/receiving parameters, jogging the amplifier, and autotuning,

all monitors are disabled.
27
Mapping I/O Monitors
The I/O Setup monitors the selected physical I/O signals. The user must determine
which logical signals are mapped to the configurable physical signals.
To view or change the current I/O mapping, click on the button in the Servo
Setup Toolbar, or select I/O from the Servo Setup menu.
The following dialog appears:
Figure 15: I/O Setup Screen
Note: Items in the Physical Signal column describe items in the Pin No. column.
The leftmost column lists the physical signals that can be configured. The middle
column describes the connector pin number of those signals. The Logical Signal
column is a list of the logical signals that can be mapped to the physical signals in a
particular row.
In Sigma II Series servo amplifiers, the signals are categorized into input signals
and output signals, as shown below.
28
Figure 16: I/O Setup Screen for Sigma II
To change the mapping of an I/O, click on the down arrow in the rightmost column
of the desired signal. A list of available logical signals appears. Select the
appropriate logical signal by clicking on it.
Click OK to accept the new configuration, or Cancel to cancel the changes and
return to the main screen.
29
ALARMS
Overview
Sigma Win displays the alarm status of the amplifier. The alarm monitor on the
Monitor panel indicates if there is an alarm condition. The current alarm and alarm
history can then be viewed and/or cleared.
The Alarm tab as shown below contains all this information.
Figure 17: Alarm Tab
Viewing and Clearing Alarms
The Current Alarm table notes when the servo amplifier is in an alarm state. The
table shows the alarm code and brief description of the alarm.
To clear an alarm, click on the Clear Alarm button. However, if the cause of the
alarm persists, the alarm will recur each time Sigma Win scans the amplifier, until
the alarm cause is resolved. The screen is updated to reflect new alarm conditions.
Note: The operator panel on the amplifier or the hand-held operator displays
“A.99” to indicate the “No alarm” state.
To obtain further details about an alarm and possible solutions, see Appendix A, or
click on the right mouse button and select Help from the menu.
30
Alarm History
The Sigma amplifiers store a history of the previous ten alarms. Sigma Win
displays them in the Alarm History table. For each alarm stored, the table shows
the order of the alarm, the alarm code and a brief description of the alarm.
When a new alarm occurs, the new alarm is stored as number zero and the rest of
the alarms move up numerically (down on the screen) in order of their occurrence;
the last alarm is discarded. Sigma Win reflects this change as soon as the new
alarm is detected.
31
ADVANCED TOPICS
PARAMETERS
Overview
This section describes how to view and edit the User Parameters in online and
offline modes. The User Parameters define the characteristic of the amplifier.
User parameters can be read from or written to the servo amplifier. Sigma Win
verifies the validity of the data both from and to the amplifier.
Note: In some Sigma manuals, parameters are referred to as “user constants.”
Figure 18: User Parameter Table Tab
Online help is available for all parameters by clicking the right mouse button while
the cursor is over the desired parameter. Select Help from the resulting menu.
Viewing and Editing Parameters
The Parameter tab displays the Parameter Table and allows you to view and edit all
parameters associated with the connected servo amplifier. Different amplifiers have
different sets of parameters with different values. In online mode, after connecting
to the amplifier, the current set of parameter values are read from the servo
32
amplifier and stored in the Parameter Table. In offline mode, when loading a file
from the disk, the values are read from the file. When creating a new file, the
default values are read from the database.
The Parameter Table contains the following columns:
• "Changed" Flag (*) - This column is used to indicate whether the user changed a parameter
value from that which was read from the servo amplifier or loaded from a file.
• Category - Parameters are divided into groups according to functionality of the parameter.
• Cn No. or Dn No. (*) - Each parameter has a number associated with it, for example Cn-05.
• Code - A short code that represents the parameter.
• Description(*) - A short description of the parameter.
• Value (*) - The current value of the parameter (not necessarily the value in the amplifier). This
is the only field that can be edited.
• Units (*) - The units in which the parameter is measured.
• Servo Value - The last known value of the parameter in the servo amplifier. When the Value
field is changed in respect to this field, the Servo Value text is colored blue.
• Min - The minimum value allowed for this parameter.
• Max - The maximum value allowed for this parameter.
• Default - The factory default value for this parameter.
Note: Only fields marked with a * are shown in Basic User level.
Note: To obtain further details about the function of a parameter and related
information, click the mouse on the relevant row, and press the F1 key.
The list of parameters may be sorted according to any of the columns. Click once
on the header of the column to sort the list of parameters in ascending order of the
selected column. Click once more to sort in descending order.
Editing
• A value with a white background on the parameter screen represents an adjustment-type inte-
ger parameter. To edit this parameter, double-click on the field and type in the desired value,
or use the two little arrows on the right side of the value. Clicking the up arrow increments the
number by one, and clicking the down arrow decrements the number by one. Sigma Win veri-
fies that the value falls in the range between the minimum value and the maximum value of the
parameter (Min ≤ Value ≤ Max).
• Represents a selection-type integer parameter - when this button is clicked, a list of possible
values is displayed in a dropdown box beneath the button. Select a value and double-click on
it; press enter, or click anywhere else on the parameter screen.
• A bit selection parameter - when this button is clicked the dialog box shown below appears.
Each selection represents one bit of the parameter. A checked box means that the bit is ON (1),
and an unchecked box means that the bit is OFF (0). Click OK to accept the values, or Cancel
to discard all changes.
33
Figure 19: Bit Selection Parameter Screen
• A nibble selection (Sigma II only) - when this button is clicked, the dialog shown below
appears. Each drop-down box contains the possible values for a parameter nibble. Select the
desired values for each nibble. Click OK to accept the values, or Cancel to discard all
changes.
Figure 20: Nibble Selection Parameter Screen
Note: Read the adjacent Units field to determine the type of field the button
represents.
34
Reading and Writing Parameters
The current state of the Parameter Table can be written to the servo amplifier. To
send the entire Parameter Table to the amplifier, click on the button. To
send the current parameter, click on the button.
To read the Parameter Table from the amplifier, use the button. To read the
current parameter, click on the button.
Clicking with the right mouse button while the mouse is located over the Parameter
Table can also access the read and write functions.
Loading and Saving Parameters
The current state of the parameter table can be saved to the disk. Later, the
parameter data can be retrieved and re-loaded into Sigma Win.
To save the parameter table to the disk, select the Save item from the File menu or
click on the button. Select the Save As item to save the parameters with
other then the current file name.
While online, select Import Parameter File from the File menu.
The Import Parameter function loads the values in the file for all the existing
parameters in the parameter table.
While offline, select Open Parameter File from the File menu.
Sigma Win parameter files have the default file extension *.YPM.
Printing Parameters
To print the current parameter table, select the Print item from the File menu or
click on the button.
Restoring Default Parameters
Sigma Win allows restoration of the amplifier default values to the parameter table.
To restore the parameters to the servo amplifier, the user must send the parameters
to the servo amplifier.
35
Select the Restore Defaults item from the Parameters menu to restore the defaults
of the parameter table.
Software Reset
This feature is valid for the following Sigma servo amplifiers:
• SGDH-***E
• SGDM-***DA
Note: If the amplifier does not support software reset, the relevant menu selection
is disabled.
After changing parameters in the servo amplifier changes do not take effect until the
main power is recycled (see the appropriate Sigma amplifier users manual). In the
Sigma II series, the user can use this function instead. After this function is called,
the parameters in the servo amplifier all take effect without powering the servo
amplifier OFF and then ON.
36
AUTOTUNING
In order to obtain optimal performance from the Sigma servo amplifier, it must be
tuned. This ensures that the servo system features minimal positioning time,
minimal vibration, and an accurate path of motion
Servo tuning requires matching the machine configuration and rigidity. This
requires a great deal of experience and is quite complicated.
Sigma servo amplifiers incorporate autotune functions that automatically measure

the machine characteristics and make the necessary servo gain adjustments.
Autotuning allows even an inexperienced user to tune the servo system.
The Sigma series amplifiers offer a standard autotuning function called "Offline
Autotuning." Most models and version also offer an Advanced Autotune that takes
longer to complete and requires more user interaction.
Sigma II series amplifiers offer “Online Autotuning,” an adaptive tuning function

which replaces the standard autotuning function.
! C A U TIO N
The Autotuning function rotates the motor at speeds up to 5000

RPM. Make sure all personnel and all equipment are away from
the motor, and all couplings are fastened before turning the servo
ON.
Offline Autotuning
SGDA-***S SGDE-***S
SGDA-***P SGDE-***P
SGDB-***D SGDL-***S
DR2-**** SGDL-***P
DR2-****-F SGDF-***S
SGDC-***SA ver. 3 and higher SGDF-***P
37
To access the autotune functions, switch to the Monitors and Parameters mode by
clicking on the button; select the Autotune tab. The dialog shown below
appears:
Figure 21: Autotune Tab - Offline Autotuning
Offline Autotuning requires the user to set a rigidity level for the application and
then initiate movement of the motor shaft. While the motor is rotating, the
performance is analyzed, and the suggested parameter adjustments are displayed.
To autotune a servo system using Offline Autotuning, follow the procedure below:
1. Click on the Standard Autotune button to select standard autotune.
2. Verify that the autotune speed is set at the desired level.
Note: It is recommended to set the Autotune Speed to 500rpm or higher.
3. Verify that the Rigidity Level matches the servo application. If unsure about
setting this, see the online help or Appendix C of this manual.
38
4. Press the Change button if either of the settings needs to be changed. The
following dialog appears:
Figure 22: Offline Autotuning Settings
5. To change the speed setting, type in the desired speed. To change the rigidity
level, move the arrow on the slider to the desired level of rigidity. Click OK to
accept and return. Click Cancel to cancel the changes and return
6. Click on the Mode button to start autotune mode.
7. Ensure the motor is clear from all obstructions. Click the Servo button to turn
the servo on.
8. Note: If the servo signal is controlled by an applied external /S-ON signal, or if

the user parameter switch for masking /S-ON signal is ON, the Servo button
does not control the servo ON/OFF status.
9. To tune for motor movement in the clockwise direction of rotation, click on the
button and hold the left mouse button down. To tune for motor
movement in the counter-clockwise direction of rotation, click on the
button and hold the left mouse button down.
10. Hold the mouse button down until autotuning is complete. The status bar
indicates the operation status.
11. When the autotuning is complete, release the mouse button; the grid of
parameters is updated to show the results. A screen prompt appears to inquire
whether to save these new gains or revert to the old ones. The grid shows the
old parameter values and the suggested new ones. If the prompt dialog covers
the parameter grid, click on the mouse while over the caption of the prompt
dialog and move the dialog until the grid values are displayed.
39
Online Autotuning
• SGDM-***D ver. 2 and higher

• SGDM-***DA
• SGDH-***E
Note: If the servo amplifier does not support Online Autotuning, the online
autotune tab will be disabled.
clicking on the button (if the button is disabled, it has already been selected)
and select the Autotune tab. The dialog will look like the one as shown below:
Figure 23: Autotune Tab - Online Autotuning
Online Autotuning requires a rigidity level be set for the application. The tuning
parameters are updated as a result of the rigidity level. Once set, the amplifier uses
these parameters while the application is "active" to calculate an internal inertia
ratio which is the basis for the performance of the servo loop gains. The user
selects whether to have this ratio calculated continuously or to have it calculated
once, after power-up. When the user is satisfied with the performance, the internal
ratio can be made permanent by transferring that value to a User Parameter.
Follow the steps below to autotune servo systems using Online Autotuning:
1. Click on the Online Autotune button to select online autotuning.
40
2. Verify that the rigidity level matches the servo application. If unsure how to set
this, see the online help or Appendix C of this manual.
3. Verify that the autotune mode is set correctly.
4. If either of the settings must be changed, press the Change button. The
Figure 24: Online Autotuning Settings
5. To change the rigidity level, move the arrow on the slider to the desired level of
rigidity. Choose the correct Autotune Mode. Click OK to accept and return,
Click Cancel to discard the changes and return.
6. The servo system now operates with a new level of rigidity.
7. Once satisfied with the performance of the servo system, click on Save to make
the results of the Online Autotune permanent.
Advanced (High Precision) Autotuning
SGDA-***S ver. 2 and higher SGDE-***S ver. 1 and higher

SGDA-***P ver. 2 and higher SGDE-***P ver. 1 and higher
SGDB-***D ver. 3 and higher SGDL-***S ver. 1 and higher
DR2-**** ver. 3 and higher SGDL-***P ver. 1 and higher
DR2-****-F ver. 3 and higher SGDF-***S ver.
SGDC-***SA ver. 3 and higher SGDF-***P ver.
SGDM-***D ver 2 and higher SGDM-***DA
SGDH-***E
Note: If the amplifier does not support Advanced Autotuning, the Advanced
Autotuning button is disabled.
41
clicking on the button (if the button is disabled, it has already been selected)
and select the Autotune tab. The dialog shown below appears.
Figure 25: Autotune Tab - Advanced Autotuning
Sigma Win offers a high precision advanced autotuning function. The Advanced
Autotune requires the user to set a rigidity level for the application and then initiate
movement of the motor shaft. While the motor is rotating, the performance is
analyzed and the suggested adjustments to parameters are displayed.
To autotune a servo system using Advanced Autotuning, follow the procedure

below:
1. Click on the Advanced Autotune button to select advanced autotune.
2. Verify that the autotune speed is set at the desired level.
Note: It is recommended to set the Autotune Speed to 500rpm or higher.
3. Verify that the Rigidity Level matches the servo application. If unsure how to
set this, see the online help or Appendix C of this manual.
42
4. Press the Change button if either of the settings must be changed. The
Figure 26: Advanced Autotuning Settings
5. To change the Speed setting, type in the desired speed. To change the rigidity
level, move the arrow on the slider to the desired level of rigidity.
6. If needed, click on the Advanced button to set the Stability of the Speed Loop
and the Stability of the Position Loop. The settings dialog appears as shown
below:
Figure 27: Advanced Autotuning Settings - Expanded View
7. Adjust the Stability setting as needed.
8. Click OK to accept and return. Click Cancel to cancel the changes and return.
9. Click on the Mode button to start autotune mode.
10. Ensure the motor is clear from all obstructions. Click the Servo button to turn
the servo on.
43
11. Note: If the servo signal is controlled by an applied external /S-ON signal, or if
the user parameter switch for masking /S-ON signal is ON, the Servo button
does not control the servo ON/OFF status.
12. To start tuning, click on the button. The motor rotates at the selected
speed. After each rotation, performance data is retrieved from the amplifier.
the direction of rotation will alternate between forward and reverse for each
tuning cycle.
13. As soon as the data from the motor rotation is retrieved from the servo
amplifier, the following graph is shown. This graph overlays the Feedback
Speed (blue) with the Reference Speed (Red). The closer the two graphs are to
each other, the better the results. In addition, the Torque Reference is displayed.
Figure 28: Advanced Autotuning Results
15. Exit the Graph Viewer
This completes one iteration of Advanced Autotuning. To tune further, repeat this
procedure, beginning with step 12. This procedure can be repeated up to 7 times.
To restart the entire advanced autotuning process, click on the Reset button and
repeat this procedure from step 2.
44
TUNING
Overview
The autotuning functions use an algorithm with a large safety margin for
adjustments of gains. The autotuning functions are designed to tune as broad a
spectrum of servo systems as possible. However, some systems may not be able to
be tuned to a high enough degree of response to fit specific applications (e.g.,
machines with very low rigidity or high fluctuation of response).
In such cases, the user must tune the servo system manually. This is done by
observing the results after adjusting the parameters affecting the servo loop control.
Manual Tuning
To access the Manual Tuning functions, switch to the Monitors and Parameters
mode by clicking on the button (if the button is disabled, it has already been
selected) and select the Manual Tuning tab. The dialog shown below appears.
Figure 29: Manual Tuning Tab
This is the Manual Tuning Tab, as it appears in the Advanced User level. If the
user level were set to Basic, only the grid of Standard Tuning Parameters would be
visible.
45
The Standard Tuning Parameters contain the basic parameters needed to tune the
amplifier to the servo application. These same parameters are affected by
Autotuning.
The Advanced Tuning Parameters are a grid of secondary parameters that affect the
performance of the servo system.
The value of these parameters can be edited in the same manner as the Parameter
Table tab. (See page 32.)
Note: All changes in the Manual Tuning screen are reflected immediately in the
servo amplifier.
In addition to the parameter grids, there are two more selections that affect the servo
systems:
Use Secondary Torque Reference Filter - If the servo amplifier supports the
function for a secondary torque reference filter, this is enabled. Select the checkbox
next to the caption, to select this option.
Mode Switch Configuration - Click on Mode Switch to configure the behavior of

the Mode Switch operations.
Setting the Mode Switch
The Mode Switch is used to fully optimize the performance of the amplifier to
achieve high speed positioning. The Mode Switch is a trigger that automatically
switches over the amplifier internal speed control mode from Proportional/Integral
to Proportional speed control, and vice versa when specified conditions are
satisfied.
The Mode Switch can be used to
• Suppress overshooting during acceleration or deceleration (for speed control).

• Suppress undershooting during positioning, and shorten the setting time (for position control).
46
After the Mode Switch button is clicked, the follow dialog appears:
Figure 30: Mode Switch Settings Screen
To set up the Mode Switch and the trigger conditions:
1. Select the Use Mode Switch checkbox. This enables the trigger conditions.
2. Select one of the four trigger conditions (Torque Reference, Speed,

Acceleration, or Position Error).
3. Enter the trigger value.
4. To disable the Mode Switch, de-select the Use Mode Switch checkbox.
5. Press OK to accept the setting and return. Press Cancel to cancel the changes
and return.
47
Special Adjustments
Sigma Win provides adjustments for offsets in reference signals, analog outputs,
and monitors.
Use Speed and Torque reference adjustments, for example, when the amplifier is
working in speed mode with no zero clamp.
Note: All changes in the Adjustment screen are reflected immediately in the servo
amplifier.
The following adjustment functions are included in this tab
1. Automatic Tuning of Analog Reference Offset

2. Manual Adjustment of Speed Reference Offset
3. Manual Adjustment of Torque Reference Offset
4. Manual Adjustment of Analog Monitor Output
5. Manual Adjustment of Analog Monitor Output Gain
6. Automatic Tuning of Motor Current Offset
7. Manual Adjustment of Motor Current Offset
These features are valid for the following Sigma servo amplifiers:
• SGDA-***S • SGDE-***S
• SGDB-***D • SGDL-***S
• DR2-**** • SGDF-**CS
• DR2-***F • SGDM-***D
• SGDC-***SA • SGDH-***E
• SGDM-***DA •
Note: If the amplifier does not support special adjustments, the Adjustments tab is disabled.
48
Models Available Adjustments

SGDA***S 1 and 2 only
SGDB***D
DR2-****
SGDC-***SA
SGDE-***S
SGDL-***S
SGDF-**CS
SGDM-***D All adjustments
SGDM-***DA
SGDH-***E
To access the Adjustments functions, switch to the Monitors and Parameters mode
by clicking on the button (if the button is disabled, it has already been
selected), and select the Adjustments tab. The dialog shown below appears.
Figure 31: Adjustments Tab
Adjustments are accomplished as follows:
• To adjust the Speed and Torque References, click an up or down arrow in the Speed Reference
or Torque Reference value field. Click the up arrow to increment the number by one, and click
the down arrow to decrement the number by one.
• To automatically adjust the Speed and Torque References, click on the Automatic button
49
located next to the Speed and Torque Reference values.

• To adjust the Analog Monitor Offset, first select the channel to adjust by clicking on the chan-
nel selection box and selecting one of the values. Next, click on the up or down arrow in the
Analog Monitor Offset value field. Clicking the up arrow increments the number by one;
clicking the down arrow decrements the number by one.
• To adjust the Analog Monitor Offset Gain, first select the channel to adjust by clicking on the
channel selection box and selecting one of the values. Next, click on the up or down arrow in
the Analog Monitor Offset Gain value field. Clicking the up arrow increments the number by
one; clicking the down arrow decrements the number by one.
• To adjust the Motor Current Detection Offset, first select the Motor Phase to adjust by clicking
on the Motor Phase selection box and selecting one of the values. Next, click on the up or
down arrow in the Motor Current Detection Offset value field. Clicking the up arrow incre-
ments the number by one; clicking the down arrow decrements the number by one.
• To automatically adjust the Motor Current Detection Offset, click on the Automatic button
located next to the Motor Current Detection Offset value field.
50
DATA TRACING
Overview
The Data Tracing function is used to display oscilloscope-style graphs that reflect
the performance data of the Sigma amplifier. Sigma Win allows the user to define
the parameters to track and display the graph. The user can save graphs and display
them later. Sigma Win offers an option to print out the graphs with the related
information regarding the performance and status of the amplifier at the time of the
trace.
The Sigma Series servo amplifier has one type of data graphing standard (static)
tracing. The Sigma II Series has one additional type, cyclic tracing.
The process of Data Tracing has two parts: Setup and Viewing.
Standard (Static Data Tracing)
• SGDA-***S • SGDE-***S
• SGDA-***P • SGDE-***P
• SGDB-***D • SGDL-***S
• DR2-**** • SGDL-***P
• DR2-****-F • SGDF-***S
• SGDC-***SA • SGDF-***P
• SGDM-***D • SGDM-***MA
• SDGH-***E
Note: If the amplifier does not support static data tracing, the standard data tracing
button is disabled.
To access the standard trace screen, switch to the Monitors and Parameters mode by
clicking on the button (if the button is grayed out, it has already been selected).
51
Select the Data Tracing tab and click on the Standard Tracing button. The dialog
shown below appears:
Figure 32: Standard Data Tracing Screen
52
To setup the standard tracing, click on the Setup button. The standard trace setup
dialog appears, as shown below:
Figure 33: Standard Data Trace Setup
To define the data which is to be tracked, and the look of the graph, click on Setup.
Up to two analog traces and two digital traces can be defined for each trace object.
Select the data to be traced from the Trace Select list.
Figure 34: Trace Setup
Choose the color of the graph from the color drop-down box, and select the
thickness of the graph lines from the thickness box. For analog traces, the range of
the graph may be changed by adjusting the Maximum and Minimum values. Press
53
OK to accept the changes, or Cancel to discard the changes. This brings back the
Standard Trace Setup dialog.
Figure 35: Standard Data Trace Setup
Define the Data Trace sampling settings and the trigger conditions as follows:
1. Select the fixed sample time between each data point by entering the desired
sample time in the Sample Time field. Use the up arrow to increment the
sample time, and the down arrow to decrement the sample time. The Total
Sample Time field is updated as the Sampling Time field changes.
2. Total Sample Time = Sampling Time × the number of points that can be cached
(1000 or 500 - servo amplifier dependent).
3. Enter the desired time period for pre-trigger data to be displayed in the Pre-
Trigger Time field. Use the up arrow to increment the sample time, and the
down arrow to decrement the pre-trigger time.
4. Select the Trigger Type. The selections in this field depend on the user
selection in the Servo Data and Servo I/O fields. The amplifier only uses one of
those selected as a trigger. Another option is to select “No Trigger.”
5. Enter an appropriate level in the Trigger Level field. The unit and caption of
this field change in relation to the Trigger Type field.
6. In the Edge Type field, select one of the trigger edge conditions. The data
tracing can be triggered on the rising edge, falling edge, or any edge of the
54
trigger signal. To start tracing without waiting for a trigger, choose the “none”
selection.
Press OK to accept the settings, or Cancel to dismiss the changes. This completes
the setup phase of standard tracing.
Viewing Trace Graphs
To begin tracing the selected data, click on the Start button. The selection is
transmitted to the amplifier. The data is stored as soon as the trigger occurs (if a
trigger condition was selected.). When there is no trigger, the data is stored as soon
as the amplifier starts to execute the command. To cancel the operation, press
Abort.
When all the points have been cached on the amplifier, Sigma Win commands the
amplifier to transmit all the data back to the computer. The data is then displayed
on the graphs.
The current trace data can be saved to the disk, retrieved, and re-loaded in Sigma
Win. To save the trace data to the disk, click on the Save button. To load trace
data from the disk, click on the Load button.
To print the current trace, click on the Print button.
Sigma Win Standard Data Trace files have the default file extension *.YDM.
Cyclic Data Tracing
This feature is valid for the following servo amplifiers:
• SGDM-***D
• SDGM-***DA
• SGDH-***E
Note: If the amplifier does not support cyclic data tracing, the cyclic tracing button
is disabled.
To access the cyclic trace screen, switch to the Monitors and Parameters mode by
clicking on the button (if the button is grayed out, it is already selected). Select
55
the Data Tracing tab and click on the Cyclic Tracing button. The dialog shown
below appears:
Figure 36: Cyclic Tracing Screen
Setup
To setup the cyclic tracing, click on the Setup button. The cycle trace setup dialog
appears, as shown below.
Figure 37: Cyclic Trace Setup
56
To define the data which is to be tracked, and the look of the graph, click on setup.
Figure 38: Trace Setup
Up to two analog traces and two digital traces can be defined for each trace object.
Select the data to be traced from the Trace Select list.
Choose the color of the graph from the color drop-down box, and select the
thickness of the graph lines from the thickness box. For analog traces, the range of
the graph may be changed by adjusting the Maximum and Minimum values. Press
OK to accept the changes, or Cancel to discard the changes.
Using the Sample Interval value, enter the line between samples. Press OK to
accept the settings, or Cancel to dismiss the changes. This completes the setup
phase of cyclic tracing.
Viewing Trace Graphs
To begin Cyclic Tracing of the selected data, click on the Start button. To stop
Cyclic Tracing of the selected data, click on the Stop button.
The graphs update in real time, as the values on the servo amplifier are updated.
The current trace can be saved to the disk, retrieved, and re-loaded in Sigma Win.
To save the trace to the disk, click on the Save button. To load a trace to the disk,
click on the Load button.
To print the current graphs, click on the Print button. Graphs can be printed only
when the trace is not active.
Sigma Win Cyclic Data Trace Graph files have the default file extension *.YDG.
57
START/STOP SEQUENCES
The Start and Stop Sequences are designed to customize the beginning and end of a
motor rotation. These allow the application to perform smoothly and consistently,
for example: hold at a vertical stopping point, limit the rate of acceleration, and
smooth out the input.
To set or view the Start and Stop Sequence settings, click on the button in the
Servo Setup Toolbar or select Start/Stop from the Servo Setup menu.
The Start and Stop Sequences Setup dialog appears.
Figure 39: Start/Stop Sequences Setup Screen
To determine how the amplifier stops for overtravels, click on the Overtravel Stop
Mode field and select the desired method. Next click on the Overtravel After Stop
Mode field and select the desired method.
To determine how the amplifier stops for Servo OFF or Alarms, click on Servo OFF
and Alarms Stop Mode field and select the desired method. Next click on the Servo
OFF or Alarms After Stop Mode field and select the desired method.
58
Customize the Soft Start behavior of the amplifier by editing the Soft Start
Parameter values.
Customize the Mechanical Brake behavior of the amplifier by editing the

Mechanical Brake Parameter values.
59
ORIGIN SEARCH
• SGDM-***D
• SGDM-***DA
• SGDH-***E
Note: If the amplifier does not support origin search, the origin search button and
menu selection are disabled.
The Origin Search is designed to position the motor shaft at the origin C pulse
position. This function is used when the motor shaft must be aligned with the
machine.
Origin Search must be run without any couplings connected.
Note: The Origin Search function rotates the motor at a fixed speed of 60rpm.
! CAUTION
The Origin Search function rotates the motor. Make sure all
personnel and all equipment are cleared away from the motor before
turning the servo ON.
Figure 40: Origin Search Screen
60
To search for the origin the servo amplifier in a forward or reverse direction do the
following:
1. Make sure the motor is clear from all obstructions. Click the Servo button to
turn the servo on. When the servo signal is activated, the LED graphic turns
green.
2. Note: If the servo signal is controlled by an external /S-ON signal or the user
parameter switch for masking /S-ON signal is ON, the Servo button does not
control the servo ON/OFF status.
3. To search for the origin in a clockwise direction of rotation, click on the

button and hold the left mouse button down. To search for the origin in a
counter-clockwise direction of rotation, click on the button and hold the
left mouse button down.
4. When the mouse button is released, the motor stops rotating.
Click Close or press the ESC key to return to the main Sigma Win window.
61
WORKING OFFLINE
Working in the offline mode refers to using Sigma Win while not connected to a
servo amplifier, or when the amplifier power is OFF. In the Offline mode, the only
actions available to the user are load, edit, and save of parameter files, and display
of Data Trace files. All other functions are disabled.
There are three ways to enter Offline mode.
1. While viewing the Servo Selection screen (see Figure 10, page 21), the user
clicks Cancel to dismiss the screen and use Sigma Win without selecting an
amplifier. Sigma Win is in offline mode with no data loaded.
2. During an online session with a servo amplifier, the user disconnects from the
amplifier. This is achieved by selecting the Go Offline item from the Operation
menu or by clicking on the button in the main toolbar. Sigma Win goes
offline, and retains the loaded data.
3. During a session with a servo amplifier, online or offline, the user closes the
current session. This is achieved by clicking on the button in the main
toolbar. Sigma Win is in offline mode with no data loaded.
While in offline mode:
• To begin working with a new amplifier, using the default factory values, select the New item
from the File menu or click on the button. The Servo Selection Dialog is displayed with
all the models that are included in the Sigma Win database. After the user selects the desired
model, Sigma Win prompts the user for some additional information.
1. The user is prompted to select the model with the power, voltage and
rating from the list of possible models. For example, if the user
selection was SDGA-***P, the user might select the SDGA-01AP.
2. The user is prompted to select a motor from the list of possible motors.
3. Sigma Win then loads the default values that match the user selections.
• To load a parameter table from the disk, select the Open item from the File menu or click on
the button
• To save the parameter table to the disk, select the Save item from the File menu or click on the
button. To save the parameters with other then the current file name, select the Save As
item
Sigma Win parameter files have the default file extension of *.YPM.
62
USER OPTIONS
Sigma Win also offers a few user options. To access the User Options dialog, select
User Options from the View menu. The following dialog appears:
Figure 41: User Options Screen
Skill Level Setting
Sigma Win has two skill levels of operation: Basic User level and Advanced User
level. The Basic User level is designed to present the user with a simplified view of
Sigma Win. The parameter table is simplified by displaying only important
parameters as well as displaying only partial information about each parameter. In
addition, some of the user functions of Sigma Win are disabled while in Basic level.
To change the user level, select the desired option in the Skill Level box
The current user level is indicated on the status bar.
Startup Tab Setting
After launching Sigma Win, the parameter tab in the Monitors and Parameters
section is displayed. To change the default tab, click on the arrow on the Startup
Tab box and select one of the tabs in the list that is shown.
Servo Scanning Setting
Sigma Win can be configured to automatically scan for connected servo amplifiers
after the application is run. The default setting of this option is ON. To change the
setting, click on the Scan checkbox.
63
COMMUNICATION SETTINGS
To access the Communications Setup dialog, select Communication Settings from

Options on the View menu. The following dialog displays:
Figure 42: Communications Setup Screen
Choose one of the available COM port selections to assign a port that Sigma Win
will use to communicate with the servo amplifiers.
Select the communication protocol to use from the Protocol options.
The communication protocol is the serial interface hardware type the computer uses
to communicate with the servo amplifier.
Standard Sigma Win usage is RS-232. If the servo amplifier is configured at an

axis address different than 0, enter the correct address in the Address field.
Working with Multiple Servo Amplifiers
• SGDA-***S • DR2-****-F
• SGDA-***P • SGDC-***SA
• SGDB-***D • SGDF-***P
• DR2-**** • SGDC-***SA
• SGDM-***D • SGDM-***MA
• SGDH-***E
Note: If the amplifier does not support work with multiple amplifiers, the relevant options are
disabled.
Sigma Win can be configured to communicate with multiple servo amplifiers. In

order to do this; two conditions must be met.
64
1. The PC must have an RS-422 serial port. Select RS-422 as the Communication
Protocol. Enter the highest axis address to scan for servo amplifiers. The
default value is 15 (0xF).
2. Special cables must be used. See Appendix B for cable layouts.
Sigma Win can communicate with only one servo amplifier at a time. However, it
can scan the serial port for all the attached servo amplifiers and display a list. The
user can then choose an amplifier for connection. From that point on, all
communications are with the selected servo amplifier.
65
APPENDIX A - TROUBLESHOOTING
ALARM TROUBLESHOOTING
SGDA-***S / SGDA-***P
Absolute Encoder Data Error [A.00]
Display and Outputs

Alarm Code
Alarm Name Alarm Output
Output
A.00 ALO1 ALO2 ALO3
Absolute OFF OFF OFF OFF
Encoder Data
Error
OFF: Output transistor is OFF
ON: Output transistor is ON
Status When Alarm Occurred
At power ON
• Speed Control and Cn-01 Bit 1 = 0, see F1

• Speed Control and Cn-01 Bit 1 = 1, see A, B, C, D, E, F
At SEN signal input
• See A, B, C, D, E, F
Cause Remedy
A Absolute encoder power is Use the amplifier power supply for the absolute
not supplied by the ampli- encoder
fier.
B Incorrect absolute encoder Check and correct the absolute encoder wiring
wiring (PA, PB, RESET,
SEN signal [for speed con-
trol], etc.).
1. Letters appearing in boldface type represent preferred choices.
66
Cause Remedy
C Absolute encoder malfunc- Speed control (Cn-01 bit 1 = 0), Turn SEN sig-
tioned. nal OFF and back ON (see note).
Speed Control (Cn-01 bit 1 = 1) or position con-
trol turn amplifier power OFF and back ON.
D Incorrect user parameter Set Cn-01 bit E to 0.
setting. Incremental
encoder used with Cn-01
Bit E set to 1.
E Absolute encoder is defec- Replace motor
tive.
F Circuit board (1PWB) is Replace amplifier
defective.
Note: Alarm A.00 is reset when the power is turned OFF and then back ON. It is
not reset by the normal alarm reset.
Note: Resetting the SEN Signal

When resetting the SEN signal (i.e., turning it OFF and then back ON) for
any reason, keep the SEN signal at the high level for more than 1.3 seconds
before turning it OFF.
Parameter Breakdown [A.02]
Display and Outputs

Alarm Code
Output
A.02 ALO1 ALO2 ALO3
Parameter OFF OFF OFF OFF
Breakdown
At power ON
• See A, B
Cause Remedy
A Power turned OFF while Replace amplifier
saving parameters. Alarm
occurred at the next power
ON.
67
Cause Remedy
B Circuit board (1PWB) is Replace amplifier
defective.
Parameter Setting Error [A.04]
Display and Outputs

Alarm Code
Output
A.04 ALO1 ALO2 ALO3
Setting Error
At power ON
• See A, B
Cause Remedy
A An out-of-range parameter Reset all out-of-range parameters, otherwise
was previously loaded or reload correct parameters
set.
defective.
Overcurrent [A.10]
Display and Outputs

Alarm Code
Output
A.10 ALO1 ALO2 ALO3
Overcurrent ON OFF OFF OFF
During servomotor operation
68
• See A, B, C, D, E
When servo ON (S-ON) signal turned ON
• See D, E
At power ON
• See D
Cause Remedy
A Wiring grounded between Check and correct wiring.
servo amplifier and servo-
motor.
B Servo amplifier ambient Bring servo amplifier ambient temperature to
temperature exceeds 55° C. 55°C.
Note: Alarm cannot be reset while power tran-
sistor module temperature exceeds 90°C.
C Servomotor U, V, or W Replace servomotor.
phase grounded.
D Circuit board (1PWB) Replace servo amplifier.
defective.
Power transistor defective.
E Current feedback circuit, Replace servo amplifier.
power transistor, DB relay,
or circuit board defective.
Position Error Pulse Overflow [A.31]
Display and Outputs

Alarm Code
Output
A.31 ALO1 ALO2 ALO3
Position Error ON ON OFF OFF
Pulse Over-
flow (posi-
tion control
only)
69
• Overflow during high-speed operation, see A

• No feedback pulse returned after reference pulse input, see B, F
• Normal operation but overflow when large reference input, see C, D, E
At power ON
• See F
Cause Remedy
A Servomotor wiring incor- Check and correct wiring. (Check A-, B-, C-
rect. phase pulses correct at 2CN.)
B Encoder wiring incorrect Check and correct wiring. (Check A-, B-, C-
(disconnection, short cir- phase pulses correct at 2CN.)
cuit, power supply, etc.).
C Servo amplifier adjustment Increase speed loop gain (Cn-04) and/or posi-
incorrect. tion loop gain (Cn-1A).
D Servomotor overloaded. Reduce load torque and inertia. Otherwise,
replace with larger capacity servomotor.
E Position reference pulse fre- Decrease reference pulse frequency.
quency too high. Use smoothing function.
Change electronic gear ratio.
F Circuit board (1PWB) Replace servo amplifier.
defective.
Overvoltage [A.40]
Display and Outputs

Alarm Code
Output
A.40 ALO1 ALO2 ALO3
Overvoltage OFF OFF ON OFF
At power ON
• See E, F
• During motor deceleration, see A, D
70
• During normal operation, see B, C, D
Cause Remedy
A Load inertia high and motor Change operating conditions.
speed too high. Use regenerative unit.
If multiple units are used, connect all P, N termi-
nals in parallel.
B Load exceeds capacity of Change operating conditions.
regenerative unit.
C Servomotor speed too high. Reduce motor speed.
E Input voltage too high. Change input voltage to normal value.
defective.
Overspeed [A.51]
Display and Outputs

Alarm Code
Output
A.51 ALO1 ALO2 ALO3
Overspeed ON OFF ON OFF
At servo ON (S-ON) signal turned ON
• During high-speed servomotor rotation after reference input (alarm detected at
110% maximum speed), see A, B, C, D, E
At power ON
• See E
Cause Remedy
Encoder wiring incorrect
(disconnection, short cir-
71
Cause Remedy
B Incremental encoder power Use the servo amplifier power supply for the
not supplied from servo encoder.
amplifier.
C Noise in encoder wiring. Separate encoder wiring from main wiring cir-
cuits.
D Incorrect user constant Set user constant Cn-11 to the correct number of
(number of encoder pulses) pulses.
setting.
E Circuit board (1PWB) Replace servo amplifier.
defective.
Display and Outputs

Alarm Code
Output
A.70 ALO1 ALO2 ALO3
Absolute ON ON ON OFF
Encoder Data
Error
At power ON
• See E
• See A, B, D
When speed reference input
• No servomotor rotation, see B, C, D

• During normal operation, see D, E
Cause Remedy
A Servomotor wiring incor- Check wiring and connectors at servomotor
rect or disconnected.
B Encoder wiring incorrect or Check wiring and connectors at encoder
disconnected.
72
Cause Remedy
C Load greatly exceeds rated Reduce load torque and inertia. Otherwise,
torque. replace with larger capacity servomotor.
D Incremental encoder power Use the servo amplifier power supply for the
amplifier.
defective.
Encoder Error [A.80]
Display and Outputs

Alarm Code
Output
A.80 ALO1 ALO2 ALO3
Encoder Error
(only if abso-
lute encoder
is used)
At power ON
• Speed Control and Cn-01 Bit 1 = 0, see C

• Speed Control and Cn-01 Bit 1 = 1, see A, B, C
• Position control, see A, B, C
• See A, B, D, E
Cause Remedy
A Incorrect absolute encoder Check and correct the absolute encoder wiring.
trol], etc.
73
Cause Remedy
B Absolute encoder malfunc- For speed control (Cn-01 Bit 1 = 0), turn SEN
tioned. signal OFF and back ON.
For speed control (Cn-01 Bit 1 = 1) or position
control, turn servo amplifier power OFF and
back ON.
C Circuit board (1PWB) Replace servo amplifier
defective.
D Error occurred in absolute For speed control (Cn-01 Bit 1 = 0), turn SEN
encoder. signal OFF and back ON (if servo motor is
rotating, first turn servo OFF).
Another encoder alarm dis- For speed control (Cn-01 Bit 1 = 1) or position
played when SEN signal or control, turn servo amplifier power OFF and
power supply turned back back ON.
ON.
E Servo amplifier miscounted Separate encoder wiring from main wiring cir-
pulses (positional displace- cuits.
ment) or malfunctioned due For speed control (Cn-01 Bit 1 = 0), turn SEN
to noise. signal OFF and back ON (if servomotor is rotat-
ing, first turn servo OFF).
back ON.
Encoder Back-up Alarm [A.81]
Display and Outputs

Alarm Code
Output
A.81 ALO1 ALO2 ALO3
Encoder
Back-up
Error (only if
absolute
encoder
issued)
At power ON
• Speed Control and Cn-01 Bit 1 = 0, see B
74
• Speed Control and Cn-01 Bit 1 = 1, see A, C

• Position Control, see A, C
When SEN signal turned ON Cn-01 Bit 1 = 0
• See A, C
Cause Remedy
A The following power sup- Follow absolute encoder set-up procedures.
plied to the absolute
encoder all failed:
+5V supply
Battery (ER6V C3)
Internal capacitor
B Circuit board (1PWB) Replace servo amplifier.
defective.
C Absolute encoder malfunc- Replace servo amplifier.
tioned.
Encoder Checksum Error [A.82]
Display and Outputs

Alarm Code
Output
A.82 ALO1 ALO2 ALO3
Encoder
Check-sum
Error (only if
absolute
encoder is
used)
At power ON

• Speed Control and Cn-01 Bit 1 = 1, see A, B
• Position Control, see A, B
75
When SEN signal turned ON
• Cn-01 Bit 1 = 0, see A

• During operation (see note), see A
Cause Remedy
A Abnormality during abso- Follow absolute encoder set-up procedures.
lute encoder memory check. Replace servomotor if error occurs frequently.
defective.
Note: An absolute encoder error (A.80) is given initially if a check-sum error

(A.82) is generated during operation.
The check-sum error (A.82) occurs after turning the SEN signal (or servo
amplifier power supply) OFF and back ON.
However, the check-sum error (A.82) does occur during operation if the host
controller is receiving the S-phase signal (serial data).
Encoder Battery Alarm [A.83]
Display and Outputs

Alarm Code
Output
A.83 ALO1 ALO2 ALO3
Encoder
Battery Error
At power ON

76
• Cn-01 Bit 1 = 0, see A, B

• During operation (see note), see A, B
Cause Remedy
A Battery not connected. Check and correct battery connection.
Battery connection defec-
tive.
B Battery voltage below spec- Install new battery and turn SEN signal (or
ified value. servo amplifier) ON.
Specified values: 2.8V.
C Circuit board (1PWB) Replace servo amplifier.
defective.
Note: No alarm occurs at the servo amplifier when a battery error (A.83) is
generated. The battery error (A.83) occurs the next time the SEN signal (or
servo amplifier) turns ON. However, the battery error (A.83) can be read
during operation if the host controller is receiving the S-phase signal (serial
data).
Absolute Encoder Error [A.84]
Display and Outputs

Alarm Code
Output
A.84 ALO1 ALO2 ALO3
Encoder Data
Error (only if
absolute
encoder is
used)
At power ON

• Speed Control and Cn-01 Bit 1 = 1, see A
• Position Control, see A
77
• Cn-01 Bit 1 = 0, see A

Cause Remedy
A Absolute encoder malfunc- For speed control (Cn-01 Bit 1 = 0), turn SEN
control, turn amplifier power OFF and back ON.
Replace servomotor if error occurs frequently.
B Circuit board (1PWB) Replace amplifier.
defective.
Note: No alarm occurs at the servo amplifier when a data error (A.84) is generated.
The data error (A.84) occurs the next time the SEN signal (or servo
amplifier) turns ON. However, the data error (A.84) can be read during
operation if the host controller is receiving the S-phase signal (serial data).
Encoder Overspeed [A.85]
Display and Outputs

Alarm Code
Output
A.85 ALO1 ALO2 ALO3
Encoder
Overspeed
(only if abso-
lute encoder
is used)
At power ON

78
• Cn-01 Bit 1 = 0, see A
Cause Remedy
A Absolute encoder turned Turn ON encoder power supply (or SEN signal
ON at a speed exceeding or servo amplifier power supply) at a speed not
400rpm. exceeding 400rpm.
B Circuit (1PWB) defective. Replace servo amplifier.
Reference Input Read Error [A.B1]
Display and Outputs

Alarm Code
Output
A.B1 ALO1 ALO2 ALO3
Reference OFF OFF OFF OFF
Input Read
Error (for
speed/torque
control only)
At power ON
• See C
• See A, B
Cause Remedy
A Part malfunctioned in refer- Reset alarm and restart operation.
ence read-in unit (A/D con-
verter, etc.).
B Part defective in reference Replace servo amplifier.
read-in unit (A/D con-
verter, etc.).
defective.
79
Overrun [A.C1]
Display and Outputs

Alarm Code
Output
A.C1 ALO1 ALO2 ALO3
Servo ON OFF ON OFF
Overrun
At power ON
• User constant Cn-01 Bit 0= 0, see E
Occurred 1 to 3 seconds after power ON
• User constant Cn-01 Bit 0 = 1, see A, B, C, D, E
On speed reference input
Cause Remedy
A Servomotor wiring incor- Check wiring and connectors at servomotor.
B Encoder wiring incorrect or Check wiring and connectors at encoder.
disconnected.
C Incremental encoder power Use the servo amplifier power supply for the
amplifier.
D Encoder defective. Replace servomotor.
defective.
80
Phase Detection Error [A.C2]
Display and Outputs

Alarm Code
Output
A.C2 ALO1 ALO2 ALO3
Encoder ON OFF ON OFF
Phase Detec-
tion Error
At power ON
• See D
• See A, B, C, D
• See A, B, C, D,
Cause Remedy
A Noise in encoder wiring. Separate encoder wiring from main wiring cir-
cuits.
poor connection.
C Encoder defective. Replace servomotor.
D Circuit (1PWB) defective. Replace servo amplifier.
A-, B-Phase Disconnection [A.C3]
Display and Outputs

Alarm Code
Output
A.C3 ALO1 ALO2 ALO3
Encoder A-, ON OFF ON OFF
B-phase Dis-
connection
81
At power ON
• User constant Cn-01 Bit 0= 0, see D
• User constant Cn-01 Bit 0 = 1, see A, B, C
• See A, B, C, D
• See A, B, C, D
Cause Remedy
A Encoder wiring incorrect or Check wiring and connectors at encoder.
poor connection.
B Noise in encoder wiring. Separate encoder wiring from main wiring cir-
cuits.
C Encoder defective. Replace servomotor
defective.
C-Phase Disconnection [A.C4]
Display and Outputs

Alarm Code
Output
A.C4 ALO1 ALO2 ALO3
C-phase Dis-
connection
82
At power ON
• User constant Cn-01 Bit 0= 0, see C
• User constant Cn-01 Bit 0 = 1, see A, B, C, D
• See A, B, C, D
• See A, B, C, D
Cause Remedy
poor connection.
cuits.
defective.
Power Loss Alarm [A.F3]
Display and Outputs

Alarm Code
Output
A.F3 ALO1 ALO2 ALO3
Power Loss OFF ON OFF ON
Error
At power ON
• See A
83
• See B
Cause Remedy
A Time between turning After turning power OFF, wait more than the
power OFF and back ON power holding time (5 to 15s, according to type)
was shorter than the power before turning the power back ON.
holding time.
B If any of the following Check the power supply.
power supply conditions are
met during motor operation: Terms
Complete power failure: Complete power failure = Power failure where
half cycle of supply fre- voltage drops to zero
quency Voltage drop = Power failure where voltage
Voltage drop: full cycle of drops, but not to zero
supply frequency
Note: Because of detector
lag and detector margin,
power loss of 30 to 55ms
does not cause an alarm.
Digital Operator Display and Alarm Name [CPF00]
Display and Outputs

Alarm Code
Output
CPF00 ALO1 ALO2 ALO3
Digital Not Specified Not Specified Not Specified Not Specified
Operator
Transmission
Error 1
Note: This alarm is not stored in alarm traceback function memory.
At power ON
• Digital operator connected before servo amplifier power turned ON, see A, B,
C, D
Digital operator connected to servo amplifier while power turned ON.
84
• See A, B, C, D
Cause Remedy
A Cable defective or poor Check connector connections.
contact between digital Replace cable.
operator and servo ampli-
fier.
B Malfunction due to external Separate digital operator and cable from noise
noise. source.
Digital Operator Transmission Error [CPF01]
Display and Outputs

Alarm Code
Output
Operator
Transmission
Error 2
During operation
• See A, B, C, D
Cause Remedy
fier.
noise. source.
85
Normal Operation [A.--]*
Display and Outputs

Alarm Code
Output
A.99 ALO1 ALO2 ALO3
Normal OFF OFF OFF OFF
Operation
Indicates normal operation. Not an alarm.
*Both the hand-held operator and the operator panel display “A.99” rather than A.--
.
86
SGDB-***D
Display and Outputs

Alarm Code
Output
A.00 ALO1 ALO2 ALO3
Encoder Data
Error
At power ON
• Cn-01 Bit 1 = 0, see F

• Cn-01 Bit 1 = 1, see A, B, C, D, E, F
At SEN signal input
Cause Remedy
A Absolute encoder power not Use the servo amplifier power supply for the
supplied from the servo absolute encoder
amplifier.
SEN signal, etc.
C Absolute encoder malfunc- If Cn-01 bit 1 = 0, turn SEN signal OFF and
tioned. back ON (see note).
If Cn-01 bit 1 = 1, turn servo amplifier power
OFF and back ON.
Bit E set to 1.
tive.
defective.
87

Display and Outputs

Alarm Code
Output
A.02 ALO1 ALO2 ALO3
Breakdown
At power ON
• See A, B
Cause Remedy
writing parameters. Alarm
ON.
defective.
Display and Outputs

Alarm Code
Output
A.04 ALO1 ALO2 ALO3
Setting Error
88
At power ON
• See A, B
Cause Remedy
set.
defective.
Overcurrent [A.10]
Display and Outputs

Alarm Code
Output
A.10 ALO1 ALO2 ALO3
• See A, B, D
• See C, D
At power ON
• See C
Cause Remedy
motor.
89
Cause Remedy
B Servomotor U, V, or W Replace servomotor.
phase grounded.
defective.
D Current feedback circuit, Replace servo amplifier.
Regenerative Error Detection [A.30]
Display and Outputs

Alarm Code
Output
A.30 ALO1 ALO2 ALO3
Regenerative ON ON OFF OFF
Error
Detection
• See A, B
Occurred approximately 1 second after the main circuit power ON
• See A, B, C
Occurred when the control power turned ON
• See D
Cause Remedy
A Regenerative transistor is Replace servo amplifier.
abnormal.
B Disconnection of the regen- Replace servo amplifier or regenerative resistor
erative resistor unit. unit.
C Regenerative resistor unit Check wiring of the regenerative resistor unit.
disconnected (for more than
6.0kW).
90
Overvoltage [A.40]
Display and Outputs

Alarm Code
Output
A.40 ALO1 ALO2 ALO3
At power ON
• See A, B, C, D
Occurred approximately 0.6 seconds after the main circuit power turned ON
• See A, D
• See E
Cause Remedy
A The power supply voltage is Check power supply.
not within the range of
specifications.
B Load exceeds capacity of Check specifications of load inertia and over-
the regenerative unit. hanging load.
C Regenerative transistor is Replace servo amplifier.
abnormal.
D Rectifying diode defective. Replace servo amplifier.
Fuse blown.
Inrush current-limited resis-
tor disconnected.
E Servo amplifier defective. Replace servo amplifier.
91
Overspeed [A.51]
Display and Outputs

Alarm Code
Output
A.51 ALO1 ALO2 ALO3
• During high-speed servomotor rotation after reference input, see A, B, C, D, E
At power ON
• See E
Cause Remedy
amplifier.
cuits.
setting.
defective.
92
Overload (high load), [A.72] Overload (low load) [A.71]
Display and Outputs

Alarm Code
Output
A.71, A.72 ALO1 ALO2 ALO3
Overload ON ON ON OFF
(high load),
Overload
(low load)
At power ON
• See E
• See A, B, D

• During normal operation, see C, D
Cause Remedy
disconnected.
amplifier.
defective.
93
Display and Outputs

Alarm Code
Output
A.80 ALO1 ALO2 ALO3
Encoder Error
(only if abso-
lute encoder
is used)
At power ON
• Cn-01 Bit 1 = 0, see C

• Cn-01 Bit 1 = 1, see A, B, C
• See A, B, D, E
Cause Remedy
SEN signal, etc.).
B Absolute encoder malfunc- At Cn-01 Bit 1 = 0, turn SEN signal OFF and
tioned. back ON.
At Cn-01 Bit 1 = 1, turn servo amplifier power
OFF and back ON.
defective.
D Error occurred in absolute At Cn-01 Bit 1 = 0, turn SEN signal OFF and
encoder. back ON (if servo motor is rotating, first turn
servo OFF).
Another encoder alarm dis- At Cn-01 Bit 1 = 1, turn servo amplifier power
played when SEN signal or OFF and back ON.
power supply turned back
ON.
94
Cause Remedy
ment) or malfunctioned due At Cn-01 Bit 1 = 0, turn SEN signal OFF and
to noise. back ON (if servomotor is rotating, first turn
servo OFF).
OFF and back ON.
Display and Outputs

Alarm Code
Output
A.81 ALO1 ALO2 ALO3
Encoder
Back-up
Error (only if
absolute
encoder
issued)
At power ON

• See A, C
Cause Remedy
encoder all failed:
+5V supply
Battery (ER6V C3)
Internal capacitor
defective.
95
Cause Remedy
tioned.
Encoder Check-sum Error [A.82]
Display and Outputs

Alarm Code
Output
A.82 ALO1 ALO2 ALO3
Encoder
Check-sum
Error (only
when 12-bit
absolute
encoder is
used)
At power ON
• Cn-01 Bit 1 = 0, see B

• Cn-01 Bit 1 = 1, see A, B
• Cn-01 Bit 1 = 0, see A

Cause Remedy
defective.

96
Display and Outputs

Alarm Code
Output
A.83 ALO1 ALO2 ALO3
Encoder
Battery Error
At power ON
• Cn-01 Bit 1 = 0, see C

• Cn-01 Bit 1 = 1, see A, B
• Cn-01 Bit 1 = 0, see A, B

Cause Remedy
tive.
defective.
97
data).
Display and Outputs

Alarm Code
Output
A.84 ALO1 ALO2 ALO3
Encoder Data
Error (only if
absolute
encoder is
used)
At power ON
• Cn-01 Bit 1 = 0, see B

• Cn-01 Bit 1 = 1, see A
• Cn-01 Bit 1 = 0, see B

• During operation (see note), see B
Cause Remedy
A Absolute encoder malfunc- At Cn-01 Bit 1 = 0, turn SEN signal OFF and
tioned. then back ON.
At Cn-01 Bit 1 = 1, turn amplifier power OFF
then back ON.
B Circuit board (1PEB) defec- Replace amplifier.
tive.
generated. The data error (A.84) occurs the next time the SEN signal (or
servo amplifier) turns ON. However, the data error (A.84) can be read
98
data).
Display and Outputs

Alarm Code
Output
A.85 ALO1 ALO2 ALO3
Encoder
Overspeed
(only when
absolute
encoder is
used)
At power ON
• Cn-01 Bit 1 = 0, see B

• Cn-01 Bit 1 = 1, see A
• Cn-01 Bit 1 = 0, see A
Cause Remedy
Heat Sink Overheated [A.A1]
Display and Outputs

Alarm Code
Output
A.A1 ALO1 ALO2 ALO3
99
Display and Outputs

Alarm Code
Output
A.A1 Heat ON ON ON ON
Sink Over-
heated
• See A, B, C, D
• See E
Cause Remedy
A The ambient temperature of Alter conditions so that the ambient temperature
the amplifier exceeds 55°C. goes below 55°C.
B The air flow around the heat Follow installing method and provide sufficient
sink is bad. surrounding space as specified.
C Fan stopped. Replace amplifier.
D Amplifier is running under Reduce load.
overload.
E Amplifier defective. Replace amplifier.
Display and Outputs

Alarm Code
Output
A.B1 ALO1 ALO2 ALO3
Input Read
Error
100
At power ON
• See C
• See A, B
Cause Remedy
verter, etc.).
verter, etc.).
defective.
Overrun [A.C1]
Display and Outputs

Alarm Code
Output
A.C1 ALO1 ALO2 ALO3
Servo ON OFF ON OFF
Overrun
At power ON
101
Cause Remedy
disconnected.
amplifier.
defective.
Display and Outputs

Alarm Code
Output
A.C2 ALO1 ALO2 ALO3
Phase
Detection
Error
At power ON
• See D
• See A, B, C, D
102
• See A, B, C, D,
Cause Remedy
cuits.
poor connection.
Display and Outputs

Alarm Code
Output
A.C3 ALO1 ALO2 ALO3
B-phase Dis-
connection
At power ON
• See A, B, C, D
• See A, B, C, D
Cause Remedy
poor connection.
103
Cause Remedy
cuits.
defective.
Display and Outputs

Alarm Code
Output
A.C4 ALO1 ALO2 ALO3
Encoder C- ON OFF ON OFF
phase Discon-
nection
At power ON
• See A, B, C, D
• See A, B, C, D
Cause Remedy
poor connection.
cuits.
104
Cause Remedy
defective.
Open Power Phase [A.F1]
Display and Outputs

Alarm Code
Output
A.F1 ALO1 ALO2 ALO3
Power Line OFF ON OFF OFF
Open Phase
At main circuit power supply ON
• See A, B
• See C
Cause Remedy
A One phase (R, S, T) of the Check power supply.
main circuit power supply is Check wiring of the main circuit power supply.
disconnected. Check MCCB, noise filter, magnetic contactor.
B There is one phase where Check power supply.
the line voltage is low.
C Amplifier defective. Replace amplifier.
Display and Outputs

Alarm Code
Output
A.F3 ALO1 ALO2 ALO3
Error
105
• See A, B
• See A, C
Cause Remedy
A Although power loss alarm Set the user constant Cn-01 bit 5 to 0.
is not necessary, its user
constant is set valid.
B Time between turning After turning power OFF, wait for at least 0.5
power OFF and back ON seconds before turning the power back ON.
was shorter than 0.5 sec-
onds.
C If any of the following Check the power supply.
met during motor operation:
Complete power failure: Terms
half cycle of supply fre- Complete power failure = power failure where
quency. voltage drops to zero.
Voltage drop: full cycle of
supply frequency. Voltage drop = power failure where voltage
Note: Because of detector drops, but not to zero.
lag or detector margin, there
may be no alarm even if the
above values are exceeded.
Digital Operator Transmission Error 1 [CPF00]
Display and Outputs

Alarm Code
Output
Operator
Transmission
Error 1
106
At power ON
C, D
• See A, B, C, D
Cause Remedy
fier.
noise. source.
Display and Outputs

Alarm Code
Output
Operator
Transmission
Error 2
During operation
• See A, B, C, D
Cause Remedy
fier.
noise. source.
107
Normal Operation [A.--]
Display and Outputs

Alarm Code
Output
A.99 ALO1 ALO2 ALO3
Operation
.
108
SGDC-***SA
Display and Outputs

Alarm Code
Output
A.00 ALO1 ALO2 ALO3
Encoder Data
Error
At power ON
• Cn-01 Bit 1 = 0, see F

• Cn-01 Bit 1 = 1, see A, B, C, D, E, F
At SEN signal input
Cause Remedy
A Absolute encoder power not Use the servo amplifier power supply for the
supplied from the servo absolute encoder
amplifier.
SEN signal, etc.
C Absolute encoder malfunc- If Cn-01 bit 1 = 0, turn SEN signal OFF and
tioned. back ON (see note).
If Cn-01 bit 1 = 1, turn servo amplifier power
OFF and back ON.
Bit E set to 1.
tive.
defective.
109

Display and Outputs

Alarm Code
Output
A.02 ALO1 ALO2 ALO3
Breakdown
At power ON
• See A, B
Cause Remedy
writing parameters. Alarm
ON.
defective.
Display and Outputs

Alarm Code
Output
A.04 ALO1 ALO2 ALO3
Setting Error
110
At power ON
• See A, B
Cause Remedy
set.
defective.
Overcurrent [A.10]
Display and Outputs

Alarm Code
Output
A.10 ALO1 ALO2 ALO3
• See A, B, D
• See C, D
At power ON
• See C
Cause Remedy
motor.
111
Cause Remedy
phase grounded.
defective.
Overvoltage [A.40]
Display and Outputs

Alarm Code
Output
A.40 ALO1 ALO2 ALO3
At power ON
• See A, B, C
Occurred approximately 0.6 seconds after the main circuit power turned ON
• See A, C
• See D
Cause Remedy
A The power supply voltage is Check power supply.
specifications.
C Fuse blown. Replace servo amplifier.
112
Overspeed [A.51]
Display and Outputs

Alarm Code
Output
A.51 ALO1 ALO2 ALO3
• During high-speed servomotor rotation after reference input, see A, B, C, D, E
At power ON
• See E
Cause Remedy
amplifier.
cuits.
setting.
defective.
113
Overload (high load) [A.71], Overload (low load) [A.72]
Display and Outputs

Alarm Code
Output
A.71, A.72 ALO1 ALO2 ALO3
(high load),
Overload
(low load)
At power ON
• See E
• See A, B, D

• During normal operation, see C, D
Cause Remedy
disconnected.
amplifier.
defective.
114
Display and Outputs

Alarm Code
Output
A.80 ALO1 ALO2 ALO3
Encoder Error
(only if abso-
lute encoder
is used)
At power ON
• Cn-01 Bit 1 = 0, see C

• Cn-01 Bit 1 = 1, see A, B, C
• See A, B, D, E
Cause Remedy
SEN signal, etc.).
B Absolute encoder malfunc- At Cn-01 Bit 1 = 0, turn SEN signal OFF and
tioned. back ON.
OFF and back ON.
defective.
D Error occurred in absolute At Cn-01 Bit 1 = 0, turn SEN signal OFF and
encoder. back ON (if servo motor is rotating, first turn
servo OFF).
Another encoder alarm dis- At Cn-01 Bit 1 = 1, turn servo amplifier power
played when SEN signal or OFF and back ON.
power supply turned back
ON.
115
Cause Remedy
ment) or malfunctioned due At Cn-01 Bit 1 = 0, turn SEN signal OFF and
to noise. back ON (if servomotor is rotating, first turn
servo OFF).
OFF and back ON.
Display and Outputs

Alarm Code
Output
A.81 ALO1 ALO2 ALO3
Encoder
Back-up
Error (only if
absolute
encoder
issued)
At power ON

• See A, C
Cause Remedy
encoder all failed:
+5V supply
Battery (ER6V C3)
Internal capacitor
defective.
116
Cause Remedy
tioned.
Display and Outputs

Alarm Code
Output
A.82 ALO1 ALO2 ALO3
Encoder
Check-sum
Error (only
when 12-bit
absolute
encoder is
used)
At power ON
• Cn-01 Bit 1 = 0, see B

• Cn-01 Bit 1 = 1, see A, B
• Cn-01 Bit 1 = 0, see A

Cause Remedy
defective.

117
Display and Outputs

Alarm Code
Output
A.83 ALO1 ALO2 ALO3
Encoder
Battery Error
At power ON
• Cn-01 Bit 1 = 0, see C

• Cn-01 Bit 1 = 1, see A, B
• Cn-01 Bit 1 = 0, see A, B

Cause Remedy
A Battery not connected Check and correct battery connection.
tive.
defective.
118
data).
Display and Outputs

Alarm Code
Output
A.84 ALO1 ALO2 ALO3
Encoder Data
Error (only if
absolute
encoder is
used)
At power ON
• Cn-01 Bit 1 = 0, see B

• Cn-01 Bit 1 = 1, see A
• Cn-01 Bit 1 = 0, see B

• During operation (see note), see B
Cause Remedy
A Absolute encoder malfunc- At Cn-01 Bit 1 = 0, turn SEN signal OFF and
tioned. then back ON.
At Cn-01 Bit 1 = 1, turn amplifier power OFF
then back ON.
B Circuit board (1PEB) defec- Replace amplifier.
tive.
119
Display and Outputs

Alarm Code
Output
A.85 ALO1 ALO2 ALO3
Encoder
Overspeed
(only when
absolute
encoder is
used)
At power ON
• Cn-01 Bit 1 = 0, see B

• Cn-01 Bit 1 = 1, see A
• Cn-01 Bit 1 = 0, see A
Cause Remedy
Heat Sink Overheated [A.A1]
Display and Outputs

Alarm Code
Output
A.A1 ALO1 ALO2 ALO3
120
Display and Outputs

Alarm Code
Output
Heat Sink ON ON ON ON
Overheated
• See A, B, C, D
• See E
Cause Remedy
B The air flow around the heat Follow installing method and provide sufficient
sink is bad. surrounding space as specified.
D Amplifier is running under Reduce load.
overload.
Display and Outputs

Alarm Code
Output
A.B1 ALO1 ALO2 ALO3
Input Read
Error
121
At power ON
• See C
• See A, B
Cause Remedy
verter, etc.).
verter, etc.).
defective.
Overrun [A.C1]
Display and Outputs

Alarm Code
Output
A.C1 ALO1 ALO2 ALO3
Servo ON OFF ON OFF
Overrun
At power ON
122
Cause Remedy
disconnected.
amplifier.
defective.
Display and Outputs

Alarm Code
Output
A.C2 ALO1 ALO2 ALO3
Phase
Detection
Error
At power ON
• See D
• See A, B, C, D
• See A, B, C, D,
Cause Remedy
cuits.
123
Cause Remedy
poor connection.
Display and Outputs

Alarm Code
Output
A.C3 ALO1 ALO2 ALO3
B-phase Dis-
connection
At power ON
• See A, B, C, D
• See A, B, C, D
Cause Remedy
poor connection.
cuits.
defective.
124
Display and Outputs

Alarm Code
Output
A.C4 ALO1 ALO2 ALO3
phase Discon-
nection
At power ON
• See A, B, C, D
• See A, B, C, D
Cause Remedy
poor connection.
cuits.
defective.
125
Converter Error [A.F4]
Display and Outputs

Alarm Code
Output
A.F3 ALO1 ALO2 ALO3
Error
• See D, E, F
• See A, B, C
• See H
Occurred approximately 1 second after the main circuit power ON
• See E, F, G
Cause Remedy
A One phase (L1, L2, L3) of Check power supply.
the main circuit power sup- Check wiring of the main circuit power supply.
ply is disconnected. Check MCCB, noise filter, magnetic contactor.
B There is one phase where Check power supply.
126
Cause Remedy
C If any of the following Check the power supply.
met during motor operation:
Complete power failure: Terms
half cycle of supply fre- Complete power failure = power failure where
quency. voltage drops to zero.
Voltage drop: full cycle of
supply frequency. Voltage drop = power failure where voltage
Note: Because of detector drops, but not to zero.
lag or detector margin, there
may be no alarm even if the
above values are exceeded.
D The power supply voltage is Check power supply.
specifications.
E Rectifying diode defective. Replace converter.
Fuse blown.
Inrush current-limited resis-
tor disconnected.
Regenerative transistor is
abnormal.
F Disconnection of the regen- Replace converter or regenerative resistor unit.
erative resistor unit.
G Regenerative resistor unit Check wiring of regenerative resistor unit.
disconnected (for more than
15 type).
H Converter defective. Replace converter
Display and Outputs

Alarm Code
Output
Operator
Transmission
Error 1
At power ON
C, D
127
• See A, B, C, D
Cause Remedy
fier.
noise. source.
Display and Outputs

Alarm Code
Output
Operator
Transmission
Error 2
During operation
• See A, B, C, D
Cause Remedy
fier.
noise. source.
128
Display and Outputs

Alarm Code
Output
A.99 ALO1 ALO2 ALO3
Operation
.
129
DR2-*** / DR2-****-F
Display and Outputs

Alarm Code
Output
A.00 ALO1 ALO2 ALO3
Encoder Data
Error
At power ON
• Speed Control and Cn-01 Bit 1 = 0, see F

• Speed Control and Cn-01 Bit 1 = 1, see A, B, C, D, E, F
At SEN signal input
Cause Remedy
A Absolute encoder power not Use the amplifier power supply for the absolute
supplied from the amplifier. encoder
trol], etc.
C Absolute encoder malfunc- Speed control (Cn-01 bit 1 = 0), Turn SEN sig-
tioned. nal OFF and back ON (see note).
Speed Control (Cn-01 bit 1 = 1) or position con-
trol turn amplifier power OFF and back ON.
Bit E set to 1.
tive.
defective.
130

Display and Outputs

Alarm Code
Output
A.02 ALO1 ALO2 ALO3
Breakdown
At power ON
• See A, B
Cause Remedy
saving parameters. Alarm
ON.
defective.
Display and Outputs

Alarm Code
Output
A.04 ALO1 ALO2 ALO3
Setting Error
131
At power ON
• See A, B
Cause Remedy
set.
defective.
Overcurrent [A.10]
Display and Outputs

Alarm Code
Output
A.10 ALO1 ALO2 ALO3
Note: Alarm A10 is reset when the power is turned OFF and back ON. It is not
reset by the normal alarm reset.
• See D, E
At main circuit power ON
• See D
Cause Remedy
motor.
132
Cause Remedy
phase grounded.
defective.
Fuse Blown [A.20]
Display and Outputs

Alarm Code
Output
A.20 ALO1 ALO2 ALO3
Fuse Blown OFF ON OFF OFF
At control power ON
• See A
• See B, C
Cause Remedy
A Circuit board (1PWB) Replace servo amplifier.
defective.
B Fuse is blown, Replace servo amplifier.
C Main circuit diode module Replace servo amplifier.
defective.
133
Display and Outputs

Alarm Code
Output
A.31 ALO1 ALO2 ALO3
Pulse Over-
flow (posi-
tion control
only)

At control power ON
• See F
Cause Remedy
defective.
134
Overvoltage [A.40]
Display and Outputs

Alarm Code
Output
A.40 ALO1 ALO2 ALO3
• See E
At control power ON
• See F

Cause Remedy
speed too high. Use regenerative resistor or regenerative unit.
regenerative unit.
defective.
Overspeed [A.51]
Display and Outputs

Alarm Code
Output
A.51 ALO1 ALO2 ALO3
135
Display and Outputs

Alarm Code
Output
110% maximum speed), see A, B, C, D, E
At power ON
• See E
Cause Remedy
amplifier.
cuits.
setting.
defective.
Display and Outputs

Alarm Code
Output
A.70 ALO1 ALO2 ALO3
136
Display and Outputs

Alarm Code
Output
Absolute ON ON ON OFF
Encoder Data
Error
At power ON
• See E
• See A, B, D

Cause Remedy
disconnected.
amplifier.
defective.
Display and Outputs

Alarm Code
Output
A.80 ALO1 ALO2 ALO3
137
Display and Outputs

Alarm Code
Output
Encoder Error
(only if abso-
lute encoder
is used)
At control power ON

• Speed Control and Cn-01 Bit 1 = 1, see A, B, C
• See A, B, D, E
Cause Remedy
trol], etc.
B Absolute encoder malfunc- For speed control (Cn-01 Bit 1 = 0), turn SEN
back ON.
defective.
D Error occurred in absolute For speed control (Cn-01 Bit 1 = 0), turn SEN
encoder. signal OFF and back ON (if servo motor is
rotating, first turn servo OFF).
Another encoder alarm dis- For speed control (Cn-01 Bit 1 = 1) or position
played when SEN signal or control, turn servo amplifier power OFF and
power supply turned back back ON.
ON.
138
Cause Remedy
ment) or malfunctioned due For speed control (Cn-01 Bit 1 = 0), turn SEN
to noise. signal OFF and back ON (if servomotor is rotat-
ing, first turn servo OFF).
When Cn-01 Bit 1 = 1, turn servo amplifier
power OFF and back ON.
Display and Outputs

Alarm Code
Output
A.81 ALO1 ALO2 ALO3
Encoder
Back-up
Error (only if
absolute
encoder
issued)
At power ON

• See A, C
Cause Remedy
encoder all failed:
+5V supply
Battery (ER6V C3)
Internal capacitor
defective.
139
Cause Remedy
tioned.
Display and Outputs

Alarm Code
Output
A.82 ALO1 ALO2 ALO3
Encoder
Check-sum
Error (only if
absolute
encoder is
used)
At Control power ON

• Cn-01 Bit 1 = 0, see A

Cause Remedy
defective.

140
Display and Outputs

Alarm Code
Output
A.83 ALO1 ALO2 ALO3
Encoder
Battery Error
At power ON

• Cn-01 Bit 1 = 0, see A, B

Cause Remedy
A Battery not connected Check and correct battery connection.
tive.
defective.
data).
141
Display and Outputs

Alarm Code
Output
A.84 ALO1 ALO2 ALO3
Encoder Data
Error (only if
absolute
encoder is
used)
At power ON

• Cn-01 Bit 1 = 0, see A

Cause Remedy
A Absolute encoder malfunc- For speed control (Cn-01 Bit 1 = 0), turn SEN
control, turn amplifier power OFF and back ON.
defective.
142
Display and Outputs

Alarm Code
Output
A.85 ALO1 ALO2 ALO3
Encoder
Overspeed
(only if abso-
lute encoder
is used)
At control power ON

• Cn-01 Bit 1 = 0, see A
Cause Remedy
Display and Outputs

Alarm Code
Output
A.B1 ALO1 ALO2 ALO3
143
Display and Outputs

Alarm Code
Output
Input Read
Error (for
speed/torque
control only)
At control power ON
• See C
• See A, B
Cause Remedy
verter, etc.).
verter, etc.).
defective.
Overrun [A.C1]
Display and Outputs

Alarm Code
Output
A.C1 ALO1 ALO2 ALO3
Servo ON OFF ON OFF
Overrun
144
At control power ON
Cause Remedy
disconnected.
amplifier.
D Encoder defective Replace servomotor.
defective.
Display and Outputs

Alarm Code
Output
A.C2 ALO1 ALO2 ALO3
Phase Detec-
tion Error
Incremental
Encoder
Initial Pulse
Error
145
• See A, B, C
At control power ON
• See D, E, F, G, H
• See E, F, G
• See H,
Cause Remedy
cuits.
poor connection.
C Encoder defective Replace servomotor.
D Noise in encoder wiring. Separate encoder wiring from main wiring cir-
cuits.
E Encoder wiring incorrect or Check wiring and connectors at encoder.
poor connection.
F Encoder defective. Replace servomotor
G Absolute encoder is used. Set the following user parameters:
Cn-02 bit 9 = 1
Cn-11 (number of encoder pulses)
A-, B-Phase Disconnection [A.C3], External PG A-, B-phase disconnection [A.C6]
Display and Outputs

Alarm Code
Output
A.C3 / A.C6 ALO1 ALO2 ALO3
146
Display and Outputs

Alarm Code
Output
A.C3: ON OFF ON OFF
Encoder A-,
B-phase Dis-
connection
A.C6:
External PG
A-, B-phase
Disconnec-
tion (only for
full-closed
loop specifi-
cation)
At control power ON
• See A, B, C, D
• See A, B, C, D
Cause Remedy
poor connection.
cuits.
defective.
147
C-Phase Disconnection, [A.C7] External PG C-phase disconnection [A.C4]
Display and Outputs

Alarm Code
Output
A.C4 / A.C7 ALO1 ALO2 ALO3
A.C4: ON OFF ON OFF
Encoder C-
phase Discon-
nection
A.C7:
External PG
C-phase Dis-
connection
(only for full-
closed loop
specification)
• See A, B, C, D
• See A, B, C, D
Cause Remedy
poor connection.
cuits.
148
Cause Remedy
defective.
Display and Outputs

Alarm Code
Output
Operator
Transmission
Error 1
At control power ON
C, D
• See A, B, C, D
Cause Remedy
fier.
noise. source.
Display and Outputs

Alarm Code
Output
149
Display and Outputs

Alarm Code
Output
Operator
Transmission
Error 2
During operation
• See A, B, C, D
Cause Remedy
fier.
noise. source.
Display and Outputs

Alarm Code
Output
A.99 ALO1 ALO2 ALO3
Operation
.
150
SGDE-***S / SGDL-***S
Display and Outputs

Alarm Name Alarm Output ALM Output
A.02
Parameter OFF OFF
Breakdown
At power ON
• See A, B
Cause Remedy
A Power turned OFF during Replace amplifier
parameter write. Alarm
ON.
defective.
Display and Outputs

A.04
Parameter OFF OFF
Setting Error
At power ON
151
• See A, B
Cause Remedy
set.
defective.
Overcurrent [A.10]
Display and Outputs

A.10
Overcurrent OFF OFF
• See D, E
At power ON
• See D
Cause Remedy
motor.
phase grounded.
defective.
152
Cause Remedy
Display and Outputs

A.31
Position Error OFF OFF
Pulse Overflow

At power ON
• See F
Cause Remedy
defective.
153
Overvoltage [A.40]
Display and Outputs

A.40
Overvoltage OFF OFF
At power ON
• See E, F

Cause Remedy
nals in parallel.
regenerative unit.
defective.
Overspeed [A.51]
Display and Outputs

A.51
Overspeed OFF OFF
154
• See A, B, C, D
110% maximum speed), see A, B, C, D
At power ON
• See D
Cause Remedy
amplifier.
cuits.
D Circuit board (1PWB) Replace amplifier.
defective.
Overload [A.70]
Display and Outputs

A.70
Overload OFF OFF
At power ON
• See E
155
• See A, B, D
When position reference input

Cause Remedy
disconnected.
amplifier.
defective.
Overrun [A.C1]
Display and Outputs

A.C1
Servo OFF OFF
Overrun
At power ON
On position reference input
156
Cause Remedy
disconnected.
amplifier.
defective.
Display and Outputs

A.C2
Encoder OFF OFF
Phase
Detection
Error
At power ON
• See D
• See A, B, C, D
157
• See A, B, C, D,
Cause Remedy
cuits.
poor connection.
Display and Outputs

A.C3
Encoder A-, B- OFF OFF
Phase
Disconnection
At power ON
• See A, B, C, D
• See A, B, C, D
Cause Remedy
poor connection.
B Noise in encoder wiring. Separate encoder wiring from main wiring
circuits.
158
Cause Remedy
defective.
Display and Outputs

A.C4
Encoder C-phase OFF OFF
Disconnection
At power ON
• See A, B, C, D
• See A, B, C, D
Cause Remedy
poor connection.
cuits.
defective.
159
Display and Outputs

A.F3
Power Loss OFF ON
Error
At power ON
• See A
• See B
Cause Remedy
holding time.
quency. Voltage drop = Power failure where voltage
supply frequency
Display and Outputs

CPF00
160
Display and Outputs

Digital Operator Not Specified Not Specified
Transmission Error 1
At power ON
C, D
• See A, B, C, D
Cause Remedy
fier.
noise. source.
Display and Outputs

CPF01
Digital Operator Not Specified Not Specified
Transmission Error
2
During operation
161
• See A, B, C, D
Cause Remedy
fier.
noise. source.
Display and Outputs

A.99
Normal Operation OFF OFF
.
162
SDGE-****P / SDGL-****P
Display and Outputs

Alarm Code
Output
A.02 ALO1 ALO2 ALO3
Breakdown
At power ON
• See A, B
Cause Remedy
ON.
defective.
Display and Outputs

Alarm Code
Output
A.04 ALO1 ALO2 ALO3
Setting Error
At power ON
163
• See A, B
Cause Remedy
set.
defective.
Overcurrent [A.10]
Display and Outputs

Alarm Code
Output
A.10 ALO1 ALO2 ALO3
• See D, E
At power ON
• See D
Cause Remedy
motor.
phase grounded.
164
Cause Remedy
defective.
Overvoltage [A.40]
Display and Outputs

Alarm Code
Output
A.40 ALO1 ALO2 ALO3
At power ON
• See E, F

Cause Remedy
nals in parallel.
regenerative unit.
defective.
165
Overspeed [A.51]
Display and Outputs

Alarm Code
Output
A.51 ALO1 ALO2 ALO3
• See A, B, C, D
At power ON
• See D
Cause Remedy
amplifier.
cuits.
setting.
Overload [A.70]
Display and Outputs

Alarm Code
Output
A.70 ALO1 ALO2 ALO3
166
Display and Outputs

Alarm Code
Output
At power ON
• See E
• See A, B, D
When position reference input

Cause Remedy
disconnected.
amplifier.
defective.
Display and Outputs

Alarm Code
Output
A.B1 ALO1 ALO2 ALO3
167
Display and Outputs

Alarm Code
Output
Input Read
Error (for
speed/torque
control only)
At power ON
• See C
• See A, B
Cause Remedy
verter, etc.).
verter, etc.).
defective.
Overrun [A.C1]
Display and Outputs

Alarm Code
Output
A.C1 ALO1 ALO2 ALO3
Servo overrun ON OFF ON OFF
168
At power ON
Cause Remedy
disconnected.
amplifier.
defective.
Display and Outputs

Alarm Code
Output
A.C2 ALO1 ALO2 ALO3
Phase Detec-
tion Error
At power ON
169
• See D
• See A, B, C, D
• See A, B, C, D,
Cause Remedy
cuits.
poor connection.
Display and Outputs

Alarm Code
Output
A.C3 ALO1 ALO2 ALO3
B-phase Dis-
connection
At power ON
• See A, B, C, D
170
• See A, B, C, D
Cause Remedy
poor connection.
cuits.
defective.
Display and Outputs

Alarm Code
Output
A.C4 ALO1 ALO2 ALO3
phase Discon-
nection
At power ON
• See A, B, C, D
171
• See A, B, C, D
Cause Remedy
poor connection.
cuits.
defective.
Display and Outputs

Alarm Code
Output
A.F3 ALO1 ALO2 ALO3
Error
At power ON
• See A
• See B
Cause Remedy
holding time.
172
Cause Remedy
quency Voltage drop = Power failure where voltage
supply frequency
Display and Outputs

Alarm Code
Output
Operator
Transmission
Error 1
At power ON
C, D
• See A, B, C, D
Cause Remedy
fier.
noise. source.
173
Display and Outputs

Alarm Code
Output
Operator
Transmission
Error 2
During operation
• See A, B, C, D
Cause Remedy
fier.
noise. source.
Display and Outputs

Alarm Code
Output
A.99 ALO1 ALO2 ALO3
Normal Oper- OFF OFF OFF OFF
ation
174
.
175
SGDF-***S / SGDF-***S
Display and Outputs

Alarm Code
Output
A.02 ALO1 ALO2 ALO3
Breakdown
At power ON
• See A, B
Cause Remedy
ON.
defective.
Display and Outputs

Alarm Code
Output
A.04 ALO1 ALO2 ALO3
Setting Error
At power ON
176
• See A, B
Cause Remedy
set.
defective.
Overcurrent [A.10]
Display and Outputs

Alarm Code
Output
A.10 ALO1 ALO2 ALO3
• See A, B, C, D
• See C, D
At power ON
• See C
Cause Remedy
motor.
phase grounded.
defective.
power transistor, or circuit
board defective.
177
Display and Outputs

Alarm Code
Output
A.31 ALO1 ALO2 ALO3
Position Error OFF OFF ON OFF
Pulse
Overflow
At power ON
• See F

Cause Remedy
rect. phase pulses correct at CN2.)
(disconnection, short cir- phase pulses correct at CN2.)
defective.
178
Overspeed [A.51]
Display and Outputs

Alarm Code
Output
A.51 ALO1 ALO2 ALO3
• See A, B, C, D
At power ON
• See D
Cause Remedy
rect. phase pulses correct at CN2.)
amplifier.
cuits.
defective.
Overload [A.70]
Display and Outputs

Alarm Code
Output
A.70 ALO1 ALO2 ALO3
179
At power ON
• See E
• See A, B, D
When speed reference is input

Cause Remedy
disconnected.
amplifier.
defective.
Display and Outputs

Alarm Code
Output
A.80 ALO1 ALO2 ALO3
Encoder Error OFF OFF OFF OFF
180
At power ON
• See B, D
• See A, B, C
Cause Remedy
A Servo amplifier miscounted Separate encoder wiring from main wiring cir-
pulses or malfunctioned due cuits turn ON amplifier power again.
to noise.
B Incorrect encoder wiring or Check the encoder wiring and connectors at
poor connection. encoder.
C Encoder malfunctioned. Replace amplifier.
defective.
Display and Outputs

Alarm Code
Output
A.B1 ALO1 ALO2 ALO3
Input Read
Error (for
speed/torque
control only)
At power ON
• See C
181
• See A, B
Cause Remedy
verter, etc.).
verter, etc.).
defective.
Overrun [A.C1]
Display and Outputs

Alarm Code
Output
A.C1 ALO1 ALO2 ALO3
Servo ON OFF ON OFF
Overrun
At power ON
Cause Remedy
182
Cause Remedy
disconnected.
amplifier.
defective.
Display and Outputs

Alarm Code
Output
A.C2 ALO1 ALO2 ALO3
Phase Detec-
tion Error
At power ON
• See D
• See A, B, C, D
• See A, B, C, D,
Cause Remedy
cuits.
poor connection.
183
Display and Outputs

Alarm Code
Output
A.C3 ALO1 ALO2 ALO3
B-phase Dis-
connection
At power ON
• See A, B, C, D
• See A, B, C, D
Cause Remedy
poor connection.
cuits.
defective.
184
Display and Outputs

Alarm Code
Output
A.C4 ALO1 ALO2 ALO3
phase Discon-
nection
At power ON
• See A, B, C, D
• See A, B, C, D
Cause Remedy
poor connection.
cuits.
defective.
185
Display and Outputs

Alarm Code
Output
A.99 ALO1 ALO2 ALO3
Operation
.
186
SGDM-***D / SGDM-***DA / SGDH-***E
Display and Outputs

Alarm Code
Output
A.02 ALO1 ALO2 ALO3
Breakdown
At power ON
• See A, B
Cause Remedy
A Power turned OFF during Initialize parameters using Fn005 and re-input
parameter write. Alarm user settings.
occurred at the next power Replace amplifier.
ON.
defective.
Main Circuit Encoder Error [A.03]
Display and Outputs

Alarm Code
Output
A.03 ALO1 ALO2 ALO3
Main Circuit OFF OFF OFF OFF
Encoder Error
At power ON
187
• See A
Cause Remedy
A Circuit board (1PWB or Replace amplifier.
2PWB) defective.
Display and Outputs

Alarm Code
Output
A.04 ALO1 ALO2 ALO3
Setting Error
At power ON
• See A, B
Cause Remedy
A An out-of-range parameter Reset all parameters in range.
was previously set or Otherwise, re-load correct parameter.
loaded.
defective.
Combination Error [A.05]
Display and Outputs

Alarm Code
Output
A.05 ALO1 ALO2 ALO3
Combination OFF OFF OFF OFF
Error
188
At power ON
• See A, B
Cause Remedy
A The range of the servomotor Replace the servomotor so that a suitable com-
capacities that can be combination is achieved.
bined has been exceeded.
B Encoder parameters have Replace the servomotor.
not been written properly.
Overcurrent or Heat Sink Overheated [A.10]
Display and Outputs

Alarm Code
Output
A.10 ALO1 ALO2 ALO3
• See A, B, D, E, F, G, H
• See C, D
At power ON
• See C
Cause Remedy
A Wiring shorted between Check and correct wiring.
motor.
phase shorted.
189
Cause Remedy
defective.
power transistor, DB circuit,
E The ambient temperature of Alter conditions so that the ambient temperature
the amplifier exceeded falls below 55°C.
55°C.
F The air flow around the heat Follow the installation method and provide suf-
sink is bad. ficient space as specified.
G Fan stopped. Replace amplifier.
H Amplifier is operating Reduce load.
under an overload.
Note: E to H can occur with a 1.5kW to 3kW capacity amplifier.
Regenerative Error Detected [A.30]
Display and Outputs

Alarm Code
Output
A.30 ALO1 ALO2 ALO3
Error
Detected
• See A, B
• See D
Occurred approximately 1 second after the main circuit power ON.
190
• See A, B, C
Cause Remedy
A Regenerative transistor is Replace amplifier.
abnormal.
B Disconnection of the regen- Replace amplifier or regenerative resistor.
erative resistor.
C Regenerative unit discon- Check wiring of the external regenerative resis-
nected (for an external tor.
regenerative resistor).
D Amplifier defective. Replace amplifier.
Regenerative Overload [A.32]
Display and Outputs

Alarm Code
Output
A.32 ALO1 ALO2 ALO3
Overload
• See A, B
Cause Remedy
A Regenerative power Use an external regenerative resistor that
exceeds the allowable matches the regenerative power capacity.
value.
B Alarm occurs although an Correct parameter Pn600.
external regenerative resis-
tor is used and the tempera-
ture rise of the regenerative
resistor is small.
191
Main Circuit DC Voltage Error Detected: Overvoltage [A.40]
Display and Outputs

Alarm Code
Output
A.40 ALO1 ALO2 ALO3
• See A, B, C, D
Occurred when main circuit power turned ON
• See A, D
• See E
Cause Remedy
A The power supply voltage is Check the power supply.
specifications.
C Regenerative transistor is Replace amplifier.
abnormal.
D Rectifying diode defective. Replace amplifier.
Main Circuit Voltage Error Detected: Undervoltage [A.41]
Display and Outputs

Alarm Code
Output
A.41 ALO1 ALO2 ALO3
Undervoltage OFF OFF ON OFF
192
• See A, B, C
Occurred when main circuit power turned ON
• See A, B, C
• See D
Cause Remedy
A The power supply voltage is Check the power supply.
specifications.
B Fuse blown. Replace amplifier.
C Rectifying diode defective. Replace amplifier.
Overspeed [A.51]
Display and Outputs

Alarm Code
Output
A.51 ALO1 ALO2 ALO3
• See A
• During high-speed servomotor rotation after reference input, see B, C
193
At power ON
• See D
Cause Remedy
A Servomotor wiring incor- Check and correct wiring. (Check for U-, V-,
rect. and W-phase wiring errors.)
B Position or speed reference Lower the reference input values.
input is too large.
C Incorrect reference input Check and correct parameter settings.
gain settings.
defective.
Overload: High Load [A.71] and Overload: Low Load [A.72]
Display and Outputs

Alarm Code
Output
A.71 and ALO1 ALO2 ALO3
A.72
Overload: ON ON ON OFF
High and
Overload:
Low
At power ON
• See C
• See A
When speed reference is input
• No servomotor rotation, see B
194
• During normal operation, see B
Cause Remedy
B Load greatly exceeds rated Reduce load torque and inertia. Otherwise,
C Circuit board (1PWB) Replace amplifier.
defective.
Dynamic Brake Overload [A.73]
Display and Outputs

Alarm Code
Output
A.73 ALO1 ALO2 ALO3
Dynamic ON ON ON OFF
Brake
Overload
At power ON
• See B
When servo OFF signal turned ON
• See A
Cause Remedy
A The product of the square of Lower the rotational speed.
rotational motor speed and Lower the load inertia.
the combined inertia of the Minimize the use of the dynamic brake.
motor and load (rotation
energy) exceeds the capac-
ity of the dynamic brake
resistor built into the ampli-
fier.
defective.
195
Overload of Surge Current Limit Resistor [A.74]
Display and Outputs

Alarm Code
Output
A.74 ALO1 ALO2 ALO3
Overload of ON ON ON OFF
Surge
Current Limit
Resistor
At power ON
• See B
When main circuit power turned ON or OFF
• See A
Cause Remedy
A Frequently turning the main Do not repeatedly turn ON/OFF the main circuit
circuit power ON/OFF. power.
defective.
Heat Sink Overheated [A.7A]
Display and Outputs

Alarm Code
Output
A.7A ALO1 ALO2 ALO3
Heat Sink ON ON ON OFF
Overheated
196
• See A, B, C, D
When control power turned ON
• See E
Cause Remedy
B The air flow around the heat Follow installation methods and provide suffi-
sink is insufficient. cient space.
D Amplifier is operating Reduce load.
under overload.
Note: This alarm display tends to occur only with a 30W to 1000W amplifier.
Absolute Encoder Back-up Error [A.81]
Display and Outputs

Alarm Code
Output
A.81 ALO1 ALO2 ALO3
Encoder
Back-up
Error
At power ON
• Pn002.2 = 0 or 2, see A, B, C
197
• Pn002.2 = 1, see C
Cause Remedy
A The following power sup- Follow absolute encoder set-up procedure.
plies to the absolute encoder
all failed:
• +5V supply
• Battery power
B Absolute encoder malfunc- Replace servomotor.
tioned.
defective.
Display and Outputs

Alarm Code
Output
A.82 ALO1 ALO2 ALO3
Encoder OFF OFF OFF OFF
Checksum
Error
At power ON
• See A, B
When SEN signal turned ON; pn002.2 = 0 or 2
• See A
During operation
• See A, B
Cause Remedy
A Error during encoder mem- Follow absolute encoder set-up procedure.
ory check. Replace servomotor if error occurs frequently.
defective.
198
Absolute Encoder Battery Error [A.83]
Display and Outputs

Alarm Code
Output
A.83 ALO1 ALO2 ALO3
Encoder
Battery Error
At power ON
• Pn002.2 = 0 or 2, see A, B, C
• Pn002.2 = 1, see C
Cause Remedy
tive.
B Battery voltage below spec- Install a new battery while the control power to
ified value ( 2.7V). amplifier is ON. After replacement, turn ON
the power again.
defective.
Note: No alarm occurs at the amplifier if the battery error occurs during operation.
Display and Outputs

Alarm Code
Output
A.84 ALO1 ALO2 ALO3
Encoder
Data Error
199
At power ON
• See A
During operation
• See B
Cause Remedy
A Faulty encoder. Replace the servomotor if the problem occurs
often.
B Operational error in encoder Check and correct wiring around the encoder
caused by external noise. (grounding of the servomotor, separation
between the encoder cable and the servomotor
power cable, insertion of toroidal cores onto
cables, etc.)
Absolute Encoder Overspeed [A.85]
Display and Outputs

Alarm Code
Output
A.85 ALO1 ALO2 ALO3
Encoder
Overspeed
At power ON
• See A, B
Cause Remedy
A Absolute encoder turned Turn ON power supply with the servomotor
ON at a speed exceeding stopped.
200rpm.
200
Cause Remedy
defective.
Encoder Overheated [A.86]
Display and Outputs

Alarm Code
Output
A.86 ALO1 ALO2 ALO3
Encoder OFF OFF OFF OFF
Overheated
• See A, B
Occurred when the control power turned ON.
• See C, D
Cause Remedy
the servomotor is high. falls below 40°C.
B Servomotor is operating Reduce load.
under overload.
defective.
D Encoder defective. Replace amplifier.
Reference Speed Input Read Error [A.b1]
Display and Outputs

Alarm Code
Output
A.b1 ALO1 ALO2 ALO3
Speed Input
Read Error
201
At power ON
• See C
• See A, B
Cause Remedy
A Error in reference read-in Reset alarm and restart operation.
unit (e.g., A/D converter).
B Reference read-in unit Replace amplifier.
faulty (e.g., A/D converter).
defective.
Reference Torque Input Read Error [A.b2]
Display and Outputs

Alarm Code
Output
A.b2 ALO1 ALO2 ALO3
Torque Input
Read Error
At power ON
• See C
202
• See A, B
Cause Remedy
A Error in reference read-in Reset alarm and restart operation.
unit (e.g., A/D converter).
B Reference read-in unit Replace amplifier.
faulty (e.g., A/D converter).
defective.
Servo Overrun [A.C1]
Display and Outputs

Alarm Code
Output
A.C1 ALO1 ALO2 ALO3
Servo ON OFF ON OFF
Overrun
At power ON
• Parameter Pn50A.1 = 7, see D
• See A, B, C, D
When servo ON (/S-ON) signal turned ON
• See A, B, C, D
• See A, B, C
Cause Remedy
disconnected.
203
Cause Remedy
defective.
Absolute Encoder Clear Error and Multi-turn Limit Setting Error [A.C8]
Display and Outputs

Alarm Code
Output
A.C8 ALO1 ALO2 ALO3
Absolute ON OFF ON OFF
Encoder
Clear Error
and Multi-
turn Limit
Setting Error
At power ON
• See A, B
When resetting multi-turn clear encoder alarm
• See A, B
Cause Remedy
B Amplifier defective. Replace amplifier.
Encoder Communications Error [A.C9]
Display and Outputs

Alarm Code
Output
A.C9 ALO1 ALO2 ALO3
Communica-
tions Error
204
At power ON
• See A, B, C
• See A, B, C
Cause Remedy
disconnected.
B Encoder defective. Replace servomotor.
Encoder Parameter Error [A.CA]
Display and Outputs

Alarm Code
Output
A.CA ALO1 ALO2 ALO3
Parameter
Error
At power ON
• See A, B
Cause Remedy
B Amplifier defective. Replace amplifier.
205
Encoder Echoback Error [A.Cb]
Display and Outputs

Alarm Code
Output
A.Cb ALO1 ALO2 ALO3
Echoback
Error
At power ON
• See A, B, C
Cause Remedy
disconnected.
B Encoder defective. Replace servomotor.
Multi-turn Limit Disagreement Alarm [A.CC]
Display and Outputs

Alarm Code
Output
A.CC ALO1 ALO2 ALO3
Multi-turn ON OFF ON OFF
Limit Dis-
agreement
Alarm
At power ON
206
• See A, B
Cause Remedy
A The amplifier Multi-turn Change the setting of parameter Pn205.
Limit Setting parameter
(pn205) has been set incor-
rectly.
B The multi-turn limit has not Ensure the Multi-turn Limit Setting (Pn205)
been set in the encoder. parameter in the amplifier is correct; create a
Multi-turn Limit Disagreement Alarm (A.CC),
and then execute the encoder multi-turn limit
setting change (Fn013).
Note: This alarm only occurs for the new version of SGDM amplifiers (SGDM-
*DA).
Position Error Pulse Overflow [A.d0]
Display and Outputs

Alarm Code
Output
A.d0 ALO1 ALO2 ALO3
Pulse
Overflow
At power ON
• See E
• Overflow occurs during high speed rotation, see A.

• Operation is normal, bur overflow occurs when long reference is input, see B,
C, D.
207
• Reference pulse is input property, but feedback pulse is not returned, see E.
Cause Remedy
A Servomotor wiring incor- Check wiring and connectors at encoder.
rect or poor connections.
B Amplifier was not correctly Increase speed loop gain (Pn100) and position
adjusted. loop gain (Pn102).
C Motor load was excessive. Reduce load torque or inertia. If problem not
corrected, replace with a larger capacity motor.
D Position reference pulse fre- Increase or decrease reference pulse frequency.
quency was too high. Add smoothing function.
Correct electronic gear ratio.
E Circuit board (1PWB) Replace amplifier.
defective.
Power Line Open Phase [A.F1]
Display and Outputs

Alarm Code
Output
A.F1 ALO1 ALO2 ALO3
Power Line OFF ON OFF OFF
Open Phase
• See A, B
• See C.
Cause Remedy
A One phase (L1, L2, or L3) Check power supply.
of the main circuit power Check wiring of the main circuit power supply.
supply is disconnected. Check MCCB, noise filter, magnetic contactor.
B There is one phase in which Check power supply.
Note: A and B tend to occur in a 500W capacity (or higher) amplifier.
208
Display and Outputs

Alarm Code
Output
Digital Not specified Not specified Not specified Not specified
Operator
Transmission
Error 1
At power ON - digital operator connected before amplifier power turned ON.
• See A, B, C, D
Digital operator connected to amplifier while power turned ON
• See A, B, C, D.
Cause Remedy
operator and amplifier.
noise. source.
Display and Outputs

Alarm Code
Output
Digital Not specified Not specified Not specified Not specified
Operator
Transmission
Error 2
During operation
209
• See A, B, C, D.
Cause Remedy
operator and amplifier.
noise. source.
Normal Operation [A.– –]
Display and Outputs

Alarm Code
Output
A. – – ALO1 ALO2 ALO3
Normal OFF OFF OFF ON
Operation
210
APPENDIX B - PC to SERVO CABLES

SIGMA SERIES CABLES
Sigma Series
Amplifier
Rear view of the computer
RS232C 3CN
D-SUB 9-pin (Female) D-SUB 9-pin (Male)
RS-232C Single-Axis Connection
Connecting directly to the RS-232C Port
RS-232C port Sigma Series Amplifier 3CN

Clamp with hood Clamp with hood
RXD 2 TXD
TXD 4 RXD
RTS
CTS
0V 9 S-GND
FG Case
Maximum cable length: 2m
211
RS-422A Multi-Axis Connection
Connecting to the RS-422A Port
RS-422A port Sigma Series Amplifier 3CN

RXD 1 TXD
*RXD 2 *TXD
TXD 3 TXD
*TXD 4 *RXD
FG Case
6 *RXD
7 RT
0V 9 0V
3CN
Note: Only pins 6 and 7 must be shorted on the connector farthest from the RS-422A port.
SIGMA II SERIES CABLES
Sigma II Series
Amplifier
Rear view of the computer
RS232C
7CN
D-SUB 9-pin (Female) 3M Connector

Solder Connecto
Case: 10314-52A0-008
Connector: 10114--3000VE
212
RS-232C Single-Axis Connection
Connecting directly to the RS-232C Port

RS-232C port Sigma II Series Amplifier 7CN
RXD 2 2 *TXD
TXD 3 4 *RXD
0V 5 14 0V
DTR 4
DSR 6
Shield
FG Case
RTS 7
CTS 8
CD 1
RS-422A Multi-Axis Connection

Connecting to the RS-422A Port
RS-422A port Sigma II Series Amplifier 7CN
RXD 1 TXD
*RXD 2 *TXD
TXD 3 TXD
*TXD 4 *RXD
FG Case
6 *RXD
7 RT
0V 14 0V
7CN
Note: Only pins 6 and 7 must be shorted on the connector farthest from the RS-422A port.
213
APPENDIX C - Autotuning Rigidity Levels

SUGGESTED RIGIDITY LEVELS FOR SIGMA SERIES AMPLIFIERS
Drive Method Suggested Rigidity Levels

Ball screw with direct drive 3-7
Ball screw with gear reduction 2-3
Timing belt 1-3
Chain 1-2
Harmonic gear 1-2
214
APPENDIX D - Sigma Win Uninstall

Drive Method Suggested Rigidity Levels
Ball screw with direct drive 3-7
Ball screw with gear reduction 2-3
Timing belt 1-3
Chain 1-2
Harmonic gear 1-2
UNINSTALL INFORMATION
List of Installed Files
Sigma Win installs the following files onto your hard disk in two directories
The default installation directory for the application is C:\PROGRAM

FILES\YASKAWA\SIGMA WIN J
Main Application Files
File Name Function Installed IN

sigmawin.exe Main application file Application Directory
svwin.mdb Servo amplifier database Application Directory
svwin.chm Application help file Application Directory
parameters.chm
svwin.dll Support DLL of the application Application Directory
Parmhelper.dll Support DLL of the application Application Directory
Parmserver.dll Support DLL of the application Application Directory
Motor.db Motor database Application Directory
Microsoft Foundation Class Support Files

mfc42.dll MFC library Windows System Directory
Msvcrt.dll Cc runtime lib Windows System Directory
Olepro32.dll Property page support (for OCX support) Windows System Directory
Msvcirt.dll C runtime lib Windows System Directory
Msvcrt40.dll C runtime lib Windows System Directory
All.dll Atl lib Windows System Directory
215
DAO and Jet Support Files

dao350.dll DAO version 3.5 DAO Directory
dao2535.tlb DAO version 2.5/3.5 backward compati- DAO Directory
ble type lib
Msjter35.dll Jet and DAO error message DLL Windows System Directory
msjint35.dll Localized Jet and DAO error strings Windows System Directory
msvcrt40.dll C runtime DLL 319k version 4.20.6038 Windows System Directory
msjet35.dll Jet database engine version 3.5 Windows System Directory
vbajet32.dll VBA Jet expression service Windows System Directory
vbar332.dll VBA runtime Windows System Directory
Spread OCX

ss32x25.ocx Farpoint Spread OCX Windows System Directory
Chart F/X OCX

Stxbar.dll Chart F/X OCX Windows System Directory
Ctx4032.ocx Chart F/X OCX Windows System Directory
Sigma Win creates a program menu under the Start menu (which defaults to
Yaskawa Software) and creates the following three program items.
1. Sigma Win (the Sigma Win communication program)
2. Sigma Win Help (Sigma Win associated help file)
3. YTraceView (trace file viewer)
Uninstalling Sigma Win
Follow the procedure detailed below to uninstall Sigma Win:
216
1. Click on the Start button on the Windows taskbar. The start menu opens.
2. Choose Settings. The Settings folder opens.
3. Choose Control Panel. The Control Panel folder opens.
4. Click on Add/Remove Program.
5. Scroll down the list of programs until Sigma Win is shown.
6. Click on Sigma Win.
7. Click on Add/Remove.
8. The Uninstaller for Sigma Win will run.
217
R
704-0020-030 CAD #D8530B
SUBJECT: Ultimax v2.XX Software Patch Utility List
5/13/97
Originator Date Mgr. Ultimax Products Group Date
List, Ultimax v2.XX Patch Utility 704-0020-030 Rev. B Page 1

RECORD OF CHANGES
Engineering Document 704-0020-030 CAD #D8530B

By By
A 14009 Original Release MAD 5/15/97
B 14547 Added information on v1.01 through
v1.06. BVP 2/16/99

I. INTENT
The purpose of this document is to provide a list of features that are released on the Patch Utility diskette (007-
4123-010).
II. SCOPE
This patch utility will be used to upgrade Ultimax v2.XX systems between software releases. Each patch diskette
will be released using a manufacturing notice. All of the fixes and enhancements in each patch will be
incorporated into the next software release. This will provide an easy and quick way to respond to customers
and still maintain a manageable method of tracking the software fixes and enhancements.
Included on this diskette is a file named PX_XX.TXT. X_XX will be the revision of the patch diskette. This diskette
will contain a brief description of the changes on the patch diskette. PX_XX.TXT can be viewed with any ASCII
editor.
III. LIST OF FEATURES FOR V1.00
A. Ladder Modifications
The following table describes the ladders that are modified and the changes to those ladders. All of these
ladder files have been update to v1.01 and should be revised on the ECN of the next Ultimax v.2xx
software release.
File Name Description
B30SIN, B30SOUT v1.01 Modified I/O mapping. Includes Auxiliary M-code, Siemens
Reset bit, Probe I/O rearrangement, and Jog direction reverse logic.
B30YIN, B30YOUT v1.01 Modified I/O mapping. Includes Auxiliary M-code, Probe I/O
rearrangement, and Jog direction reverse logic.
BMC42IN, v1.01 Modified I/O mapping. Includes Auxiliary M-code, Siemens
BMC42OUT Reset bit, Probe I/O rearrangement, and Jog direction reverse logic.
MSC_000 v1.01 Modification to TIS screen to accommodate type-0, 1, and 2
ATC’s. Fixed minor bug where after a manual mode ATC cycle with a
tool insert, the Tool In Spindle prompt field remained *** after operator
did insert and pressed Start P.B.. Rapid Override Enable / Disable
modifications.
SPIN_000 Modified Spindle override to be +/- rpm defined by N95:216 (defaults
to +/- 640 if parameter value = 0). Corrected spindle speed clamping
for minimum and maximum motor and tool RPM values.
TCHGR002 Added “anti-bit” for chip enclosure door, increased FLL length to 35
(from 20) for error clearing, corrected selector switch rotate bug, and
implemented Rapid Override disable for ATC cycle Z up and down
movement. Modified Diagnostics Z axis moves to include unclamp /
clamp sequence when ATC magazine is in right position.
ENGLISH.HRL Adds fields on Auto Run screen for override percentages, adds
softkey for enable / disable Rapid Override, removes Spindle Orient
softkey from ATC diagnostics screen.

B. Additions to Integrator Configuration Parameters
The following changes are description changes only. These descriptions should be given to the
following parameters. Although, if these descriptions are not changed, the functionality of the control
will not be affected.
Parameter Parameter Tag Description Default

Number Value
N95:215 SPINDLE OVERRIDE Specifies the range +/- range 0
RANGE in RPM that the spindle speed
may be overridden. A value
of 200 would yield a range of
+/- 200 RPM. A value of 0 will
default to +/- 640 RPM. The
“step value” will equal
parameter value divided by
32.
N95:216 ATC RAPID OVERRIDE When set =1 allows the Z axis 0
ENABLE movement during an ATC
cycle to be overridden. This
parameter is effective only
when the Disable Rapid
Override parameter is
disabled.
N95:217 DISABLE RAPID When set=1, the Rapid 0
OVERRIDE override value will always be
100% regardless of feedrate
override pot setting and when
set=0 the rapid override will
be 0 to 100% depending on
feedrate override pot setting.
This parameter can be
toggled via softkey from the
Auto Run screen. Auto Run
screen also now has DRO
fields to display current
feedrate and override
percentages. When this
parameter is toggled, it’s state
is retained, even after
machine shutdown and
powere up.
N95:218 JOG DIRECTION When enabled (set =1) the 0
REVERSE Rapid Jog buttons and
incremental handwheel
controls will be reversed. This
parameter is intended
primarily for the Japanese
market.

IV. LIST OF FEATURES FOR V1.01
This disk contains the following files:
B30SIN.REX 6/6/97 v1.02 input map

BMC42IN.REX 6/6/97 v1.02 input map
AMPL_000.REX 6/6/97 v1.01 Servo Amp logic
MSTST000.REX 6/6/97 v1.01 Machine Setup and Test
JOG_000.REX 6/19/97 v1.01 Axis Jog Logic
TCHGR002.REX 6/6/97 v1.02 Type-2 ATC Logic
CAL_000.REX 6/9/97 V1.01 Calibration Logic
Also included is the following revised language file:
ENGLISH.HRL 5/29/97
Specifically fixed / changed:
- Input mapping for Siemens spindle machines modified to read

all fault signals.
- Incremental (handwheel) jogging uses velocity-mode for smoother

operation. Can now jog past software travel limits.
- Rotary "B" Axes supported.
- Minor bugs in Spindle Test cycle corrected (no longer requires

that axes be calibrated).
- Toolchanger manual remove/insert sequence refined. Support for

Servo Fault/Reset corrected.
The following ladder files were modified for Ultimax v2.01 RRB 1:
AMPL_000.REX
B30SIN.REX
B30SOUT.REX
B30YIN.REX
B30YOUT.REX
BMC42IN.REX
BMC42OUT.REX
CAL_000.REX
JOG_000.REX
MSC_000.REX
MSTST000.REX
SPIN_000.REX
TCHGR002.REX
ENGLISH.HRL
P1_01.TXT

V. LIST OF FEATURES FOR V1.02
No software changes were made to v1.02 for Ultimax v2.10. The description file was only changed. The following
ladder files were modified:
P1_02.TXT
VI. LIST OF FEATURES FOR V1.03

The ladder TCHGR000.REX fixes problems seen with the type 0 tool changer
ATC board. The fix allows the ATC to work with a new design ATC board.
The problem was during CCW magazine moves, there was no braking and the
magazine would drift CCW and finally create an ATC fault. Also, the pressing
of the Magazine Rotate pushbutton will now reset the COR off timer.
The ladder IOTST000.REX has a timer fix that previously caused the DCIO
loopback test not to function.
This was before the release of Utimax v2.11.
The following ladder files were modified:
IOTST000.REX
TCHGR000.REX
P1_03.TXT
VII. LIST OF FEATURES FOR V1.04

P1_04.TXT
VIII. LIST OF FEATURES FOR V1.05

P1_05.TXT

IX. LIST OF FEATURES FOR V1.06
P1_06.TXT
X. Patch Utility Installation Procedure
________1. Insert the ULTIMAX 3 VERSION 2.XX PATCH diskette into the floppy drive.
________2. Select Auxiliary Mode and select the “UPGRADE SYSTEM FILES”. Select the “YES” softkey to copy
the files.
________3. Upon completion, the prompt “Do you have another set of system disks?” will appear. Select the
“NO” softkey.
________4. Reset the system by cycling the power.

B and BX Documents
D8033 753-3000-002 Operational Check of the RS232 Ports in BX Series

Mills
D8328 757-3050-001 Preventive Maintenance Procedure - HURCO
Servo Motor Tachometer (404-4003-003)
MANUFACTURING DOCUMENT
757-3050-001 REV: A ECN #

R
03/30/83 CAD #D8328
SUBJECT: PREVENTATIVE MAINTENANCE PROCEDURE -

HURCO 401-4003-003 SERVO MOTOR-TACHOMETER
I. MOTOR SERVICE LIFE
1. Brushes may be replaced one time for motor or tachometer. When replacement brushes
wear to length described below, the motor must be returned to a suitable service center
for commutator service, or replaced.
II. MOTOR BRUSH REMOVAL
1. Position axes to allow easy access to servo motors.
2. Remove machine from service by disconnecting power and attaching "Out of Service
for Maintenance" tag to disconnect switch.
3. Remove appropriate motor covers to gain access to motor. Remove motor from machine
if necessary.
4. Remove motor brushes by rotating caps counterclockwise. Reference Figure 1, Item 1.
5. Measure length of each brush. Motor brush length when now is .5 inch.. The minimum
length acceptable is .20 inch. Reference Figure 2.
6. If both motor brushes measure more than .20 inch in length, brush replacement is not
necessary. See IV MOTOR CLEANING AND BRUSH REPLACEMENT.
7. If either brush length is less than .20 inch, replace both brushes with new items, Hurco
part number 401-4003-010.
III. TACHOMETER BRUSH REMOVAL
1. Remove tachometer brushes by rotating caps counterclockwise. Reference Figure 1,

Item 2.
2. Measure length of each brush. Tachometer brush length when new is .43 inch.
Minimum length acceptable is .20 inch.
________________________________ _______ _______________________________ _______

2
3. If both tachometer brushes measure more than .20 inch in length, brush replacement is
not necessary. See IV.
4. If either brush length is less than .20 inch, replace both items with new items, Hurco part
number 401-4003-005.
IV. MOTOR CLEANING AND BRUSH REPLACEMENT
CAUTION
Eye protection such as full face shield or approved safety glasses must be worn during
the following cleaning operation. Use only a pressure regulated air nozzle with a 30
PSI rating, or a nozzle rated less than 30 PSI. Permanent eye damage may result if
these precautions are not strictly followed.
1. Place a pressure regulated air nozzle at any one brush mounting hole with all brushes
removed from motor and tachometer. Clean interior of motor with air blast, rotate motor
shaft if possible during air blast.
2. Repeat at each brush mounting hole.
3. Insert new brushes and tighten caps.
4. When replacing used but acceptable tachometer brushes, note wear marks on end of
brush and insert so as to keep the same orientation and wear direction.
5. Motor and axis movement may be slightly rough during seat-in period of new brushes.
6. Record new brush installation to allow compliance with motor service life not in Section
I, above.
PICTURES
3
MAX I and MAX II
D8319 757-4002-039 Dual Axis 2 Configuration: Jumpers and Firmware

D8331 757-3050-004 Power Supply Setup Procedure
D8409 757-4001-079 Ultimax II RS232 Checkout Procedure
R
757-4002-039 REV: A ECN #13074
04/04/94 CAD #D8319
SUBJECT: Dual Axis 2 Configuration: Jumpers and Firmware
I. INTENT:
To configure the correct Jumper Settings and Axis Firmware for Dual Axis 2.
II. SCOPE:
Covers the chronological progression of Ultimax 2 machine types from MD1 through 40SLV.
III. PROCEDURE:
A. Diagnostic Engineers and Order Entry Personnel:
1. When a customer or field engineer places an order for a Dual Axis 2 part
number, take that information in advisement. Follow the remainder of this
procedure to verify that the requester is ordering the correct 415-0176-1XX Dual
Axis 2 board.
2. Obtain the following additional information from the person requesting the Dual
Axis 2 board:
a. Machine Type. What kind of machine will the board be installed in?
The machine type must match those defined in Table 1, column 1.
b. Software Version. Which software version is the customer running?
The version will be one of three (3) categories: 1) V7.00 thru V7.24, 2)
V8.0 thru V8.51, or 3) V8.6.
c. Axis Type. Is the board controlling XY axes, ZS axes, or Rotary
Table. If it is a ZS board, what kind of spindle is it? Or, if it is a Rotary,
what kind? Refer to Table 1, column 5 for proper nomenclatures.
3. After recording the Machine Type, Software Version, and Axis Type, find the
description in Table 2, column 1 that contains all three of those parameters.
When you find a match, move to the end of that row in Table 2. That is the DA2
Board Part Number that you will ship to the customer.
4. The order may be placed by one of two methods:
a. To follow the normal manufacturing process that routes work orders
through Electronic Certification, simply enter an order for the Dual Axis 2
part number. Note: This method is subject to the standard lead times of
the manufacturing floor. The actual board delivery date may be up to
several days after the order is placed.
b. For faster shipments, explode the board part number and place orders
for its subcomponents. These should include a 415-0176-604T board,
two (2) blank EPROMs, and two (2) blank EPROM labels. Note: This
method requires a trained and authorized individual to follow the
configuration procedure you are reading now. Jumpers must be set
according to the required Dual Axis 2 part number, and EPROMs
programmed per the corresponding Axis Firmware part numbers.
B. Trained and Authorized Board Configuration Personnel:
Responsible Reviewed Reviewed
______________________ _______ ______________________ _______ ______________________ _______

Originator Date Engineering Manager Date Product Team Leader Date
757-4002-039 REV A
1. Jumper Settings
a. In Table 2, find the Wiring Type that corresponds to the Dual Axis 2 Part
Number being shipped or installed.
b. Given the Wiring Type, set the board jumpers per Table 3. Jumpers are
numbered consecutively on the board from left-to-right, top-to-
bottom.
c. Note: For 3 position jumpers, pin numbers are consecutive:
1 2 3
For 6 position jumpers, pin numbers are as follows:
6 5 4
1 2 3
2. EPROM Programming
a. Given the Dual Axis 2 Part Number (415-0176-1XX), refer to Table 2 for
the correct Axis Firmware Part Number.
b. Program each EPROM as defined in its programming document. Or,
duplicate the master part.
c. Make & affix labels per the programming document or master.
d. Install EPROMs in the Board Location defined in Table 2. (A-Channel is
location U34, B-Channel is U37.)
2
757-4002-039 REV A
Table 1: Machine Type, Axis Firmware, and Axis Type
Machine V7.24 & Prior V8.0 thru V8.6 Axis Type

Type V8.51
MD1/3 450-3001-246 450-3001-248 N/S Axis
includes: 450-3001-258 450-3001-259 N/S Standard Spindle
MD1, 450-3001-501 450-3001-503 N/S Yaskawa Spindle
MB1R, 450-3001-847 450-3001-847 N/S Lange Rotary
(MB2R 450-3001-363 450-3001-363 N/S J&S Rotary
V8.53P)
BMC10/15 450-3001-322 450-3001-324 N/S Axis
450-3001-334 450-3001-335 N/S Spindle
450-3001-847 450-3001-847 N/S Lange Rotary
450-3001-363 450-3001-363 N/S J&S Rotary
KM3/3P V1 450-3001-313 450-3001-320 450-3010-007 Axis
450-3001-316 450-3001-317 450-3001-317 Spindle
450-3001-363 450-3001-363 450-3001-363 J&S Rotary
450-3001-363 450-3001-363 450-3001-363 M&M Rotary
BMC20-50 450-3001-374 450-3001-376 450-3010-007 Axis
OEM V1 450-3001-386 450-3001-387 450-3001-387 Spindle
450-3001-847 450-3001-847 450-3001-847 Lange Rotary
450-3001-363 450-3001-363 450-3001-363 J&S Rotary
450-3001-362 450-3001-362 450-3001-362 Tsuda. (30-50)
DECKEL 450-3001-464 450-3001-465 N/S Axis
450-3001-470 450-3001-471 N/S Spindle
450-3001-885 450-3001-885 N/S Deckel Rotary
BMC20-50 450-3001-505 450-3001-509 450-3010-007 Axis
V2 450-3001-512 450-3001-514 450-3001-514 Spindle
450-3001-365 450-3001-847 450-3001-847 Lange Rotary
450-3001-366 450-3001-366 450-3001-366 Tsudakoma Rotary
450-3001-363 450-3001-363 450-3001-363 J&S Rotary
KM3/3P V2 N/A 450-3001-320 450-3010-007 Axis
N/A 450-3001-317 450-3001-317 Spindle
N/A 450-3001-366 450-3001-366 Tsudakoma Rotary
N/A 450-3001-363 450-3001-363 J&S Rotary
N/A 450-3001-363 450-3001-363 M&M Rotary
KM5P N/A 450-3001-509 450-3010-007 Axis
N/A 450-3001-317 450-3001-317 Spindle
N/A 450-3001-366 450-3001-366 Tsudakoma Rotary
N/A 450-3001-363 450-3001-363 J&S Rotary
N/A 450-3001-363 450-3001-363 M&M Rotary
40SLV N/A 450-3001-509 450-3010-007 Axis
N/A 450-3001-514 450-3001-513 Spindle
N/S = Not Supported at this time
N/A = Not Applicable to this machine type
3
757-4002-039 REV A
Table 2: Machine Type, Wiring Type, EPROM Number, and DA2 Part Number.
Machine Type Wiring A-Channel B-Channel Seq. Existing
Firmware Version Type EPROM EPROM Number Board
Axis Type (U34) (U37)
MD1/3 V7.24 XY 1 450-3001-246 450-3001-246 1 -143T
MD1/3 V7.24 ZS Standard 2 450-3001-246 450-3001-258 2 -144T
MD3 V7.24 ZS Yaskawa 8 450-3001-246 450-3001-501 3 -145T
MD1/3 V8.0/8.51 XY 1 450-3001-248 450-3001-248 4 -101T
MD1/3 V8.0/8.51 ZS Standard 2 450-3001-248 450-3001-259 5 -102T
MD3 V8.0/8.51 ZS Yaskawa 8 450-3001-248 450-3001-503 6 -146T
BMC10/15 V7.24 XY 9 450-3001-322 450-3001-322 7 -147T
BMC10/15 V7.24 ZS 10 450-3001-322 450-3001-334 8 -148T
BMC10/15 V8.0/8.51 XY 9 450-3001-324 450-3001-324 9 -104T
BMC10/15 V8.0/8.51 ZS 10 450-3001-324 450-3001-335 10 -105T
KM3/3PV1 V7.24 XY 1 450-3001-313 450-3001-313 11 -149T
KM3/3PV1 V7.24 ZS 4 450-3001-313 450-3001-316 12 -150T
KM3/3PV1 V8.0/8.51 XY 1 450-3001-320 450-3001-320 13 -106T
KM3/3PV1 V8.0/8.51 ZS 4 450-3001-320 450-3001-317 14 -107T
KM3/3PV1 V8.6 XY 1 450-3010-007 450-3010-007 15 -151T
KM3/3PV1 V8.6 ZS 4 450-3010-007 450-3001-317 16 -152T
BMC20-50V1 V7.24 XY 5 450-3001-374 450-3001-374 17 -108T
BMC20-50V1 V7.24 ZS 6 450-3001-374 450-3001-386 18 -153T
BMC20-50V1 V8.0/8.51 XY 5 450-3001-376 450-3001-376 19 -154T
BMC20-50V1 V8.0/8.51 ZS 6 450-3001-376 450-3001-387 20 -155T
BMC20-50V1 V8.6 XY 5 450-3010-007 450-3010-007 21 -156T
BMC20-50V1 V8.6 ZS 6 450-3010-007 450-3001-387 22 -157T
Deckel V7.24 XY 5 450-3001-464 450-3001-464 23 -158T
Deckel V7.24 ZS 6 450-3001-464 450-3001-470 24 -159T
Deckel V8.0/8.51 XY 5 450-3001-465 450-3001-465 25 -112T
Deckel V8.0/8.51 ZS 6 450-3001-465 450-3001-471 26 -113T
BMC20-50V2 V7.24 XY 5 450-3001-505 450-3001-505 27 -116T
BMC20-50V2 V7.24 ZS 6 450-3001-505 450-3001-512 28 -117T
BMC20-50V2 V8.0/8.51 XY 5 450-3001-509 450-3001-509 29 -160T
BMC20-50V2 V8.0/8.51 ZS 6 450-3001-509 450-3001-514 30 -161T
BMC20-50V2 V8.6 XY 5 450-3010-007 450-3010-007 21 -137T
BMC20-50V2 V8.6 ZS 6 450-3010-007 450-3001-514 31 -140T
KM3/3PV2 V8.0/8.51 XY 5 450-3001-320 450-3001-320 13 -126T
KM3/3PV2 V8.0/8.51 ZS 6 450-3001-320 450-3001-317 14 -127T
KM3/3PV2 V8.6 XY 5 450-3010-007 450-3010-007 15 -139T
KM3/3PV2 V8.6 ZS 6 450-3010-007 450-3001-317 16 -142T
KM5P V8.6 XY 5 450-3010-007 450-3010-007 21 -139T
KM5P V8.6 ZS 6 450-3010-007 450-3001-317 16 -142fT
40SLV V8.0/V8.51 XY 5 450-3001-509 450-3001-509 29 -160T
40SLV V8.0/8.51 ZS 6 450-3001-509 450-3001-514 30 -161T
40SLV V8.6 XY 5 450-3010-007 450-3010-007 21 -137T
40SLV V8.6 ZS 6 450-3010-007 450-3001-513 33 -138T
Lange Rotary 7 450-3001-847 450-3001-847 34 -119T
J&S/M&M Rotary 3 450-3001-363 450-3001-363 35 -103T
Tsudakoma BMC30-50V1 Rotary 7 450-3001-362 450-3001-362 36 -110T
MAXTsudakoma BMC20-50V2 7 450-3001-366 450-3001-366 37 -118T
Rotary
MAX2 Deckel Rotary 7 450-3001-885 450-3001-885 38 -115T
MAX32 KM3/3PV1 V7.24 XY 1 450-3001-313 450-3001-313 11 -T
MAX32 KM3/3PV1 V7.24 ZS 4 450-3001-313 450-3001-316 12 -T
MAX32 KM3/3PV1 V8.0/8.51 XY 1 450-3001-320 450-3001-320 13 -T
MAX32 KM3/3PV1 V8.0/8.51 ZS 4 450-3001-320 450-3001-317 14 -T
4
757-4002-039 REV A
MAX32 KM3/3PV1 V8.6 XY 1 450-3010-007 450-3010-007 15 -T

MAX32 KM3/3PV1 V8.6 ZS 4 450-3010-007 450-3001-317 16 -T
MAX32 BMC20-50V1 V7.24 XY 5 450-3001-374 450-3001-374 17 -T
MAX32 BMC20-50V1 V7.24 ZS 6 450-3001-374 450-3001-386 18 -T
MAX32 BMC20-50V1 V8.0/8.51 5 450-3001-376 450-3001-376 19 -T
XY
MAX32 BMC20-50V1 V8.0/8.51 6 450-3001-376 450-3001-387 20 -T
ZS
MAX32 BMC20-50V1 V8.6 XY 5 450-3010-007 450-3010-007 21 -T
MAX32 BMC20-50V1 V8.6 ZS 6 450-3010-007 450-3001-387 22 -T
Table 3: DA2 Jumper Setting by Wiring Type
Jumper # Jumper Setting

ò Wiring Type ð 1 2 3 4 5 6 7 8 9 10
TB1 1-2 1-2 1-2 1-2 2-3 2-3 2-3 1-2 1-2 1-2
TB2 (6 pos.) 1-2 1-2 1-2 1-2 1-6 1-6 1-6 1-2 1-2 1-2
4-5 4-5 4-5 4-5 3-4 3-4 3-4 4-5 4-5 4-5
TB3 (6 pos.) 1-2 1-2 1-2 1-2 1-6 1-2 1-6 1-2 1-2 1-2
4-5 4-5 4-5 4-5 3-4 4-5 3-4 4-5 4-5 4-5
TB4 1-2 1-2 1-2 1-2 2-3 1-2 2-3 1-2 1-2 1-2
TB5 1-2 1-2 1-2 1-2 1 1 1 1 1 1
TB6 1 1-2 1 1-2 1 1-2 1 1-2 1 1-2
TB7 1-2 1 1-2 1 1-2 1 1-2 1 1-2 1
TB8 1-2 1-2 1-2 1-2 1 1-2 1 1-2 1-2 1-2
TB9 1-2 1-2 1-2 1-2 1 1-2 1 1-2 1-2 1-2
TB10 1-2 1-2 1-2 1-2 1 1-2 1 1-2 1-2 1-2
TB11 1 1 1 1 1 1 1-2 1 1 1
TB12 1 1 1 1 1 1 1 1 1 1
TB13 (6 pos.) 2-3 2-3 2-3 2-3 2-3 2-3 2-3 2-3 2-3 2-3
4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5
TB14 2-3 2-3 2-3 2-3 2-3 2-3 2-3 2-3 2-3 2-3
TB15 2-3 2-3 2-3 2-3 2-3 2-3 2-3 2-3 2-3 2-3
TB16 (6 pos.) 2-3 2-3 2-3 2-3 2-3 2-3 2-3 2-3 2-3 2-3
4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5
TB17 2-3 2-3 2-3 2-3 2-3 2-3 2-3 2-3 2-3 2-3
TB18 2-3 2-3 2-3 2-3 2-3 2-3 2-3 2-3 2-3 2-3
TB19 1 1-2 1 1-2 1 1-2 1 1-2 1 1-2
TB20 1 1 1-2 1 1 1 1-2 1 1 1
TB21 (6 pos.) 2-5 1-6 2-5 2-5 2-5 2-5 2-5 2-5 2-5 1-6
3-4 3 3-4 3-4 3-4 3-4 3-4 3-4 3-4 3
TB22 1-2 1-2 1-2 1-2 1-2 1-2 1-2 1-2 1-2 1-2
5
757-3050-004 REV: A ECN #

R
01/14/86 CAD #D8331
SUBJECT: POWER SUPPLY SET-UP PROCEDURE (BMC)
I. SCOPE
Adjustment and verification of power supply distribution throughout the machine.
II. TEST EQUIPMENT REQUIRED
Digital Voltmeter (DVOM)
III. PROCEDURE
A. Reference Figure 1 for potentiometer locations.
B. Carefully adjust the appropriate potentiometer to produce the voltage ranges shown
below. (Use 20 VDC range, except as noted.)
NOTE:Positive meter lead goes on the first pin number listed.
CNC-TB4 ALLOWABLE RANGE NOTE

11R to 21R + 5.10 to + 5.30 VDC -------------------------
28R to 21R + 12.00 to + 13.00 VDC -------------------------
32R to 21R - 12.00 to - 13.00 VDC -------------------------
36R to 21R + 24.00 to + 25.00 VDC (Use 200 VDC Range)
C. Other terminals to verify:
MAIN CARD CAGE
Pin 84 to 86 = + 5.10 to + 5.20 VDC

Pin 8 to 86 = +12.00 to +13.00 VDC
Pin 80 to 86 = -12.00 to -13.00 VDC
________________________________ _______ _______________________________ _______

FRONT CONSOLE CARD CAGE AREA
CRT Controller PCB 415-0174-001
Pin 2 to 1 = + 4.90 to + 5.20 VDC

Pin 4 to 6 = +12.00 to +13.00 VDC
Pin 5 to 6 = -12.00 to -13.00 VDC
Tape Controller PCB 415-0178-001
Pin 2 to 1 = + 4.90 to + 5.20 VDC

Pin 4 to 6 = +12.00 to +13.00 VDC
Pin 5 to 6 = -12.00 to -13.00 VDC
Tape Drive PCB (Part of 426-0003-005 Assembly)
Pin 3 to 2 = +12.00 to +13.00 VDC

Pin 4 to 2 = + 5.00 to + 5.20 VDC
Front Panel Cable Connect PCB 415-0193-002
TB52-1 to TB52-5 = + 5.00 to + 5.20 VDC

TB52-2 to TB52-6 = + 5.00 to + 5.20 VDC
TB52-3 to TB52-5 = +12.00 to +13.00 VDC
TB52-4 to TB52-6 = -12.00 to -13.00 VDC
TB52-7 to TB52-8 = + 5.00 to - 5.20 VDC
D. Torque seal R1, R12, R16 and R23.
PICTURE
2
MAX 32
D8267B 757-4002-031 Revision B Parameters for MAX 32 Dual Axis Software Version 1.40
D8767 C 757-4002-031 Revision C Parameters for MAX 32 Dual Axis Software Version 1.40
D8267 D 757-4002-031 Revision D Parameters for MAX 32 Dual Axis Software Version 1.53
D8267E 757-4002-031 Revision E Parameters for MAX 32 Dual Axis Software Version 1.60
D8417 757-4002-047 DSP 2 Jumper Settings
D8425 757-4004-001 MAX II-32 Hardware Doc.
D8427 757-4004-002 CPU Assembly Instructions
D8430 757-4002-057 Eng. Doc., MAX3/MAX32 CMOS Setup
D8531 757-4002-136 Field Service Retrofit Procedure
D8532 757-4002-137 CMOS Settings, Max 32
D Special Max 32 Problems and Fixes
D8533 757-4002-138 MAX 32 Retrofit Kit (486 CPU) Test Procedure
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
ENGINEERING DOCUMENT 757-4002-031 Revision B CAD # D8267
SUBJECT: Parameters for MAX 32 Software Version 1.30 [002-4123-004]
R

A 12617 Original Issue 15 MAY 93
B 12876 v1.30 update to add KM3 V1 machines 15 OCT 93
I. INTENT
To provide documentation of the default parameter values loaded by the executive software.
II. APPLICABILITY
Applicable to all Dual Axis V1/V2 BMC Max 32 Machining Centers and all Dual AxisV2 Kneemill Max 32 Machines.
III INDEX
page 1 V2 BMC 20 Machine
page 5 V2 BMC 40 SLV Machine
page 7 V2 KM5P Machine
page 8 V2 KM5P ASC Machine
page 9 V2 KM3 Machine
page 10 V2 KM3P Machine
page 11 NON V2 KM3 Machine
page 12 NON V2 KM3 Auto Spindle Machine
page 13 NON V2 KM3P Machine
page 14 NON V2 KM3P Auto Spindle Machine
page 15 BMC 20 (V1 and OEM) Machine
page 19 BMC 20-50 (V1 and OEM) Machine Configuration Switch Settings
_________________________________________ _________ _________________________________________ _________

Originator Date Machine Tool Design Group Date
V2 BMC 20 Machine
<Enter>,100,<Enter> SCREEN
** AXIS PARAMETERS ** X Axis Y Axis Z Axis ** SPINDLE PARAMETERS ** 4K Spindle 6K Spindle 10K Spindle
Axis Pitch Metric Metric Metric Orient Mechanism Present Yes Yes Yes
Counts per Revolution 5000 5000 5000 Clamp / Unclamp Present Yes Yes Yes
Distance per Revolution 10 mm 10 mm 10 mm Minimum Tap RPM 40 60 40
Calibrate To Limit Switch Velocity 200 200 200 Maximum Tap RPM 800 800 800
Load Meter Bar One Value 20 20 20 Spindle Purge Time 30 Minutes 30 Minutes 30 Minutes
Load Meter Overload Value 110 110 110 Load Meter Bar One Value 20 20 20
Load Meter Overload Value 80 80 80
Spindle Control Type Closed Loop Closed Loop Closed Loop
Spindle Brake Enable Time N/A N/A N/A
AMR Relay Present Yes Yes Yes
Fault Signal Logic 0 0 0
** MACHINE CONFIGURATION ** ** ROTARY PARAMETERS ** A Axis B Axis

Maximum ATC Magazine Count 16 Rotary Resolution SW1 - 8 = 0 4000 4000
Maximum X Travel (mm) 560 Rotary Resolution SW1 - 8 = 1 2000 2000
Maximum Y Travel (mm) 358 Maximum RPM 10.5 10.5
Maximum Z Travel (mm) 358
Calibration Direction User Selectable ** CRP 3 PCB Switch Settings **
Maximum Motor Speed (RPM) 8000 SW1 1 2 3 4 5
Maximum Spindle Speed (RPM) 4000, 6000, 10000 4K Spindle 0 0 0 0 0
ATC Type (mag up/down = 0) per machine 6K Spindle 0 0 0 0 1
Verify Chip Door Upon ESTOP No 10K Spindle 0 0 0 1 0
** AXIS ACCEL SETUP **

X Axis Accel Factor 150000
Y Axis Accel Factor 150000
Z Axis Accel Factor 120000
X Axis Gain Factor 20
Y Axis Gain Factor 20
Z Axis Gain Factor 20
Turbo Option Enabled per machine
Exactor Option Enabled per machine
Max32 Software Version 1.30 Parameters 757-4002-031 Rev. B 1
V2 BMC 25 Machine


V2 BMC 30 Machine


V2 BMC 40 Machine


V2 BMC 40 SLV Machine


V2 BMC 50 Machine
** AXIS PARAMETERS ** X Axis Y Axis Z Axis ** SPINDLE PARAMETERS ** 4K Spindle 6K Spindle
Axis Pitch Metric Metric Metric Orient Mechanism Present Yes Yes
Counts per Revolution 5000 5000 5000 Clamp / Unclamp Present Yes Yes
Distance per Revolution 10 mm 10 mm 10 mm Minimum Tap RPM 40 60
Calibrate To Limit Switch Velocity 200 200 200 Maximum Tap RPM 800 800
Load Meter Bar One Value 20 20 20 Spindle Purge Time 30 Minutes 30 Minutes
Load Meter Overload Value 110 110 110 Load Meter Bar One Value 20 20
Load Meter Overload Value 80 80
Spindle Control Type Closed Loop Closed Loop
Spindle Brake Enable Time N/A N/A
AMR Relay Present Yes Yes
Fault Signal Logic 0 0

Maximum Spindle Speed (RPM) 4000, 6000 4K Spindle 1 0 0 0 0
Verify Chip Door Upon ESTOP No

V2 KM5P Machine
** AXIS PARAMETERS ** X Axis Y Axis Z Axis ** SPINDLE PARAMETERS **

Axis Pitch Metric Metric Metric Orient Mechanism Present No
Counts per Revolution 5000 5000 5000 Clamp / Unclamp Present No
Distance per Revolution 10 mm 10 mm 10 mm Minimum Tap RPM 100
Calibrate To Limit Switch Velocity 200 200 200 Maximum Tap RPM 1000
Load Meter Bar One Value 20 20 20 Spindle Purge Time 30 Minutes
Load Meter Overload Value 110 110 110 Load Meter Bar One Value N/A
Load Meter Overload Value N/A
Spindle Control Type Contact
Spindle Brake Enable Time 1250
AMR Relay Present Yes
Fault Signal Logic 0

Maximum X Travel (mm) 787.4 Rotary Resolution SW1 - 8 = 0 4000 4000
Maximum Y Travel (mm) 355.6 Rotary Resolution SW1 - 8 = 1 2000 2000
Maximum Z Travel (mm) 152.4 Maximum RPM 10.5 10.5
Calibration Direction User Selectable
Maximum Spindle Speed (RPM) 3800 ** CRP 3 PCB Switch Settings **
Verify Chip Door Upon ESTOP No SW1 1 2 3 4 5
KM5P 1 0 1 0 0


V2 KM5P ASC Machine
Distance per Revolution 10 mm 10 mm 10 mm Minimum Tap RPM 100
Spindle Control Type DAC Contact ASC
AMR Relay Present Yes

Maximum X Travel (mm) 787.4 Rotary Resolution SW1 - 8 = 0 4000 4000
Maximum Y Travel (mm) 355.6 Rotary Resolution SW1 - 8 = 1 2000 2000
Maximum Z Travel (mm) 152.4 Maximum RPM 10.5 10.5
Maximum RPM in High Gear 3800 SW1 1 2 3 4 5
Minimum RPM in High Gear 650 KM5P ASC 1 0 1 0 1
Maximum RPM in Low Gear 450
Minimum RPM in Low Gear 80
V2 KM3 Machine

Axis Pitch Inch Inch Inch Orient Mechanism Present No
Distance per Revolution 0.4 in 0.4 in 0.4 in Minimum Tap RPM 100
AMR Relay Present No

Maximum Y Travel (mm) 350 Rotary Resolution SW1 - 8 = 1 2000 2000
Maximum Z Travel (mm) 127 Maximum RPM 10.5 10.5
KM3 1 0 1 1 0


V2 KM3P Machine

Load Meter Overload Value 110 110 110 Load Meter Bar One Value 20
Load Meter Overload Value 80
Spindle Control Type DAC Contact
Spindle Brake Enable Time N/A
AMR Relay Present No

KM3P 1 0 1 1 1


V1 KM3 Machine

Load Meter Bar One Value 20 20 20 Spindle Air Purge Time On Delay 30
AMR relay Present No

Maximum Spindle Speed (RPM) 4000 ** MP PCB Switch Settings **
Verify Chip Door Upon ESTOP No SW1 4 3 2 1
KM3 1 1 0 1


V1 KM3 Auto Spindle Machine


KM3 Auto Spindle 1 0 0 1


V1 KM3P Machine


KM3P 1 1 1 0


V1 KM3P Auto Spindle Machine


KM3P Auto Spindle 1 0 1 0


BMC 20 (V1 and OEM) Machine
Spindle Control Type Open Loop Open Loop Open Loop

Maximum Motor Speed (RPM) 8000
Maximum Spindle Speed (RPM) 4000, 6000, 10000
ATC Type (mag up/down = 0) per machine



** AXIS PARAMETERS ** X Axis Y Axis Z Axis ** SPINDLE PARAMETERS ** 4K Spindle 6K Spindle

Distance per Revolution 10 mm 10 mm 10 mm Minimum Tap RPM 40 60
Calibrate To Limit Switch Velocity 200 200 200 Maximum Tap RPM 800 800
Load Meter Bar One Value 20 20 20 Spindle Purge Time 30 Minutes 30 Minutes
Load Meter Overload Value 110 110 110 Load Meter Bar One Value 20 20
Load Meter Overload Value 80 80
Spindle Control Type Open Loop Open Loop
Spindle Brake Enable Time N/A N/A
AMR Relay Present Yes Yes

Maximum Spindle Speed (RPM) 4000, 6000
BMC 20-50 (OEM and V1)
Machine Configuration Switch Settings
** MACHINE TYPE ** ** ATC MAGAZINE ** ** SPINDLE RPM **

SW1 1 2 SW1 3 4 SW2 1 2
BMC 20 1 1 16 Stations 1 1 3000 1 1
BMC 30 0 0 20 Stations 0 0 4000 0 0
BMC 40 0 1 24 Stations 0 1 6000 0 1
BMC 50 1 0 30 Stations 1 0 10000 1 0
** SPINDLE CLUTCH ** ** SOLENOID TYPE ** ROTARY RESOLUTION

SW3 2 SW3 1 SW3 4
Clutch 0 Single-ended 0 2000 1
No-Clutch 1 Double-ended 1 4000 0

ENGINEERING DOCUMENT 757-4002-031 Revision C CAD # D8267
SUBJECT: Parameters for MAX 32 Dual Axis Software Version 1.40
R

A 12617 Original Issue (filename D8267A.DOC) 15 MAY 93
B 12876 v1.30 update to add KM3 V1 machines (filename D8267B.DOC) 15 OCT 93
C 13119 v1.40 update (filename D8267C.DOC) 31 MAY 94
I. INTENT
II. APPLICABILITY
Applicable to all Dual Axis BMC Max 32 Machining Centers and all Dual Axis Kneemill Max 32 Machines.
III INDEX
page 7 V2 KM5P Manual/ASC Machine
page 8 V2 KM3 Manual/Auto Spindle Machine
page 9 V2 KM3P Manual/Auto Spindle Machine
page 10 NON V2 KM3 Manual/Auto Spindle Machine
page 11 NON V2 KM3P Manual/Auto Spindle Machine
_________________________________________ _________ _________________________________________ _________

V2 BMC 20 Machine
<enter>, 100, <enter> ** MACHINE CONFIGURATION **
** PHYSICAL PARAMETERS ** X Axis Y Axis Z Axis ** PHYSICAL PARAMETERS ** 4K Spindle 6K Spindle 10K Spindle
Distance per Revolution 10 mm 10 mm 10 mm Spindle Air Purge Time On Delay 30 minutes 30 minutes 30 minutes
Calib: To Lim Sw Velocity 5080mmpm 5080mmpm 5080mmpm Load Meter Bar One Value 20 20 20
Load Meter Bar One Value 20 20 20 Load Meter Overload Value 80 80 80
Load Meter Overload Value 110 110 110 Spindle Control Type Open Loop Vel Open Loop Vel Open Loop Vel
Fault Signal Logic 0 0 0 AMR Relay Present Yes Yes Yes
Maximum Travel 560 mm 358 mm 358 mm Fault Signal Logic 0 0 0
Leadscrew Mapping Yes Yes Yes - MORE -
Spindle Brake Enable Time n/a n/a n/a
** VERTICAL PARAMETERS ** X Axis Y Axis Z Axis Minimum Tap RPM 40 60 40
Coordinate Frame Sense Positive Positive Negative Maximum Tap RPM 800 800 800
** MACHINE PARAMETERS ** ** VERTICAL PARAMETERS ** 4K Spindle 6K Spindle 10K Spindle

Machine Class Vertical Machine Wiring Logic Inverted Inverted Inverted
Calibrate Direction User Selectable Maximum Motor Speed 6,000 6,000 6,000
Verify Chip Door Upon ESTOP No Maximum Spindle Speed 4,000 6,000 10,000
Swing Table Present No
Alarm Light Present No ** TOOL CHANGE PARAMETERS **
Tool Changer Present Yes
CRP 3 PCB SW1 Switch Settings Maximum ATC Magazine Count 16
-3 -2 -1 ATC Type (mag up/down = 0) Per ATC Type
off off off Z Tool Change Position (Height) ATC Specific
<enter>, 103, <enter> SCREEN

Max32 Dual Axis Software Version 1.40 Parameters 757-4002-031 Rev. C 1
V2 BMC 25 Machine

on off off Z Tool Change Position (Height) ATC Specific

V2 BMC 30 Machine

off on off Z Tool Change Position (Height) ATC Specific

V2 BMC 40 Machine

on on off Z Tool Change Position (Height) ATC Specific



V2 BMC 50 Machine
** PHYSICAL PARAMETERS ** X Axis Y Axis Z Axis ** PHYSICAL PARAMETERS ** 4K Spindle 6K Spindle

Distance per Revolution 10 mm 10 mm 10 mm Spindle Air Purge Time On Delay 30 minutes 30 minutes
Calib: To Lim Sw Velocity 5080mmpm 5080mmpm 5080mmpm Load Meter Bar One Value 20 20
Load Meter Bar One Value 20 20 20 Load Meter Overload Value 80 80
Load Meter Overload Value 110 110 110 Spindle Control Type Open Loop Vel Open Loop Vel
Fault Signal Logic 0 0 0 AMR Relay Present Yes Yes
Maximum Travel 1320 mm 762 mm 600 mm Fault Signal Logic 0 0
Spindle Brake Enable Time n/a n/a
** VERTICAL PARAMETERS ** X Axis Y Axis Z Axis Minimum Tap RPM 40 60
Coordinate Frame Sense Positive Positive Negative Maximum Tap RPM 800 800
** MACHINE PARAMETERS ** ** VERTICAL PARAMETERS ** 4K Spindle 6K Spindle

Machine Class Vertical Machine Wiring Logic Inverted Inverted
Calibrate Direction User Selectable Maximum Motor Speed 4,800 4,800
Verify Chip Door Upon ESTOP No Maximum Spindle Speed 4,000 6,000
off off on Z Tool Change Position (Height) ATC Specific

V2 KM5P Manual/ASC Machine
** PHYSICAL PARAMETERS ** X Axis Y Axis Z Axis ** PHYSICAL PARAMETERS ** Manual ASC

Axis Pitch Metric Metric Metric Orient Mechanism Present No No
Counts per Revolution 5000 5000 5000 Clamp / Unclamp Present No No
Calib: To Lim Sw Velocity 5080mmpm 5080mmpm 5080mmpm Load Meter Bar One Value n/a n/a
Load Meter Bar One Value 20 20 20 Load Meter Overload Value n/a n/a
Load Meter Overload Value 110 110 110 Spindle Control Type Contact DAC Contact ASC
Maximum Travel 787.4 mm 355.6 mm 152.4 mm Fault Signal Logic 0 0
Spindle Brake Enable Time 1250 1250
** MACHINE PARAMETERS ** ** VERTICAL PARAMETERS ** Manual ASC

Tool Changer Present No
CRP 3 PCB SW1 Switch Settings Maximum ATC Magazine Count n/a
-3 -2 -1 ATC Type (mag up/down = 0) n/a
on off on Z Tool Change Position (Height) n/a

V2 KM3 Manual/Auto Spindle Machine
** PHYSICAL PARAMETERS ** X Axis Y Axis Z Axis ** PHYSICAL PARAMETERS ** Manual Auto Spindle
Axis Pitch Inch Inch Inch Orient Mechanism Present No No
Distance per Revolution 0.4 in 0.4 in 0.4 in Spindle Air Purge Time On Delay 30 minutes 30 minutes
Calib: To Lim Sw Velocity 200 ipm 200 ipm 200 ipm Load Meter Bar One Value 20 20
Load Meter Overload Value 110 110 110 Spindle Control Type Contact DAC Contact
Fault Signal Logic 0 0 0 AMR Relay Present No No
Coordinate Frame Sense Positive Positive Negative Maximum Tap RPM 1,000 1,000
** MACHINE PARAMETERS ** ** VERTICAL PARAMETERS ** Manual Auto Spindle



V2 KM3P Manual/Auto Spindle Machine



NON V2 KM3 Manual/Auto Spindle Machine



NON V2 KM3P Manual/Auto Spindle Machine



Spindle Brake Enable Time 1250 1250 1250









SW1 1 2 SW1 3 4 SW2 1 2
BMC 20 1 1 16 Stations 1 1 3000 1 1
BMC 30 0 0 20 Stations 0 0 4000 0 0
BMC 40 0 1 24 Stations 0 1 6000 0 1
BMC 50 1 0 30 Stations 1 0 10000 1 0

SW3 2 SW3 1 SW3 4

ENGINEERING DOCUMENT 757-4002-031 Revision D CAD # D8267
R

D 13386 v1.53 update (filename D8267D.DOC) 4 APR 95
I. INTENT
II. APPLICABILITY
III INDEX
_________________________________________ _________ _________________________________________ _________

V2 BMC 20 Machine


Max32 Dual Axis Software Version 1.53 Parameters 757-4002-031 Rev. D 1
V2 BMC 25 Machine


V2 BMC 30 Machine


V2 BMC 40 Machine




V2 BMC 50 Machine







KRP PCB SW1 Switch Settings Maximum ATC Magazine Count n/a






MP PCB SW1 Switch Settings Maximum ATC Magazine Count n/a






CRP PCB SW1 Switch Settings Maximum ATC Magazine Count 16








SW1 1 2 SW1 3 4 SW2 1 2
BMC 20 1 1 16 Stations 1 1 3000 1 1
BMC 30 0 0 20 Stations 0 0 4000 0 0
BMC 40 0 1 24 Stations 0 1 6000 0 1
BMC 50 1 0 30 Stations 1 0 10000 1 0

SW3 2 SW3 1 SW3 4

ENGINEERING DOCUMENT 757-4002-031 Revision E CAD # D8267
R

D 13386 v1.53 update (filename D8267D.DOC) 4 APR 95
E 13581 v1.60 update to add max./min. programmable RPM (filename D8267E.DOC) 18 DEC 95
I. INTENT
II. APPLICABILITY
III INDEX
_________________________________________ _________ _________________________________________ _________

Originator Date Control Systems Integration Date
V2 BMC 20 Machine
Maximum Programmable RPM 4,000 6,000 10,000
Minumum Programmable RPM 40 60 40


Max32 Dual Axis Software Version 1.60 Parameters 757-4002-031 Rev. E 1

V2 BMC 25 Machine
Minimum Programmable RPM 40 60 40



V2 BMC 30 Machine



V2 BMC 40 Machine






V2 BMC 50 Machine

Maximim Programmable RPM 4,000 6,000
Minimum Programmable RPM 40 60




Maximum Programmable RPM 3,800 3,800















Minimum Programmbale RPM 40 60 40













SW1 1 2 SW1 3 4 SW2 1 2
BMC 20 1 1 16 Stations 1 1 3000 1 1
BMC 30 0 0 20 Stations 0 0 4000 0 0
BMC 40 0 1 24 Stations 0 1 6000 0 1
BMC 50 1 0 30 Stations 1 0 10000 1 0

SW3 2 SW3 1 SW3 4

R
757-4002-047 REV: A ECN #13108
05/03/94 CAD #D8417
SUBJECT: Max32 DSP2 Jumper Settings
I. INTENT:
To configure the correct Jumper Settings for DSP2.
II. SCOPE:
Covers the chronological progression of machine types from MD1 through 40SLV. Applies to
Ultimax 2 machines that have been retrofitted with a Max32/DSP control.
III. PROCEDURE:
A. Diagnostic Engineers and Order Entry Personnel: Verifying the Request
1. When a customer or field engineer places an order for a DSP2 part number,
take that information in advisement. Follow the remainder of this procedure to verify
that the requester is ordering the correct 415-0247-1XXT DSP2 board.
2. Obtain the following additional information from the person requesting the DSP2
board.
a. Machine Type. What kind of machine will the board be installed in?
The machine type must match those defined in Table 1, column 1.
b. Axis Type. Is the board controlling XYZS axes or Rotary Table. If it is
an XYZS board, what kind of spindle is it? Or, if it is a Rotary, what
kind? Refer to Table 1 for proper nomenclatures.
3. After recording the Machine Type and Axis Type, find the description in Table 2,
column 1 that contains both of those parameters. When you find a match, move
to the end of that row in Table 2. That is the DSP2 board part number
that you will ship to the customer.
4. The order may be placed by one of two methods:
a. To follow the normal manufacturing process that routes work orders
through Electronic Certification, simply enter an order for the DSP2
-1XXT part number. Note: This method is subject to the standard lead
times of the manufacturing floor. The actual board delivery date may be
up to several days after the order is placed.
b. For faster shipments, place an order for the pre cycled board: 415-0247-
602T, and configure the jumpers before shipment. Note: This method
requires a trained and authorized individual to follow the configuration
procedure you are reading now. Jumpers must be set according to the
required DSP2 -1XXT part number.
B. Trained and Authorized Board Configuration Personnel: Setting Jumpers

1. In Table 2, find the Wiring Type that corresponds to the DSP2 Part
Number being shipped or installed.
2. Given the Wiring Type, set the board jumpers per Table 3. Jumpers locations
are grouped in the order listed in Table 3.
______________________ _______ ______________________ _______ ______________________ _______

757-4002-047 REV. A
Table 1: Machine Type and Axis Type
Machine Type Axis Type

MD1/3 XYZS Standard
includes: XYZS Yaskawa
MD1, MB1R, Lange Rotary
(MB2R J&S Rotary
V8.53P)
BMC10/15 XYZS
Lange Rotary
J&S Rotary
KM3/3P V1 XYZS
J&S Rotary
M&M Rotary
BMC20-50 XYZS
OEM V1 Lange Rotary
J&S Rotary
Tsuda. (30-50)
DECKEL XYZS
Deckel Rotary
BMC20-50 V2 XYZS
Lange Rotary
Tsudakoma Rotary
J&S Rotary
KM3/3P V2 XYZS
Tsudakoma Rotary
J&S Rotary
M&M Rotary
KM5P XYZS
Tsudakoma Rotary
J&S Rotary
M&M Rotary
40SLV XYZS
2
757-4002-047 REV. A
Table 2: Machine/Axis Type vs. Wiring Type

Machine Type Wiring P/N
Axis Type Type Suffix
MD1/3 XYZS 1 -101T
MD3 XYZS Yaskawa 2 -102T
BMC10/15 XYZS 3 -103T
KM3/3PV1 XYZS 1 -101T
BMC20-50V1 XYZS 4 -104T
Deckel XYZS 4 -104T
BMC20-50V2 XYZS 5 -105T
KM3/3PV2 XYZS 1 -101T
KM5P XYZS 4 -104T
40SLV XYZS 4 -104T
Lange Rotary 6 -106T
J&S/M&M Rotary 7 -107T
Tsudakoma BMC30-50V1 Rotary 6 -106T
Tsudakoma BMC20-50V2 Rotary 6 -106T
Deckel Rotary 6 -106T
3
757-4002-047 REV. A
Table 3: DA2 Jumper Setting by Wiring Type
Jumper # Jumper Setting

ò Wiring Type ð 1 2 3 4 5 6 7
JU5 1 1 1 1 1 1 1
JU7 2-3 2-3 2-3 1-2 1-2 1-2 2-3
JU12 2-3 2-3 2-3 1-2 1-2 1-2 2-3
JU8 2-3 2-3 2-3 1-2 1-2 1-2 2-3
JU6 1-2 1-2 1 1 1 1 1
JU11 1 1 1 1 1 1 1
JU13 2-3 2-3 2-3 1-2 1-2 1-2 2-3
JU16 2-3 2-3 2-3 1-2 1-2 1-2 2-3
JU14 2-3 2-3 2-3 1-2 1-2 1-2 2-3
JU15 1-2 1-2 1 1 1 1 1-2
JU20 1 1 1 1 1 1 1
JU21 2-3 2-3 2-3 1-2 1-2 1-2 2-3
JU17 2-3 2-3 2-3 1-2 1-2 1-2 2-3
JU22 2-3 2-3 2-3 1-2 1-2 1-2 2-3
JU23 1-2 1-2 1 1 1 1 1-2
JU26 1 1 1 1 1 1 1
JU29 1-2 1 1 1 1 1 1
JU31 1-2 1-2 1-2 1-2 1-2 1-2 1-2
JU32 1-2 1-2 1-2 1-2 1-2 1-2 1-2
JU37 1-2 1-2 1-2 1-2 3-4 3-4 3-4
JU33 * * * * * * *
JU34 * * * * * * *
JU35 * * * * * * *
JU36 * * * * * * *
JU4 INT0 INT0 INT0 INT0 INT0 INT0 INT0
JU2 N N N N N N N
* Set JU33-JU36 per axis encoder type:

1-2 active LOW marker pulse
2-3 active HIGH marker pulse
4
MAX32 HARDWARE CONFIGURATIONS 02/03/94
SYSTEM HARD DRV ASSY. HARD DRIVE CPU ASSY BIOS ODD BYTE BIOS EVEN BYTE
2MB RAM 130M HD 002-3513-005T 426-0056-018 002-3311-042T 450-3005-037 450-3005-038
(STANDARD) (STANDARD) ST3145 SEAGATE (STD)
4M RAM 130M HD 002-3513-005T 426-0056-018 002-3311-042T 450-3005-039 450-3005-040
ST3145 SEAGATE
8M RAM 130M HD 002-3513-005T 426-0056-018 002-3311-042T 450-3005-041 450-3005-042
ST3145 SEAGATE
R
757-4004-002 REV: B ECN #12382
1/11/93 CAD #D8427
SUBJECT: ULTIMAX II-32 CPU (HURCO 002-3311-027)

ASSEMBLY & TEST PROCEDURE

B 12382 Moved graphics board from J7 to J8. 1/11/93
I. INTENT:
To serve as a guide in the assembly & testing of the Ultimax II-32 Standard CPU Assembly (002-3311-027).
II. SUB-ASSEMBLY PART NUMBER REFERENCE:
SUB-ASSEMBLY P/N
STANDARD:
CPU MAIN BOARD - iSBC 386SX02 415-0166-904
HURCO SBX GRAPHICS CONTROLLER 415-0220-901
IC, FLOATING POINT COPROCESSOR 450-1001-043
EPROM BIOS FOR QUANTUM ELS42AT HDD
AND 2MB RAM:
ODD BYTE 450-3005-051
EVEN BYTE 450-3005-052
III. OUTLINE:
There are two (2) main sections of which the assembly consists:
1) Main CPU board configuration.

2) VADD station testing.
NOTE: ESD precautions must be followed during the entire assembly procedure due to the static
sensitivity of the components involved.
________________________________ _______ _______________________________ _______

SECTION 1: MAIN CPU BOARD CONFIGURATION
The following four steps detail Hurco's required modifications to Intel's cpu board.
STEP 1) PREREQUISITE:
• Position CPU board on a firm, level, static free surface.
STEP 2) STRAPPING:
• Configure the jumpers per 415-0166-904 print.

NOTE: There are a total of three jumpers removed and four added.
• Install the wire wraps as shown in the "LOCAL INTERRUPT MATRIX -904" detail.
STEP 3) COPROCESSOR INSTALLATION:

Using figure 1 as a guide, intstall the Coprocessor (450-1001-043) in the socket as
detailed below.
• Remove the math coprocessor from its antistatic package, being cardful not to touch
the pins on the chip.
• Locate pin 1 of both the socket and the math coprocessor and verify that the pins
and the socket are aligned.
• Insert the math coprocessor's pins in the socket receptacles. Press the chip down
firmly until it seats, being careful not to bend the pins.
NOTE:MAKE SURE THE MAIN BOARD IS SUPPORTED UNDER THE

SOCKET WHEN APPLYING PRESSURE OR DAMAGE TO THE PCB MAY
RESULT.
PIN 1
FIGURE 1
N80387SX-16
MMOX CONNECTOR
STEP 4) BIOS INSTALLATION:
Using Figure 2 as a guide, install the standard 2 MB/42 MB Memory Configuration BIOS (450-
3005-051 and -052) as detailed in the following note.
• NOTE: The JEDEC sites can accommodate 32 pin devices but are configured for 27512
EPROMS, which are 28 pin devices. Therefore, both ODD and EVEN parts should be shifted
such that socket pins 1, 2, 31, and 32 are left unused.
TOPVIEW
D
VE
D
FIGURE 2
O
E
U24 U45 1
2
J9 J10 J11 J12
SECTION 3: FINAL ASSEMBLY
The final assembly is very simple, the only tool required is a flathead screwdriver. Please refer to Figure 3
for a mechanical representation of the following procedure:
FIGURE 3
GRAPHICS BOARD
J8 (415-0220-901)
CPU BOARD
(415-0166-904)
TIGHTEN
6 SCREWS
STEP 1) At this point of the process you should have two (2) distinct pieces of hardware: 1) Hurco SBX
Graphics Board w/nylon fasteners 415-0220-901 and 2) fully configured CPU baseboard.
STEP 2) Remove the three (3) nylon screws from the bottom of the SBX Graphics board and save for
STEP 3. Plug the Graphics Board into the CPU's SBX site J8.
STEP 3) Find the three (3) nylon screws removed in STEP 2. Thread the screws into their standoffs from
the non-component side of the CPU assembly. Firmly tighten all six (6) nylon screws, being
careful not to strip them.
SECTION 4: VADD STATION TESTING
SETUP:
Insure the following on the VADD Station prior to testing the CPU Assembly.
A.) The Hard Drive harness (located on the front of the rack) is in the LOCAL (?) mode.
B.) COM1 and COM2 LOOPBACK connectors are in place on the left side of the rack.
C.) The HARD DRIVE PCB, DUAL AXIS 3 PCB's, and MEMORY PCB are
installed.
D.) That the Graphics CRT is connected to the Hurco SBX Graphics Board.
E.) The PRINTER is connected to the LPT1 port.
F.) The KEYBOARD is connected to the KEYBOARD port.
TEST PROCEDURE:
A.) Insure that the TEST BLOCK is installed on the CPU PCB E113 to E127.
B.) Install the CPU Assembly into the VADD rack in the first slot and connect all associated
harnesses
C.) Apply power to the VADD Station and insure that the RESET LED (located near the power
switch) comes ON, then goes OFF. If the CPU fails to boot, double check all connections.
Return any defective assembly to the manufacturer.
D.) After power up a menu will appear at the bottom of the CRT. Select #1 (CPU TEST).
E.) The CPU Test will start with an inspection of a full screen of test patterns. Press ENTER if OK.
F.) The VADD Station will then go into automatic mode and test the wire wrap and shunt
configuration. If there is a failure check the assembly drawing for the proper wire wrap and
shunt configuration.
G.) The Graphics CRT should be monitored at this time to watch for any failures.
H.) Next the Multibus Memory & I/O is tested. The system will write approximately 1 Meg of data
to the Memory PCB and then read it back. The I/O is located on the Dual Axis 3 PCB.
I.) The last test is the Watch Dog Timer test. It should reboot the system when a count of
approximately 180 milliseconds is reached. All failures will be printed out after the reboot is
complete and #1 (CPU TEST) is chosen agian from the main menu.
R
757-4002-057 REV: C ECN #13312
3/22/96 CAD #D8430
SUBJECT: ENG. DOC., MAX32 CMOS SETUP

B 13659 Corrected battery polarity 3/22/96
C 14302 Made this document exclusive to Max32 “386” 5/19/98
I. INTENT:
To provide instruction on:
1) Installing a battery on the Max32 CPU.
2) Programming HDD and memory settings in CMOS.
II. SCOPE:
Applies to Max32 CPUs that have BIOS version 450-3005-081 (odd) and -082 (even).
III. PROCEDURE:
A. Battery Installation. Before setting up the Max32 CMOS, ensure that a good
Rayovac model 844-1 battery (Hurco 413-8001-019) is installed on the CPU. Installation
is as follows.
1. Feed battery leads underneath the video adapter toward J14.
2. Adhere the battery’s velcro backing to the CPU, centering the battery over U80
and U81 as shown below.
J14
BATT
Responsible Reviewed / Approved
______________________ _______ ______________________ _______

757-4002-057 REV C
3. Plug battery connector into J14, BLK conductor at pin 1, RED conductor at pin 4.
4. When battery is connected, voltage between J14 pins 4 (+) and 1 (-) should read
between 3.6V and 5.0V.
B. CMOS Setup
Description:
Hardware configuration information is stored in a CMOS device on the CPU board. The
device is made nonvolatile when a battery is connected to it. Max32 controls have two
hardware options which are configurable: the hard drive type and the amount of memory.
The new BIOS EPROM set contains a second utility which allows setup of hard drive and
memory on a Max32 machine. The utility was written to communicate with the Max32
console. It only allows access to hard drive and memory setup. The remaining CMOS
setup parameters are always the same.
How to access the utility:

There are two ways to invoke the utility. The first method is automatic. If an existing
configuration mismatch is detected then the utility comes up automatically on system
reset. For example, a system has 4 megabytes of RAM and the user enters 8 in the
config. utility. The next time the control is reset the config. utility will automatically come
up because of the mismatch.
The second method for accessing the utility is to press the CLEAR key immediately
after resetting the control. A message will always appear for approximately 5 seconds
after reset to indicate that pressing CLEAR will invoke CMOS setup. If the CLEAR key
is not pressed then the control will go on and attempt to boot the Ultimax software.
How to use the CMOS setup utility:

The CMOS setup utility has a section for hard drive configuration and RAM
configuration. A blinking cursor indicates which field is being edited. The ADVANCE
and BACK keys are used to scroll through the fields. The ENTER key is used to store
numeric data in the current field. If the value entered is not valid the field is cleared and
the data remains unchanged. To correct an entry press the CLEAR key and start over.
A detailed description of each field follows:
Hard drive type - the acceptable range of values for this field is 1 through 49. Drive
types 1 through 47 are preset and types 48 & 49 are user configurable. The preset types
handle many different hard drives but not all (especially the newer high capacity drives).
Each hard drive type contains parameters for number of cylinders, number of heads,
precomp, landing zone, and sectors per track. Use softkeys 1 & 2 to scroll through the
various hard drive types. If there are no entries which match the drive parameters for
the hard drive in use then type 48 or 49 must be used. The fields for hard drive
parameters (cylinders, heads, etc...) may only be edited when hard drive type is 48 or
49.
#Cylinders - the number (non zero) of cylinders (also known as tracks) for the hard
drive. The proper value should be taken from the spec. sheet for the hard drive in use.
This field can only be accessed when hard drive type is 48 or 49.
#Heads - the number (non zero) of heads (also known as sides) for the hard drive. The
proper value should be taken from the spec. sheet for the hard drive in use. This field
can only be accessed when hard drive type is 48 or 49.
2
757-4002-057 REV C
Precomp. - the cylinder where write precompensation occurs. The proper value should
be taken from the spec. sheet for the hard drive in use. This field can only be accessed
when hard drive type is 48 or 49.
Landing zone - the cylinder location where the heads go when the drive shuts down.
The proper value should be taken from the spec. sheet for the hard drive in use. This
field can only be accessed when hard drive type is 48 or 49.
#Sectors - the number (non zero) of sectors per track for the hard drive. The proper
value should be taken from the spec. sheet for the hard drive in use. This field can only
be accessed when hard drive type is 48 or 49.
Capacity - the number of megabytes storage capacity based on the hard drive
parameters. This field cannot be edited. The number of megabytes is determined with
the formula: CYLINDERS * HEADS * SECTORS PER TRACK * 512 BYTES PER
SECTOR = capacity in bytes.
RAM configuration - the total number of megabytes of RAM installed on the CPU
board. The only acceptable values are 2, 4, and 8.
How to exit the utility:

There are two softkeys which are used to exit the utility. Softkey 8 will write the hard
drive and RAM configuration data to the CMOS device then exit. Softkey 7 will abort
any changes to CMOS and simply exit.
3
R
757-4002-136 CAD #D8531
SUBJECT:
MAX 32 FIELD SERVICE RETROFIT PROCEDURE

MAX 32 Field Service Retrofit Procedure 757-4002-136, Rev. A
RECORD OF CHANGES

By
A 13991 Original Release (Formerly Field Service
Document M32_RETA.doc, Rev. E.)
I. INTENT
To provide a standardized procedure for the retrofitting/upgrading of earlier Hurco

Max 2 Control Systems to the current Max 32 format.
II. APPLICABILITY
The affected machine types are listed inside (refer to Index). This is the only procedure
to be used at customer installations to help achieve factory-proven performance.
III. INDEX
Pages 3 through 5 Pre-installation ‘checkoff’.

Pages 6 through 14 Power Cabinet and Console area hardware modifications.
Pages 15 and 16 The First Power-up.
Page 17 Remote Jog Option.
Pages 18 through 21 Machine Configuration, Machine Steup and Final Checkout.
Pages 22 and 23 Max 32 Dual Axis to DSP Upgrade and Fanuc Orient Card
Setup.
Pages A1 through A5 Reference listing of Max 32 component parts and assemblies.
Page A6 Max 32 Power Supply mounting options.
Pages A7 through A12 ‘In case of trouble’ (Max 32 software recovery sequences).
Pages A13 through A15 Reference document list and Software version applicability.
2
This Document is to be completed upon Installation of the Max32 Retro-fit, returned to Hurco Mfg. Co. along with service
report, and filed with Customer Service Department.
MAX 32 RETROFIT
Date: / /
Company Name:
Address
City, State, Zip
Phone: (____)-
Contact:
Machine Type:
Serial Number:
Hardware Options: Check ONE each line:

Memory (CPU Ram): o 16Mb o 32Mb
Remote Jog: o Yes o No
Axis Controller: o DSP2 o Dual Axis
Software Options: Check ALL that apply:

o 3D o Pocket o Turbo o Exactor
o Probing o Insert o DXF o _________
Software Ver.
Mark items below N/A if Non-Applicable:

Indexer: Make: Model:
Rotary Table: Make: Model:
Probe: Make: Model:
List Anything Special about this machine:
3
Max32 Field Service Retrofit Procedure

Quality at Install Report
The answers to the following questions will help us to judge the overall quality of MAX32 installs. Please be thorough in
filling out this questionnaire. This feedback will allow us to address issues needing attention in a timely fashion. Each
question has an area for a comment, give as much detail as possible and feel free to attach additional pages if needed.
Customer satisfaction is out prime objective. A good, clean, high quality install is the first step in this process.
1) What type of install was this?

Very Good Good Average Below Average Poor
2) Electrical Problems (wiring, circuit boards, adjustments ....) YES NO

COMMENTS:
3) Mechanical Problems
YES NO
COMMENTS:
4) Customer’s responsibilities
YES NO
COMMENTS:
5) Parts shorted (install kit,....) YES

NO
COMMENTS:
6) Extra parts (install kit)

YES NO
COMMENTS:
7) Shipping damage
YES NO
COMMENTS:
PLEASE RETURN SHEET 1 & 2 WITH SERVICE REPORT TO HURCO!!!!
4
I. PRE-INSTALLATION
A. Fill in all Customer & Machine information listed on previous page. Make copies as required and
send in a completed copy with the Service Report.
B. Verify the kit inventory against Options ordered. Refer to Appendix A, Max32 Field Service
Parts Kit.
C. Secure Machine Configuration. Compare the following Secret Screen information with the
current software version (7.24, 8.0, 8.51, 8.52, 8.60):
Refer to FSB 1174-A
1. 100 / 639 Machine Configuration.
2. 101 / 488 Tool Changer Height Setting
Note: need to reset & verify ATC Height upon completion of Retrofit.
3. 102 / 642 Lead Screw Map; save to Floppy Disk and create a hard copy.
4. 103 V8.60 TURBO; for Dual Axis retrofits, record TURBO Accel/Gain
Parameters
D. Have customer save all ULTIMAX II programs to Floppy Disk or use the Ultimax
Communications Utility (CONUPDN.EXE) to save the programs to a PC.
E. You must verify correct operation of Spindle Drive, Axis Drives, Tool Changer, Rotary Axis,
and other functions before proceeding. Make all repairs to the machine before starting the
MAX32 retrofit. DO NOT MAX32 ANY MACHINE THAT IS NOT FULLY OPERATIONAL!!!
F. For Max32 DSP2 upgrades from Max32 Dual Axis, see section XI.
G. Power down the control to begin retrofit.
5
II. CNC POWER CABINET MODIFICATIONS
A. Remove MAXII Power Supply and install MAX3 Power Supply (PS) per appendix C.
Note: check for clearance of door latches and interlock on KM3/3P-nonV2.
B. Power up Machine and test PS DC outputs. Adjust Pot R59 on PS while monitoring the 5VDC
output. Set at 5.2VDC. Fill in chart below.
Note: For machines with CRT Controller 1 BD. Set 5VDC to 5.4VDC
Voltage Pos. Meter Lead Neg. Meter Lead Actual Reading
+24VDC J2-1(blu) J2-7(gry) ____________
+24VDC J2-2(blu) J2-8(gry) ____________
+12VDC J2-3(brn) J2-9(gry) ____________
+12VDC J2-4(brn) J2-7(gry) ____________
+12VDC J2-5(brn) J2-8(gry) ____________
-12VDC J2-6(org) J2-9(gry) ____________
+5VDC J2-10(yel) J2-7(gry) ____________
+5VDC J2-11(yel) J2-8(gry) ____________
+5VDC J2-12(yel) J2-9(gry) ____________
C. Card Rack Area.
1. Inspect and clean the Card Rack. If the card rack is excessively dirty, the customer
is to be billed seperately.
2. Remove the following PCBs and RETURN THEM TO HURCO:

a. CPU/RS232/GRAPHICS PCB ASSY
b. MEMORY PCB
c. DISK CONTROLLER PCB
d. If DSP2 Option, remove the DUAL AXIS PCBs.
D. Install ribbon cable(423-6823-005) onto HDD/SNOOPER Board assembly
6
F. Remove and discard the existing COMM Panel/HR Meter from side of cabinet.
1. Install "NEW" FDD into COMM Panel, using the following hardware supplied in the
Parts Kit:
101-5006-002 M3 x 8 SHCS 4 pc
110-0067-004 M3 Internal Lockwasher 4 pc
FDD J2 TB4
1 (GREEN) +5VDC
2 (BLACK) RET
3 (WHITE) RET
4 (RED) +12VDC
2. Mount the MAX32 COMM PANEL ASSY (002-2541-004) per machine type chart
below:
Mactype Where to mount.
BMC-V2 Use existing cut out.
BMC-V1 Use existing cut out.
BMC-OEM Use Enclosure Box (MAX II Disk Drive Box)
KM5 Use existing cut out.
KM3/3P-V2 Use existing cut out.
KM3/3P-nonV2 Use Enclosure Box (MAX II Disk Drive Box)
3. Use the Disk Enclosure Box (002-3413-006) to mount the COMM Panel in machines
that do not have a cut out. This will require a 1-1/2 inch conduit Knock-out Punch and a 3/8
inch drill bit.
4. Route COMM 1 & 2, FDD, & Parallel cables up to CPU in Rack. Dress all cables into
panduit for a neat appearance.
5. Locate the Security button and install into button holder on Parallel Port.
6. BMC-V2, KM3/3P-V2, & KM5 use a 24VDC Hour Meter. Remove the original Hour meter
and install it into new panel. The KM3/3P non-V2 and BMC-OEM/V1 original Hour meter is
115VAC. Use the following chart to hook up & rewire the NEW 24VDC Hour meter or
leave the current Hour meter as is:
Machine type Relay Panel +24VDC COM

KM3/3P nonV2 KRP1 TB3-28 TB3-39
BMC-OEM/V1 CRP1 TB3-12 TB3-17
BMC-V2 and KM5 Note: GND Wire (Shields) attach to CRP2 TB2 RTN Terminal
KM3/3P-V2 Note: GND Wire (Shields) attach to Gnd Term Block left of Card Rack.
7
G. Install CPU PCB ASSY & SNOOPER PCB ASSY into card rack per Card Rack Decal.
Note: The old P2 Ribbon cable that was on the MAX-II CPU is no longer required; fold into the
panduit.
H. Remove & return to HURCO the Old Dual FDD's if so equipped. Install blank cover plate
(802-2600-086) plate from Retrofit kit. Use the M5 x 12MM BHCS, M5 Hex nut, and M5
Washers. Drill cabinet and add BHCS as required to fill all holes.
I. For BMC-OEM/V1 or KM3/3P-nonV2, add a D-body pin & wire/jumper from MP J1-18 to
DC Common to disable the CHIP DOOR INTERLOCK error Message.
NOTE: Cut wire at MP J1-18 leaving enough wire on pin to solder a length of
green wire (supplied in Max32 kit) long enough to route to DC Common.
If no pin exists in MP J1-18 use the Pins form the console area modification
leaving about1/4 inch of wire on the pin when you cut it out of console
harness (J61).
8
III. CONSOLE AREA MODIFICATIONS
A. Remove J61 (DB50 connector) from FPCC PCB. Remove the shell and remove the following
pins with pin extraction tool:
1. 4 (White)
2. 20 (Red)
3. 21 (Black)
4. 37 (Green)
5. 38 (Brown)
Cut-off pins and strip 1/8" of insulation for each conductor.
Note: When cutting pins leave a small amount of wire. You might need them later.
B. Solder the CRTC/MP Harness (423-6202-099) to these wires, matching the color code. Utilize
1/8" heat shrink on all 5 connections. Reassemble the D shell and dress cable properly. Route the
CRTC/MP adapter harness to the P1 connector on the CRT Controller PCB.
Note: The Green wire on J1-2 mates with P1-4 on CRT Controller PCB. The Green wire
is on Top-Front, when looking at PCB with the Console lid open.
C. For CRT Controller 1 PCB (415-0174-001), install MAX2-32 2716 CRT EPROM
(450-3001-192) in IC socket U18.
D. For CRT Controller 2 PCB (415-0174-002), install MAX 2-32 2764 CRT EPROM
(450-3001-193) in IC Socket U17.
E. On CRT Controller 2 PCB, ensure that Jumper X3A is set to 2-3.
9
IV. PCB MODIFICATIONS

A. Perform the following modifications to all of the Dual Axis PCB’s (type 1 and 2) and the Machine Personality PCB.
If DSP2 Option, only modify the Machine Personality PCB.
PCB Type Cuts Note: Cut the Pin on the IC, between
DA-1 U60-13 the IC Body and PCB surface, and
DA-2 U42-13 bend the pin away from IC body. DO
MP-1 U67-6 NOT CUT PCB TRACES OR LANS
MP-2 U67-6
MP-3 U80-3
B. For Machine Personality PCB 1, change the following Jumpers (note that S3-8 must be ON for all machine
types):
MP1 Jumper
TB1 1-2
TB6 5-8
TB7 4-9
Note: Be carefull not to break off TB1 when installing MP PCB.
C. For Machine Personality 2 and 3 PCBs, change the following Jumpers:
MP2 or MP3 Jumper

SP1 1-2
SP6 1-2
SP7 1-2
D. Install the Console Accelerator PCB into the Machine Personality PCB. Be sure to align the notch on the 8251 IC
with the notch on the Console Accelerator PCB. Remove the 8251 IC (U42) from socket, and install the Console
Accelerator PCB (415-0256-001) into IC socket U42. Carefully re-install the 8251 IC into the Console
Accelerator PCB as pins on the Console Accelerator PCB are very brittle and break easily!
E. For all BMCs, set SW1 switches(ON PERSONALITY BOARD) to OFF to force new software to read new
machine type from CRP switches. Note that V1.52 (or greater) no longer reads any machine type switch setting;
machine type is set in the Machine Configuration screen for these versions.
F. For Dual Axis Option, install the appropriate firmware:

MACHINE TYPE AXIS SPINDLE ROTARY
KM3/3P (all) 450-3010-007 450-3001-317 450-3001-363
KM5P 450-3010-007 450-3001-317 450-3001-366
BMC-OEM/V1 450-3010-007 450-3001-388 450-3001-362
BMC-V2 450-3010-007 450-3001-514 450-3001-366
40SLV 450-3010-007 450-3001-513 450-3001-366
Note: Must use above EPROMs. If not in kit, order EPROMs needed!!!
If BMC-20LR and Exactor Option, refer to TIN 1031.
V. MODIFICATIONS FOR DSP2 OPTION

10
A. For BMC-V2
1. Remove D-body shell at AC1/J2 of the SPINDLE Harness (423-6806-006).
2. Push out Pin 13 (Gray) using the Pin Extraction Tool and heatshrink to insulate.
3. Locate Spindle Harness (2CN to S2CN), PN 423-6800-004, from the retrofit kit.
Attach the end with the gray Honda connector to the Yaskawa Spindle Drive 2CN
socket. Route the other end of the Harness through Panduit to AC1/J2 at Card Rack.
4. Remove all six pins from the plug labeled S2CN with a pin extraction tool. Discard
plug. Cut off all 3 black wires and heat shrink to insulate.
5. Install remaining pins into AC1/J2 as follows:
AC1/J2 Color 2CN

12 Red 17
25 White 19
13 Green 15
6. Locate the 1CN connector on Yaskawa Spindle Drive, and remove shell.
7. Use the Pin Extraction Tool and remove the jumper from 1CN-12 to 1CN-28.
Discard jumper.
8. Insert the female pin of the Gray Wire Harness (423-6836-001) into 1CN-12 and
re-assemble shell body. Route the Harness through pandunit to AC1/J2 connector.
Remove Pin AC1/J2-18. Heatshrink and tiewrap to insulate. Insert Pin from
Harness routed from 1CN-12 into AC/J2-18. Reassemble shell and dress harness
with tie wraps.
B. For BMC-OEM/V1, modify the AC1/J2 (423-6802-006) SPINDLE harness as follows:
1. Remove D-body shell AC1/J2.
2. Push out Pin 13 using Pin Extraction Tool and reinsert into Pin location 21.
3. Wrap with heatshrink and reattach D-body shell.
11
C. For KM3/3P-V2, KM5P - no modifications are required to any harness.

Note: KM3/P-V2/MAX400 AMPS(Set P8 & P9 to 2-3/if P8 & P9 not present add
15 ohm resistor between E4 and E6. NOTE: CUT TRACE BETWEEN E4 & E6
BEFORE INSTALLING RESISTOR!
D. For KM3/3P-nonV2:
1. Modify the AC2/P2 (423-6182-002) Y AXIS harness as follows:
a. Remove the D-body shell AC2/P2.
b. Push out Pin 17 using the Pin Extraction Tool and reinsert into Pin location 5.
c. Push out Pin 24 using the Pin Extraction Tool, strip insulation 3/8” above the pin,
and add solder.
d. Solder short jumper wire to Pin 24 wire (black) and heatshrink.
e. Reinsert Pin 24.
f. Attach other end of short jumper to Pin and insert into Pin location 23.
g. Reattach D-body shell.
2. Modify the AC1/P2 (423-6184-002) as follows:
a. Remove the D-body shell AC1/P2.
b. Push out Pin 17 using the Pin Extraction Tool and reinsert into Pin location 5.
c. Reattach D-body shell.
E. Configure Jumpers on DSP2 PCB per Engineering Document 757-4002-047, MAX32 DSP2
Jumper Settings (use 415-0247-902 for reference only).
Check that jumpers JU33 through JU36 (marker) are set properly for the Encoder Marker type.
F. Remove all Dual Axis PCBs and install the XYZS DSP2 PCB into slot next to Personality PCB.
If Rotary A or Rotary/Tilt AB, install AB DSP2 PCB into the next available card rack slot, and
configure per Engineering Document 757-4002-047.
Note: SW1 switches are all off for XYZS configuration and only SW1-1 is set to on for AB
configuration.
12
G. Plug Cables into DSP2 PCB per table below and use a permanent marker to re-label connector
plugs:
Dual Axis OLD LABEL AXIS DSP2 NEW LABEL

AC1-J1(P1) Z DSP2-J7
AC1-J2(P2) S DSP2-J8
AC2-J1(P1) X DSP2-J5
AC2-J2(P2) Y DSP2-J6
AC2-J1(P1) a DSP2-J5
AC2-J2(P2) b DSP2-J6
H. Interrupt Cycle Push Button Installation:
1. Place the Max 32/DSP Interrupt Cycle decal above the E-Stop switch and mark center
location.
2. Make a hole in console lid using a 59/64 inch drill bit, a 3/4 inch knock out punch, or a 7/8”
hole saw.
3. Install Interrupt Cycle decal (703-1005-382) and Max32 Interrupt Harness

(423-6835-001).
Dissassembly of the Interrupt Harness may be required to install the pushbutton. The
conductor wiring at the Max32 Opt/Interface PCB TB1 connector for the Interrupt Cycle
pushbutton is as follows:
TB1 COLOR
1 Black
2 Brown
3 Red
4 Orange
4. Remove the P104, P105 and P106 ribbon cables from the Program Entry PCB. Using a pair
of diagonal wire cutters clip the locking tabs off the three connectors.
5. Install the Max32 Option Interface PCB (415-0259-00x) using 5 standoffs and 4-40 nylon
screws supplied in kit. Make a Ground lead from the upper left screw to the Mecca ground
stud in the bottom of Console.
Note: use the PHMS 4-40 metal screw on this ground lead.
6. Reconnect the P104, P105, & P106 ribbon cables to the Max32 Option Interface PCB.
13
7. Plug in the Interrupt Cycle Push Button to TB1 on the Max32 Option Interface PCB.
Connect wires per following table:
TB1- Color Signal TO

7 Black +24V_RTN FPCC TB52-8
6 Red +24V DC FPCC P56-2 (Splice to red wire)
5 Orange Lamp_Signal FPCC J61-29 (remove pin 29, splice
together, & shrink wrap; do not
reinsert)
8. If there is no Remote Jog Unit attachment to the Max32 Option Interface PCB then short all
of the JP1 Jumpers (per 415-0259-002). If there is a Remote Jog Unit attached then set all of
the JP1 Jumpers open (per 415-0259-003). See section VII for Remote
Jog installation.
VI. POWER UP:
14
Since Max32 Dual Axis software has already been factory loaded, the first boot-up should be
uneventful. However, if problems are encountered, please refer to alternate bootup and recovery
techniques in the Appendix section of this document.
The following sequence of events should occur upon first power-up of MAX 32:
1. Observe that the green LED on CPU PCB is "ON" (will then flicker during normal operation).
The Yellow LED should never be on; if it is, it indicates that there has been a Bus timeout (a
system fault).
NOTE: the BIOS information will not be displayed; the screen will be blank with the cursor in
the lower left corner.
2. The BIOS will perform a memory check of Base Memory and Extended Memory.
NOTE: the memory check information will not be displayed; the screen will be blank with the
cursor in the lower left corner. If cursor does not display verify TP1/SP1 on MP PCB.
3. Drive is active (per the BIOS). If this does not occur then the Floppy Drive is not being
recognized by the BIOS and the system bootup will halt (no error message will be displayed on
the CRT).
4. The BIOS will then search for the Boot Sector on the Floppy Disk Drive first and, if not found,
then the Hard Disk Drive.
a. If the HURCO.LDR is found then the CRT Driver is loaded followed by the display
of the “Loading Executive, Please Wait” message.
b. If DOS is found on the Floppy Disk Drive diskette then the COMMAND.COM is
executed (unless replaced by the AUTOEXEC.BAT file) which prompts for the
Current Date followed by the Current Time (neither of the prompts are displayed on
the CRT).
NOTE: if an AUTOEXEC.BAT file is used, ensure that the INT10.EXE file is the
first command, which will load the CRT Driver.
c. If neither the HURCO.LDR or DOS is found on the Floppy Disk Drive or the Hard
Disk Drive then the system will stop executing indefinitely.
NOTE: no error message will be displayed; this most frequently occurs if a
non-system diskette is in the Floppy Disk Drive on power up.
1. After following the Max32 Bootup Sequence, the Personality Status LED will SOON latch on and
the Front Console LEDs will all be lit. The “Loading Executive...” message will then be erased.
2. The Text CRT will then display:
Front Panel Initialized. Serial CRT System
15
Memory Manager Initialized
Insert the Machine Configuration disk to load Config files
At the prompt to insert the Machine Configuration disk, press the CLEAR key followed by
the INC key to load the defaults. The following two error messages will then be displayed:
a. CAUTION: DEFAULT MACHINE CONFIGURATION PARAMETERS HAVE
BEEN LOADED.
b. LEADSCREW MAP NOT FOUND. DEFAULTS HAVE BEEN LOADED
3. Insert the proper Machine Configuration Parameters per TIN 1061.
4. Install the Leadscrew Compensation per TIN 1063.
5. Next, load any Optikey Software Option diskettes.
VII. REMOTE JOG OPTION
1. Remove the Override Pots and Incremental Encoder from the Console lid.
16
2. Install the Remote Jog unit carrier plate (PN 902-1509-007) and spacer plate
(PN 802-2642-035) using the 3/8” nuts and lockwashers supplied in kit.
3. Drill a 59/64” hole in the bottom of Console near the Mecca ground stud. Use a 3/4” NPT
pipe tap and tap the hole.
4. Install the Remote Jog Harness through hole and tighten against the Console shell.
5. Remove the P104, P105 and P106 ribbon cables from the Program Entry PCB. Using a pair
of diagonal wire cutters clip the locking tabs off the three connectors.
6. Install the Max32 Option Interface PCB (415-0259-003) using 5 standoffs and 4-40 nylon
screws supplied in kit. Make a Ground lead from the upper left screw to the Mecca ground
stud in the bottom of Console.
Note: use the PHMS 4-40 metal screw on this ground lead.
7. Reconnect the P104, P105, & P106 ribbon cables to the Max32 Option Interface PCB.
8. Plug the Jog harness into J2 of the Max32 Option Interface PCB. All of the Jumpers at JP1
should be open.
9. Remove Incremental Jog handwheel and the Override pot knobs and install Decal (the kit
contains a decal for BMC and for KM3/3P). For KM3/3P machines, remove the Spindle
Override pot, cut wires and use appropriate decal.
10. Check that Jumpers RJU/JP1 and RJU/JP2 in Remote Jog Unit are both set to 2-3.
VIII. MACHINE CONFIGURATION SCREEN
A. Enter Machine, Axis, and Spindle Configuration Parameters per the Engineering Document 757-
4002-031 for Dual Axis, or 757-4002-034 for DSP2 as listed in Appendix D.
17
1. Select AUXILIARY mode.
2. Select the SYSTEM CONFIGURATION softkey.
3. Select the MACHINE CONFIGURATION softkey.
4. Enter "Enter, 100, Enter" to enter into the Machine Configuration Edit screen.
NOTE: the Control may reboot after entering certain parameters but the parameters
will automatically be saved to the Hard Drive before the reboot occurs.
B. Enter the Dual Axis Turbo (if required), or the DSP2 Axis Tuning Parameters.
1. Select MANUAL mode.
2. Select the CHANGE TOOL OR DIAGNOSTICS softkey.
3. Select the ATC AND MACHINE DIAGNOSTICS softkey.
4. Enter “Enter, 103, Enter” to display the Turbo setup for Dual Axis systems (if required)
or the Axis Tuning Parameters for DSP2 systems.
C. Enter the Lead Screw Map.
1. In Manual mode, the machine must be calibrated.
2. Select the CHANGE TOOL OR DIAGNOSTICS softkey.
3. Select the ATC AND MACHINE DIAGNOSTICS softkey.
4. Enter “Enter, 102, Enter” to access the Lead Screw Map Setup screen.
5. Load in the original Lead Screw Map

a. from the Machine Configuration Disk, or
b. by selecting the Dual Axis Defaults softkey (if Dual Axis system), or by
c. manually entering the compensation for both the Forward and Reverse Maps for
each axis.
6. Backlash Compensation may be added to the Map by selecting the BACKLASH

COMPENSATION softkey, or if Dual Axis Option, by setting the appropriate switches
on the Dual Axis board.
(Note that the Backlash Compensation does not take the place of the Reverse Map; at a
minimum, the Reverse Map should be identical to the Forward Map with compensation
added to the values, or using the switches on the Dual Axis PCBs.)
18
7. Save the Lead Screw Map to the Hard Drive and to the Machine Configuration Disk.
IX. MACHINE SETUP AND VERIFICATION
A. Setup Servo Amps per the following Engineering Documents:
1. For BMC-V2 and KM5P (Yaskawa Servo Drive);

a. Dual Axis Option: 757-4001-092
19
b. DSP2 Option: 757-4002-007
2. For BMC-OEM/V1 (Fanuc Servo Drive):

b. DSP2 Option:
3. For KM3/3P-V2 and 40SLV (MAX400 Servo Drive):

b. DSP2 Option: _______________
4. For KM3/3P-nonV2 (Randtronics Servo Drive):

a. Dual Axis Option: ____________
b. DSP2 Option: ____________
B. Setup Spindle Drive per Engineering Document
1. For BMC-V2 (Yaskawa Spindle Drive):

b. DSP2 Option: 757-4002-008
2. For BMC-OEM/V1 (Fanuc Spindle Drive):

a. Dual Axis Option:
I. Fanuc AC3S/18P/22P: 757-4001-073
II. Fanuc Digital: 757-4001-061
III. Fanuc Analog: 757-4001-062
b. DSP2 Option:
3. For KM5P ASC: 757-3012-020
C. Set Load Meters per Engineering Document

1. For BMC-V2:
a. Dual Axis Option: __________
b. DSP2 Option: 757-4002-023
D. Verify Full Machine Travel Limits by running a Cycle program with Tool Change Position
parameter set to YES.
E. Set/Verify ATC Height. Cycle ATC 100 times (if applicable).
X. FINAL CHECKOUT
A. Remove the old Card Rack layout Decal from door, and install new Decal from Kit.
B. Remove the Mil or DB25 connector on the customer’s RS232 cable and install the DB9
connector from the Kit to this cable. Verify that the Serial Ports function properly.
20
(see appendix A from Max 32 programming manual, PN 704-0001-651)
C. Instruct customer on the usage of the C Hard Drive and the A Floppy Drive. Assist customer in
loading ULTIMAXII programs into the control and saving programs to the Hard Drive.
Note: ULTIMAX II had a 12 Character File Name Limit while Max32, being DOS- based, has
an 8 Character File Name Limit (cannot use the 3 character extension; it must be HDB or HD3).
Longer file names will be prompted to rename.
D. Verify that all Options are installed and accessible and instruct the customer on any new Software
Options that were purchased with this Retrofit.
E. Make a copy of the Machine Configuration Parameter sheet for this machine and note any
variations for this Machine on the sheet Leave a copy with the Machine Configuration Disk
for future reference.
F. If any parameters were changed from the default setting then also send a copy along with the
Service Report and include an explanation for the modification.
G. Service installation charges are variable or included with the purchase price. Verify with Regional
Service Manager for the correct charge.
XI . MAX32 DUAL AXIS TO DSP UPGRADE
A. Verify all machine functions.
B. Save all Dual Axis configuration files and leadscrew mapping to disk.
C. Upgrade Executive from Dual Axis to DSP.

21
D. Power down the control.
E. Boot Dos (w/int 10).
F. Delete Config\V1_XX contents.
G. Replace the Dual Axis boards with the DSP board and make modifications per the
DSP upgrade procedure. See Section V.
H. Power the control up.
I. Hit the CLEAR key, then the INC key to bypass each prompt to insert the machine
configuration disk.
J. Depress Manual, ATC & Machine Diagnostics, Machine Diagnostics. Hit the
<ENTER> key, type <103>, hit the <ENTER> key.
After entering all axis tuning parameters, you must BEGIN TUNE and STORE
AXIS PARAMETERS for each axis.
K. Go to Auxiliary, System Configuration, Machine Configuration, hit the

<ENTER> key, type <100>, hit the <ENTER> key and enter all axis parameters
and machine parameters.
L. Exit. (The control will reboot and store all configuration parameters.)
M. Verify all machine functions.
N. Load the leadscrew mapping parameters into the machine. Depress Manual, ATC
& MACHINE DIAGNOSTICS, MACHINE DIAGNOSTICS. Hit the
<ENTER> key, type <102>, hit the <ENTER> key. Select LOAD DATA FROM
DISK and select the floppy drive. Select the STORE DATA ON DISK softkey
and select HARD DRIVE. Verify leadscrew mapping loaded to hard drive.
O. Save DSP configuration files and leadscrew mapping to floppy disk.
XII. MAX32 DSP FANUC ORIENT CARD SETUP
A. Goto SPINDLE CONTROL TYPE in the ENTER 100 ENTER screen and
change the SPINDLE CONTROL TYPE from OPEN LOOP to CLOSED
LOOP.
B. Follow Engineering Document 757-4001-060
22
C. After completing setup change the SPINDLE CONTROL TYPE back to OPEN
LOOP VELOCITY.
D. Verify orient operation. Cycle the tool changer.
23
Appendix MAX32 PARTS, DOCUMENT and RECOVERY REFERENCES 757-4002-136, Rev. A
PART NUMBER DESCRIPTION UM QUANTITY

002-2516-019 KIT, MAX2-32 CUSTOMER
704-0001-598 MANUAL, ULTIMAX 3 PROGRAM PC 1
704-0001-628 MANUAL, MAX 3 NC PROGRAMMING PC 1
704-0001-651 MANUAL, MAX32 PROGRAMMING PC 1
705-0001-047 PROGRAM PAD, ENGLISH PC 1

002-2541-004 ASSY, MAX32 COMM. PANEL
108-5002-001 BHSCS, M4 X 0.7 X 8MM DIN PC 2
108-5002-002 BHSCS, M4X7X10 BHCS PC 2
108-5002-003 BHSCS, M4X.7X12 PC 4
110-0066-006 LOCKWASHER,M4 EXT TOOTH PC 6
117-1002-001 NUTSERT, M4 PC 6
117-1002-006 NUTSERT, M3 X 0.5 PC 2
405-1003-003 HOURMETER, 24VDC STEMCO PC 1
406-0961-019 DUST CAP, DB25 ANTI-STATIC PC 1
406-0961-020 PANEL BASE,WITH HOOD T&B PC 1
406-0961-023 DUST CAP, DB-9 PINS MALE PC 2
406-0963-004 REAR PANEL MOUNT JACK SKT ST 3
416-0003-010 SOFTWRE SEC. BUTTON HOLDER PC 1
423-6822-004 HARNESS, MAX3 PARALLEL PC 1
423-6821-003 HARNESS, MAX3 RS232 PORTS PC 1
703-0006-149 LABEL,PORT 1 PC 1
703-0006-150 LABEL,PORT 2 PC 1
802-2602-029 BRACKET,HD FLOPPY DISK MTG PC 1
802-2600-051 PLATE, MAX2-32 COMMON PC 1
416-0003-009 SOFTWARE SECURITY BUTTON PC 1

007-3003-003T ASS’Y, MAX 32, 486 CPU (tested & configured)
007-3003-003 ASS’Y, MAX 32, 486 CPU
415-0624-901 PCB ASS’Y, MULTIBUS, 486 CPU PC 1
415-0220-901 GRAPHICS PCB ASS’Y PC 1
415-0250-903 SIMM, 72 PIN, 8MB PC 2

002-3409-003 PKG, MAX3 UPGRADE DISK PROTECTION
614-0002-094 BOX, UNFOLDED MAX BOX W/LABEL PC 1
614-0004-007 FOLDER, ULTIMAX SOFTWARE PC 1
614-0007-004 BAG, 3 X 5 ANTISTATIC PC 1
703-1005-264 LABEL, ATTN STAT SENS CONT PC 1
703-1005-350 LABEL, NOTICE READ AGREE PC 1
712-0001-009 FOAM, CORE INSERT PC 1

415-0177-9077T PCB ASS’Y, MACHINE PERSONALITY 3 (Tested)
415-0177-907 PCB ASS’Y, MACHINE PERSONALITY 3 PC 1
A-1

002-3413-006 ASSY, MAX2-32 DISK
108-5005-003 BHSCS, M8X16MM DIN9427 PC 1
109-0001-003 PHMS, 4-40X1/4 PC 1
109-6010-004 PHMS,4-40 X 1/4 NYLON PC 4
110-0129-010 STANDOFF, NYLON PCB PC 5
406-2005-030 WIRE, 18 GA GREEN/YELLOW FT 1.4
406-7001-006 RING TONGUE, #6 18/22 GA PC 1
415-0259-002 PCB, MAX32 OPT INTERFACE PC 1

002-3507-004 ASSY, MAX32 REMOTE JOG
110-0200-001 RUBBER BUMPER PC 4
404-0083-003 CONTACT BLOCK PC 1
404-4161-009 PUSHBUTTON ACT.,RED,MUSHROOM PC 1
404-4161-010 FLANGE, EMERGENCY STOP PC 1
406-1688-001 WIRE, 300V, 22 AWG, BROWN IN 10
406-1688-002 WIRE, 300V, 22 AWG, RED IN 5
406-1688-003 WIRE, 300V, 22AWG, ORANGE IN 10
406-1688-004 WIRE, 300V, 22 AWG, YELLOW IN 10
406-1688-005 WIRE, 300V, 22 AWG, GREEN IN 10 For
406-1688-006 WIRE, 300V, 22 AWG, BLUE IN 10 Reference
406-1688-007 WIRE, 300V, 22 AWG, VIOLET IN 10 only
406-1688-008 WIRE, 300V, 22 AWG, GRAY IN 10
406-1688-009 WIRE, 300V, 22 AWG, WHITE IN 10
406-1688-010 WIRE, 300V, 22 AWG, BLACK IN 5
407-0011-073 POT,CTS#UA3825,10K,LINEAR PC 2
415-0270-005 PCB, MAX32 REMOTE JOG PC 1
416-0248-063 ENCODER, PANEL, 120 CPR PC 1
603-1001-016 KNOB, MS91528-3S2B CRANK PC 1
603-1001-017 KNOB, MS91528-1HH2B DOUBLE PC 2
423-4401-143 ENCODER HARNESS, (W/RESISTORS) PC 1

002-3507-006 OPTION, MAX32 REMOTE JOG
002-3507-004 ASSY, MAX32 REMOTE JOG PC 1
110-0066-012 LOCKWASHER,EXT M8 PC 3
110-5001-005 WASHER,FLAT M8 PC 3
117-5015-001 HEX NUT, M8 PC 3
423-6831-002 HARNESS, MAX2/32 REMOTE PC 1
614-0002-027 BOX, 18" X 12" X 10" PACK PC 1
703-1005-381 LABEL, MAX32 KMILL PC 1
703-1005-385 LABEL, MAX32 REMOTE JOG PC 1
802-2642-035 PLATE, SPACER MAX2/32 PC 1
902-1509-007 TRAY, MAX2/32 REMOTE JOG PC 1
A-2

007-3432-001 RETROFIT KIT, MAX2-32
002-2541-004 ASSY, MAX32 COMM. PANEL PC 1
007-3003-003 ASS’Y, MAX32, 486 CPU PC 1
007=0019-001 ASSY, MAX32 HD PC 1
101-5006-002 SHCS, M3X.5X8 PC 4
108-5003-003 BHCS, M5 X 10 PC 2
108-5003-004 BHCS, M5 X 12MM PC 16
110-0066-009 LOCKWASHER,M5 EXT TOOTH PC 20
110-0067-004 LOCKWASHER,M3 INT TOOTH PC 4
117-5012-001 HEX NUT, M5 PC 18
406-0803-241 SHUNT, 2 POSITION 1/4 HEIGHT PC 10
406-0804-030 CONNECTOR SHELL, 9 POS PC 2
406-0965-004 FERRULE, 18 AWG RED PC 3
406-0965-007 FERRULE, 14 AWG YELLOW PC 15
406-2003-022 WIRE, 14GA GREEN/YELLOW IN 96
406-2005-030 WIRE, 18 GA GREEN/YELLOW FT .5
406-4005-067 CONNECTOR,FEML W/LATCHES PC 1
406-5001-006 TIE WRAP, MEDIUM PC 12
406-5001-015 TIE WRAP MOUNT,PANDUIT PC 10
406-0521-014 CABLE HOOD,9 CONTACT SIE PC 2
406-6481-001 HEATSHRINK, 1/16" IN 6
406-6481-005 HEATSHRINK, 3/8" BLACK IN 6
406-6481-006 HEATSHRINK, 1/2" BLACK IN 6
406-7001-041 SPADE LUG, #8 16/22 GA RED PC 3
406-7505-010 CLAMPS, RIBBON CABLE 2" PC 5
413-0008-013 POWER SUPPLY, QUAD OUT SW PC 1
415-0256-001 PCB, CONSOLE ACCELERATOR PC 1
423-0129-003 HARNESS, MAX32 AC POWER PC 1
423-6202-099 HARNESS, MAX2-32 CRTC/MP PC 1
423-6208-008 HARNESS, MAX2-32 DISK PC 1
423-6823-005 HARNESS, MAX2-32 HARD PC 1
423-6823-007 HARNESS, MAX2-32 FLOPPY PC 1
426-0056-007 DISK DRIVE, 3.5" FD 1.44M PC 1
427-0005-003 FLOPPY DISK, BLANK 3.5" HT PC 10
450-3001-192 EPROM, MAX2-32 2716 CRT PC 1
450-3001-193 EPROM, MAX2-32 2764 CRT PC 1
614-0002-069 BOX, 200# 25 X 17 X 11 7/8 PC 1
703-0006-182 LABEL, MAX2-32 CARD RACK PC 1
802-2600-086 COVER PLATE, MAX32 PC 1
802-2602-012 BRACKET,POWER SUPPLY MOUNT PC 2

002-3513-005T PCB ASSY, MAX32 HD
614-0009-005 BOX, ANTISTATIC 14 X 11 PC 1
708-0001-004 BAG, 15 X 18 STATIC SHIELD PC 1
007-0019-001 PCB ASS’Y, MAX32 (Dual Axis sftwr)
426-0056-017 HARD DRIVE, 3.5” IDE PC 1
108-0002-001 BHCS, 6-32 X 1/4” PC 5
110-0061-002 LOCKWASHER, #6 EXT TOOTH PC 5
415-0254-001 PCB ASSY, MAX2-32 SNOOPER PC 1
A-3

002-3520-001 MAX 32 DSP2
109-0001-003 PHMS, 4-40X1/4 PC 1
109-6010-004 PHMS, 4-40X1/4 NYLON PC 4
406-0802-066 CONN, IDC TAP 22-16 AWG PC 2
406-5001-003 TIEWRAP, SMALL PC 5
406-7001-006 RING TONGUE, #6 18/22 GA PC 1
415-0247-003T PCB, DSP2 XYZS MOTION PC 1
423-6800-004 HARNESS, CRP/S2CN TO SPINDLE PC 1
423-6835-001 HARNESS, MAX32 INTERRUPT PC 1
423-6836-001 HARNESS, MAX32 SERVO PC 1
614-0002-078 BOX, HARD DRIVE ASSY PC 1
703-1005-382 LABEL, MAX 32 INT CYCLE PC 1

415-0250-904 SIMM, 72 PIN, 16MB (“32MB Option”) PC 2

002-3520-002 OPTION, MAX 32 REMOTE JOG
002-3507-006 OPTION, MAX32 REMOTE JOG PC 1
109-0001-003 PHMS, 4-40X1/4 PC 1
109-6010-004 PHMS, 4-40X1/4 NYLON PC 4
406-0802-066 CONN, IDC TAP 22-16 AWG PC 2
406-5001-003 TIEWRAP, SMALL PC 5
406-7001-006 RING TONGUE, #6 18/22 GA PC 1
415-0247-003 PCB, DSP2 XYZS MOTION PC 1
423-6800-004 HARNESS, CRP/S2CN TO SPINDLE PC 1
423-6835-001 HARNESS, MAX32 INTERRUPT PC 1
423-6836-001 HARNESS, MAX32 SERVO PC 1
614-0002-078 BOX, HARD DRIVE ASSY PC 1
703-1005-382 LABEL, MAX 32 INT CYCLE PC 1

002-3520-004T OPTION, MAX 32 4TH/5TH
415-0247-004 PCB, DSP2 ROTARY MOTION PC 1

002-4121-011 PKG, MAX 32 DA V1.4X (4M)
002-3409-003 PKG, MAX3 UPGRADE DISK PROT PC 1
427-0005-003 FLOPPY DISK, BLANK 3.5” HD PC 2
703-0010-003 LABEL, BLANK DISKETTE PC 4
704-0004-013 INSTRUCTION, MAX3 SOFTWARE PC 1
704-0020-008 LIST, MAX32 V1.4 SOFTWARE PC 1
A-4

002-4121-012 PKG, MAX 32 DSP V1.4X (4M)
002-3409-003 PKG, MAX3 UPGRADE DISK PROT PC 1
704-0004-013 INSTRUCTION, MAX3 SOFTWARE PC 1

002-4123-008 PKG, MAX 32 DA V1.3X BMC/KM
002-2516-019 KIT, MAX2-32 CUSTOMER KI 1
416-0003-002 SOFTWARE PROTECTION KEY PC 1
450-3001-317 EPROM, KMILL I/O CONTROLLER PC 1
450-3001-366 EPROM, ROTARY AXIS PC 2
450-3001-388 EPROM, 20-50 OEM/V1 SPINDLE PC 1
450-3001-513 EPROM. V2 DIAG SPINDLE PC 1
450-3001-514 EPROM, 20-50 V2 SPINDLE PC 1
450-3010-007 EPROM, 2732A AXIS PC 1
708-0001-013 FOLDER, MAX3 SOFTWARE DISK PC 1
712-0002-005 BAG, 13”X18” ZIPLOC PLASTIC PC 1

002-4123-009 PKG, MAX 32 DSP V1.3X V2
002-2516-019 KIT, MAX2-32 CUSTOMER KI 1
416-0003-002 SOFTWARE PROTECTION KEY PC 1
708-0001-013 FOLDER, MAX3 SOFTWARE DISK PC 1
712-0002-005 BAG, 13”X18” ZIPLOC PLASTIC PC 1
A-5
Old PS Mounting Holes
Drill "NEW" 7/32" Dia. Thru Hole Drill "NEW" 7/32" Dia. Thru Hole
2 Places
MAX-3 DC PS MAX-3 DC PS
8-32 X 5/16" B.H.C.S. (2) 8-32 X 5/16" B.H.C.S. (2)
FAN FAN
3MM X 5MM B.H.C.S. (2) 3MM X 5MM B.H.C.S. (2)
J2 J2
1 1
KM3/P-V2 BMC-V2 NON MRP, ARP

Mount Power Supply on Mount Power Supply in
Left Wall of CNC Cabinet Place of old Power Supply.
3MM X 5MM B.H.C.S. (2)

Drill & Tap M3 "NEW" Hole
8-32 X 5/16" B.H.C.S. (2)
Old PS Mounting Holes
MAX-3 DC PS
J2
FAN
1
BMC-V2 MRP & ARP

KM5P
Mount Power Supply in
Place of old Power Supply.
A-6
The MILLKEY.EXE Hurco utility program which allows the reprogramming of the Software Protection Keys is
functional for Max32 but the screens will not be displayed. To use MILLKEY with a standard AT keyboard, all of the
entries will be entered without a display verification, nor will any of the menus be displayed.
Therefore, to reprogram the Software Protection Key, either:

1. remove the Software Protection Device from the Serial Port, attach to a Parallel Port of a PC,
and run MILLKEY, or
2. enter the commands “blind” from the AT keyboard attached to the Max32 CPU.
To enter the commands “blind”, do the following:
A. Insert a bootable DOS diskette into the Floppy Disk Drive and turn the Machine Power On.
B. After approximately one minute, press the Enter key twice (to skip the Date and Time prompts).
C. Insert the Field Service Utility Disk into the Floppy Disk Drive and type “INT10”. The screen should now display
A>.
D. Type “MILLKEY” (the screen will go blank). Note that throughout the use of Millkey that the cursor will jump
around the screen until exit from Millkey which returns the A prompt. At anytime, you can return to the A prompt by
doing the following keystrokes:
1. Press Enter four or five times
2. Type “10” followed by Enter
3. Press Enter four or five times
4. Type “4” followed by Enter
E. Use the following keystrokes to maneuver within Millkey:

DESCRIPTION KEYSTROKES
1. Enter the password ******** Enter
2. Select “Program Key” from the Main Menu 2 Enter
3. Select Version Number * Enter
1 - V1.00 4 - V1.22
2 - V1.14 5 - V1.30
3 - V1.21 6 - V1.40
(“10 Enter” returns to the Main Menu)
4. Select Options (number and enter for each option) * Enter
1 - 3D Mold 11 - Remove all options
2 - Insert Pocket 13 - Return to Main Menu
3 - Ulti-Pocket
4 - Probing
5 - Exactor
6 - Turbo
7 - DXF
5. If no Options or done with Options Enter
6. Select Language (English is default) Enter
(“19 Enter” returns to the Main Menu)
7. Millkey displays verification of programming, Enter
press any key to Exit to return to Main Menu
8. At the Main Menu, select “Exit” 4 Enter
Remove the Field Service Utility Disk and cycle the Machine Power to restart ULTIMAX.
A-7
Power-up sequence when no executive has been preloaded. (A formatted and

partitioned Hard Drive is assumed....)
Note: Within 5 seconds following power up, hit the clear key on the console to enter the CMOS setup.
Now load the correct Hard Drive parameters (Ref. TIN 1064 Rev B).
A. DOS Bootup to load Executive onto the Hard Drive

IMPORTANT NOTE: Between November 1995 and July, 1997, all of the Hard Drives shipped
in Max32 Retrofit Kits had no Executive on them; however, they will be partitioned and
formatted. Refer to TIN 1075 for correct Hard Drive settings.
1. Insert your Max 32 RESCUE DISK(427-0010-002) into the floppy disk drive and turn on power.
After it has completed reformat insert the Field Service Utility Disk (or a DOS-bootable diskette) into
the Floppy Disk Drive and cycle the Machine Power On.
2. Connect a standard AT keyboard to the CPU using the Keyboard Adaptor/Extender Harness (423-
6824-005).
3. If the Field Service Utility Disk has not been setup with an AUTOEXEC.BAT for Max32 then DOS
will prompt to enter the Date and Time (note that nothing will be displayed on the screen). Press Enter
twice to bypass the Date and Time prompts.
4. Enter the following command to load the CRT Driver to display the DOS prompt:
a. A:\MAX\INT10.EXE
To create an AUTOEXEC.BAT for Max32 (which skips steps 3 and 4 above):
a. Use DISKCOPY to make a copy of the Field Service Utility Disk

b. On the second Field Service Utility Disk, rename the AUTOEXEC.M32 file to
AUTOEXEC.BAT (if this file does not exist, use an ASCII editor to create an
AUTOEXEC.BAT with INT10 as the1st line and PROMPT $P$G as the 2nd)
line and copy to the second disk.
c. Relabel the second Field Service Utility Disk to indicate “Max32”
5. Change to the C Drive and delete the EXECPROG file, all of the .LAN files, and the CONFIG
subdirectory, IF THEY EXIST ( Follow Steps 5a thru 5c). If these files don’t exist go to step
A-8
6 and continue with upgrade.
a. Change the attributes of the EXECPROG and .LAN files with the following
commands:
i. ATTRIB -RSH C:\EXECPROG
ii. ATTRIB -RSH C:\*.LAN
b. Delete the EXECPROG file and the .LAN files with the following commands:
i. DEL C:\EXECPROG
ii. DEL C:\*.LAN
c. Delete the CONFIG subdirectory with the following commands (note that all sub-
directories need to be deleted):
i. CD\CONFIG\V1_XX NOTE: enter the number for XX
ii. DEL *.SYS
iii. repeat steps i. and ii. for all subdirectories under CONFIG.
6. Insert the Executive Disk 1 into the Floppy Disk Drive and copy the following files, in
order:
a. COPY A:HURCO.LDR C:\
b. COPY A:EXECPROG.001 C:\
7. Insert the Executive Disk 2 into the Floppy Disk Drive and copy all of the files:
a. COPY A:EXECPROG.002 C:\
b. COPY A:*.LAN C:\
8. Insert the Executive Disk 3 into the Floppy Disk Drive and copy all of the files:
a. COPY A:*.LAN C:\
9. Insert the Field Service Utility Disk into the Floppy Disk Drive and enter the following
commands from the C prompt:
a. A:\MAX\COMBINE EXECPROG.001 EXECPROG.002 EXECPROG
b. DIR (confirm that the EXECPROG file size equals the size of EXECPROG.001 plus
EXECPROG.002)
c. DEL EXECPROG.00? (use DIR to confirm that the two EXECPROG files are
deleted)
d. A:\MAX\BOOTMERG A:\MAX\BOOTSTRP.BIN C: to copy the bootsector onto
Drive C
10. Remove the diskette from the Floppy Disk Drive and cycle the Machine Power Off .
11. Insert the OPTIKEY to program the new Security Button.

Note: A:\MAX\MILLBOY will only work if the security button has been previously
programmed.
A-9
MAX32 PARTS, DOCUMENT and RECOVERY REFERENCES 757-4002-136, Rev. A
12. Remove OPTIKEY disk and cycle power OFF/ON
per TIN 1064. When complete, the Control will automatically reboot.
B. MAX 32 Bootup from Floppy Disk
on. The “Loading Executive, Please Wait” message will be displayed after following the
2. When prompted, insert the EXECUTIVE_2 diskette into the Floppy Disk Drive.
CLOSED.
Console LEDs will all be lit. The “Loading Executive...” message will then be erased.
4. The Text CRT will then display:
Serial CRT System

Memory Manager Initialized
Insert the Machine Configuration disk to Back up Config files
5. At the prompt to insert the Machine Configuration diskette, do not insert the Machine
not remove the EXECUTIVE_2 diskette. Instead, press the
The system will then create a default Machine Configuration and store this on the
EXECUTIVE_2 diskette.
not found, and Defaults have been loaded.
7. After the Machine Configuration screen is displayed, select the EXIT softkey.
the upgrade, inserting the proper diskettes when prompted.
9. When completed, remove the diskette from the Floppy Disk Drive and cycle the
A-
10. Verify the proper Machine Configuration Parameters per TIN 1061.
11. If the Executive is not running, proceed to step A or step C.
C. DOS Bootup and recovery
1. Insert the Field Service Utility Disk (or a DOS-bootable diskette) into the Floppy Disk Drive
and cycle the Machine Power On.
2. Connect a standard AT keyboard to the CPU using the Keyboard Adaptor/Extender Harness
(423-6824-005).
3. If the Field Service Utility Disk has not been setup with an AUTOEXEC.BAT for Max32
then DOS will prompt to enter the Date and Time (note that nothing will be displayed on the
screen). Press Enter twice to bypass the Date and Time prompts.
4. Enter the following command to load the CRT Driver to display the DOS prompt:
a. A:\MAX\INT10.EXE
5. At the A prompt, enter the following:

a. FORMAT C:
b. Set the Volume Label to EXECUTIVE_1 (must be all capitalized letters)
6. When formatting is complete, insert the Field Service Utility Disk and enter:
a. A:\MAX\BOOTMERG A:\MAX\BOOTSTRP.BIN C:
7. Repeat steps 6-15 from A above.
8. If problems still persist, repeat steps 1-4.
D. Partitioning Hard Drive:

Note: Must take Hard Drive to a Max3 control or a PC to do the following.
1. Change to the C prompt and enter the following command to repartition the Hard
Drive: A:FDISK
a. Select 3 to Delete Partition or Logical DOS Drive; delete every partition
displayed.
b. Select 1 to Create DOS Partition or Logical DOS Drive.
A-11
I.) create the C Partition and assign 10M of the Hard Disk Drive
ining space
d. Quit FDISK and return to the C prompt

FORMAT D: to format the Hard Disk Drive D
3. Enter FORMAT C:
4. Repeat steps 6-15 from A above.
757-3012-020 B
757-4001-060 C tup Procedure for BMC 20/50
757-4001-061 Fanuc Digital Spindle Drive Setup Procedure for BMC 30/50
757-4001-062 Fanuc Analog Spindle Drive Setup Procedure for BMC 20/50
757-4001-065 Fanuc Servo Amplifier Setup Procedure for BMC 20/50
757-4001-073 Fanuc AC3S/18P/22P Spindle Drive Setup Procedure
757-4001-092 BMC20/50 IP/V2 Yaskawa Servo Amplifier Setup Procedure
12
757-4001-093 D Yaskawa Spindle Setup Procedure for BMC 20/50 and MHP-20/30
757-4001-116 A BMC-40SLV MAX 400 Servo Amp Set-up Procedure
757-4002-007 B BMC 20/50 ULTIMAX 3 Yaskawa Servo Amp Setup Procedure
757-4002-008 A BMC 20/50 ULTIMAX 3 Yaskawa Spindle Amp Setup Procedure
757-4002-023 A ULTIMAX 3 Spindle Load Bar Setup Procedure
757-4002-031 A Parameters for MAX 32 Software Version 1.21
757-4002-031 B Parameters for MAX 32 Software Version 1.30
757-4002-031 C Parameters for MAX 32 Dual Axis Software Version 1.40
757-4002-031 D Parameters for MAX 32 Dual Axis Software Version 1.5x
757-4002-034 A Parameters for MAX 32 DSP2 Software Version 1.30
757-4002-034 B Parameters for MAX 32 DSP2 Software Version 1.40
757-4002-034 C Parameters for MAX 32 DSP2 Software Version 1.5x
757-4002-039 A Dual Axis 2 Configuration: Jumpers and Firmware
757-4002-047 A Max32 DSP2 Jumper Settings
757-4002-057 B MAX3/MAX32 CMOS SETUP.
757-4002-137 A Advanced Screen CMOS settings for ‘486 CPU system.
757-4002-138 A MAX 32 Kit Setup & Test Procedure.
B. ENGINEERING DRAWINGS
002-2541-004 A Assy, ULTIMAX II-32 Comm Panel

002-4122-015 A Harness, AT Keyboard Adapter
415-0247-003 B PCB Assy, DSP2 Motion Control XYZS
415-0247-004 B PCB Assy, DSP2 Motion Control ABCD
415-0247-902 B PCB Assy, DSP2 Motion Control
415-0254-001 B PCB Assy, Snooper Drive
415-0259-001 A PCB Assy, Remote Jog Interface
415-0259-002 A PCB Assy, MAX 32 Opt Int No RJ
415-0259-003 A PCB Assy, MAX 32 Opt Int for RJ
415-0259-902 A PCB Assy, MAX 32 Option Interface
423-6202-099 A Harness, CRTC/MP Adapter
423-6208-008 A Harness, Disk Power
423-6800-001 D Harness Assy, CRP2/1CN to Spindle Drv (83”)
423-6800-002 D Harness Assy, CRP2/1CN to Spindle Drv (51”)
423-6800-003 C Harness, CRP/S2CN to Spindl 2CN (86”)
423-6821-001 B Harness, RS232 Ports MAX 3 (48”)
423-6821-003 B Harness, RS232 Ports MAX 3 (124”)
423-6822-002 B Harness, Parallel Port MAX 3 (48”)
423-6822-004 B Harness, Parallel Port MAX 3 (124”)
423-6824-005 A Harness, Keyboard Adapter/Extender
423-6835-001 A Harness, MAX32 Int. Cycle
423-6836-001 A Harness, MAX32 Servo Mode
ALL MAX 32 DUAL AXIS RELEASES (current in Bold)
MINIMUM DATE
MACHINE MEMORY RELEASED
V1.20 BMC 20-50 (OEM/V1/V2) 2M 02 Feb 93
V1.21 BMC 20-50 (OEM/V1/V2) 2M 19 May 93

KM3/3P (V2)
A-13
KM5P (Manual/ASC)
V1.30 BMC 20-50 (OEM/V1/V2) 2M 25 Oct 93

KM3/3P (non-V2/V2)
KM5P (Manual/ASC)
V1.31 BMC 20-50 (OEM/V1/V2) 2M 16Jan 95

KM3/3P (non-V2/V2)
KM5P (Manual/ASC)
V1.40 BMC 20-50 (OEM/V1/V2) 4M 27 May 94

KM3/3P (non-V2/V2)
KM5P (Manual/ASC)
V1.53 BMC 20-50 (OEM/V1/V2) 4M 10APR 95

KM3/3P (non-V2/V2)
KM5P (Manual/ASC)
V1.54 BMC 20-50(OEM/V1/V2) 4M 26SEPT95

KM3/P (NON V2/V2)
KM5/P (MANUAL/ASC)
V1.60 BMC 20-50(OEM,V1,V2) 4M FEB96

KM3/P (NON-V2/V2)
KM5/P (MANUAL/ASC)
V1.61 BMC 20-50(OEM,V1,V2) 4M MAR96

KM3/P (NON-V2/V2)
KM5/P (MANUAL/ASC)
ALL MAX 32 DSP2 RELEASES (current in Bold)
MINIMUM DATE
MACHINES MEMORY RELEASED
V1.30 BMC 20-50 (V2) 2M 25 Oct 93
V1.31 BMC 20-50 (V2) 2M 16 Jan 95
A-14
V1.40 BMC 20-50 (V2) 4M 27 May 94

KM3/3P (V2)
KM5P (Manual/ASC)
V1.53 BMC 20-50 (OEM/V1/V2) 4M 10 APR 95

KM3/3P (non-V2/V2)
KM5P (Manual/ASC)
V1.54 BMC 20-50(OEM/V1/V2) 4M 26SEPT

KM3P (NON V2/V2)
KM5/P(MANUAL/ASC)
V1.60 BMC 20-50(OEM/V1/V2) 4M FEB 96

KM3P (NON V2/V2)
KM5/P(MANUAL/ASC)
V1.61 BMC 20-50(OEM/V1/V2) 4M MAR 96

KM3P (NON V2/V2)
KM5/P(MANUAL/ASC)
A-15
757-4002-137
R
757-4002-137 CAD #D8532
SUBJECT:
MAX 32 CPU BOARD CMOS SCREEN SETTINGS
_M. J. Whittemore Jr. ____ 6/12/97 _Michael Caron_________ 6/12/97

Page 1 of 7
757-4002-137 Rev C CAD #
D8532
757-4002-137
RECORD OF CHANGES
Engineering Document CAD # D8532

757-4002-137
REVISIONS:
By
B 14372 Removed hard drive chart, added FWG 10/2/98
procedure, and reference to 757-4002-166 Phil Stewart 9/28/98
(Hard Drive Parameters for CMOS Setup)
C 14508 1)Protected Mode Window Enable was 0 B. Van Paris 12/23/98
Page 2 of 7
757-4002-137 Rev C CAD #
D8532
757-4002-137
I. INTENT:
This document is intended to provide the necessary information to set MAX 32 CMOS
for proper operation.
II. SCOPE:
This document applies to the MAX 32 CPU board part numbers 415-0624-001, -002,
and –003. Document 757-4002-166 (CN D8577) is required for information for setting
proper hard disk drive parameters. If an external monitor and a video card are not
available, refer to page seven for the “No See – Mos” procedure to enter CMOS values
for the hard disk drive parameters.
III. PROCEDURE:
1. Install the VGA pcb into the 486 CPU pcb.

2. Install the external monitor to the J7 connector on the 486 CPU pcb.
3. Install the external keyboard to the J8 connector on the 486 CPU pcb.
4. Upon control boot-up, strike the DELETE key on the external keyboard to enter the
CMOS setup. NOTE: If you are unable to enter the CMOS setup – power down
control. Place jumper across E74 to E79 and power up for 10 to 20 seconds,
then power down. Remove jumper, then power up and strike the DELETE key
again to enter CMOS setup. This procedure resets the CPU pcb.
5. Use the information in the following table set the CMOS in step 6:
<F1> Pressing the <F1> key brings up a screen for the current item. The system
beeps if you press the <F1> key on an option for which there is no help.
<Esc> Pressing the <Esc> key takes you back to the previous screen. Pressing it in
the Main, Advanced, Security, or Exit screen allows you to “Exit Discarding
Changes”.
<Enter> Pressing the <Enter> key selects the current item or option.
↑>
<↑ ↑ > key changes the selection to the previous item or option.
Pressing the <↑
↓>
<↓ ↓ > key changes the seletion to the next item or option.
Pressing the down <↓
← > <→
<← →> ← > or right <→
Pressing the left <← → > keys in the Main, Advanced, Security, or
Exit
menu screen changes the menu screen. Pressing either key in a subscreen
does nothing.
<F5> Pressing the <F5> key allows you to “Load Setup Defaults”.
<F6> Pressing the <F6> key allows you to “Discard Changes”.
<F10> Pressing the <F10> key allows you to “Exit Saving Changes”
Page 3 of 7
757-4002-137 Rev C CAD #
D8532
757-4002-137
6. Verify the correct CMOS parameters per the following tables:
Standard Screen CMOS Settings
Main Screen CMOS Setup

System Date XX
System Time XX
Floppy A: TPE 1.44 Mb, 3.5
Floppy B: TPE Disabled
Hard Disk C: ST31720A or ST3630A *
Hard Disk D: Not Installed
Hard Disk E: Not Installed
Hard Disk F: Not Installed
Language English
Boot Options Press Enter
Video Mode EGA / VGA
Mouse Not Installed
Base Memory 640KB
Extended Memory 16KB
* = varies according to manufacturer and model
Hard Disk Setup
Hard Disk Type User Definable
Number of Cylinders 1024
Number of Heads 16
Number of Sectors 50
Maximum Capacity 400 MEG
Initialization Timeout 10 Seconds
IDE Translation Mode Auto Detected
Multiple Sector Settings Auto Detected
Fast Programmed I/O Mode Auto Detected
BOOT OPTIONS
Boot Sequence A; First, Then C:
System Cache Enabled
Boot Speed Turbo
Num Lock Off
Setup Prompt Enabled
Hard Disk Pre-Delay 3 Seconds
Typematic Programming Rate Default
Page 4 of 7
757-4002-137 Rev C CAD #
D8532
757-4002-137
ADVANCED CMOS SETTINGS START ON THE NEXT PAGE
Advanced Screen CMOS Settings
Peripheral Configuration:
PCI IDE Interface Enabled
PCI Floppy Drive Interface Enabled
Serial Port 1 Address Com1, 3F8h

Serial Port 2 Address Com 2, 2F8h
Parallel Port Address LPT1, 378h
Parallel Port Mode Compatible
Serial Port 1 IRQ IRQ4

Serial Port 2 IRQ IRQ3
Parallel Port IRQ IRQ7
Advanced Chipset Configuration:
Base Memory Size 640kb
ISA Bus Speed Compatible
SIMM Parity Detection Disabled
Byte Merging Disabled

PCI IDE PreFetch Buffers Disabled
Latency Timer (PCI Clocks) 66
Onboard Network Chip Disabled
User EPROM Expansion Bus Disabled
PCI - SCSI Disabled

Multibus Memory & I/O Configuration:
Real Mode Base Address 0
Real Mode Base Address 00
Real Mode Multibus Offset 0000
Real Mode Memmory Window Enable Disabled
Protected Mode Base Address 00D0

Protected Mode Limit Address 00D0
Protected Mode Multibus Offset 00
Protected Mode Window Enable Enabled
I/O Local Base Address 80

I/O Local Limit Address 8F
I/O Multibus Offset 0
I/O Window Enable Enabled
Multibus-PCI Busy Retry Disabled

Multibus Posted I/O Writes Disabled
Multibus Posted Memory Writes Disabled
PCI I/O ISA Aliases Disabled
Page 5 of 7
757-4002-137 Rev C CAD #
D8532
757-4002-137
‘486 CPU Board CMOS Settings - cont’d
Multibus Dual Port Configuration:

D.P. #1 Multibus Base Address 0
D.P. #1 Multibus Limit Address 00
D.P. #1 Local Offset 0
D.P. #1 Enable Disabled
D.P. #2 Multibus Base Address 0

D.P. #2 Multibus Limit Address 00
D.P. #2 Local Offset 0
D.P. #2 Enable Disabled
Multibus-PCI Master Abort Disabled

Multibus-PCI Target Abort Disabled
Multibus Cycle Timeout Enabled

Multibus Cycle Timeout Interrupt Disabled
Multibus Bus Request Timeout Disabled

IRQ Configuration:
IRQ5 Used By ISA/Multibus
IRQ11 Available
IRQ15 Available
6. When parameters are correct, select “F10” and “EXIT” on keyboard to exit and save
values.
7. Machine will reboot.
8. Power down control, remove the VGA pcb fron the CPU pcb. Reboot the control.
Page 6 of 7
757-4002-137 Rev C CAD #
D8532
757-4002-137
No See – Mos
This is a procedure to re-enter the CMOS values to the hard drive without the use of an
external monitor and video card. NOTE: This procedure must be followed carefully to be
completed successfully.
1. Install your keyboard and select Control, Alt, Delete or Cycle power, then select the
delete key to enter the CMOS set-up. The power up “time window” to select “Delete” to
enter the parameters is approximately 6 seconds. After “Delete” is selected, it will take
approximately 5 seconds before the CMOS screen will boot-up.
2. Select the arrow down key 4 times to get down to the hard drive set-up parameter.
3. Select “Enter”.
4. Select down arrow once.
5. Enter “1024” for the Cylinders.
7. Enter “16” for the number of Heads.
9. Enter “50” for the number of Sectors.
11. Select “f10” to exit and save.
12. Select “Enter” to save.
13. Control should re-boot.
Page 7 of 7
757-4002-137 Rev C CAD #
D8532
M32PD.DOC
Rev-F
2/17/98
Max32 Reported Problems and Solutions
Problem: Text CRT only shows a cursor in the lower left of CRT. After completing the Retro-fit
and turning on the main power for the first time, the text CRT only shows a blinking cursor
in the lower left of the CRT.
Solution: Check the P1/J1 CRTC cable that you’re wired during the retrofit. The green wire on
Pin 2 of the harness mates with PCB socket pin 4. (The green wire will be on top closest
to the front of the console).
Did you correctly modify the jumpers on the CRTC Brd.?
Verify the wiring from the CRTC-P1 connector to the MP-P2 connector. (Use OHM meter).
Is the EPROM correctly inserted into the CRTC board?
Verify the Console Accelerator PCB added to the MP PCB U42 socket is correctly installed
and that the 8251 IC is installed correctly into the Console Accelerator PCB.
Did you plug the MP-J2 plug back into the Machine Personality Board?
Replace the CRTC Board.
_____________________________________________________________________________________
Problem: Axis will not jog.
Solution: Did you make the modifications to the Dual Axis Boards?
Did you install the correct Linear Axis and Spindle EPROMS into the Dual Axis Boards?
Did you enter all parameters in the 100 and 103 screens?
Do you have the DSP2 board jumpered correctly?
Did you cut the correct pin on the Dual Axis Boards?
_____________________________________________________________________________________
Problem: Control will boot and get locked up at the point where it looks for the “Last Edit Program”
Solution: Verify ribbon cables on CPU and HDD are seated correctly.
Verify CPU and HDD are seated into backplane correctly.
Boot DOS and delete the (*.HD3) file, then reboot the control.
Replace the CRTC Board.
_____________________________________________________________________________________
Problem: “Memory size will not support stack requirements” displayed on Text CRT.
Solution: Verify you have installed 4 or 8 Meg of memory. You must enter CMOS Setup and
Enter in correct amount of memory installed on CPU then hit “Exit and Save” softkey.
_____________________________________________________________________________________
Page 1
M32PD.DOC
Rev-F
2/17/98
Problem: “Disk Sub System Failed To Initialize” displayed on Text CRT.
Solution: Use Max32 Hard Drive Rescue Disk to repair HDD.

Boot DOS and repair HDD.
Verify all connections to HDD and CPU.
Scan HDD for virus.
Replace HDD.
Problem: Screens are blank after completing Retrofit.
Solution: Verify that the TP1 shunt on the Personality Board has not broken off or the shunt
has not slipped off the pins.
Verify Pin 37 & 38 at the Personality Board are not swapped (We have found two instances
were the pins at the P2 connector at the Personality board were swapped. This was done
by the vendor when the harness was made. These two pins are not used on Max I
and Max II controls).
Replace 450-3005-081 & 082 BIOS with programmed BIOS sent with Retrofit kit.
_____________________________________________________________________________________
Problem: When booting off of the HDD the control will get locked up on the Language files
and then reboot.
Solution: Swap RAM memory or replace.
_____________________________________________________________________________________
Problem: Control is locked up at “Executing power on Diagnostics”
Solution: Verify HDD type 48 or 49 has correct HDD parameters (Cylinders, Heads, Sectors....)
Scan for viruses.
Verify Machine Personality Jumpers are correct.
Boot the MAX32 Rescue Disk (PN 427-0010-002) then boot DOS and copy all
Executive files per retro procedure.
_____________________________________________________________________________________
Problem: After completing the Upgrade the spindle speed pot works properly until you get to
mid range on potentiometer and the RPM begins to decrease.
Solution: Verify that the Spindle parameters in the 100 screen are set correctly.
_____________________________________________________________________________________
Problem: Limit switch detected on axis X, Y, & Z
Solution: Verify that the axis proms are in correctly and are the correct ones for machine.
Verify Dual Axis board plugs are plugged into the correct boards.
_____________________________________________________________________________________
Page 2
M32PD.DOC
Rev-F
2/17/98
Problem: Axis jogs minus when plus is depressed or plus when minus is depressed.
Solution: Verify all jumpers on Dual Axis board are correct.
_____________________________________________________________________________________
Problem: Chip Enclosure Door is open message will not clear after doing MPJ1-18
modification.
Solution: Verify no cold solder joints on MPJ1-25 (4 wires are solder to J1-25).
Resolder connection. This is the VDC source.
_____________________________________________________________________________________
Problem: BMC20 V1 will not Tap.
Solution: Verify CRP1 SW3-2 is OFF. Machine must think it has a clutch.
_____________________________________________________________________________________
Problem: Control will boot and get locked at (INITIALIZING AXIS CONTROLLER BOARDS)
Solution: Remove the Dual Axis cards and verify the control will or won’t boot. Replace if needed.
Replace machine Personality Board (Use PN 415-0177-004T or R or 012T or R).
_____________________________________________________________________________________
Problem: The Text information is very unstable after boot up (Shaky Screen).
Solution: Verify that all ground lugs are tight in the control and on the card rack-paying special
attention to the grounds on the back door of the CRTs
_____________________________________________________________________________________
Problem: At first power up after Retro the spindle will orient and the ATC will do a tool change.
Solution: Verify SW3-1 on the CRP1 Board is correct.

Verify the cable from the FPCC to the Power on/Motion Hold/Start Pushbutton PCB is not
crimped under the trackball when the lid is closed.
_____________________________________________________________________________________
Problem: After booting DOS you try to get a directory of C: or/and D: and the message
INVALID MEDIA TYPE is displayed.
Solution: You must repartition and reformat C: or/and D: .
_____________________________________________________________________________________
Page 3
M32PD.DOC
Rev-F
2/17/98
Problem: At first power up after retro the screen shows LOADING EXECUTIVE
and the control reboots.
Solution: Verify that all files are copied to the HDD correctly.
Verify the FDD cable is oriented correctly and that the end labeled F-DRIVE (gray plug)
is plugged into the floppy drive and the (blue plug) is plugged into the CPU.
_____________________________________________________________________________________
Problem: After completing retro on a KM3P (OEM/V1/V2) you get a motion error
on Z-axis if you calibrate the axis and jog to the Z plus or Z minus limit switch.
Solution: Follow T.I.N. 1038.
_____________________________________________________________________________________
Problem: After completing the MAX32 DSP retro all axis runaway if you bring up servo power.
Solution: Verify all jumper settings on the DSP board.
_____________________________________________________________________________________
Problem: After completing the MAX32 retro you find that while X axis is running at or
above 250-IPM Y-axis begins to drift or VICE VERSA. This has only been seen
on BMC 20-50 (OEM/V1).
Solution: Verify that the harness from the CRP1 to the FANUC Triple Axis Drive has proper
Shielding per wiring diagrams in manuals. We have found that some machines are
Missing the shield connection to the ground bar.
Verify that all ground bar connections are tight.
_____________________________________________________________________________________
Problem: After completing the MAX32 DA upgrade you select an axis and get “MOTION ERROR”
or select Spindle On and get the message “SPINDLE FAULT”.
Solution: Verify that while doing the IC modifications to the DA PCBs you did not cut any
traces on the PCB. (Example: On a DA II PCB you would cut U42 Pin 13 and
in the process cut the trace that goes around the outside of the IC. This trace jumpers
PIN 12,14,15,1,2,3).
Problem:_ Random problems with tool changer functions. Magazine will not go left or right, or
Up and down, etc….
Solution: Check the position of the HDD. If it is mounted facing the personality PCB, re-mount the
HDD facing the CPU PCB. Noise can cause the relays on the personality PCB to not work
Page 4
M32PD.DOC
Rev-F
2/17/98
Correctly or consistent.
_____________________________________________________________________________________
__
Problem: Machine won't boot-up and the Personality PCB is not lit.
Solution: Check disk drive for a program disk in the drive. Max 32 does not issue an error message
If there is disk in the drive.
_____________________________________________________________________________________
Page 5
757-4002-138 REV: A CAD # D8533

R
SUBJECT: MAX32 RETROFIT KIT (486 CPU) TEST PROCEDURE
Wesley Shelton
REVISIONS:

By
A 14418 Release
I. INTENT:
To provide a standardized test procedure for the MAX32 “486” Retrofit Kit.
II. SCOPE:
Applies to the MAX 32 retrofit kit.
III. PROCEDURE:
SETUP
1. Set up the simulator for the DSP configuration.
A. Ensure the DSP bd. is in the card rack.
B. Change the motion control selection switch to the DSP position.
2. Unpack and inspect the CPU Bd.
A. Check for any shipping or handling damage.
B. Check Graphics Bd. is mounted securely.
C. Check jumper settings and wire wrap per the CPU print.
3. Connect VGA card to the CPU Bd.
4. Insert the CPU Card in to the simulator card rack.
5. Unpack and Inspect the Snooper Bd. and hard drive.
A. Visually check the power harness is properly soldered to the Snooper Bd.
B. Check hard drive for signs of mishandling.
6. Assemble the hard drive onto the Snooper Bd.. Be sure to attach the ground wire to the hard
drive case.
7. Leave the hard drive power connector disconnected from the hard drive.
8. Connect the ribbon cable to the hard drive and insert the snooper bd. into the card rack ensuring
that the power connector is accessible.
9. Attach the AC and DC harnesses to the power supply.
10. Put the power supply on the simulator. Connect the AC harness to the AC power cable but do
not connect the DC harness to the card rack.
11. Unpack and inspect the COM panel.
12. Use two screws to temporarily attach the floppy drive to the COM panel.
13. Remove the security key from the software package and insert it into the security key holder.
14. Find the floppy drive ribbon cable in the kit and attach it to the floppy drive.
15. Attach the RS232 and Parallel port loop back connectors to the COM panel ports.
16. Set the COM panel on the holding block in the simulator. Connect the floppy ribbon, parallel
port, and RS232 cables to the CPU. Also connect the floppy power cable from the simulator to
the floppy drive.
TEST
1. Ensure that the power supply is not connected to the card rack. With a voltmeter check the DC
voltages from the power supply.
From - To No Load Vdc Loaded Vdc

Black - Yellow +5 +5 - +5.2
Black - Blue +24 +24 - +26
Black - Brown +14 +12 - +12.2
Black - Orange -14 -12 - -12.2
2. Turn off power and attach the power supply to the card rack and turn power back on.
3. Adjust the voltages to specification.
+5 volts
adjustment
One pot for +24,

+12, and -12
5. Ensure power connector is not connected to the hard drive and turn the power back on.
5. Check the DC voltages in the hard drive power connector.
GRN - RED +5 Volts

BLK - WHT +12 Volts
6. If the voltages are OK turn power off and connect the hard drive to the power harness.
7. Connect the hard drive ribbon cable to the CPU Bd.
8. Connect the VGA cable from the monitor to the CPU Bd.
9. Put the Max32 Installation disk into the floppy drive and turn power on.
10. Setup the CMOS settings according to the proper CMOS setup procedure.
11. Exit CMOS and allow the system to boot off of the setup disk.
12. Follow the instructions on the screen, pressing the appropriate keys and inserting the Max32
product disks when prompted.
13. Power off the simulator and insert the Optikey disk, from the kit, into the floppy drive and
power back on. The Optikey disk will boot and prompt you with instructions, follow them and
this will program the security key.
*Note - The console must be used the AT keyboard will not work with Optikey!
14. Reset the simulator and the control should come up with the executive.
15. Restore machine config.
A. Go to the “Auxiliary” screen
B. Put the config disk into the floppy drive.
C. Press the F2 softkey twice.
16. Run QAPLUS to test the system.
A. Reboot the simulator with the QAPlus disk in the floppy drive.
B. At the A: prompt type “Q” and enter.
C. Follow the instructions provided on the VGA screen until the main menu screen is
reached.
D. Highlight Diagnostics and press the Enter key.
E. Highlight Options and press the Enter key.

F. Toggle on the Halt On Error and the Beep On Error parameters by highlight them
and then pressing the space bar. (A diamond should appear in the parentheses)
Toggle the Pause control off. (The diamond should disappear)
G. Press the ESC key.
H. Highlight Module Tests and press “Enter”.
I. Highlight the Video tests and deselect it.
J. Set up the COM port test parameters.
a. Highlight COM Port and press “Tab”.
b. Toggle on all parameters except the Printer parameter
c. Press the “+” key on the number keypad to set up the 2nd COM Port.
d. Press the “ESC” key.
K. Set up the LPT1 port test parameters.
a. Highlight LPT ports and press “Tab”.
b. Toggle on Data port and External Loopback parameters only.
c. Press the “ESC” key.
L. Highlight Run All Selected Tests and press “Enter”.
M. When tests are finished press the “ESC” key until the Main Menu Exit is reached
and press “Enter”.
17. Remove the QAPlus disk and reboot the system to allow the executive to load.
18. Power on the servos, calibrate the axes and run the cycle program for 1 hour.
19. After the system has cycled press the Single Cycle button and continue to single cycle through
the program until all axes are in the 0 position and verify that the indicators on the motors are
pointing to the 0 mark.
20. Stop the program from running and enter hidden screen “571” and recheck the COM ports, and
the floppy drive.
21. Power off the simulator and remove and pack the kit components for placement into the store
room.
MAX III
D8076 757-4002-001 002-3311-015 CPU Assembly & Test Procedure

D8094-2 757-4002-016 MAX 3 Hardware Configurations
D8096 757-4002-018 MAX 3 Software Package Procedure (STD) for Production
D8225 450-3005-001/002 MAX 3 BIOS FIRMWARE
D8260G 704-0004-021 Ultimax3 / Max32 Executive Software Upgrade Procedure
D8300 757-4002-021 MAX 3 Alternate CPU Assembly & Test Procedure
D8303 757-4002-023 Spindle Load Bar Setup Procedure
D8304 757-4002-024 Procedure, 1CN/S1CN Cable Modification for Ultimax 3 V1.10
Software or Later
D8306 757-4002-026 Ultimax 3 Spindle Drive DAC Offset Adjustment Procedure for
V1.10 Software and Later
D8307 757-4002-027 Assembly FMA-10S-2.54U
D8308 757-4002-028 MAX 3 DSP/Axis Tune Parameters
D8310 757-4002-029 MAX 3 DSP Parameters
D8310B 757-4002-029 Parameters for ULTIMAX 3 Software Version 1.40
Revision B
D8310C 757-4002-029 Parameters for ULTIMAX 3 Mbus Software Version 1.53
Revision C
D8427 757-4004-002 ULTIMAX II-32 CPU (HURCO 002-3311-027)
D8430 757-4002-057 Max 3 CMOS Setup
D8447 757-4002-069 MAX3/32 CMOS Setup (TIN 1064)
D8436 704-0004-026 Optikey Install Instructions
D0000
D8491C 704-0020-021 Ultimax3 / Max 32 Upgrade Procedure
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
R 757-4002-001 REV: B ECN #12189
06/09/92 CAD #D8076
SUBJECT: ULTIMAX 3 CPU 002-3311-015 ASSEMBLY & TEST

PROCEDURE
I. INTENT:
To serve as a guide in the assembly & testing of the Ultimax 3 standard CPU Assembly (002-3311-015).
SUB-ASSEMBLY P/N
STANDARD:
VGA MODULE - iSBC 272 415-0220-002
VGA MODULE - iSBC 272H 415-0220-003
FPCP - BOX MEMORY CONFIG BIOS - 27512
ODD BYTE 415-3005-025
EVEN BYTE 415-3005-026
III. OUTLINE:
There are four (4) main sections of which the assembly consists:
1) Main CPU board preparation,

2) VGA Module(s) preparation,
3) Final assembly,
________________________________ _______ _______________________________ _______

SECTION 1: MAIN CPU BOARD PREPARATION
STEP 2) STRAPPING:
• Configure the jumpers per 415-0166-903.

• Install the wire wraps as shown in the "LOCAL INTERRUPT MATRIX" detail.

detailed below.

RESULT.
PIN 1
FIGURE 1
N80387SX-16
MMOX CONNECTOR
Using Figure 2 as a guide, install the standard 2 MB/42 MB Memory Configuration BIOS as
detailed in the following note.
TOPVIEW
D
VE
D
FIGURE 2
O
E
U24 U45 1
2
J9 J10 J11 J12
SECTION 2: VGA MODULE(S) PREPARATION
The VGA modules should be configured per drawings 415-0220-002 and 415-0220-003. The CPU
board assembly requires two (2) VGA modules: an iSBC272 and an iSBC272H. All assembly
hardware will be contained within the VGA module packaging and should be retained for final
assembly. For the ULTIMAX application, the factory default jumper configuration is correct.
Therefore, no board preperation is required.
The final assembly is very simple, the only tools required are a flathead screwdriver and a
phillipshead screwdriver. Please refer to Figure 3 for a mechanical representation of the following
procedure:
1.0 Inch
typical - 3 places 2-56 Pan Head Screws (4)
0.25 Inch
4-40 Nylon Screw
J1
STIFFENER
VGA MODULES
J1
0.525", 4-40 0.525"
Male/Female STACKING
Nylon Standoff CONNECTOR
0.625", 4-40
Female/Female
Nylon Standoff
CPU MAIN BOARD

0.25 Inch
4-40 Nylon Screw
PIN 1
FIGURE 3
KEY
STEP 1) At this point of the process you should have three (3) distinct pieces of hardware: 1) A fully
configured CPU baseboard, 2) Two (2) VGA modules that appear identical, and 3) Two (2)
plastic bags of hardware.
STEP 2) Remove the board stiffener which is attached to the MMOX connector on the CPU baseboard.
There should be four phillips head screws holding it in place. These screws will not be long
enough to retain two (2) modules in place, so they can be discarded. Retain the board stiffener
for use in step 5.
STEP 3) Attach three (3) female/female nylon spacers with 4-40 nylon screws using the appropriate holes
on the CPU baseboard. These should be snug tight.
STEP 4) Position a VGA module on top of the nylon spacers such that the orientation matches Figure 3
and the holes are aligned. Attach three (3) female/male nylon spacers thru the VGA board and
snug them down. Make sure that the four (4) holes for the MMOX connector interface remain
aligned during this process.
STEP 5) Position a stacking connector block on top of the gold MMOX footprint on the VGA module.
Make sure that the pin 1 key on the connector block is aligned before proceeding. See Figure 3
for more information. Position the second VGA module on top of the assembly. Use four (4)
4-40 nylon screws to hold the assembly together. Do not tighten. Using four (4) one (1) inch
pan head screws and the board stiffener that was removed in step 1, secure the connector
assembly end. Tighten all screws making sure not to overtorque the connector screws causing
board warpage.
SETUP:
A.) The Hard Drive harness (located on the front of the rack) is in the LOCAL mode.
installed.
D.) That both CRT's are connected to the VGA1 and VGA2 ports.
TEST PROCEDURE:
harnesses
switch) comes ON, then goes OFF.
D.) A power on self test will be performed. Watch for and correct any error messages
displayed before continuing.
E.) After power up a menu will appear at the bottom of the CRT. Select #1 CPU TEST.
F.) The CPU Test will start with an inspection of a full screen of characters. Press ENTER if OK.
G.) Next a color bar will appear, if OK press ENTER. NOTE that this test will occur twice, once for
each CRT as it tests the VGA PCB's.
H.) The VADD Station will then go into automatic mode and test the wire wrap and shunt
I.) The CRT's should be monitored at this time to watch for any failures.
J.) Next the Multibus Memory & I/O is tested. The system will write approximately 1 Meg of data
K.) The last test is the Watch Dog Timer test. It should reboot the system when a count of
complete and #1 CPU TEST is chosen agian from the main menu.
ULTIMAX HARDWARE CONFIGURATIONS 01/24/92
SYTEM HARD DRV ASSY. HARD DRIVE CPU ASSY BIOS ODD BYTE BIOS EVEN BYTE
2MB RAM 40MB HD 002-4114-001 BED 426-0056-005 002-3311-003 450-3005-001 450-3005-002
(STANDARD-OLD) -003 KNEE ST157A SEAGATE
4M RAM 40 MB HD 002-4114-001 BED 426-0056-005 002-3311-004 450-3005-003 450-3005-004
-003 KNEE ST157A SEAGATE
8M RAM 40MB HD 002-4114-001 BED 426-0056-005 002-3311-005 450-3005-005 450-3005-006
-003 KNEE ST157A SEAGATE
2M RAM 42MB HD 002-4114-009 BED 426-0056-010 002-3311-015 450-3005-025 450-3005-026
(STANDARD-NEW) -010 KNEE ST351A/X SEAGATE
4M RAM 42MB HD 002-4114-009 BED 426-0056-010 002-3311-016 450-3005-027 450-3005-028
-010 KNEE ST351A/X SEAGATE
8M RAM 42MB HD 002-4114-009 BED 426-0056-010 002-3311-017 450-3005-029 450-3005-030
-010 KNEE ST351A/X SEAGATE
2M RAM 89MB HD 002-4114-002 BED 426-0056-006 002-3311-006 450-3005-007 450-3005-008
-004 KNEE ST3096A SEAGATE (REV. B) (REV. B)
4M RAM 89MB HD 002-4114-002 BED 426-0056-006 002-3311-007 450-3005-009 450-3005-010
8M RAM 89MB HD 002-4114-002 BED 426-0056-006 002-3311-008 450-3005-011 450-3005-012
SECOND SOURCE HARD DRIVES - STRUCTURE IS NOT TIED 01/24/92

SYTEM HARD DRV ASSY. HARD DRIVE CPU ASSY BIOS ODD BYTE BIOS EVEN BYTE
2M RAM 52MB HD 002-4114-005 BED 426-0056-008 002-3311-009 450-3005-013 450-3005-014
-007 KNEE LPS52AT QUANTUM
4M RAM 52MB HD 002-4114-005 BED 426-0056-008 002-3311-010 450-3005-015 450-3005-016
8M RAM 52MB HD 002-4114-005 BED 426-0056-008 002-3311-011 450-3005-017 450-3005-018
2M RAM 105MB HD 002-4114-006 BED 426-0056-009 002-3311-012 450-3005-019 450-3005-020
4M RAM 105MB HD 002-4114-006 BED 426-0056-009 002-3311-013 450-3005-021 450-3005-022
8M RAM 105MB HD 002-4114-006 BED 426-0056-009 002-3311-014 450-3005-023 450-3005-024
2
HURCO MANUFACTURING COMPANY
ECN 13661
704-4002-018 Rev B CAD #: D8096B
10/01/96
SUBJECT: Ultimax 3/PCMax Software Duplication Procedure
1.0 INTENT
The intent of this procedure is to identify the steps needed to create the Ultimax
3/PCMax standard software diskette package.
2.0 APPLICABILITY
This is applicable to Ultimax 3/PCMax software packages.
3.0 EQUIPMENT REQUIRED
Makedisk station.
4.0 PROCEDURE
4.1 Power on the PC, CRT and printer. Ensure that ribbon cable and security button
holder is connected to the cable.
4.2 Select MAKEDISK from the menu.
4.3 Insure the diskette labels are positioned correctly on the printer.
NOTE: Failure to align the labels will cause them to be printed crooked and they
will need to be done again.
4.4 Enter your User Name.
4.5 Enter your Password.
4.6 Press any key to continue.
4.7 Enter the part number that is to be made.
Optikey Install Instructions

Page 1 of 3
4.8 Enter how many packages that are to be made. The screen should say “Put a
blank disk in the floppy drive and hit ENTER for any key to continue”. Put a
blank disk in the drive and hit ENTER.
4.9 The program will now format the disk, load the FAT files and load part of the
executive software. Upon completion of the first disk, the program will go back
and check the disk and display “ The disk does not appear to be blank. Should
it be used anyway?”. At this point remove the first disk and place it off to the
side taking extreme caution not to get it mixed up with the others. The printer
will also print a label.
4.10 Load a second disk into the drive and hit ENTER. The program will format the
disk. load the FAT files and finish loading the executive software. Upon
completion of this second disk it will load the appropriate language files (Ultimax
only). The printer will now print the label for the second diskette. The message
“ The disk does not appear to be blank. Should it be used anyway?” will appear.
At this point remove that disk and place it off to the side taking extreme caution
not to get it mixed up with the others.
4.11 Load the third diskette into the drive and hit ENTER. The program will format
the last diskette. The remaining language files will be copied to the diskette
(Ultimax only). The printer will print the label for the last diskette.
4.12 Remove the third diskette and place to the side taking extreme caution not to get
it mixed up with the others.
4.13 At this point the program will go back to step 4.9 and ask for the first diskette if
more than one package is to be programmed.. If only one package is to be
programmed, the program will go back to step 4.7. Hit ENTER to quit or enter
another part number.
4.14 Once the printer has advanced the labels, place the labels on their respective
diskettes. and place them in the protective folder (if required).
Programming the Security Device
The security device will be programmed using an Optikey diskette(s). The Makedisk Utility
will not be used to program security devices.
If the product is Mill software, the security device will be programmed on the control card cage
using the Optikey diskette(s) called out on the BOM. After the security key is programmed,
the Optikey diskette(s) will be placed in the software package that is packed with the control
kit.
If the product is the PC software, the security device will be programmed on any computer (it
can be the makedisk computer) using the Optikey diskette(s) called out on the BOM. The
Optikey diskette(s) will be packed with the PC software package to be delivered to the

Page 2 of 3
customer. If for some reason the security device did not get programmed, the customer can
use Optikey diskette(s) shipped with the software to program the security device.
PROGRAMMING THE SECURITY DEVICE
1. Place the security button in the holder and attach the holder to the parallel printer port of
the computer.
2. a. Programming a security device using Optikey diskettes is done by placing the Optikey
diskette in the drive A: of the computer being used and booting the computer.
2. b. Another way to use the Optikey diskette, is to place the Optikey diskette in a floppy drive
of that computer. Switch to the prompt for that drive and type OPTIKEY.
3. After the Optikey program is started, follow the directions on the screen.
IMPORTANT
The Optikey diskette that is used to program the security key MUST be the diskette
shipped with the software package. If an unused Optikey diskette is shipped with the
software, another blank key could be programmed by the customer. DO NOT mix
Optikey diskettes.

Page 3 of 3
MAX 3 BIOS FIRMWARE
Drawing no: 450-3005-001 & 002 Cad no: D8225.DOC
Revision:__________ PIN no:_____________________
Drawn by: __________________ Approved:____________________
=========================================================
Description: Max 3 BIOS firmware (2 EPROM set) to be used on CPU

assembly 002-3311-003. This set has the following configuration:
* 2 Megabytes RAM
* 40 Megabyte Hard Drive (Seagate ST157A)
Checksum: Generated by Data I/O 288 programmer:
450-3005-001 (Odd byte) = 7332h.

450-3005-002 (Even byte) = 5462h.
Device type: 27512 or 27C512.
HURCO part no: 450-3005-001 (Odd byte).

450-3005-002 (Even byte).
Label: 450-3005-001 450-3005-002

ODD BYTE EVEN BYTE
7332 5462
7-9-91 7-9-91
01/23/98
GMS:gms
R Hurco Manufacturing
Ultimax 3/Max32 Executive Software Upgrade Procedure
704-0004-021 Rev G D8260G

6/11/98
ULTIMAX 3 or Max32 Executive software resides on the hard disk and is upgraded by loading new
software from a set of 3 1/2" floppy diskettes shipped to you in this package. During the upgrade process,
all part programs stored on the hard disk are completely safe and are retained in their directories. Be
sure to save your program to disk and then erase it in the control memory before doing the upgrade.
UPGRADE PROCEDURE
1. With Machine Power On:
a. Select the Auxiliary mode
b. Select the UPGRADE EXECUTIVE softkey (may have to press the MORE softkey to display this
menu option). The operator will be prompted to continue with the upgrade.
c. Select the YES softkey; pressing the NO softkey aborts the upgrade
d. A blinking reverse video message "Insert EXECUTIVE_1" is displayed on the CRT
2. Insert the Executive diskette labeled Disk 1 into the Floppy Disk Drive. If the wrong diskette (or no
diskette) is inserted into the Floppy Disk Drive, the "Insert EXECUTIVE_1" message will still be
displayed. The upgrade may be aborted by pressing the EXIT softkey.
NOTE: Selecting abort or removing the upgrade master diskette before copying is completed does
not corrupt the previous executive software.
3. The copy operation starts immediately upon insertion of the correct diskette. As each file is copied
from the Executive diskette onto the Hard Disk Drive, it is listed on the screen. When all files are
copied, a blinking reverse video message "Insert EXECUTIVE_2" is displayed.
4. If additional master diskettes are part of this upgrade package, the blinking reverse video message is
repeated. Continue to load Executive diskettes until all are copied to the Hard Disk Drive.
5. After all Executive diskette files are copied to the Hard Disk Drive, the new Executive program is
verified. When complete, the "EXECUTIVE UPGRADE COMPLETE" message is displayed.
6. Remove the Executive diskette from the Floppy Disk Drive and store all of the Executive diskettes in
a safe place.
PROPRIETARY INFORMATION
INFORMATION CONTAINED HEREIN IS THE PROPERTY OF HURCO MANUFACTURING COMPANY, INC. NO REPRODUCTION OR DISCLOSURE OF THIS INFORMATION SHALL BE
MADE BY THE RECIPIENT TO ANY OTHER PERSON OR ORGANIZATION WITHOUT THE PRIOR WRITTEN CONSENT OF HURCO MANUFACTURING COMPANY, INC.
___________________________________________________________________________________
704-0004-021 Rev G Page 1 of 2
7. If an Optikey diskette package is sent with this upgrade then follow the “OPTIKEY INSTALL
INSTRUCTIONS” document (704-0004-026, D8436).
8. Cycle the Machine Power Off and On and verify the Executive Software Version in Input mode.
9. Retrieve the Machine Configuration diskette and insert into the Floppy Disk Drive:
a. Select Auxiliary mode
b. Select the SYSTEM CONFIGURATION softkey
c. Select the MACHINE CONFIGURATION softkey
d. Select the BACKUP CONFIGURATION softkey to update the configuration on the diskette
___________________________________________________________________________________
704-0004-021 Rev G Page 2 of 2
R 757-4002-021 REV: A ECN #12189
06/09/92 CAD #D8300
SUBJECT: ULTIMAX 3 ALTERNATE CPU ASSEMBLY & TEST

PROCEDURE
I. INTENT:
To serve as a guide in the assembly & testing of the Ultimax 3 alternate CPU Assemblies:
(002-3311-003 thru -008, -016, -017).
II. OUTLINE:
1) Assembly reconfiguration,
III. SUB-ASSEMBLY PART NUMBER REFERENCE:
SUB-ASSEMBLY P/N QTY
002-3311-003T:
CPU ASSY, ULTIMAX 3 STANDARD 002-3311-015 1 PC
2MB/40 MB MEMORY CONFIG BIOS - 27512
ODD BYTE 415-3005-001 1 PC
EVEN BYTE 415-3005-002 1 PC
002-3311-004T:
1 MB FAST PAGE 80 nS DRAM w/PARITY 415-0250-001 2 PC
ODD BYTE 415-3005-003 1 PC
EVEN BYTE 415-3005-004 1 PC
002-3311-005T:
ODD BYTE 415-3005-005 1 PC
EVEN BYTE 415-3005-006 1 PC
002-3311-006T:
ODD BYTE 415-3005-007 1 PC
EVEN BYTE 415-3005-008 1 PC
________________________________ _______ _______________________________ _______

002-3311-007:
ODD BYTE 415-3005-009 1 PC
EVEN BYTE 415-3005-010 1 PC
002-3311-008T:
ODD BYTE 415-3005-011 1 PC
EVEN BYTE 415-3005-012 1 PC
002-3311-016T:
ODD BYTE 415-3005-027 1 PC
EVEN BYTE 415-3005-028 1 PC
002-3311-017T:
ODD BYTE 415-3005-029 1 PC
EVEN BYTE 415-3005-030 1 PC
SECTION 1: ASSEMBLY RECONFIGURATION
The following steps detail the modifications to the 002-3311-015 CPU assy required to reconfigure it for alternate
hardware configurations.
STEP 2) BIOS UPDATE:

• Remove both EPROMS 450-3005-025 and -026.
• Using Figure 1 as a guide, install the proper Memory Configuration BIOS EPROMS as found in the
SUB-ASSEMBLY PART NUMBER REFERENCE listing above.
NOTE: The JEDEC sites can accommodate 32 pin devices but are configured for 27512 EPROMS, which are 28
pin devices. Therefore, both ODD and EVEN parts should be shifted such that socket pins 1, 2, 31, and 32 are left
unused.
STEP 3) MEMORY MODULE INSTALLATION (as required):

NOTE: When a CPU assy requires the addition of 2 or 4 memory modules, the following steps should be
completed to assure reliable installation. Reference figure 1.
• SIMM's must be populated in order from J9 to J12.
• Holding the SIMM's by the edges only, remove thenm from their antistatic package.
• Position the SIMM correctly and insert the bottom edge into the socket slot. Press down firmly while
maintaining the angle of insertion.
• Make sure the SIMM seats correctly. If not, gently spread the retaining clips just enough to permit the
top edge of the SIMM to be pulled away from the clips and reset.
• When the SIMM seats correctly, hold eash end and gently push the top edge toward the slot retaining
clips until the SIMM snaps into place.
TOPVIEW
N D
E D
FIGURE 1 V
E O
U24 U45 1
2
J9 J10 J11 J12
SETUP:
A.) The Hard Drive harness (located on the front of the rack) is in the LOCAL mode.
installed.
• When testing 002-3311-003, -004, or -005 assemblies, the standard (002-4114-009)
HARD DRIVE PCB must be replaced by the 002-4114-001.
• When testing 002-3311-006, -007, or -008 assemblies, the standard (002-4114-009)
HARD DRIVE PCB must be replaced by the 002-4114-002.
D.) That both CRT's are connected to the VGA1 and VGA2 ports.

TEST PROCEDURE:
harnesses
switch) comes ON, then goes OFF.
D.) A power on self test will be performed. Watch for and correct any error messages
displayed before continuing.
E.) After power up a menu will appear at the bottom of the CRT. Select #1 CPU TEST.
F.) The CPU Test will start with an inspection of a full screen of characters. Press ENTER if OK.
G.) Next a color bar will appear, if OK press ENTER. NOTE that this test will occur twice, once for
each CRT as it tests the VGA PCB's.
H.) The VADD Station will then go into automatic mode and test the wire wrap and shunt
I.) The CRT's should be monitored at this time to watch for any failures.
J.) Next the Multibus Memory & I/O is tested. The system will write approximately 1 Meg of data
K.) The last test is the Watch Dog Timer test. It should reboot the system when a count of
complete and #1 CPU TEST is chosen agian from the main menu.
757-4002-023 REV: A ECN #12426

R
10/21/92 CAD #D8303
SUBJECT: ULTIMAX 3 SPINDLE LOAD BAR SETUP PROCEDURE
I. INTENT
To provide a standard adjustment procedure for Ultimax 3 Spindle Load Meter.
II. APPLICABILITY
Applies to all Ultimax 3 Machining Centers with V1.10 Software and later.
III. PROCEDURE
A. Spindle Load Meter Bar Adjustment:
1. Release <E-Stop>, press <Manual>, <Power On>, <Start>.
2. Go to ATC and Machine Diagnostics screen, <Change Tool or Diagnostics>

softkey, <ATC and Machine Diagnostics> softkey.
3. Enter hidden diagnostics screen <Enter>, 101, <Enter>.
4. Select <Toggle Load Bar Display> softkey, then <Exit>.
5. Enter Matrix Tune Diagnostics screen <Enter>, 103, <Enter>.
6. On the spindle drive display, access CN-08 control constant, <No./Data>,

<Mode/ > (three times), < > (seven times).
7. Display and set data for 200. <No./Data>, Use the <Mode/ > key to select the
digit to be changed and the < > key to change the digit to the desired value then
press and hold the <Home/Set> key for 3 seconds to set the data.
8. Access CN-07 and set the data for 1.00.
9. Press the <Home/Set> and <Alarm Reset> keys at the same time to display the
Full Scale Load Bar on the CRT.
________________________________ _______ _______________________________ _______

10. Repeat Steps 6-8, decreasing CN-08 data by 5 each time until 22 segments or
Overload is shown on the Spindle Load Bar.
Note: CN-07 data must be displayed before pressing <Home/Set> and

<Alarm Reset> keys.
11 Set spindle drive to UN-03 (% of Torque display). Verify CRT load display
closely matches drive display (eadh load bar segment equals approximately
4%).
12. <Enter>, 101, <Enter> and turn diagnostics display off by pressing
highlighted softkey number.
13. <Exit>, <Manual>.
2
757-4002-024 REV: B ECN #12438

R
10/27/92 CAD #D8304
SUBJECT: FIELD MODIFICATION FOR 1CN/S1CN CABLE,

423-6800-001, -002 REVISIONS A-D, FOR USE WITH ULTIMAX 3 V1.10
SOFTWARE AND LATER
I. INTENT
The intent of this document is to provide a procedure for field modifications of the 1CN cable,
423-6800-001, -002 Revison A-D, for use with Ultimax 3 V1.10 software and later versions.
II. APPLICABILITY
Applicable to all Machining Centers equipped with Ultimax 3, software version V1.10 and
later.
III. PROCEDURE
1. Remove female pin from 1CN-12 with Honda pin extractor. Cut wire flush from 1CN-
28.
2. Insert female pin end of gray wire into 1CN-12 and tie wrap gray wire to cable at 2
places on cable exposed from wire way.
3. Assemble connector.
4. Route gray wire through wire ways to CRP3 S1CN.
5. Remove male pin from S1CN-5 with Honda pin extractor.
6. Insert male pin end of gray wire into S1CN-5 and tie wrap at 3 places on cable exposed
from wire way.
7. Assemble connector.
8. With VOM, verify continuity of wire from S1CN-5 to 1CN-12.
9. Connect cable to CRP3 and spindle drive.
________________________________ _______ _______________________________ _______

757-4002-026 REV: A ECN #12426

R
10/23/92 CAD#D8306
SUBJECT: ULTIMAX 3 SPINDLE DRIVE DAC OFFSET ADJUSTMENT

PROCEDURE FOR V1.10 AND LATER

I. INTENT
To provide a standardized procedure for Ultimax 3 Spindle Drive DAC command offset
adjustment for machining centers with V1.10 software and later.
II. APPLICABILITY
Applied to all Ultimax 3 machining centers with V1.10 software and later.
III. PROCEDURE
A. Adjustment of DAC offset.
1. Release <ESTOP>, press <MANUAL>, <POWER ON>, <START>.
2. Enter Diagnostics hidden screen. <CHANGE TOOL OR DIAGNOSTICS>

softkey, <ATC AND MACHINE DIAGNOSTICS> softkey, <ENTER>, 101,
<ENTER>.
3. Select <TOGGLE LOAD BAR DISPLAY>, <TOGGLE ACTUAL DISPLAY>,

<TOGGLE FOLLOWING ERROR DISPLAY> softkeys, <EXIT> softkey.
4. Enter Matrix 4 Axis Tune hidden display, <ENTER>, 103, <ENTER>.
________________________________ _______ _______________________________ _______

5. Select <SPINDLE> softkey, <SPINDLE ON>, <START>, <SPINDLE OFF>. The
spindle will begin tuning itself. (Be aware that the spindle may oscillate CW/CCW
dramatically if the drive has a large offset.) When complete press <RESET
SERVOS AND SPINDLE> softkey and repeat step 5. The spindle will remain
energized this time.
6. Press <SPINDLE OFF> several times while observing the spindle reaction. If the
spindle cogs CN-40 on the spindle drive will need to be adjusted. Press <RESET
SERVOS AND SPINDLE> softkey.
NOTE: If the system is in the Axis Tune Display, the Spindle On Relay (SOR)
will remain enabled after it is initially energized. Press <SPINDLE ON>
then <SPINDLE OFF> to energize SOR. To denergize SOR, press
<RESET SERVOS AND SPINDLE> softkey.
NOTE: CN-40 Cannot be changed if the spindle drive is enabled.
7. Access CN-40 on the spindle drive. Press <NO./DATA>, <MODE/ > four times.
The zero will be flashing on the CN-01 display. Press < > three times,
<MODE/ >, < > nine times, <MODE/ >, < >. The display will now read CN-
40.
8. Access CN-40 data and change by desired amount. Press <NO./DATA>, use the
<MODE/ > key to select digit to be changed and the < > key to change desired
amount. (P = positive, (-) = negative)
If the spindle cogs in the CW direction, looking down at the table, add a more
negative number. If the spindle cogs in the CCW direction, looking down at the
table, add a more positive number.
9. Press and hold <HOME/SET> until the display stops rapid flashing to set data.
10. Repeat Steps 5-9 until spindle does not cog when <SPINDLE OFF> is pressed.
11. <RESET SERVOS AND SPINDLE> softkey, <EXIT> softkey, <EXIT> softkey.
12. Enter the diagnostics screen and toggle the selected display off.
13. <EXIT> softkey <MANUAL>.
2
757-4002-027 REV: A ECN #12467
R
11/03/92 CAD#D8307
SUBJECT: ASSEMBLY OF FM2A-10S-2.54 U CONNECTOR FOR ULTIMAX 3

CONSOLES

A Original Issue 11/03/92
I. INTENT
To provide a standard procedure for properly fitting connector FM2A-10S-2.54 U to Ultimax

3 controls.
II. APPLICABILITY
Applicable to all Ultimax 3 Consoles.
III. PROCEDURE
1. Strip gray outer shielding back 1/2 inch.
2. Remove foil from insulated and ground wire.
3. Trim edge of wires, if required so they are all even in length.
4. Place wires into slots on connectors restraining strap (Fig. 1). Let the wires overhang a
little so they can be bent over and placed in the slots on the side.
5. Line up the arrow of the connector (Fig. 2) with the white wire on one side of the
restraining strap.
6. You need to bend the cable down before you can clamp the two pieces together. This
will allow the lip on the connector (Fig. 2) to go over the wires.
7. Connect Figure 3 to Figure 1 & 2 by sliding the connector into the slots as shown on the
drawing.
8. Connect Figure 4 to Figure 3. Then, place the restraints (Fig. 5) on both sides and screw
together.
________________________________ _______ _______________________________ _______
Page 1 of 2
Page 2 of 2
FIG. 2
FIG. 5
FIG. 4
FIG. 1
FIG. 3
Page 3 of 2
757-4002-028 REV: A ECN # 12466

R
09 NOV 92 CAD # D8308
SUBJECT: ULTIMAX 3 DSP / AXIS TUNE PARAMETER DEFINITIONS
I. INTENT
To provide standard definitions associated with the DSP algorithm parameters.
II. APPLICABILITY
Applies to all Ultimax 3 Machining Centers with V1.10 Software and later.
Parameter Descriptions
The values of the axis tune parameters are primarily related to the mechanical specification of
the machine: leadscrew pitch, ratio of axis position encoder to distance traveled and the number of
encoder counts per revolution. In addition, the parameter values are influenced by the machine constant
(Km).
Vmax => voltage from the DSP DAC that is to represent maximum velocity command (RPM) for the
servo amplifier
Constant => gain constant within the DSP algorithm
max Velocity => maximum velocity rating for the axis. [distance per second]
position resolution => final system resolution as seen by the DSP. [counts per distance]
Vmax * Constant
Km =
max Velocity * position resolution
________________________________ _______ _______________________________ _______

Definitions of Terms:
Proportional >The term is responsible for the basic servo system stability.
[stiffness of the system]
Integral >The integral (I) term increases the DAC value over time to close the final position
to zero following error once the axis has been commanded to a stop. This term is
selectively activated by the executive software only during the final deceleration frame.
Due to mechanical friction, a properly tuned main algorithm (no overshoot) results in the
axis stopping several counts short of the target destination when at zero velocity. The I
term will then move the axis into its final target destination. The magnitude of the I term
sets how quickly any remaining following error is eliminated. Axis overshoot, when
reaching the stop position target, can result if too large of a I term is selected.
I Limit >This term is used in conjunction with the I term. The I Limit term scales the
maximum DAC value that the Integral term can generate to eliminate the residual
following error. Appropriate values for the Integral term and I Limit will yield quick
elimination of residual following error with no position overshoot.
The I Limit range is 0 to 14, with 14 providing the maximum limiting effect on the Integral
term.
Derivative >This term has a "dampening effect" to add to system stability.

[system dampening as a result of velocity feedback information]
Feed
Forward
Velocity >This term is the DAC value predictor or estimator based on the velocity commanded.
[reduces following errors introduced by system inertia and the affect of the
Derivative term]
Max Accel >This term sets the maximum acceleration rate that the axis will be expected to
execute. It is derived from the mechanical and electrical specifications that the maximum
acceleration rate the system can perform lowered by 30% for design headroom.
[units hard coded in inches per minute squared]
Max Abort
Accel >This term is set high enough to invoke the full current capability of the servo
This value is usually set 2 to 3 times greater than the Max Accel term. The Abort Accel
value is used whenever an axis over travel limit switch or EM Stop condition occurs.
[units hard coded in inches per minute squared]
2
FE Halt >This term establishes the maximum following error allowed before stopping all
axes and posting a following error fault for the associated axis.
[units hard coded in inches]
Following error is proportional to velocity. The commanded target actually leads the desired navigation
path when the axis is running at a velocity. The mechanical system is always chasing this theoretical
target. With properly tuned parameters, following error is kept small while providing tight servo loop
performance.
DAC Balance >This term is used as the integration value when performing the DAC offset
compensation test. Any DAC offset that exists in the electrical path to the servo amp,
is determined and a DAC bit weight assigned to null out the offset's effect. A small
DAC command value is sent out to move a short distance in one direction and then the
polarity is reversed. The number of encoder counts are recorded. If there is a
discrepancy, then an offset value will be added to the appropriate direction. The offset
value is then included in each DAC command calculation to properly compensate the
command. This DAC offset value is retained until the DAC offset test command is
reissued and the offset is recalculated
It is important to adjust the servo amplifier balance pot using the Hurco DAC offset cycle in the 101
screen Axis Balance Adjustment immediately after powering on the machine. The servo amp balance
must be set within plus and minus 20 mV. When the machine is first powered up, no DAC offset value is
assigned. The servo amp balance pot needs to be adjusted prior to issuing a DAC offset test command.
The DAC offset test command is issued each time the machine is calibrated or if axis diagnostics is
enabled. During machine calibration, the test order is Spindle, Z, X, Y, a then b.
In Position >This term sets the allowable number of counts either side of the target position. This
count bandwidth is used for the Axis Ready test (when to display the commanded
position on the CRT and process the next move).
The following terms are used as gain multipliers within the DSP algorithm and are therefore unitless:
Integral Proportional Feed Forward Derivative DAC Balance Integral Limit
The DSP system contains a 12 bit DAC (plus 2048, minus 2048). This equals 4.8 mV per bit command
resolution. The main CPU interpreter sends down navigation frame of 20 milliseconds. The DSP system
then divides the frame up into 200 microsecond blocks of information and reads axis position every 100
microseconds. DAC changes occur every 100 microseconds. The duty cycle of the DAC changes can
therefore yield a sub-millivolt output DAC.
Spindle Drive Servo Mode becomes effective only during tapping. The wire modification to the S1CN
harness allows software to switch the spindle drive between velocity mode and servo mode. In servo
mode, the spindle drive provides tighter speed control over the 0 to 2500 RPM range. Servo mode
operation above 2500 RPM is not valid according to the drive manufacturer.
3
ENGINEERING DOCUMENT 757-4002-029 Revision A CAD # D8310
SUBJECT: Parameters for ULTIMAX 3 Software Version 1.21 [002-4123-005]
R

I. INTENT
II. APPLICABILITY
Applicable to all BMC Ultimax 3 Machining Centers and the Ultimax 3 MD1 Machines.
III INDEX
page 2 BMC 20 Machine including a fourth axis Koma 151R Rotary Table
page 4 BMC 25
page 8 UK BMC 30
page 10 40 SLV Machine including a fourth axis Koma RNCX251DC Rotary Table
page 14 BMC 50 Machine including a five axes Lange Rotary / Tilt Table
page 16 BMC 80
page 18 MD1 Machine including a fourth axis (DC) Rotary Table
page 20 Supported Rotary Tables
_________________________________________ _________ _________________________________________ _________

BMC 20 Machine, including the four axis Koma 151R table
** AXIS PARAMETERS ** X Axis Y Axis Z Axis ** AXIS PARAMETERS ** 4K Spindle 6K Spindle 10K Spindle
Machine Wiring Logic Normal Normal Inverted Machine Wiring Logic Inverted Inverted Inverted
Axis Pitch Metric Metric Metric Counts per (Spindle Motor) Revolution 1,024 1,024 1,024
Counts per Revolution 5,000 5,000 5,000 In Position Tolerance 1,024 counts 1,024 counts 1,024 counts
Limit Switch to Marker Distance 7 mm 7 mm 7 mm Orient Mechanism Present Yes Yes Yes
Distance per Revolution 10 mm 10 mm 10 mm Clamp / Unclamp Present Yes Yes Yes
In Position Tolerance 3 counts 3 counts 3 counts Minimum Tap RPM 40 60 100
Calib: To Lim Sw Velocity [ inch / min ] 200 200 200 Maximum Tap RPM 2,000 2,000 2,000
Calib: To Marker Velocity [ inch / min ] 20 20 20 High / Low Winding Present Yes Yes Yes
Positive Limit Switch Signal Logic 0 0 0 High Winding RPM 2,000 2,000 2,000
Negative Limit Switch Signal Logic 0 0 0 Spindle Purge Time 30 minutes 30 minutes 30 minutes
Load Meter Bar One Value 20 20 20 Load Meter Bar One Value 20 20 20
Load Meter Overload Value 110 110 110 Load Meter Overload Value 80 80 80
** MACHINE CONFIGURATION ** ** ROTARY PARAMETERS ** Koma 151R a Axis

Maximum ATC Magazine Count 16 Rotary Resolution (counts / degree) 4,000
Maximum X Travel 620 mm Maximum RPM 20
Maximum Y Travel 365 mm Clamp Mechanism Present Yes
Maximum Z Travel 410 mm Clamp Signal Present Yes
Calibration Direction Choose Clamp Signal Logic 0
Maximum Motor Speed Pick to calibrate RPM Unclamp Signal Present Yes
Maximum Spindle Speed Set to machine design Unclamp Signal Logic 0
ATC Type (mag up/down = 0) Per ATC type Fault Signal Present Yes
Verify Chip Door Upon ESTOP No Fault Signal Logic 1
Machine Wiring Logic Normal
Limit Switch Present Yes
Limit Switch to Marker Distance 6 Degrees
CRP 3 PCB Switch Settings a Limit Switch Signal Logic 0
SW 1 Backlash Compensation Table Specific
-5 -4 -3 -2 -1 In Position Tolerance 4 Counts
4K Spindle off off off off off Calib: To Lim Sw Velocity 200
6K Spindle on off off off off Calib: To Marker Velocity 100
10K Spindle off on off off off Table Ratio (Driver : Driven) 90 : 1
Ultimax 3 Software Version 1.21 Parameters 757-4002-029 Rev. A 2

MATRIX4 Axis Tune Diagnostics X Axis Y Axis Z Axis 4K Spindle 6K Spindle 10K Spindle Koma 151R a Axis
Integral: 200 200 200 30 30 30 10
Proportional: 3,800 3,800 3,800 400 400 400 5,000
Feedforward: 1,000 1,000 1,000 1,850 1,850 1,850 250
Derivative: 400 400 600 1,000 1,000 1,000 30
Integral Limit 12 12 12 5 5 5 11
Output Loop Gain 1 1 1 1 1 1 1
Integral Bandwidth 200 200 200 1,024 1,024 1,024 200
DAC Balance: 0 0 0 0 0 0 0
DAC Balance Limit: 0 0 0 0 0 0 0
Maximum Acceleration: 140,000 140,000 140,000 120,000 120,000 100,000 750,000
Maximum Abort Accel: 300,000 300,000 300,000 120,000 120,000 100,000 750,000
Following Error Halt: 0.25 inch 0.25 inch 0.25 inch 3,000 degrees 3,000 degrees 3,000 degrees 2 degrees
Tap Deceleration: n/a n/a n/a 120,000 120,000 100,000 n/a

BMC 25 Machine
** MACHINE CONFIGURATION **
Maximum ATC Magazine Count 24
Maximum X Travel 620 mm CRP 3 PCB Switch Settings
Maximum Y Travel 410 mm SW 1
Maximum Z Travel 510 mm -5 -4 -3 -2 -1
Calibration Direction Choose 4K Spindle off off on off off
Maximum Motor Speed Pick to calibrate RPM 6K Spindle on off on off off
Maximum Spindle Speed Set to machine design 10K Spindle off on on off off
ATC Type (mag up/down = 0) Per ATC type

BMC 25 Machine
MATRIX4 Axis Tune Diagnostics X Axis Y Axis Z Axis 4K Spindle 6K Spindle 10K Spindle
Integral: 100 100 100 30 30 30
Proportional: 3,800 3,800 3,800 400 400 400
Feedforward: 1,000 1,000 1,000 1,750 1,750 1,750
Derivative: 300 300 300 500 500 500
Integral Limit 11 11 11 10 10 10
Output Loop Gain 1 1 1 1 1 1
Integral Bandwidth 200 200 200 1,024 1,024 1,024
DAC Balance: 0 0 0 0 0 0
DAC Balance Limit: 0 0 0 0 0 0
Maximum Acceleration: 140,000 140,000 140,000 100,000 100,000 80,000
Maximum Abort Accel: 300,000 300,000 300,000 100,000 100,000 80,000
Following Error Halt: 0.25 inch 0.25 inch 0.25 inch 3,000 degrees 3,000 degrees 3,000 degrees
Tap Deceleration: n/a n/a n/a 100,000 100,000 80,000


Maximum X Travel 762 mm Maximum RPM 10.5
4K Spindle off off off on off Calib: To Lim Sw Velocity 200
6K Spindle on off off on off Calib: To Marker Velocity 100
10K Spindle off on off on off Table Ratio (Driver : Driven) 180 : 1

Integral: 100 100 100 30 30 30 10
Proportional: 3,800 3,800 3,800 400 400 400 4,000
Feedforward: 1,000 1,000 1,000 1,750 1,750 1,750 250
Derivative: 300 300 300 500 500 500 30
Integral Limit 11 11 11 10 10 10 5
DAC Balance: 0 0 0 0 0 0 0

UK BMC 30 Machine
Maximum X Travel 1,020 mm CRP 3 PCB Switch Settings
Maximum Y Travel 510 mm SW 1
Calibration Direction Choose 4K Spindle off off on on off
Maximum Motor Speed Pick to calibrate RPM 6K Spindle on off on on off
Maximum Spindle Speed Set to machine design 10K Spindle off on on on off

UK BMC 30 Machine
Integral: 100 100 100 30 30 30
Proportional: 3,800 3,800 3,800 400 400 400
Feedforward: 1,000 1,000 1,000 1,750 1,750 1,750
Derivative: 420 420 200 500 500 500

40 SLV Machine, including the four axis Koma RNCX251DC table
** MACHINE CONFIGURATION ** ** ROTARY PARAMETERS ** Koma RNCX251DC a Axis

Maximum X Travel 1,020 mm Maximum RPM 10.5
4K Spindle off off on on off Calib: To Lim Sw Velocity 200
6K Spindle on off on on off Calib: To Marker Velocity 100
10K Spindle off on on on off Table Ratio (Driver : Driven) 90 : 1

40 SLV Machine, including the four axis Koma RNCX251DC table
MATRIX4 Axis Tune Diagnostics X Axis Y Axis Z Axis 4K Spindle 6K Spindle 10K Spindle RNCX251DC a Axis
Integral: 200 200 200 30 30 30 10
Proportional: 3,800 3,800 3,800 400 400 400 3,800
Feedforward: 1,000 1,000 1,000 1,750 1,750 1,750 1,000
Derivative: 500 500 500 500 500 500 300
Integral Limit 12 12 12 10 10 10 5
DAC Balance: 0 0 0 0 0 0 0


Maximum X Travel 1,020 mm Maximum RPM 10.5
4K Spindle off off on on off Calib: To Lim Sw Velocity 200
6K Spindle on off on on off Calib: To Marker Velocity 100
10K Spindle off on on on off Table Ratio (Driver : Driven) 180 : 1

Integral: 200 200 200 30 30 30 10
Proportional: 3,800 3,800 3,800 400 400 400 4,000
Feedforward: 1,000 1,000 1,000 1,750 1,750 1,750 250
Derivative: 300 300 300 500 500 500 30
Integral Limit 12 12 12 10 10 10 11
DAC Balance: 0 0 0 0 0 0 0

BMC 50 Machine, including the five axis Lange rotary / tilt table
** AXIS PARAMETERS ** X Axis Y Axis Z Axis ** AXIS PARAMETERS ** 4K Spindle 6K Spindle

Machine Wiring Logic Normal Normal Inverted Machine Wiring Logic Inverted Inverted
Axis Pitch Metric Metric Metric Counts per (Spindle Motor) Revolution 1,024 1,024
Counts per Revolution 5,000 5,000 5,000 In Position Tolerance 1,024 counts 1,024 counts
Limit Switch to Marker Distance 7 mm 7 mm 7 mm Orient Mechanism Present Yes Yes
Distance per Revolution 10 mm 10 mm 10 mm Clamp / Unclamp Present Yes Yes
In Position Tolerance 3 counts 3 counts 3 counts Minimum Tap RPM 40 60
Calib: To Lim Sw Velocity [ inch / min ] 200 200 200 Maximum Tap RPM 2,000 2,000
Calib: To Marker Velocity [ inch / min ] 20 20 20 High / Low Winding Present Yes Yes
Positive Limit Switch Signal Logic 0 0 0 High Winding RPM 1,600 1,600
Negative Limit Switch Signal Logic 0 0 0 Spindle Purge Time 30 minutes 30 minutes
Load Meter Bar One Value 20 20 20 Load Meter Bar One Value 20 20
Load Meter Overload Value 110 110 110 Load Meter Overload Value 80 80
** MACHINE CONFIGURATION ** ** ROTARY PARAMETERS ** Lange a Axis Lange b Axis

Maximum ATC Magazine Count 20 Rotary Resolution (counts / degree) 2,000 2,000
Maximum X Travel 1,325 mm Maximum RPM 5 5
Maximum Y Travel 762 mm Clamp Mechanism Present Yes Yes
Maximum Z Travel 600 mm Clamp Signal Present No No
Calibration Direction Choose Clamp Signal Logic 0 0
Maximum Motor Speed Pick to calibrate RPM Unclamp Signal Present Yes Yes
Maximum Spindle Speed Set to machine design Unclamp Signal Logic 0 0
ATC Type (mag up/down = 0) Per ATC type Fault Signal Present No No
Verify Chip Door Upon ESTOP No Fault Signal Logic 1 1
Machine Wiring Logic Normal Normal
Limit Switch Present Yes Yes
Limit Switch to Marker Distance 6 Degrees 6 Degrees
CRP 3 PCB Switch Settings a Limit Switch Signal Logic 0 0
SW 1 Backlash Compensation Table Specific Table Specific
-5 -4 -3 -2 -1 In Position Tolerance 4 Counts 4 Counts
4K Spindle off off off off on Calib: To Lim Sw Velocity 200 200
6K Spindle on off off off on Calib: To Marker Velocity 100 100
Table Ratio (Driver : Driven) 60 : 1 72 : 1

BMC 50 Machine, including the five axis Lange rotary / tilt table
MATRIX4 Axis Tune Diagnostics X Axis Y Axis Z Axis 4K Spindle 6K Spindle Lange a Axis Lange b Axis
Integral: 200 200 200 30 30 500 500
Proportional: 2,000 2,000 1,000 400 400 20,000 20,000
Feedforward: 900 900 1,400 1,750 1,750 1,500 1,500
Derivative: 420 350 200 500 500 500 500
Integral Limit 12 12 13 10 10 7 7
Integral Bandwidth 100 100 100 1,024 1,024 100 100
DAC Balance: 0 0 0 0 0 0 0
Following Error Halt: 0.25 inch 0.25 inch 0.25 inch 3,000 degrees 3,000 degrees 2 degrees 2 degrees
Tap Deceleration: n/a n/a n/a 60,000 60,000 n/a n/a

BMC 80 Machine
** AXIS PARAMETERS ** X Axis Y Axis Z Axis ** AXIS PARAMETERS ** 4K Spindle 6K Spindle

Maximum X Travel 1,325 mm CRP 3 PCB Switch Settings
Maximum Y Travel 1,270 mm SW 1
Calibration Direction Choose 4K Spindle on on on on on
Maximum Motor Speed Pick to calibrate RPM 6K Spindle on on on on on
Maximum Spindle Speed Set to machine design

BMC 80 Machine
MATRIX4 Axis Tune Diagnostics X Axis Y Axis Z Axis 4K Spindle 6K Spindle

Integral: 200 200 200 30 30
Proportional: 2,000 2,000 1,000 400 400
Feedforward: 900 900 1,400 1,750 1,750
Derivative: 420 350 200 500 500
Integral Limit 12 12 13 10 10
Output Loop Gain 1 1 1 1 1
Integral Bandwidth 100 100 100 1,024 1,024
DAC Balance: 0 0 0 0 0
DAC Balance Limit: 0 0 0 0 0
Maximum Acceleration: 140,000 140,000 140,000 60,000 60,000
Maximum Abort Accel: 300,000 300,000 300,000 60,000 60,000
Following Error Halt: 0.25 inch 0.25 inch 0.25 inch 3,000 degrees 3,000 degrees
Tap Deceleration: n/a n/a n/a 60,000 60,000

MD1 Machine, including a fourth axis DC Rotary table
** AXIS PARAMETERS ** X Axis Y Axis Z Axis ** AXIS PARAMETERS ** 6K Spindle 30 Taper 6K Spindle 40 Taper
7 1/2 Horsepower 10 Horsepower
Axis Pitch English English English Counts per (Spindle Motor) Revolution 1,024 1,024
Limit Switch to Marker Distance 0.3 inch 0.3 inch 0.3 inch Orient Mechanism Present Yes Yes
** MACHINE CONFIGURATION ** ** ROTARY PARAMETERS ** a Axis (DC)

Maximum X Travel 762 mm Maximum RPM 4
on off off on on Calib: To Lim Sw Velocity 200
Calib: To Marker Velocity 100
Table Ratio (Driver : Driven) 90 : 1

MD1 Machine, including a fourth axis DC Rotary table
MATRIX4 Axis Tune Diagnostics X Axis Y Axis Z Axis 6K Spindle30 Taper 6K Spindle 40 Taper a Axis (DC)
Integral: 100 100 100 10 10 10
Proportional: 3,800 3,800 3,800 400 400 3,800
Feedforward: 1,000 1,000 1,000 1,850 1,850 1,000
Derivative: 300 300 300 500 500 300
Integral Bandwidth 100 100 100 1,024 1,024 50
Following Error Halt: 0.25 inch 0.25 inch 0.25 inch 3,000 degrees 3,000 degrees 2 degrees
Tap Deceleration: n/a n/a n/a 130,000 250,000 n/a

Supported Rotary Tables
** ROTARY PARAMETERS ** Koma 151R Koma 251R RNCX251DC Koma 301R Lange a Axis Lange b Axis
Rotary Resolution (counts / degree) 4,000 4,000 4,000 4,000 2,000 2,000
Maximum RPM 20 10.5 10.5 10.5 5 5
Clamp Mechanism Present Yes Yes Yes Yes Yes Yes
Clamp Signal Present Yes Yes Yes Yes No No
Clamp Signal Logic 0 0 0 0 0 0
Unclamp Signal Present Yes Yes Yes Yes Yes Yes
Unclamp Signal Logic 0 0 0 0 0 0
Fault Signal Present Yes Yes Yes Yes No No
Fault Signal Logic 1 1 1 1 1 1
Machine Wiring Logic Normal Normal Normal Normal Normal Normal
Limit Switch Present Yes Yes Yes Yes Yes Yes
Limit Switch to Marker Distance 6 Degrees 6 Degrees 6 Degrees 6 Degrees 6 Degrees 6 Degrees
a Limit Switch Signal Logic 0 0 0 0 0 0
Backlash Compensation Table Specific Table Specific Table Specific Table Specific Table Specific Table Specific
In Position Tolerance 4 Counts 4 Counts 4 Counts 4 Counts 4 Counts 4 Counts
Calib: To Lim Sw Velocity 200 200 200 200 200 200
Calib: To Marker Velocity 100 100 50 100 100 100
Table Ratio (Driver : Driven) 90 : 1 180 : 1 90 : 1 180 : 1 60 : 1 72 : 1
MATRIX4 Axis Tune Diagnostics

Integral: 10 10 10 10 500 500
Proportional: 5,000 4,000 3,800 4,000 20,000 20,000
Feedforward: 250 250 1,000 250 1,500 1,500
Derivative: 30 30 300 30 500 500
Integral Bandwidth 200 200 100 200 100 100
Following Error Halt: 2 Degrees 2 Degrees 2 Degrees 2 Degrees 2 Degrees 2 Degrees

ENGINEERING DOCUMENT 757-4002-029 Revision B CAD # D8310
SUBJECT: Parameters for ULTIMAX 3 Software Version 1.40
R

B 13119 v1.40 software release, added Gemini Universal (filename D8310B.DOC) 31 MAY 94
I. INTENT
II. APPLICABILITY
Applicable to all Ultimax 3 BMC Machines, MD1 Machines, and the Gemini Universal Machines.
III INDEX
page 2 BMC 20 Machine
page 8 UK BMC 30 Machine
page 10 40 SLV Machine
page 18 MD1 Machine
page 20 Gemini Universal Machine
_________________________________________ _________ _________________________________________ _________

BMC 20 Machine
In Position Tolerance 3 counts 3 counts 3 counts High / Low Winding Present Yes Yes Yes
Calib: To Lim Sw Velocity 5080mmpm 5080mmpm 5080mmpm Spindle High Winding Threshold RPM 2,000 2,000 2,000
Calib: To Marker Velocity 508mmpm 508mmpm 508mmpm Spindle Air Purge Time On Delay 30 minutes 30 minutes 30 minutes
Positive Limit Switch Signal Logic 0 0 0 Load Meter Bar One Value 20 20 20
Negative Limit Switch Signal Logic 0 0 0 Load Meter Overload Value 80 80 80
Load Meter Bar One Value 20 20 20 Spindle Control Type Close Loop Vel Close Loop Vel Close Loop Vel
Maxinum Travel 620 mm 365 mm 410 mm Fault Signal Logic 0 0 0
Coordinate Frame Sense Positive Positive Negative Maximum Tap RPM 2,000 2,000 2,000
Machine Wiring Logic Normal Normal Inverted
Calibrate Home Position 0 mm 0 mm 0 mm ** VERTICAL PARAMETERS ** 4K Spindle 6K Spindle 10K Spindle
Calibrate Limit Switch Negative Negative Positive Machine Wiring Logic Inverted Inverted Inverted
Axis Usage Table Table Head Maximum Motor Speed Per calib RPM Per calib RPM Per calib RPM
Maximum Spindle Speed 4,000 6,000 10,000
** MACHINE PARAMETERS ** ** TOOL CHANGE PARAMETERS **

Machine Class Vertical Tool Changer Present Yes
Verify Chip Door Upon ESTOP No ATC Type (mag up/down = 0) Per ATC Type
Swing Table Present No Z Tool Change Position (Height) ATC Specific
Alarm Light Present No
CRP 3 PCB SW1 Switch Settings
-3 -2 -1
off off off
Ultimax 3 Software Version 1.40 Parameters 757-4002-029 Rev. B 2

BMC 20 Machine
Integral: 200 200 200 30 30 30
Proportional: 3,800 3,800 3,800 400 400 400
Feedforward: 1,000 1,000 1,000 1,850 1,850 1,850
Derivative: 400 400 600 1,000 1,000 1,000

BMC 25 Machine

-3 -2 -1
on off off

BMC 25 Machine
Integral: 100 100 100 30 30 30
Proportional: 3,800 3,800 3,800 400 400 400
Feedforward: 1,000 1,000 1,000 1,750 1,750 1,750
Derivative: 300 300 300 500 500 500

BMC 30 Machine

-3 -2 -1
off on off

BMC 30 Machine
Integral: 100 100 100 30 30 30
Proportional: 3,800 3,800 3,800 400 400 400
Feedforward: 1,000 1,000 1,000 1,750 1,750 1,750
Derivative: 300 300 300 500 500 500

UK BMC 30 Machine
Maxinum Travel 1,020 mm 510 mm 640 mm Fault Signal Logic 0 0 0

-3 -2 -1
on on off

UK BMC 30 Machine
Integral: 100 100 100 30 30 30
Proportional: 3,800 3,800 3,800 400 400 400
Feedforward: 1,000 1,000 1,000 1,750 1,750 1,750
Derivative: 420 420 200 500 500 500

40 SLV Machine

-3 -2 -1
on on off

40 SLV Machine
Integral: 200 200 200 30 30 30
Proportional: 3,800 3,800 3,800 400 400 400
Feedforward: 1,000 1,000 1,000 1,750 1,750 1,750
Derivative: 500 500 500 500 500 500

BMC 40 Machine

-3 -2 -1
on on off

BMC 40 Machine
Integral: 200 200 200 30 30 30
Proportional: 3,800 3,800 3,800 400 400 400
Feedforward: 1,000 1,000 1,000 1,750 1,750 1,750
Derivative: 300 300 300 500 500 500

BMC 50 Machine

In Position Tolerance 3 counts 3 counts 3 counts High / Low Winding Present Yes Yes
Calib: To Lim Sw Velocity 5080mmpm 5080mmpm 5080mmpm Spindle High Winding Threshold RPM 1,600 1,600
Calib: To Marker Velocity 508mmpm 508mmpm 508mmpm Spindle Air Purge Time On Delay 30 minutes 30 minutes
Positive Limit Switch Signal Logic 0 0 0 Load Meter Bar One Value 20 20
Negative Limit Switch Signal Logic 0 0 0 Load Meter Overload Value 80 80
Load Meter Bar One Value 20 20 20 Spindle Control Type Close Loop Vel Close Loop Vel
Maxinum Travel 1,325 mm 762 mm 600 mm Fault Signal Logic 0 0
Calibrate Home Position 0 mm 0 mm 0 mm ** VERTICAL PARAMETERS ** 4K Spindle 6K Spindle
Calibrate Limit Switch Negative Negative Positive Machine Wiring Logic Inverted Inverted
Axis Usage Table Table Head Maximum Motor Speed Per calib RPM Per calib RPM
Maximum Spindle Speed 4,000 6,000

-3 -2 -1
off off on

BMC 50 Machine

Integral: 200 200 200 30 30
Proportional: 2,000 2,000 1,000 400 400
Feedforward: 900 900 1,400 1,750 1,750
Derivative: 420 350 200 500 500

BMC 80 Machine

Maxinum Travel 1,325 mm 1,270 mm 600 mm Fault Signal Logic 0 0

-5 -4 -3 -2 -1
on on on on on

BMC 80 Machine

Integral: 200 200 200 30 30
Proportional: 2,000 2,000 1,000 400 400
Feedforward: 900 900 1,400 1,750 1,750
Derivative: 420 350 200 500 500

MD1 Machine
** PHYSICAL PARAMETERS ** X Axis Y Axis Z Axis ** PHYSICAL PARAMETERS ** 6K Spindle 30 Taper 6K Spindle 40 Taper
Axis Pitch Inch Inch Inch Counts per (Spindle Motor) Revolution 1,024 1,024
Limit Switch to Marker Distance 0.3 in 0.3 in 0.3 in Orient Mechanism Present Yes Yes
Distance per Revolution 0.3937 in 0.3937 in 0.3937 in Clamp / Unclamp Present Yes Yes
Calib: To Lim Sw Velocity 100 ipm 100 ipm 100 ipm Spindle High Winding Threshold RPM 2,000 2,000
Calib: To Marker Velocity 5 ipm 5 ipm 5 ipm Spindle Air Purge Time On Delay 30 minutes 30 minutes
Load Meter Bar One Value 5 5 5 Spindle Control Type Closed Loop Vel Closed Loop Vel
Maxinum Travel 762 mm 381 mm 406 mm Fault Signal Logic 0 0
Axis Usage Table Table Head Maximum Motor Speed Per calibrated RPM Per calibrated RPM

-5 -4 -3 -2 -1
on off off on on

MD1 Machine
MATRIX4 Axis Tune Diagnostics X Axis Y Axis Z Axis 6K Spindle30 Taper 6K Spindle 40 Taper
Integral: 100 100 100 10 10
Proportional: 3,800 3,800 3,800 400 400
Feedforward: 1,000 1,000 1,000 1,850 1,850
Derivative: 300 300 300 500 500

Gemini Universal Machine
** PHYSICAL PARAMETERS ** X Axis Y Axis Z Axis ** PHYSICAL PARAMETERS ** 4K Spindle

Axis Pitch Metric Metric Metric Counts per (Spindle Motor) Revolution 1,024
Counts per Revolution 3,000 3,000 3,000 In Position Tolerance 1,024 counts
Limit Switch to Marker Distance 15 mm 15 mm 15 mm Orient Mechanism Present No
Distance per Revolution 6 mm 6 mm 6 mm Clamp / Unclamp Present Yes
In Position Tolerance 3 counts 3 counts 3 counts High / Low Winding Present No
Calib: To Lim Sw Velocity [ inch / min ] 2794 2794 2794 Spindle High Winding Threshold RPM n/a
Calib: To Marker Velocity [ inch / min ] 508 508 508 Spindle Air Purge Time On Delay 30 minutes
Positive Limit Switch Signal Logic 0 0 0 Load Meter Bar One Value 20
Negative Limit Switch Signal Logic 0 0 0 Load Meter Overload Value 80
Load Meter Bar One Value 20 20 20 Spindle Control Type Closed Loop
Load Meter Overload Value 110 110 110 Maximum DAC Volts n/a
Fault Signal Logic 0 0 0 AMR Relay Present Yes
Maxinum Travel 500.0 mm 395.0 mm 400.0 mm Fault Signal Logic 0
** VERTICAL PARAMETERS ** X Axis Y Axis Z Axis Minimum Tap RPM 40
Coordinate Frame Sense Positive Positive Negative Maximum Tap RPM 2,000
Machine Wiring Logic Inverted Inverted Inverted
Calibrate Home Position 0.0 mm 395.0 mm 0.0 mm ** VERTICAL PARAMETERS ** 4K Spindle
Calibrate Limit Switch Machine Wiring Logic Inverted
Axis Usage Table Head Table Maximum Motor Speed 8,000
Maximum Spindle Speed 3,150
** HORIZONTAL PARAMETERS ** X Axis Y Axis Z Axis
Physical Axis X Axis Z Axis Y Axis ** HORIZONTAL PARAMETERS ** 4K Spindle
Coordinate Frame Sense Positive Positive Negative Machine Wiring Logic Inverted
Machine Wiring Logic Inverted Normal Inverted Maximum Motor Speed 8,000
Calibrate Home Position 0.0 mm 0.0 mm 0.0 mm Maximum Spindle Speed 4,000
Calibrate Limit Switch Negative Negative Positive
Negative Limit Switch Physical X- Physical Z+ Physical Y-
Axis Usage Table Table Head

Machine Class Universal Tool Changer Present No
Machine Orientation Input Available No Maximum ATC Magazine Count n/a
Verify Chip Door Upon ESTOP Yes ATC Type (mag up/down = 0) n/a
Integral: 100 100 100 10 10 10
Proportional: 3,800 3,800 3,800 400 400 3,800
Feedforward: 1,000 1,000 1,000 1,850 1,850 1,000
Derivative: 300 300 300 500 500 300

Maximum RPM 20 10.5 10.5 10.5 5 5
Limit Switch Signal Logic 0 0 0 0 0 0

Integral: 10 10 10 10 500 500
Proportional: 5,000 4,000 3,800 4,000 20,000 20,000
Feedforward: 250 250 1,000 250 1,500 1,500
Derivative: 30 30 300 30 500 500

ENGINEERING DOCUMENT 757-4002-029 Revision C CAD # D8310
SUBJECT: Parameters for ULTIMAX 3 Mbus Software Version 1.53
R

B 13119 v1.40 software release, added Gemini Universal (filename D8310B.DOC) 31 MAY 94
C 13386 Added version 1.53 parameters (filename D8310C.DOC). 4 APR 95
I. INTENT
II. APPLICABILITY
Applicable to all Ultimax 3 BMC Machines, MD1 Machines, and the Gemini Universal Machines.
III INDEX
page 8 UK BMC 30 Machine
page 10 40 SLV Machine
page 18 MD1 Machine
page 20 Gemini Universal Machine
_________________________________________ _________ _________________________________________ _________

BMC 20 Machine
Maximum Feedrate (mmpm) 10,160 10,160 10,160 Spindle Brake Enable Time n/a n/a n/a
Machine Wiring Logic Normal Normal Inverted Orient Mechanism Type Electronic Electronic Electronic

Machine Type BMC 20 Tool Changer Present Yes
Machine Class Vertical Maximum ATC Magazine Count 16
Control Relay Panel Board Type CRP2/3 CRP 3 PCB SW1 Switch Settings
Max. Prog. Contour Feedrate 5,080 mmpm -3 -2 -1
Jog Wheel Scale Factor 100 off off off
Ultimax 3 Software Version 1.53 Parameters 757-4002-029 Rev. C 2

BMC 20 Machine
Integral: 200 200 200 30 30 30
Proportional: 3,800 3,800 3,800 400 400 400
Feedforward: 1,000 1,000 1,000 1,850 1,850 1,850
Derivative: 400 400 600 1,000 1,000 1,000
Maximum Rapid Acceleration: 140,000 140,000 140,000 120,000 120,000 100,000
Maximum Contour Acceleration: 140,000 140,000 140,000 120,000 120,000 100,000
Z/S Tap Gain: n/a n/a n/a 1 1 1

BMC 25 Machine

Jog Wheel Scale Factor 100 on off off

BMC 25 Machine
Integral: 100 100 100 30 30 30
Proportional: 3,800 3,800 3,800 400 400 400
Feedforward: 1,000 1,000 1,000 1,750 1,750 1,750
Derivative: 300 300 300 500 500 500

BMC 30 Machine

Jog Wheel Scale Factor 100 off on off

BMC 30 Machine
Integral: 100 100 100 30 30 30
Proportional: 3,800 3,800 3,800 400 400 400
Feedforward: 1,000 1,000 1,000 1,750 1,750 1,750
Derivative: 300 300 300 500 500 500

UK BMC 30 Machine

Jog Wheel Scale Factor 100 on on off

UK BMC 30 Machine
Integral: 100 100 100 30 30 30
Proportional: 3,800 3,800 3,800 400 400 400
Feedforward: 1,000 1,000 1,000 1,750 1,750 1,750
Derivative: 420 420 200 500 500 500

40 SLV Machine

Machine Type BMC 40 SLV Tool Changer Present Yes

40 SLV Machine
Integral: 200 200 200 30 30 30
Proportional: 3,800 3,800 3,800 400 400 400
Feedforward: 1,000 1,000 1,000 1,750 1,750 1,750
Derivative: 500 500 500 500 500 500
Z/S tap Gain: n/a n/a n/a 1 1 1

BMC 40 Machine


BMC 40 Machine
Integral: 200 200 200 30 30 30
Proportional: 3,800 3,800 3,800 400 400 400
Feedforward: 1,000 1,000 1,000 1,750 1,750 1,750
Derivative: 300 300 300 500 500 500

BMC 50 Machine

Maxinum Travel 1,325 mm 762 mm 600 mm Fault Signal Logic 0 0
Maximum Feedrate (mmpm) 10,160 10,160 10,160 Spindle Brake Enable Time n/a n/a
Machine Wiring Logic Normal Normal Inverted Orient Mechanism Type Electronic Electronic

Jog Wheel Scale Factor 100 off off on

BMC 50 Machine

Integral: 200 200 200 30 30
Proportional: 2,000 2,000 1,000 400 400
Feedforward: 900 900 1,400 1,750 1,750
Derivative: 420 350 200 500 500
Maximum Rapid Acceleration: 140,000 140,000 140,000 60,000 60,000
Maximum Contour Acceleration: 140,000 140,000 140,000 60,000 60,000
Z/S Tap Gain: n/a n/a n/a 1 1

BMC 80 Machine

Maxinum Travel 1,325 mm 1,270 mm 600 mm Fault Signal Logic 0 0
Maximum Feedrate (mmpm) 10,160 10,160 10,160 Spindle Brake Enable Time n/a n/a

Max. Prog. Contour Feedrate 5,080 mmpm -5 -4 -3 -2 -1
Jog Wheel Scale Factor 100 on on on on on

BMC 80 Machine

Integral: 200 200 200 30 30
Proportional: 2,000 2,000 1,000 400 400
Feedforward: 900 900 1,400 1,750 1,750
Derivative: 420 350 200 500 500

MD1 Machine
** PHYSICAL PARAMETERS ** X Axis Y Axis Z Axis ** PHYSICAL PARAMETERS ** 6K Spindle 30 Taper 6K Spindle 40 Taper
Axis Pitch Inch Inch Inch Counts per (Spindle Motor) Revolution 1,024 1,024
Limit Switch to Marker Distance 0.3 in 0.3 in 0.3 in Orient Mechanism Present Yes Yes
Distance per Revolution 0.3937 in 0.3937 in 0.3937 in Clamp / Unclamp Present Yes Yes
Calib: To Lim Sw Velocity 100 ipm 100 ipm 100 ipm Spindle High Winding Threshold RPM 2,000 2,000
Calib: To Marker Velocity 5 ipm 5 ipm 5 ipm Spindle Air Purge Time On Delay 30 minutes 30 minutes
Maxinum Travel 762 mm 381 mm 406 mm Fault Signal Logic 0 0
Maximum Feedrate (ipm) 400 400 400 Spindle Brake Enable Time n/a n/a
Axis Usage Table Table Head Maximum Motor Speed Per calibrated RPM Per calibrated RPM

Machine Type MD1/MB1R Tool Changer Present Yes
Max. Prog. Contour Feedrate 200 ipm -5 -4 -3 -2 -1
Jog Wheel Scale Factor 100 on off off on on

MD1 Machine
MATRIX4 Axis Tune Diagnostics X Axis Y Axis Z Axis 6K Spindle30 Taper 6K Spindle 40 Taper
Integral: 100 100 100 10 10
Proportional: 3,800 3,800 3,800 400 400
Feedforward: 1,000 1,000 1,000 1,850 1,850
Derivative: 300 300 300 500 500


Limit Switch to Marker Distance 15 mm 15 mm 15 mm Orient Mechanism Present No
Calib: To Lim Sw Velocity [ inch / min ] 2794 2794 2794 Spindle High Winding Threshold RPM n/a
Calib: To Marker Velocity [ inch / min ] 508 508 508 Spindle Air Purge Time On Delay 30 minutes
Load Meter Bar One Value 20 20 20 Spindle Control Type Closed Loop
Load Meter Overload Value 110 110 110 Maximum DAC Volts n/a
Maxinum Travel 500.0 mm 395.0 mm 400.0 mm Fault Signal Logic 0
Maximum Feedrate (mmpm) 10,160 10,160 10,160 Spindle Brake Enable Time 1
** VERTICAL PARAMETERS ** X Axis Y Axis Z Axis Minimum Tap RPM 40
Coordinate Frame Sense Positive Positive Negative Maximum Tap RPM 2,000
Machine Wiring Logic Inverted Inverted Inverted Orient Mechanism Type Electronic
Calibrate Home Position 0.0 mm 395.0 mm 0.0 mm ** VERTICAL PARAMETERS ** 4K Spindle
Calibrate Limit Switch Machine Wiring Logic Inverted
Axis Usage Table Head Table Maximum Motor Speed 8,000
** HORIZONTAL PARAMETERS ** X Axis Y Axis Z Axis
Physical Axis X Axis Z Axis Y Axis ** HORIZONTAL PARAMETERS ** 4K Spindle
Coordinate Frame Sense Positive Positive Negative Machine Wiring Logic Inverted
Machine Wiring Logic Inverted Normal Inverted Maximum Motor Speed 8,000
Calibrate Home Position 0.0 mm 0.0 mm 0.0 mm Maximum Spindle Speed 4,000
Negative Limit Switch Physical X- Physical Z+ Physical Y-

Machine Class Universal Tool Changer Present No
Machine Orientation Input Available No Maximum ATC Magazine Count n/a
Verify Chip Door Upon ESTOP Yes ATC Type (mag up/down = 0) n/a
Integral: 100 100 100 10 10 10
Proportional: 3,800 3,800 3,800 400 400 3,800
Feedforward: 1,000 1,000 1,000 1,850 1,850 1,000
Derivative: 300 300 300 500 500 300
Z/S Tap Gain: n/a n/a n/a 1 1 n/a

Maximum RPM 20 10.5 10.5 10.5 5 5
Limit Switch Signal Logic 0 0 0 0 0 0

Integral: 10 10 10 10 500 500
Proportional: 5,000 4,000 3,800 4,000 20,000 20,000
Feedforward: 250 250 1,000 250 1,500 1,500
Derivative: 30 30 300 30 500 500

R 757-4004-002 REV: B ECN #12382
1/11/93 CAD #D8427
SUBJECT: ULTIMAX II-32 CPU (HURCO 002-3311-027)


B 12382 Moved graphics board from J7 to J8. 1/11/93
I. INTENT:
To serve as a guide in the assembly & testing of the Ultimax II-32 Standard CPU Assembly (002-3311-027).
SUB-ASSEMBLY P/N
STANDARD:
HURCO SBX GRAPHICS CONTROLLER 415-0220-901
IC, FLOATING POINT COPROCESSOR 450-1001-043
EPROM BIOS FOR QUANTUM ELS42AT HDD
AND 2MB RAM:
ODD BYTE 450-3005-051
EVEN BYTE 450-3005-052
III. OUTLINE:
1) Main CPU board configuration.

________________________________ _______ _______________________________ _______

SECTION 1: MAIN CPU BOARD CONFIGURATION
STEP 2) STRAPPING:
• Configure the jumpers per 415-0166-904 print.

• Install the wire wraps as shown in the "LOCAL INTERRUPT MATRIX -904" detail.

detailed below.

RESULT.
PIN 1
FIGURE 1
N80387SX-16
MMOX CONNECTOR
Using Figure 2 as a guide, install the standard 2 MB/42 MB Memory Configuration BIOS (450-
3005-051 and -052) as detailed in the following note.
TOPVIEW
D
VE
D
FIGURE 2
O
E
U24 U45 1
2
J9 J10 J11 J12
The final assembly is very simple, the only tool required is a flathead screwdriver. Please refer to Figure 3
for a mechanical representation of the following procedure:
FIGURE 3
GRAPHICS BOARD
J8 (415-0220-901)
CPU BOARD
(415-0166-904)
TIGHTEN
6 SCREWS
STEP 1) At this point of the process you should have two (2) distinct pieces of hardware: 1) Hurco SBX
Graphics Board w/nylon fasteners 415-0220-901 and 2) fully configured CPU baseboard.
STEP 2) Remove the three (3) nylon screws from the bottom of the SBX Graphics board and save for
STEP 3. Plug the Graphics Board into the CPU's SBX site J8.
STEP 3) Find the three (3) nylon screws removed in STEP 2. Thread the screws into their standoffs from
the non-component side of the CPU assembly. Firmly tighten all six (6) nylon screws, being
careful not to strip them.
SETUP:
A.) The Hard Drive harness (located on the front of the rack) is in the LOCAL (?) mode.
installed.
D.) That the Graphics CRT is connected to the Hurco SBX Graphics Board.
TEST PROCEDURE:
harnesses
switch) comes ON, then goes OFF. If the CPU fails to boot, double check all connections.
Return any defective assembly to the manufacturer.
D.) After power up a menu will appear at the bottom of the CRT. Select #1 (CPU TEST).
E.) The CPU Test will start with an inspection of a full screen of test patterns. Press ENTER if OK.
F.) The VADD Station will then go into automatic mode and test the wire wrap and shunt
G.) The Graphics CRT should be monitored at this time to watch for any failures.
H.) Next the Multibus Memory & I/O is tested. The system will write approximately 1 Meg of data
I.) The last test is the Watch Dog Timer test. It should reboot the system when a count of
complete and #1 (CPU TEST) is chosen agian from the main menu.
R
757-4002-057 REV: B ECN #13312
3/22/96 CAD #D8430
SUBJECT: ENG. DOC., MAX3/MAX32 CMOS SETUP

B 13659 Corrected battery polarity 3/22/96
I. INTENT:
To provide instruction on:
1) Installing a battery on the Max3 or Max32 CPU.
2) Programming HDD and memory settings in CMOS.
II. SCOPE:
Applies to Max3 and Max32 CPUs that have BIOS version 450-3005-081 (odd) and -082 (even).
III. PROCEDURE:
A. Battery Installation. Before setting up the Max3 or Max32 CMOS, ensure that a good
Rayovac model 844-1 battery (Hurco 413-8001-019) is installed on the CPU. Installation
is as follows.
2. Adhere the battery’s velcro backing to the CPU, centering the battery over U80
and U81 as shown below.
J14
BATT
______________________ _______ ______________________ _______

757-4002-057 REV A
B. CMOS Setup
Description:
Hardware configuration information is stored in a CMOS device on the CPU board. The
device is made nonvolatile when a battery is connected to it. For Max3 and Max32
controls there are two hardware options which are configurable: the hard drive type and
the amount of memory. On Max3 controls the BIOS contains a built in configuration
utility which is accessed through the AT keyboard and VGA display. On Max32 controls
the built in utility cannot be used because there is no VGA hardware. The new BIOS
EPROM set contains a second utility which allows setup of hard drive and memory on a
Max32 machine. The utility was written to communicate with the Max32 console. It only
allows access to hard drive and memory setup. The remaining CMOS setup parameters
are always the same on Max3 and Max32 machines.
How to access the utility:

There are two ways to invoke the utility. The first method is automatic. If an existing
configuration mismatch is detected then the utility comes up automatically on system
reset. For example, a system has 4 megabytes of RAM and the user enters 8 in the
config. utility. The next time the control is reset the config. utility will automatically come
up because of the mismatch.
The second method for accessing the utility is to press the CLEAR key immediately
after resetting the control. A message will always appear for approximately 5 seconds
after reset to indicate that pressing CLEAR will invoke CMOS setup. If the CLEAR key
is not pressed then the control will go on and attempt to boot the Ultimax software.
How to use the CMOS setup utility:

The CMOS setup utility has a section for hard drive configuration and RAM
configuration. A blinking cursor indicates which field is being edited. The ADVANCE
and BACK keys are used to scroll through the fields. The ENTER key is used to store
numeric data in the current field. If the value entered is not valid the field is cleared and
the data remains unchanged. To correct an entry press the CLEAR key and start over.
A detailed description of each field follows:
Hard drive type - the acceptable range of values for this field is 1 through 49. Drive
types 1 through 47 are preset and types 48 & 49 are user configurable. The preset types
handle many different hard drives but not all (especially the newer high capacity drives).
Each hard drive type contains parameters for number of cylinders, number of heads,
precomp, landing zone, and sectors per track. Use softkeys 1 & 2 to scroll through the
various hard drive types. If there are no entries which match the drive parameters for
the hard drive in use then type 48 or 49 must be used. The fields for hard drive
parameters (cylinders, heads, etc...) may only be edited when hard drive type is 48 or
49.
#Cylinders - the number (non zero) of cylinders (also known as tracks) for the hard
drive. The proper value should be taken from the spec. sheet for the hard drive in use.
This field can only be accessed when hard drive type is 48 or 49.
2
757-4002-057 REV A
Precomp. - the cylinder where write precompensation occurs. The proper value should
be taken from the spec. sheet for the hard drive in use. This field can only be accessed
when hard drive type is 48 or 49.
Landing zone - the cylinder location where the heads go when the drive shuts down.
The proper value should be taken from the spec. sheet for the hard drive in use. This
field can only be accessed when hard drive type is 48 or 49.
#Sectors - the number (non zero) of sectors per track for the hard drive. The proper
value should be taken from the spec. sheet for the hard drive in use. This field can only
be accessed when hard drive type is 48 or 49.
Capacity - the number of megabytes storage capacity based on the hard drive
parameters. This field cannot be edited. The number of megabytes is determined with
the formula: CYLINDERS * HEADS * SECTORS PER TRACK * 512 BYTES PER
SECTOR = capacity in bytes.
RAM configuration - the total number of megabytes of RAM installed on the CPU
board. The only acceptable values are 2, 4, and 8.
How to exit the utility:

There are two softkeys which are used to exit the utility. Softkey 8 will write the hard
drive and RAM configuration data to the CMOS device then exit. Softkey 7 will abort
any changes to CMOS and simply exit.
3
Hurco Companies, Inc.
OPTIKEY INSTALL INSTRUCTIONS

R
704-0004-026 Rev F CAD #: D8436
2/29/00
Optikey is an easy-to-use utility that allows customers to modify the contents of the Software Protection
Device (Key) installed on a Hurco Machining Center or PC (the Software Protection Device (Key) is
used to enable the ULTIMAX features that you have purchased). Optikey diskettes have “Optikey
Utility Diskette” printed on the label, and will also indicate the option type (i.e.: “Software Option”,
“Language Option”, “Security Modifier” or “Production Package”).
OPTIKEY UTILITY
DISKETTE Note: Each Optikey diskette contains only
R
one Software Option, Language Option, or
SOFTWARE OPTION Security Modifier. Therefore, depending upon
007-4124-003 Rev B. the extent of the upgrade, you may have
received multiple diskettes.
ULTIPOCKETS
IMPORTANT NOTICE: An Optikey diskette will only function ONE time. Therefore, it is
absolutely necessary that you use this utility only on the machining center or PC you want the
option installed on.
Furthermore, the customer assumes all responsibility for the correct operation of this utility. Failure to
correctly use this utility may result in a billable Service Call. Please follow the Instructions carefully. If
a problem occurs with Optikey, you may be requested to return any or all of the Optikey diskettes to
Hurco for analysis.
Warning
Remove any other security devices for other software packages (and any other devices) from the
parallel port during this installation procedure. Hurco will not be responsible for any damage or
data loss from any other security device (or other devices) connected to the computer during this
process. Hurco also recommends removing othe r security devices when using any Hurco security

Information contained herein is the property of Hurco Companies, Inc. No reproduction or disclosure of this information shall be made by the recipient to any other
person or organization without the prior written consent of Hurco Companies, Inc.
704-0004-026 1 of 4 D8436.DOC
device and software.

704-0004-026 2 of 4 D8436.DOC
(continued)
1. Identify your system type.

a) HURCO MACHINING CENTER: If you received the “ULTIMAX/Max32 Executive
Software Upgrade Procedure” (704-0004-021) along with this Optikey diskette, begin that
procedure first until it refers you to these Instructions.
b) ULTIMAX PC/PC+: If you received an ULTIMAX PC/PC+ Executive upgrade, then refer to
the “ULTIMAX PC/PC+ Programming Manual” for instructions on upgrading the Executive
software on your Hard Disk Drive.
c) MAX32 486 DSP: Remove the security device from the parallel printer port of the machine tool.
Then connect the security device to the parallel printer port of a PC. Follow the instructions
below for ULTIMAX PC/PC+. (ULTIMAX PC/PC+ is not required)
d) WinMax Desktop: Ensure that the security device is securely connected to the parallel printer
port of the PC the WinMax Desktop software is to be installed.
2. Insert the Optikey diskette into the Floppy Disk Drive (if you received a “Production Package”
Optikey, make sure this diskette is installed first).
3. Invoking the Optikey program.

a) HURCO MACHINING CENTER: Re-boot the Control by cycling the Machine Power OFF
and ON, or by selecting the RESET MASTER softkey in Auxiliary mode.
b) ULTIMAX PC/PC+: From the DOS prompt, change to the appropriate Floppy Disk Drive and
enter the command, “OPTIKEY.EXE”.
c) WinMax Desktop: Close all windows and shut down the PC. Boot the PC with the Optikey
diskette in the floppy disk drive.
4. The first screen displays the Security Level, Software Options, and Language Options that will be
available on your Hurco Machining Center, ULTIMAX PC/PC+ or WinMax Desktop after the
Optikey process.
IMPORTANT: Please verify that the Installation is taking place on the correct Hurco Machining Center
or PC. If not, step #5 will give you the opportunity to cancel the installation.
5. At the Warning Message.

a) HURCO MACHINING CENTER: Select Softkey 1 to proceed with the installation or Softkey
8 to stop.
b) ULTIMAX PC/PC+: Select F1 to proceed with the installation or F8 to stop.

704-0004-026 3 of 4 D8436.DOC
(continued)
c) WinMax Desktop: Select F1 to proceed with the installation or F8 to stop.
6. Upon proceeding with the installation, the device (Key) is automatically updated.
7. Have you installed all of your Optikey diskettes?

a.) If NO, insert the next Optikey diskette in the Floppy Disk Drive and repeat step #5.
If YES, press F8 (or Softkey 8) to stop.
When finished:
HURCO MACHINING CENTER: Remove the Optikey diskette from the Floppy Disk Drive and
cycle the Machine Power OFF and back ON to restore the Ultimax environment.
ULTIMAX PC/PC+: Pressing F8 returns you to DOS. You can now resume using your ULTIMAX
PC or ULTIMAX PC+.
MAX32 486 DSP: Remove the security device from the PC. Then reconnect the security device to the
parallel printer port of the machine tool.
WinMax Desktop: Pressing F8 returns you to DOS. Remove the Optikey diskette from the floppy disk
drive. Reboot the PC. You can now resume using your WinMax Desktop software.
Keep the Optikey diskette(s) in a safe place. Installing an Optikey diskette for a second time will allow
the removal of that option. To remove the option, place the Optikey diskette into the Floppy Disk Drive
and reboot the system by cycling the machine power OFF and then ON.. A prompt will appear asking if
the option is to be removed. If yes is selected, the option will be removed and placed back onto the
Optikey diskette. Removing an option from a machine must use the same Optikey diskette that was
used to install the option

704-0004-026 4 of 4 D8436.DOC
TECHNICAL INFORMATION
NOTICE
DATE: SEPTEMBER 26, 1995 ISSUE NUMBER: 1064-B
SUBJECT: MAX 3/32 CMOS SETUP SUPERSEDES NUMBER: 1064-A
PRODUCT LINE: ALL MAX 3/32 CONTROLS THAT HAVE BIOS

VERSION 450-3005-081(ODD) -082(EVEN). PAGE 1 OF 5
A. Battery Installation
Before setting up the Max3 or Max32 CMOS, ensure that a good Rayovac model 844-1 battery (Hurco
413-8001-019) is installed on the CPU.
Installation is as follows.
2. Adhere the battery’s velcro backing to the CPU, centering the battery over U80 and
U81 as shown below.
J14
BATT
ORIGINATOR: K. EVDOKIOU
REVISED BY: T. MURDEN
Hurco Manufacturing
Software Maintenance Release
Ultimax 3/Max 32 Upgrade Instructions from V1.60 or V1.61
704-0020-021 D8491
6/10/98
Read Me First
With the introduction of a new security device, the following instructions are
being distributed to assist the operator in the upgrade process. Please follow
these instructions explicitly to provide a trouble free software upgrade. These
instructions are only applicable if the current version in the machine to be
upgraded is v1.60 or v1.61. Otherwise, continue with the “Ultimax 3/Max32
Software Upgrade Procedure” included in the kit for part number 704-0004-
021.
High Voltage!!!
Warning
Remove power from the machine tool by turning the disconnect
lever to the OFF position before opening the control cabinet.
INFORMATION CONTAINED HEREIN IS THE PROPERTY OF HURCO MANUFACTURING COMPANY, INC. NO
REPRODUCTION OR DISCLOSURE OF THIS INFORMATION SHALL BE MADE BY THE RECIPIENT TO ANY OTHER PERSON
OR ORGANIZATION WITHOUT THE PRIOR WRITTEN CONSENT OF HURCO MANUFACTURING COMPANY, INC.
Page 1 of 5
UPGRADE PROCEDURE
Check the security device on the printer port on the control card cage in the
machine tool’s control cabinet to see what type it is. Refer to the appropriate Parts
List and Wiring Diagrams manual.
If the device is the DS1255 keyring, follow the “Ultimax 3/Max32 Software
Upgrade Procedure” included in the kit for part number 704-0004-021.
If the security device is the DS1410D button style, follow these instructions. These
instructions are only applicable if the current version in the machine to be upgraded
is v1.60 or v1.61.
Refer to the following illustration of security devices to determine which

procedure is necessary:
DS1410D
Perform Normal Upgrade Use this Upgrade Procedure

DS1255 Keyring DS1410D Button Style
Page 2 of 5
UPGRADE STEPS
Follow these steps to perform an upgrade for the DS1410D Button Style security
device:
1. Power up the machine tool.

2. Press the Auxiliary button.
3. Press the System Configuration ( F4) softkey.
4. Locate the Ultimax 3 Upgrade Executive Diskettes that were shipped
with these instructions. Take Diskette #2 and slide the write protect
tab so the opening is closed. Closing the tab allows writing to the
diskette.
5. Place this diskette into the floppy drive (Drive A) on the control.
6. Select the Backup Machine Configuration (F6) softkey.
7. The System Parameters screen appears with the “OK to continue?”
message and Yes (F2) and No (F1) softkey choices. Press F2 to
continue.
8. The Floppy Drive Active light flashes while the software is backed
up. A screen message appears when the backup is complete. Press the
Auxiliary button to access the Auxiliary screen again.
9. Press the Storage Functions (F1) softkey.
10. Press the Select Current Storage Drive (F6) softkey.
11. Choose the A Drive with the appropriate softkey selection.
12. Press the Disk Operations Directory ( F3) softkey.
13. Highlight the CONFIG directory and press the Change to Directory
(F1) softkey. (If necessary use the arrow keys to move the cursor
until the CONFIG directory is highlighted.)
14. Highlight the directory that corresponds with the control’s current
software version (either V1_60 for version 1.60 or V1_61 for version
1.61).
15. Press the Rename Program (F2) softkey.
Page 3 of 5
16. Using the character grid and trackball on dual screen controls, or the
pop up character grid on single screen controls, enter “V1_62.” Press
the Enter key.
Important
There must be a “.” at the end of the “V1_62”.
17. V1_62 should appear on the Current Directory screen instead of

V1_60 or V1_61.
18. Remove the floppy diskette from the drive.
19. Place Diskette #1 from the Ultimax 3 Upgrade Executive Diskettes
that came with these instructions into the floppy drive.
20. Reset the control by pressing the Reset Master (F7) softkey on the
second Auxiliary screen or by cycling power to the machine tool. The
message “Are you sure you want to continue with Reset Master?”
and Yes/No softkey selections appear. Select the Yes softkey to
continue.
21. The control will now boot from the floppy diskette. Booting from the
floppy will take a few minutes.
22. When prompted for Diskette #2, place the Diskette #2 from the
Ultimax 3 Upgrade Executive Diskettes that came with these
instructions into the floppy drive. The Floppy Drive Active light
flashes. When the Loading Executive and System Initialization
processes are complete, the Machine Configuration screen appears.
23. Perform the software upgrade using the Ultimax 3 Upgrade
Executive Diskettes that came with these instructions.
a. Press the Auxiliary button, then the More (F8) softkey,
followed by the Upgrade Executive (F6) softkey. The
screen message “OK to continue?” appears with Yes/No
softkey selections. Select the Yes softkey to continue.
b. Insert Diskette #1. The Floppy Drive Active light flashes
and the screen lists files as they are copied. The system
prompts the operator to insert Diskette #2 and Diskette #3.
Page 4 of 5
24. After the upgrade is complete, remove the diskette from the floppy
drive. Reset the control by cycling the power to the machine tool.
25. As the control resets, it will display a prompt for the Machine
Configuration Diskette. DO NOT place the Machine Configuration
diskette into the drive. Instead, place the disk used in Step 4
(Diskette #2) into the floppy drive. The control will use the directory
created in Step 16 on the diskette that was renamed to V1_62.
26. After the files from the diskette are loaded into the control, there
will be another prompt to backup the machine configuration. At this
time place the Machine Configuration diskette that originally came
with the machine into the floppy drive. The Machine Configuration
diskette will now contain the new Version x.xx configuration as well
as the previous configuration.
27. The control will display a prompt to remove the floppy diskette.
28. Store the Machine Configuration and the Version x.xx Ultimax 3
diskettes in a safe place.
29. The machine tool is now ready for use.
Follow these instructions to complete the upgrade. If you have

difficulty, please call Hurco Technical Services at (317) 298-2635
between 8:00 A.M. EST and 9:00 P.M. EST
Page 5 of 5
MAX III ISA
D8299 757-4002-054 Setup Procedure for IBM Cobalt 486BL

D8416 757-4002-046 ISA Diagnostic Software Operation / Rev C
D8419 757-4002-048 Parameters for ULTIMAX 3 ISA Software
D8428 757-4002-055 Eng. Doc., ISA IBM 486BL Harness Rework
D8438 757-4002-062 ULTIMAX 3 ISA D.C. Power Supply Checkout and Adjustment
Procedure
D8449 757-4002-071 Eng. Doc., SSM Mouse Build / Test Procedure
D8466 757-4002-087 ULTIMAX 3 / ISA Control Package Final Assembly Test
Procedures
D8467 757-4002-088 Manufacturing Test Procedures for the ULTIMAX 3 / ISA
Control Package and Associated Circuit Boards
D8468 757-4002-089 ULTIMAX 3 / ISA Card Rack Build Procedure
D8469 757-4002-090 Procedure to Zero Mx4/DSP DACS Using Mx4PRO Software
D8489 757-4002-104 Build Procedure for ULTIMAX 3 / ISA Control Package with
Pentium Processor Motherboard
D8490 757-4002-105 Setup Procedure for Hunter Industrial Pentium Motherboard
D8515 757-4002-125 Ultimax v2.XX Software Field Installation Procedure / Rev. F Rev. G
D8523 757-7002-130 Pentium Field Installation for Ultimax
D8529 757-4002-135 Ultimax Pentium Field Service Reference
D8555 757-4002-151 Laser Measurement Of Linear Positioning, v2.XX or Greater.
D8556 704-0004-033 Ultimax Ver. 2.xx Software Upgrade Procedure / Rev D Rev E
D8528 757-4002-134 Ultimax Ver. 2.xx Field Service Reference
D0000 Leadscrew Compensation Procedure For Ver. 2.xx
D8577 757-4002-166 Hard Drive Parameters For CMOS Setup
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
757-4002-054 REV: A ECN #13264

10/21/94 CAD # D8299
SUBJECT: SETUP PROCEDURE FOR IBM COBALT 486BL
I. INTENT
To provide a procedure to allow for a standard production setup of the IBM Cobalt 486BL
Motherboard. This document will provide information on the jumper configurations for the
board and proper setup of the BIOS.
II. PROCEDURE
A. Prior to installation of the motherboard into the chassis, inspect all jumper settings.
Refer to attached "Cobalt-AT 486BL Jumper Settings" and "System Board Layout".
Use default jumper settings when configuring the assembly. Note: No
Modifications should be necessary due to factory setting of defaults.
B. Install motherboard into chassis and populate unit with appropriate components.
C. Power unit on.
D. Refer to attached MR BIOS Setup procedure. All screens are marked with the correct
production settings. The BIOS must be V1.65 or greater. The version information is
located in the upper right hand corner of the setup screens. Reject any boards
that do not have the correct version. All setup screens can be entered and modified by
hitting <ENTER>. Instuctions for modifying any parameters are located along the bottom
of the screen. In addition, the hard disk settings can be auto detected upon entering the
"Fixed Disk" setup screen. Refer to "Hard Disk Setup" located in the BIOS setup screens.
Under normal conditions, setup can be manually invoked through the keyboard:
• Press <Esc> during power-on memory test.

• Press <Ctrl + Alt + Esc> during runtime.
Press F10 in the main menu to record values and exit.
________________________________ _______ _______________________________ _______

Originator Date Mgr. Electronic Systems Engineering Date
R
757-4002-046 REV: B ECN #13218
08/22/94 CAD #D8416
Rev. Description Date

A Release 04/27/94
B Connector was female on page D8416-9. 08/22/94
SUBJECT: ISA Diagnostic Software Operation
I. INTENT:
To provide instruction on operation of ISA diagnostic software.
II. SCOPE:
Applies to ISA diagnostic software designed to test one or more of the following system
components.
Hurco P/N Description

415-0605-902 CANbus Controller PCB
415-0607-902 I/O Interface PCB
415-0601-902 DC I/O Node
415-0604-902 Console Interface Node
415-0603-902 Remote Jog Node
415-0247-903 Matrix 4 AT Motion Controller
III. PROCEDURE:
A. Program Diskette Contents. The following files must be present on the program
diskette:
1. A:\ISATEST\ISATEST.EXE
2. A:\ISATEST\ISAERROR.TXT
3. A:\AUTOEXEC.BAT
B. Making your Program Diskette DOS Bootable. If you have a licensed copy of DOS
on your PC, make the program diskette DOS bootable by typing “sys a:” (or “sys b:”).
C. Testing an ISA System

1. Turn off power to the ISA control under test.
2. Install loopback test cables. (See Section E for details)
3. Insert ISA diagnostics program diskette into drive a:.
4. Connect an AT keyboard to the CPU board if desired. It is recommended that
an AT keyboard be used. If any hardware failures are detected during the
program execution, you can browse through the listing using the AT keyboard.
Otherwise, the failure report is limited to PASS/FAIL at a board level.
5. Power up the control and wait for program contents to load.
6. The default AUTOEXEC.BAT file switches the program to monochrome display
and auto start mode. This means that all installed hardware will be tested
automatically upon power up. If you need to change these switches, see
section F.
______________________ _______ ______________________ _______ ______________________ _______

Originator Date Engineering Manager Date Product Line Supervisor Date
757-4002-046 REV. B
7. If any “FAIL” flags appear next to the list of boards, hit the “F” key on the AT
keyboard to display the list of failures. Hit any key to advance to the next
failure, any other key to exit to the main menu.
D. What the Software Will NOT Do. When the diagnostic program indicates
“FAIL” next to a board, it does not necessarily mean that board needs to be replaced.
Keep in mind that this system tests itself via a series of interactive loopback harnesses.
The FAIL flags indicate that a loopback test failed when executed from the perspective of
that board. For example, during an MX4 DAC test, three circuits on three boards must
be working for the test to pass: 1) The MX4 DAC, 2) the I/O Interface voltage follower,
and 3) the CANbus Controller A/D converter. One faulty link in the chain can cause the
whole loopback system to fail. Even though you may have intended to verify only the
MX4 DAC, a failed A/D converter analog input could cause a failure in the MX4 DAC
loopback test, thus assigning a FAIL flag to a good MX4 board. The software is not
smart enough to know which boards are “known good”. Those assumptions must be
made by you, the operator.
E. Test Harnesses.
1. Harness Part Numbers. The following test cables are available for testing ISA
controls and are structured under Hurco #002-4429-001 (ASSY, ISA TEST
HARNESS KIT). It is recommended that the Customer Service organization
purchase and/or forecast the 002-4429-001 harness kit.
Hurco P/N Description Qty per kit

423-4410-001 HARNESS, ISA IOIF/MX4 TEST 1
423-4410-002 HARNESS, ISA CIN TEST 1
415-0610-001 PCB ASSY, ISA CIN TEST 1
423-4410-003 HARNESS, ISA JOG TEST 1
423-4410-004 HARNESS, ISA DCIO TEST 1
423-4410-005 HARNESS, ISA COM PORT TEST 2
423-4410-006 HARNESS, ISA LPT PORT TEST 1
2. Harness Requirements. The following table will help determine the test
harnesses required when testing a specific system component.
Board Under Test Test Harnesses Required

CANbus Controller 423-4410-001
I/O Interface 423-4410-001
DC I/O Node 423-4410-004
Console Interface Node 423-4410-002, 415-0610-001, &
423-4410-003
Remote Jog Node 423-4410-003
MX4 AT Motion Controller 423-4410-001
3. Plugging In. Test Harness connectors are labeled with a board/location

designator specifying where it is to be plugged in. For example, the “DCIO/J1”
connector on the 423-4410-004 harness should plug into the DCIO board at
connector J1.
4. Harness Schematics. See section G for harness drawings.
F. Command Line Switches. You may modify the command line switches in the
a:\autoexec.bat file for various options. Or, simply type them at the DOS prompt.
1. S - Detect all installed hardware and start one test cycle automatically.
2
757-4002-046 REV. B
2. D - Detect all installed hardware and select all functions for boards installed.
Requires AT keyboard entry to run the selected tests.
3. M - Set color scheme for monochrome display. The default display mode is
color.
(Example of syntax: “ISATEST M D” )
G. Schematics. Refer to the attached harness drawings for interconnect schematics.
3
757-4002-046 REV. B
4
757-4002-046 REV. B
5
757-4002-046 REV. B
6
757-4002-046 REV. B
7
757-4002-046 REV. B
8
757-4002-046 REV. B
9
757-4002-046 REV. B
10
757-4002-046 REV. B
11
R 757-4002-046 REV: C ECN #13636
02/21/96 CAD #D8416
SUBJECT: ISA Diagnostic Software Operation
Responsible Reviewed & Approved
________________________________ _______ _______________________________ _______

Revisions:
Date: Revision Changes Made:
Level:
04/27/94 A Release
08/22/94 B Connector was female on page D8416-9.
02/21/96 C Added diagram indicating harness connections.
I. INTENT:
To provide instruction on operation of ISA diagnostic software.
II. SCOPE:
Applies to ISA diagnostic software designed to test one or more of the following system
components.

415-0601-902 DC I/O Node
415-0604-902 Console Interface Node
415-0603-902 Remote Jog Node
415-0247-903 Matrix 4 AT Motion Controller
III. PROCEDURE:
A. Program Diskette Contents. The following files must be present on the program
diskette:
1. A:\ISATEST\ISATEST.EXE
2. A:\ISATEST\ISAERROR.TXT
3. A:\AUTOEXEC.BAT
B. Making your Program Diskette DOS Bootable. If you have a licensed copy of DOS
on your PC, make the program diskette DOS bootable by typing “sys a:” (or “sys b:”).
C. Testing an ISA System

1. Turn off power to the ISA control under test.
2. Install loopback test cables. (See Section E for details)
3. Insert ISA diagnostics program diskette into drive a:.
4. Connect an AT keyboard to the CPU board if desired. It is recommended that
an AT keyboard be used. If any hardware failures are detected during the
program execution, you can browse through the listing using the AT keyboard.
Otherwise, the failure report is limited to PASS/FAIL at a board level.
5. Power up the control and wait for program contents to load.
6. The default AUTOEXEC.BAT file switches the program to monochrome display
and auto start mode. This means that all installed hardware will be tested
automatically upon power up. If you need to change these switches, see
section F.
7. If any “FAIL” flags appear next to the list of boards, hit the “F” key on the AT
keyboard to display the list of failures. Hit any key to advance to the next
failure, any other key to exit to the main menu.
D. What the Software Will NOT Do. When the diagnostic program indicates
“FAIL” next to a board, it does not necessarily mean that board needs to be replaced.
Keep in mind that this system tests itself via a series of interactive loopback harnesses.
The FAIL flags indicate that a loopback test failed when executed from the perspective of
that board. For example, during an MX4 DAC test, three circuits on three boards must
be working for the test to pass: 1) The MX4 DAC, 2) the I/O Interface voltage follower,
and 3) the CANbus Controller A/D converter. One faulty link in the chain can cause the
whole loopback system to fail. Even though you may have intended to verify only the
MX4 DAC, a failed A/D converter analog input could cause a failure in the MX4 DAC
loopback test, thus assigning a FAIL flag to a good MX4 board. The software is not
smart enough to know which boards are “known good”. Those assumptions must be
made by you, the operator.
E. Test Harnesses.
1. Harness Part Numbers. The following test cables are available for testing ISA
controls and are structured under Hurco #002-4429-001 (ASSY, ISA TEST
HARNESS KIT). It is recommended that the Customer Service organization
purchase and/or forecast the 002-4429-001 harness kit.
Hurco P/N Description Qty per kit

423-4410-001 HARNESS, ISA IOIF/MX4 TEST 1
423-4410-002 HARNESS, ISA CIN TEST 1
415-0610-001 PCB ASSY, ISA CIN TEST 1
423-4410-003 HARNESS, ISA JOG TEST 1
423-4410-004 HARNESS, ISA DCIO TEST 1
423-4410-005 HARNESS, ISA COM PORT TEST 2
423-4410-006 HARNESS, ISA LPT PORT TEST 1
2. Harness Requirements. The following table will help determine the test
harnesses required when testing a specific system component. Refer to
the attached system block diagram for an overview of harness connections.
Board Under Test Test Harnesses Required

CANbus Controller 423-4410-001
I/O Interface 423-4410-001
DC I/O Node 423-4410-004
Console Interface Node 423-4410-002, 415-0610-001, &
423-4410-003
Remote Jog Node 423-4410-003
MX4 AT Motion Controller 423-4410-001
3. Plugging In. Test Harness connectors are labeled with a board/location

designator specifying where it is to be plugged in. For example, the “DCIO/J1”
connector on the 423-4410-004 harness should plug into the DCIO board at
connector J1.
4. Harness Schematics. See section G for harness drawings.
F. Command Line Switches. You may modify the command line switches in the
a:\autoexec.bat file for various options. Or, simply type them at the DOS prompt.
1. S - Detect all installed hardware and start one test cycle automatically.
2. D - Detect all installed hardware and select all functions for boards installed.
Requires AT keyboard entry to run the selected tests.
3. M - Set color scheme for monochrome display. The default display mode is
color.
(Example of syntax: “ISATEST M D” )
G. Schematics. Refer to the attached harness drawings for interconnect schematics.

757-4002-048 REV: I CAD # D8419
R
SUBJECT: Parameters for ULTIMAX 3 ISA Software
Responsible Tim Kaufman 5/31/94 Reviewed/Approved Mike Caron 6/3/94

_________________________________________ _________ _________________________________________ _________
Originator Date Manager, Control Systems Integration Date
A 13119 Original Issue (filename D8419A.DOC) TLK 5/31/94 MFC 6/3/94
B 13270 Version 1.52 release. Added BMC ISA and Frame A (D8419B.DOC) MOE 10/10/94 MFC 10/12/94
C 13386 Version 1.53 release, added digital drive machines and modified 30M,HT/M tuning MOE 4/4/95 MFC 4/7/95
(filename D8419C.DOC).
D 13494 Version 1.54 release. Modified 30/M and 30 HT/M tuning to improve circle TIR and DEO 9/14/95 MFC 9/16/95
quality of rigid tap.
E 13535 Version 1.60 release. Modified 30/M and 30HT/M tuning to improve Z-axis DEO 10/25/95 MFC 10/26/95
contouring and quality of rigid tap. Added Hawk 5SSM/Hawk 5M (KSL prefix)
F 13556 Version 1.60 release. Created a separate column for 30M and 30HT/M DEO 11/20/95 MFC 11/25/95
spindle parameters. Modified Load Meter values. Created a different count per
revolution value for 40/50M, with and without leadscrew encoders.
G 13706 1) Pages 21 and 22, Added 30/SSM Parameters, 2) Page2, added note, 3) Pages 3 & 5, RME 6/19/96 MFC 6/20/96
was 5mm, 4) Pages 3 & 5, was 6counts, 5) Pages 3 & 5, was 3810mmpm, 6) Page 3,
was 381 mmpm, 7) Pages 3 & 5, was negative, 8) Pages 3 & 5, changed to machine
spec., 9) Pages 3 & 5, deleted orient mechanism type, 10) Pages 3,5,7,9,11,13,15,17, &
19, added max and min programmable rpm , 11) Page 3, aded switch to high gear
breakover, 12) Page 4, was 900, 13) Page 4, was 425, 14) Pages 3 & 5, deleted max
ATC count, 15) Page 12, was 4000, 16) Page 12, was 425, 17) Page 12, was 600, 18)
Page 4, was 4000, 19) Page 4, was 900, 20) Page 4, was 600, 21) Page 4, was 11, 22)
Page 20, was 6000, 23) Page 20, added parameters for 50/50 machines without
leadscrew encoders, 24) Page 7, was 80.
H 13760 Added pages 24 thru 29 for Siemens machine parameters for (BMC4020/HT/M, DEO 7/17/96 MFC 7/30/96
BMC4020/SSM, and BMC30HT/M). Revised page 3 to add Siemens machines to
index. 1) Page 9, was 75,000, 2) Page 9, was 100,000, 3) Page 22, was 0, 4) Page 23,
was 700,000.
I 13933 1) Pages 3, 24, 25, added machine type BMC30/SSM (Siemens). 2) Even pages 4-30, DEO 12/19/96
added “Servo Drive Type” category to Machine Parameters section. 3) Even pages
8-30, added “CE Yes” to Verify Chip Door Upon ESTOP category to Machine
Parameter section. 4) Pages 27, 29, 31, Tap Deceleration was 120,000. 5) Page 28,
Maximum DAC Volts was 9.5. 6) Page 31, Max. Rapid Accel was 200,000.
7) Page20, Added counts per Rev. w/o leadscrew encoder for BMC50/50M.
Ultimax 3 Software Version 1.64 Parameters 757-4002-048 Rev. I 2

I. INTENT
To provide documentation of the default parameter values loaded with the executive software.
II. APPLICABILITY
Applicable to all Ultimax 3/486 3/P Hawk 5M, Hawk 5SSM, and BMC Machines.
III INDEX
page 4 Hawk 5M Machine (KZL Prefix)*

page 6 Hawk 5SSM/Hawk 5M (KSL Prefix)*
page 8 BMC 30/M & 30 HT/M Machines*
page 10 BMC 40/M Machine (analog drive)
page 12 BMC 40/M Machine (digital drives)*
page 14 BMC 40/50/M Machine (analog drives)
page 16 BMC 40/50/M Machine (digital drives)*
page 18 BMC 50/50/M Machine (analog drives)
page 20 BMC 50/50M Machine (digital drives)*
page 22 BMC 30/SSM Machine*
page 24 BMC 30/SSM (Siemens) Machine* I1
page 26 BMC 4020HT/M (Siemens) Machine*
page 28 BMC 4020/SSM (Siemens) Machine*
page 30 BMC 30HT/M (Siemens) Machine*
* Note, page 3: These machines have been tuned using the MX4Pro Tuning Software.G2
** Note, page 28: This DAC value is the approximate range based on performing Siemens
Maximum Spindle Speed calibration procedure. I5

Hawk 5M (KZL Prefix) Machine
** PHYSICAL PARAMETERS ** X Axis Y Axis Z Axis ** PHYSICAL PARAMETERS ** 3.5K Spindle

Counts per Revolution 2,500 2,500 5,000 Clamp / Unclamp Present No
Limit Switch to Marker Distance 3 mmG3 3 mmG3 3 mmG3 High / Low Winding Present No
Distance per Revolution 5 mm 5 mm 5 mm Spindle Air Purge Time On Delay 2 minutes
In Position Tolerance 3 counts 3 counts 3 countsG4 Load Meter Bar One Value 20
Calib: To Lim Sw Velocity 3800mmpmG5 3800mmpmG5 3800mmpmG5 Load Meter Overload Value 80
G G
Calib: To Marker Velocity 200mmpm 200mmpm 200mmpmG Spindle Control Type DAC Contact ASC
6 6 6
Positive Limit Switch Signal Logic 0 0 0 AMR Relay Present No

Negative Limit Switch Signal Logic 0 0 0 Fault Signal Logic 1
Load Meter Bar One Value 20 20 20 - MORE -G9
Load Meter Overload Value 80 80 80 Spindle Brake Enable Time 1250
Fault Signal Logic 1 1 1 Minimum Tap RPM 70
Maximum Travel 787.4 mm 355.6 mm 152.4 mm Maximum Tap RPM 1,000
Leadscrew Mapping Yes Yes Yes Max RPM in High Gear machine spec.G8
Maximum Feedrate 10160mmpm 10160mmpm 6350mmpm Min RPM in High Gear machine spec.G8
Max RPM in Low Gear machine spec.G8
** VERTICAL PARAMETERS ** X Axis Y Axis Z Axis Min RPM in Low Gear machine spec.G8
Coordinate Frame Sense Positive Positive Negative Maximum Programmable RPMG10 3800
Machine Wiring Logic Inverted Normal Inverted Minimum Programmable RPMG10 70
Calibrate Home Position 0 mm 355.6 mm 0 mm Switch to High Gear BreakoverG10 550
Calibrate Limit Switch Negative PositiveG7 Positive
Axis Usage Table Table Head ** VERTICAL PARAMETERS ** 3.5K Spindle
** MACHINE PARAMETERS ** ** TOOL CHANGE PARAMETERS **G14

Machine Type Hawk 5M Tool Changer Present No
Machine Class Vertical
Serial Mouse Present No
Control Relay Panel Board Type CRP4
Maximum Prog. Contouring Feedrate 5,080 mmpm
Jog Wheel Scale Factor 100

Servo Drive Type Yaskawa I2

Hawk 5M (KZL Prefix) Machine
MATRIX4 Axis Tune Diagnostics X Axis Y Axis Z Axis

Integral: 600 600 600
Proportional: 4,500G18 4,500G18 3,700G18
Feedforward: 2,500G12 2,500G12 2,000G19
Derivative: 950G13 950G13 970G20
Integral Limit 12G21 12 12
Output Loop Gain 1 1 1
Integral Bandwidth 200 200 200
DAC Balance: 0 0 0
DAC Balance Limit: 0 0 0
Max. Rapid Accel: 70,000 70,000 70,000
Max. Contour Accel: 70,000 70,000 70,000
Maximum Abort Accel: 100,000 100,000 100,000
Following Error Halt: 0.2 inch 0.2 inch 0.2 inch
Tap Deceleration: n/a n/a n/a

Hawk 5SSM / Hawk 5M (KSL Prefix) Machine

Counts per Revolution 2,500 2,500 5,000 Clamp / Unclamp Present No
Limit Switch to Marker Distance 3 mmG3 3 mmG3 3 mm High / Low Winding Present No
Distance per Revolution 5 mm 5 mm 5 mm Spindle Air Purge Time On Delay 2 minutes
In Position Tolerance 3 counts 3 counts 3 countsG4 Load Meter Bar One Value 20
Calib: To Lim Sw Velocity 3800mmpm G5 3800mmpm G5 3800mmpm G5 Load Meter Overload Value 80
Calib: To Marker Velocity 200mmpm 200mmpm 200mmpm Spindle Control Type DAC Contact ASC
Positive Limit Switch Signal Logic 0 0 0 AMR Relay Present No
Negative Limit Switch Signal Logic 0 0 0 Fault Signal Logic 1
Load Meter Bar One Value 20 20 20 - MORE -G9
Load Meter Overload Value 80 80 80 Spindle Brake Enable Time 1250
Fault Signal Logic 1 1 1 Minimum Tap RPM 70
Maximum Travel 787.4 mm 355.6 mm 152.4 mm Maximum Tap RPM 1,000
Leadscrew Mapping Yes Yes Yes Max RPM in High Gear Machine Spec.G8
Maximum Feedrate 10160mmpm 10160mmpm 6350mmpm Min RPM in High Gear Machine Spec.G8
Max RPM in Low Gear Machine Spec.G8
** VERTICAL PARAMETERS ** X Axis Y Axis Z Axis Min RPM in Low Gear Machine Spec.G8
Coordinate Frame Sense Positive Positive Negative Maximum Programmable RPM 3800
Machine Wiring Logic Inverted Normal Inverted Minimum Programmable RPM 70
Calibrate Home Position 0 mm 355.6 mm 0 mm Switch to High Gear Breakover 550
Calibrate Limit Switch Negative PositiveG7 Positive
** VERTICAL PARAMETERS ** 3.5K Spindle
** MACHINE PARAMETERS ** ** TOOL CHANGE PARAMETERS **G14

Machine Type Hawk 5M Tool Changer Present No
Serial Mouse Present No
Graphics Pointer Speed (SSM only) 6

Hawk 5SSM / Hawk 5M (KSL Prefix) Machine
MATRIX4 Axis Tune Diagnostics X Axis Y Axis Z Axis

Integral: 600 600 600
Proportional: 4,500 4,500 3,700
Feedforward: 2,500 2,500 2,000
Derivative: 950 950 970
Integral Limit 12 12 12
Integral Bandwidth 200 200 200
DAC Balance: 0 0 0
Max. Rapid Accel: 70,000 70,000 70,000
Following Error Halt: 0.2 inch 0.2 inch 0.2 inch
Tap Deceleration: n/a n/a n/a

BMC 30/M & 30HT/M Machine

Limit Switch to Marker Distance 9 mm 9 mm 9 mm Orient Mechanism Present Yes
In Position Tolerance 3 counts 3 counts 3 counts High / Low Winding Present Yes
Calib: To Lim Sw Velocity 5080mmpm 5080mmpm 5080mmpm Spindle High Winding Threshold RPM 2,000
Calib: To Marker Velocity 254mmpm 254mmpm 254mmpm Spindle Air Purge Time On Delay 30 minutes
Load Meter Bar One Value 1 1 1 Spindle Control Type Open Loop Vel
Load Meter Overload Value 80 80 80 Maximum DAC Volts 9.5
Maximum Travel 762 mm 458 mm 610 mm Fault Signal Logic 0
Maximum Feedrate 24000mmpm 24000mmpm 15000mmpm Spindle Brake Enable Time 1,250
Minimum Tap RPM 100
** VERTICAL PARAMETERS ** X Axis Y Axis Z Axis Maximum Tap RPM 2,000
Coordinate Frame Sense Positive Positive Negative Orient Mechanism Type Electronic
Machine Wiring Logic Normal Normal Inverted Maximum Programmable RPMG10 8000
Calibrate Home Position 0 mm 0 mm 0 mm Minimum Programmable RPM G10 100
Axis Usage Table Table Head ** VERTICAL PARAMETERS ** 8K Spindle
Machine Wiring Logic Inverted
Maximum Motor Speed Per calib RPM

Verify Chip Door Upon ESTOP No (CE “Yes”) I3 ATC Type (mag up/down = 0) 2
Alarm Light Present No Magazine Encoder Type Gray Code
Control Relay Panel Board Type CRP4 Magazine Encoder Logic Negative
Maximum Prog. Contouring Feedrate 7,620 mmpm Magazine Encoder Counts per Rev. 1,024
Jog Wheel Scale Factor 100 Non-Adjacent Tool Decel Band 80
Servo Drive Type Yaskawa I2 Adjacent Tool Decel Band 35G24
Magazine Stop Band 8
Gray Code Count Direction Negative
BMC 30/M & 30HT/M Machine

(30M) (30HT/M)
Integral: 50 50 50 0 * 0 *
Proportional: 1,700 1,700 1,700 1,300 * 1,975 *
Feedforward: 480 480 945 1,075 * 870 *
Derivative: 175 175 175 275 * 275 *
Integral Limit 13 13 13 14 * 14 *
Output Loop Gain 1 1 1 1 * 1 *
Integral Bandwidth 200 200 200 1,024 * 1,024 *
DAC Balance: 0 0 0 0 * 0 *
DAC Balance Limit: 0 0 0 0 * 0 *
Max. Rapid Accel: 140,000 140,000 140,000 175,000H1 175,000H1
Max. Contour Accel: 140,000 140,000 140,000 n/a n/a
Maximum Abort Accel: 300,000 300,000 300,000 175,000H2 175,000H2
Following Error Halt: 0.25 inch 0.25 inch 0.25 inch 3,000 degrees * 3,000 degrees *
* NOTE: These paramerters are used for control of Rigid Tapping. They must be entered by first
setting the Spindle Control Type parameter (normally Open Loop Velocity) to Closed
Loop Velocity.

BMC 40/M Machine
(Analog drives)
Load Meter Bar One Value 5 5 5 Spindle Control Type Closed Loop Vel Closed Loop Vel Closed Loop Vel
Maximum Travel 1,020 mm 510 mm 640 mm Fault Signal Logic 0 0 0
Maximum Feedrate 15000mmpm15000mmpm15000mmpm Spindle Brake Enable Time n/a n/a n/a
Minimum Tap RPM 40 60 100
** VERTICAL PARAMETERS ** X Axis Y Axis Z Axis Maximum Tap RPM 2,000 2,000 2,000
Coordinate Frame Sense Positive Positive Negative Orient Mechanism Type Electronic Electronic Electronic
Machine Wiring Logic Inverted Normal Inverted Maximum Programmable RPMG10 4000 6000 8000
Calibrate Home Position 0 mm 0 mm 0 mm Minimum Programmable RPMG10 40 60 100
Axis Usage Table Table Head ** VERTICAL PARAMETERS ** 4K Spindle 6K Spindle 10K Spindle
Maximum Motor Speed Per calib RPM Per calib RPM Per calib RPM
** MACHINE PARAMETERS **
Machine Type BMC 40 ** TOOL CHANGE PARAMETERS **
Verify Chip Door Upon ESTOP No (CE “Yes”) I3 Maximum ATC Magazine Count 24
Swing Table Present No ATC Type (mag up/down = 0) 1
Alarm Light Present No Z Tool Change Position (Height) ATC Specific
BMC 40/M Machine
(Analog drives)
Integral: 100 100 100 30 30 30
Proportional: 3,800 3,800 3,800 400 400 400
Feedforward: 1,000 1,000 1,000 1,750 1,750 1,750
Derivative: 420 420 420 500 500 500
Max. Rapid Accel: 140,000 140,000 140,000 100,000 100,000 80,000

BMC 40/M Machine
(Digital drives)
Load Meter Bar One Value 1 1 1 Spindle Control Type Open Loop Vel Open Loop Vel Open Loop Vel
Load Meter Overload Value 80 80 80 Maximum DAC Volts 9.5 9.5 9.5
Machine Wiring Logic Inverted Normal Inverted Maximum Programmable RPMG10 4000 6000 10,000
Calibrate Home Position 0 mm 0 mm 0 mm Minimum Programmable RPM G10 40 60 100


BMC 40/M Machine
(Digital drives)
Integral: 600 600 600 30 30 30
Proportional: 6200G15 6200G15 6200G15 400 400 400
Feedforward: 400 400 900 1,750 1,750 1,750
Derivative: 550G16 550G16 550G17 500 500 500
Max. Rapid Accel: 140,000 140,000 140,000 100,000 100,000 80,000

BMC 40/50/M Machine
(Analog drives)
Load Meter Bar One Value 20 20 20 Spindle Control Type Closed Loop Vel Closed Loop Vel Closed Loop Vel
Machine Wiring Logic Normal Normal Inverted Maximum Programmable RPMG10 4000 6000 10,000

BMC 40/50/M Machine
(Analog drives)
Integral: 200 600 600 30 30 30
Proportional: 3,800 4,000 4,000 400 400 400
Feedforward: 1,000 900 900 1,750 1,750 1,750
Derivative: 300 425 600 500 500 500
Max. Rapid Accel: 140,000 70,000 70,000 100,000 100,000 80,000

BMC 40/50/M Machine
(Digital drives)
Counts per Rev. w Leadscrew Encoders 5,000 5,000 5,000 In Position Tolerance 1,024 counts 1,024 counts 1,024 counts
Counts per Rev. w/o Leadscrew Encoders 9,600 9,600 9,600
Load Meter Bar One Value 1 1 1 Spindle Control Type Open Loop Vel Open Loop Vel Open Loop Vel
Load Meter Overload Value 80 80 80 Maximum DAC Volts 9.5 9.5 9.5
Machine Wiring Logic Normal Normal Inverted Maximum Programmable RPMG10 4000 6000 10,000

BMC 40/50/M Machine
(Digital drives)
MATRIX4 Axis Tune Diagnostics (With Leadscrew Encoder) (Without Leadscrew Encoder)
X Axis Y Axis Z Axis X Axis Y Axis Z Axis
Integral: 200 200 600 200 200 600
Proportional: 3,800 3,800 2,000 3,850 3,850 3,850
Feedforward: 1000 1000 900 820 820 820
Derivative: 300 300 600 375 375 375
Max. Rapid Accel: 140,000 140,000 70,000 140,000 140,000 70,000
Max. Contour Accel: 140,000 140,000 70,000 140,000 140,000 70,000
Following Error Halt: 0.25 inch 0.25 inch 0.2 inch 0.25 inch 0.25 inch 0.2 inch
Tap Deceleration: n/a n/a n/a n/a n/a n/a
Z/S Tap Gain: n/a n/a n/a n/a n/a n/a
MATRIX4 Axis Tune Diagnostics 4K Spindle 6K Spindle 10K Spindle

Integral: 30 30 30
Proportional: 400 400 400
Feedforward: 1,750 1,750 1,750
Derivative: 500 500 500
Integral Limit 10 10 10
Integral Bandwidth 1,024 1,024 1,024
DAC Balance: 0 0 0
Max. Rapid Accel: 100,000 100,000 80,000
Max. Contour Accel:
Following Error Halt: 3,000 degrees 3,000 degrees 3,000 degrees
Tap Deceleration: 100,000 100,000 80,000
Z/S Tap Gain: 1 1 1

BMC 50/50/M Machine
(Analog drives)

Maximum Travel 1,325 mm 762 mm 600 mm Fault Signal Logic 0 0
Maximum Feedrate 10160mmpm10160mmpm10160mmpm Spindle Brake Enable Time n/a n/a
Minimum Tap RPM 40 60
** VERTICAL PARAMETERS ** X Axis Y Axis Z Axis Maximum Tap RPM 2,000 2,000
Coordinate Frame Sense Positive Positive Negative Orient Mechanism Type Electronic Electronic
Machine Wiring Logic Normal Normal Inverted Maximum Programmable RPMG10 4000 6000
Calibrate Home Position 0 mm 0 mm 0 mm Minimum Programmable RPMG10 40 60
Axis Usage Table Table Head ** VERTICAL PARAMETERS ** 4K Spindle 6K Spindle
Machine Wiring Logic Inverted Inverted
Maximum Motor Speed Per calib RPM Per calib RPM

BMC 50/50/M Machine
(Analog drives)

Integral: 200 200 200 30 30
Proportional: 2,000 2,000 1,000 400 400
Feedforward: 900 900 1,400 1,750 1,750
Derivative: 420 350 200 500 500
Max. Rapid Accel: 140,000 140,000 140,000 60,000 60,000

BMC 50/50/M Machine
(Digital drives)

Counts per Rev. w Leadscrew Encoders 5,000 5,000 5,000 In Position Tolerance 1,024 counts 1,024 counts
Counts per Rev. w/o Leadscrew Encoders 9,600I7 9,600I7 9,600I7
Load Meter Bar One Value 1 1 1 Spindle Control Type Open Loop Vel Open Loop Vel
Load Meter Overload Value 80 80 80 Maximum DAC Volts 9.5 9.5
Maximum Travel 1,325 mm 762 mm 600 mm Fault Signal Logic 0 0
Maximum Feedrate 10160mmpm10160mmpm10160mmpm Spindle Brake Enable Time n/a n/a
Minimum Tap RPM 40 60
** VERTICAL PARAMETERS ** X Axis Y Axis Z Axis Maximum Tap RPM 2,000 2,000
Coordinate Frame Sense Positive Positive Negative Orient Mechanism Type Electronic Electronic
Machine Wiring Logic Normal Normal Inverted Maximum Programmable RPMG10 4000 6000
Calibrate Home Position 0 mm 0 mm 0 mm Minimum Programmable RPMG10 40 60
Axis Usage Table Table Head ** VERTICAL PARAMETERS ** 4K Spindle 6K Spindle
Maximum Motor Speed Per calib RPM Per calib RPM


BMC 50/50/M Machine
(Digital drives)
(With Leadscrew Encoder) (Without Leadscrew Encoder)G23

MATRIX4 Axis Tune Diagnostics X Axis Y Axis Z Axis X Axis Y Axis Z Axis 4K Spindle 6K Spindle
Integral: 50 50 600 200 200 600 30 30
Proportional: 2,600 2,600 2,000 3850 3850 3850 400 400
Feedforward: 750 750 900 820 820 820 1,750 1,750
Derivative: 200 200 600 375 375 375 500 500
Integral Limit 12 12 12 12 12 12 10 10
Output Loop Gain 1 1 1 1 1 1 1 1
Integral Bandwidth 100 200 200 200 200 200 1,024 1,024
DAC Balance: 0 0 0 0 0 0 0 0
DAC Balance Limit: 0 0 0 0 0 0 0 0
Max. Rapid Accel: 140,000 140,000 70,000 140,000 140,000 70,000 100,000G22 100,000G22
Max. Contour Accel: 140,000 140,000 70,000 140,000 140,000 70,000
Maximum Abort Accel: 300,000 300,000 100,000 300,000 300,000 100,000 100,000G22 100,000G22
Following Error Halt: 0.25 inch 0.25 inch 0.2 inch 0.25 inch 0.25 inch 0.2 inch 3,000 degrees 3,000 degrees
Tap Deceleration: n/a n/a n/a n/a n/a n/a 100,000G22 100,000G22
Z/S Tap Gain: n/a n/a n/a n/a n/a n/a 1 1

BMC 30/SSM Machine

In Position Tolerance 3 counts 3 counts 3 counts High / Low Winding Present Yes
Calib: To Lim Sw Velocity 5080mmpm 5080mmpm 5080mmpm Spindle High Winding Threshold RPM 2000
Fault Signal Logic 1H3 1H3 1H3 AMR Relay Present Yes
Maximum Feedrate 14986 14986 10008 Spindle Brake Enable Time 1250
Minimum Tap RPM 100
Machine Wiring Logic Normal Normal Inverted Maximum Programmable RPM 8000
Calibrate Home Position 0 mm 0 mm 0 mm Minimum Programmable RPM 100
Calibrate Limit Switch Negative Negative Positive ** VERTICAL PARAMETERS ** 8K Spindle
Axis Usage Table Table Head Machine Wiring Logic Inverted

Serial Mouse Present Yes Z Tool Change Position (Height) ATC Specific
Swing Table Present No Magazine Encoder Type Gray Code
Alarm Light Present No Magazine Encoder Logic Negative
Control Relay Panel Board Type CRP4 Magazine Encoder Counts per Rev. 1,024
Maximum Prog. Contouring Feedrate 7620 mmpm Magazine Decel Band 80
Jog Wheel Scale Factor 100 Adjacent Tool Decel Band 35
Graphics Pointer Speed 6 Magazine Stop Band 8
Servo Drive Type Yaskawa I2 Gray Code Count Direction Negative
BMC 30/SSM Machine
MATRIX4 Axis Tune Diagnostics X Axis Y Axis Z Axis 8K Spindle

Integral: 50 50 50 0 *
Proportional: 3500 3500 3500 1300 *
Feedforward: 900 900 1275 960 *
Derivative: 600 600 600 270 *
Integral Limit 13 13 13 14 *
Output Loop Gain 1 1 1 1 *
Integral Bandwidth 200 200 200 1,024 *
DAC Balance: 0 0 0 0 *
DAC Balance Limit: 0 0 0 0 *
Max. Rapid Accel: 121,000 121,000 121,000 140,000H4
Max. Contour Accel: 121,000 121,000 121,000 n/a
Maximum Abort Accel: 290,000 290,000 290,000 140,000H4
Following Error Halt: 0.25 inch 0.25 inch 0.25 inch 3,000 degrees *
Tap Deceleration: n/a n/a n/a 75,000
Z/S Tap Gain: n/a n/a n/a 1
*Note: These parameters are used for control of Rigid Tapping. They must be entered by
first setting the Spindle Control Type parameter (normally Open Loop Velocity) to Closed
Loop Velocity.

BMC 30/SSM (Siemens) Machine I1

Calib: To Lim Sw Velocity 5080mmpm 5080mmpm 5080mmpm Spindle High Winding Threshold RPM ----
Minimum Tap RPM 100

Verify Chip Door Upon ESTOP No (CE “Yes”) ATC Type (mag up/down = 0) 2
Servo Drive Type Siemens Gray Code Count Direction Negative

BMC 30/SSM (Siemens) Machine I1

Integral: 50 50 50 50 *
Proportional: 3500 3500 3500 2500 *
Feedforward: 900 900 1275 1975 *
Derivative: 600 600 600 100 *
Max. Rapid Accel: 121,000 121,000 121,000 160,000
Maximum Abort Accel: 290,000 290,000 290,000 250,000
Tap Deceleration: n/a n/a n/a 80,000
Loop Velocity.

4020HT/M (Siemens) Machine

Minimum Tap RPM 100
Calibrate Limit Switch Negative Negative Positive ** VERTICAL PARAMETERS ** 6.5K Spindle

Serial Mouse Present No Z Tool Change Position (Height) ATC Specific
Servo Drive Type Siemens I2 Magazine Stop Band 8
BMC 4020HT/M (Siemens) Machine
MATRIX4 Axis Tune Diagnostics X Axis Y Axis Z Axis 6.5K Spindle

Integral: 50 50 50 50 *
Proportional: 6000 6000 6000 2500 *
Feedforward: 2225 2225 2000 1700 *
Derivative: 700 700 700 200 *
Max. Rapid Accel: 140,000 140,000 140,000 225,000
Tap Deceleration: n/a n/a n/a 80,000 I4
Loop Velocity.

BMC 4020/SSM (Siemens) Machine

Load Meter Overload Value 0 0 0 Maximum DAC Volts 9.30-9.35** I5
Minimum Tap RPM 100

Servo Drive Type Siemens I2 Gray Code Count Direction Negative

BMC 4020/SSM (Siemens) Machine

Integral: 50 50 50 50 *
Proportional: 6000 6000 6000 2500 *
Feedforward: 2225 2225 2000 1700 *
Derivative: 700 700 700 200 *
Max. Rapid Accel: 140,000 140,000 140,000 225,000
Loop Velocity.


Minimum Tap RPM 100

Serial Mouse Present No Z Tool Change Position (Height) ATC Specific
Servo Drive Type Siemens I2 Magazine Stop Band 8


Integral: 50 50 50 50 *
Proportional: 6000 6000 6000 2500 *
Feedforward: 1655 1655 1125 1300 *
Derivative: 250 250 250 100 *
Max. Rapid Accel: 140,000 140,000 140,000 160,000 I6
Loop Velocity.

R
757-4002-055 REV: A ECN #13288
11/23/94 CAD #D8428
SUBJECT: ENG. DOC., ISA IBM 486BL HARN. REWORK
I. INTENT:
To provide a procedure for reworking IBM CPU I/O ribbon harnesses.
II. SCOPE:
Hurco’s 415-0166-906 IBM CPU board is purchased as a kit that includes:
1) 486DX266 CPU board
2) I/O ribbon harnesses
The harnesses are to be applied to the CPU’s parent assembly after the harnesses have
been modified and labeled.
III. PROCEDURE:
See attached pages.
______________________ _______ ______________________ _______ ______________________ _______

000-0000-000 REV A
2
R
757-4002-071 REV: A ECN #13509
11/08/95 CAD #D8449
SUBJECT: ENG. DOC., SSM MOUSE BUILD / TEST PROCEDURE
I. INTENT:
Verify functionality of SSM Mouse Module.
II. SCOPE:
Applies to Mouse Option Kit 002-4219-002.
III. PROCEDURE:
A. Equipment Requirements
1. Ultimax ISA Card Cage Assembly with Ultimax executive on HDD.
2. Control I/F Harness
3. Console Interface Node with 450-3001-959 firmware and keyed J16 connector.
4. Mounting Frame
5. Devices Under Test
a. 416-0252-003 Module
b. 423-4402-006 Harness
c. 802-2902-004 Bracket
B. Test Procedure
1. Assemble Module and Bracket. Add Loctite 242 to threaded studs. Install (4) 4-40 hex nuts,
tightening only slightly more than finger-tight. (Torque Spec: 0:0)
2. Mount Bracket to Mounting Frame to check for proper hole alignment, then remove.
3. Visually inspect Harness against drawing #423-4402-006.
4. Connect Harness from Mouse Module CON2 to Console Interface Node connector J16.
5. Power up all test equipment.
6. Run Control Resident Diagnostics / Console Tests / Keyboard Test.
7. Press LEFT mouse button, verify backlighting of Select key.
8. Press RIGHT mouse button, verify backlighting of Draw key.
9. Press mouse pad and verify X+, X-, Y+, and Y- operation by checking Trackball X and
Trackball Y registers on screen.
10. Package all Mouse Option components for shipment and/or installation.
______________________ _______ ______________________ _______ ______________________ _______

757-4002-062 REV: A ECN #13310

R
06 Mar 95 CAD#D8438
SUBJECT: Ultimax 3 ISA D.C. Power Supply Checkout and Adjustment Procedure.
I. INTENT
To provide a standardized procedure for the adjustment and calibration of the Deltron
quad output switching power supply used with the Ultimax 3 ISA Controller. All control power
supplies should be adjusted per this document in the controls manufacturing and certification area
prior to shipment to the floor, or inclusion in kits.
II. APPLICABILITY
Specific to all Ultimax 3 ISA control platforms.
Power Supply Type Power Rating Deltron P/N Hurco P/N Use w/DC Dist. PCB
Remote 325 w 11436XA 413-0008-013 415-0608-901
Integrated 225 w 11589XA 413-0008-021 415-0611-901
III. INDEX
ISA DC Power Supply Checkout and Adjustment - page 2

Figure 1 (Voltage Test Points) - Page 3
Figure 2 (Voltage Adjustment Locations) - Page 4
MICHAEL CARON 3/10/95

RECORD OF CHANGES
Engineering Document CAD # D8438
Revision ECN # Revision Description Pg # Date Appd Date

By
B 14140 Change 12V Vnom set. from 12.24V 3 4/27/98
2
ISA DC Power Supply Checkout & Adjustment
Power Supply Test:
• Assemble 002-4428-014
• Switch on AC power
• Without making adjustments, ensure the unloaded
DC voltages meet the following specs:
(+24v) 10 9 (+12v)
Output Vmin Vmax
(n.c.) 8 7 (-12v)
+5V 4.5 5.5
(Gnd.) 6 5 (Gnd.)
+12V 10.8 13.2
-12V -13.2 -10.8 (Gnd.) 4 3 (+5v)
+24V 20.4 27.6 (+5v) 2 1 (+5v)
Connector on P.S.
harness - Pin view
Card Cage Adjustment:
• Mount power supply to fully loaded 002-4428-012 card cage

• Perform the following steps before calibrating the MX4 DAC pots
• Connect CIN board and floppy drive
• Connect 6 ohm load resistor to 12V supply at CIN (monochrome CRT applications
only)
• Switch on AC power
• With non-conductive tool, adjust power supply voltages to meet the following specs:
(See Fig’s 1 and 2 for pot locations and voltage test points.)
Output Vmin Vnom Vmax

+5V 5.07 5.10 5.13
+12V 12.54 12.60 12.66
(Note - Should it ever become necessary to adjust voltages on an operating machine,

proceed slowly with potentiometer rotation to avoid exceeding the system Power Monitor
thresholds which will cause Max reboot and machine shutdown!)
• Check -12V and 24V auxiliary outputs to ensure they meet the following specs. Do not
make any adjustments.
Output Vmin Vmax

-12V -13.2 -11.4
+24V 22.8 26.4
3
“External” Board
(Voltage test points for the “External” style
(415-0608-901)
DC Distribution board, as well as the newer
“integrated” style board are as follows:)
+ 5v (Yel. T.P.)
(Fuse)
“Integrated” Board
(415-0611-901)
Gnd. (Blk. T.P.)
+ 24v TP5 (Fuse)
+ 12v TP4 + 12v (Brn. T.P.)
+ 5v TP3
- 12v TP2
- 12v (Orn. T.P.)
(Fuse)
Gnd. TP1
+ 24v (Blu. T.P.)
(Fuse)
Fig. 1
4
(Wago Conn.)
Integrated Power Supply

+ 5v adjust
+ 5v adjust External Power Supply
Fan
+ 12v adjust
+ 12v adjust
ac line input
ac line input
Fig. 2
5
R 757-4002-087 REV: A ECN #13636
02/21/96 CAD #D8466
SUBJECT: ULTIMAX 3 / ISA CONTROL PACKAGE FINAL

ASSEMBLY TEST PROCEDURES:
1. BENCH TEST PROCEDURES
2. BURN-IN TEST PROCEDURES
________________________________ _______ _______________________________ _______

Revisions:
Level:
02-21-96 A Release
I. INTENT:
To provide instruction on the bench and burn-in test procedures for the ULTIMAX 3/ISA Control
Card Racks and Consoles.
II. SCOPE:
Applies to all ULTIMAX 3/ISA Control Card Racks and Consoles; differences are noted where
applicable.
III. PROCEDURE:
A. BENCH TESTS. When the card rack assembly is completed, the card rack is bench
tested using the ISA/MAX3 Test Fixture and other appropriate test equipment as
described in the following procedure. See also the ISA Test Fixture System Block
Diagram included in this document for an overview of the test fixture and harness
connections.
1. Remove card rack cover; do not lose accompanying paperwork and

identification tag.
2. Check that the CPU is properly oriented (i.e., pin 1 of the component
corresponds to pin 1 of the socket and socket holes are visible on all four sides
of the CPU).
3. Check that all cables and harnesses internal to the card rack are connected
(reference ULTIMAX 3/ISA CONTROL PACKAGE BUILD PROCEDURE for
more details on cable and harness connections).
4. Verify that jumper JU2 on the Motion Controller PCB is in the “1-2” position.
5. Connect the AC power cord to the rack at the power supply ON/OFF switch.
6. Connect the 8-position Wago power loopback connector to J2 of the DC
Distribution board where it extends through the card rack wall.
7. Connect the power harness from the DC Distribution board (the 6-position and
4-position Wago connectors) to J2 of the CIN board (10-position Wago
Connector).
8. Connect the monitor cable, keyboard cable, and floppy disk drive cable (from
the CIN board) to the card rack.
9. Connect the CANbus harness from J7 of the CANbus Controller board to J20 of
the CIN board.
10. Insert the CIN test board into connectors J1 and J7 on the CIN board. Be sure
that the connectors are properly aligned as damage to the test board may occur
if alignment is incorrect.
11. Connect the following test harnesses on the CIN board:
* J12 (34 conductor ribbon cable) from the floppy disk drive.
* J17 (FDD PWR) from the floppy disk drive.
* J15 loopback connector.
* J13 to J1 on the Remote Jog.
* J3 to test load (twisted pair harness).
* Connect the ISA CIN Test Harness to J3, J4, J9 and J19 on the CIN
PCB and J2 on the CIN Test PCB.
* Connect the ISA Test Harness (connector marked TEXT CRT) to the
external load.
12. Connect the Remote Jog Node loopback connector at J2 on the Remote Jog
Node PCB.
13. Install the program key (software security device and key) on the card rack
parallel port.
14. The other test harnesses and connectors may also be connected at this time.
* I/O Interface loopback harness (connectors J1, J2 and J3 on the I/O

Interface board and J1, J2, J3 and J4 on the Honda Breakout board).
* DCIO loopback harness (connectors J1 and J2 on the DCIO board).
* COM Test/Serial Port loopback connectors (card rack serial ports 1
and 2).
15. Before turning the card rack power on, check (with an ohmmeter) that there are `
no shorts between any of the five test points on the DC Distribution board.
16. Turn the card rack power on and press the Delete key to run the BIOS Setup
procedure.
17. Check that both of the card rack fans are running prior to continuing with the
BIOS Setup procedure.
18. Perform the BIOS Setup procedure (refer to the Engineering Document
appropriate to the installed motherboard for detailed information regarding the
BIOS Setup procedure).
19. Partition and format the hard drive using the floppy disk specified for the size
and manufacturer of hard drive installed.
20. Load Executive Parts 1 and 2 from the floppy disks and check that the executive
Machine Diagnostics screen comes up.
21. Turn the card rack off, and then back on. Verify that the executive Machine
Diagnostics screen comes up again (this also tests the battery on the
motherboard).
22. Press “F8” to exit the Machine Diagnostics screen and verify that the Input
screen comes up.
23. Turn the card rack off, and remove the program key (software security device
and key) from the parallel port. Replace the program key with the parallel port
loopback connector, and turn the card rack power back on.
24. The power supply should be calibrated per Engineering Document
757-4002-062. Using a non-conductive tool, the power supply voltages should
be adjusted to 5.10V (5V supply) and to 12.24V (24V supply).
25. Run the ISATEST/Autodetect program by typing ‘i d’ (i space d) at the C prompt.
26. Set the loop count to 5, and run the tests.
27. When the tests are complete, remove the test harnesses and connectors from
the card rack. If any board did not pass all the tests, it should be removed and
replaced. The tests should be repeated to assure that all tests pass with the
replacement board.
28. Make a final check inside the card rack for the following items.
* All circuit boards are screwed down securely.

* Hard disk drive bracket is secure and its screw is tight.
* Check that the serial number for each circuit board is visible (so that
the board would not have to be removed to get its serial number).
29. Replace the card rack cover and store the card rack with its paperwork. If any
of the circuit boards were changed due to failure of a test, be sure to change the
serial number for the appropriate circuit board on the accompanying paperwork.
30. Mark the identification tag for the card rack with a “T” to indicate that it has
been tested.
B. BURN-IN TESTS: When the Bench Tests are complete, the control racks and consoles
are tested in the heat chamber as described in the procedure below:
1. Open the rear door of a Single Screen Max (SSM) cabinet or remove the cover
on a Dual Screen console.
2. Connect all harnesses from the control to the console.
3. Power up the control and perform all the tests included in the Control Resident
Diagnostics. These tests are the same for the single or dual screen console
except that the color test is not performed on the single screen console since it
is monochrome.
4. Load the console and an appropriately configured control rack (i.e., single
screen console goes with a single screen control rack, etc.) onto a heat room
cart.
5. Connect the CIN board test harnesses, loopback connector, and test board. Be
sure that the CIN test board is properly aligned in connectors J1 and J7 of the
CIN board, or damage is likely to occur. Refer to the Bench Tests section for
more detailed test harness connection instructions.
6. Leave the console cabinet door open slightly for ventilation during testing.
7. Connect the console power harness from the DC Distribution board to the
CIN board inside the console.
8. Connect the following test harnesses and loopback connectors.
* I/O Interface loopback harness (connectors J1, J2 and J3 on the I/O

Interface board and J1, J2, J3 and J4 on the Honda Breakout board).
* DCIO loopback harness (connectors J1 and J2 on the DCIO board)
if the DCIO board is installed.
* COM Test/Serial Port loopback connectors (card rack serial ports 1
and 2).
* Parallel Port loopback connector (card rack parallel port).
9. Connect the monitor(s).

10. Power up the control/monitor(s) on the heat room cart.
11. Type ‘i d’ (or ‘i m d’ for a monochrome monitor) at the C prompt and press Enter
after the boot sequence is complete (reference Engineering Document
757-4002-046 for detailed information regarding ISA Diagnostic Software
operation).
12. Select “Choose Tests . . .” from the Main Menu.
13. Select “Set Loop Count . . .” and enter 65,535 loops then press the Enter key.
14. Choose “Select Boards . . .” and disable the tests for the Remote Jog Node.
15. Return to the Main Menu and select “Run Selected Tests” and press Enter to
start the tests.
16. The controls and consoles should stay in the heat chamber for at least six hours.
The heat chamber’s temperature range should be 125° F (50° C) minimum to
140° F (60° C).
17. The controls and consoles should be checked for failures after the first two
hours in the heat chamber. If failures are found after two hours, the failed
boards should be replaced, and the tests restarted.
18. Before the controls/consoles are removed from the heat chamber (at 6 hours),
they should be warm-booted (CTRL-ALT-DEL) to verify that the control can still
be booted and everything is still working properly.
19. After testing in the heat chamber the Single Screen Max/Dual Screen Knee Mill
controls are ready to be installed in the power cabinet. The Bed Mill controls
are first tested on the simulator in the Test and Repair Department.
20. The simulator testing involves the following.
* Loading the machine configuration.

* Rebooting the control after the machine configuration is loaded.
* Balancing each of the four axes.
* Testing the limit switches for the X, Y and Z axes.
* Running a sample program (two cycles).
21. This completes the burn-in test portion of the testing.

C. SCHEMATIC: Refer to the attached schematic for an overview of the test fixture and
harness connections. Refer also to Figure 1 and Figure 2 for an overview of the final
assembly and test procedures.
R 757-4002-088 CURRENT REV: B CAD #D8467
SUBJECT: MANUFACTURING TEST PROCEDURES FOR THE

ULTIMAX 3 / ISA CONTROL PACKAGE AND
ASSOCIATED CIRCUIT BOARDS

Jeff Nolletti 3/6/96 Mike Caron 3/14/96
________________________________ _______ _______________________________ _______
Revisions:
Rev. ECN No. Revision Description Rev. By Date Appvl. By Date
A 13636 Release
B 13678 Add 3 Motion Control PCBs:
415-0247-006
415-0247-007
415-0247-008
2
I. INTENT:
To provide instruction on the procedures for testing MAX3/ISA Control packages and/or the individual
printed circuit boards incorporated in this control package.
II. SCOPE:
This document applies to the MAX3/ISA Control package and use of the MAX3/ISA test fixture. The
following components may be tested as a system, or as individual components.

415-0247-005 Mx4 Motion Controller PCB, X, Y, Z, S
415-0247-006 Mx4 Motion Controller PCB, a, b, c, d
415-0247-007 Mx4 Motion Control PCB, cnC++, X, Y, Z, S
415-0247-008 Mx4 Motion Control PCB, cnC++, a, b, c, d
415-0601-902 DC I/O Node PCB
415-0602-902 DC I/O Backplane PCB
415-0603-902 Remote Jog Node PCB
415-0604-902 Console Interface Node PCB
415-0606-902 FDD Transceiver PCB
415-0609-901 Honda Breakout PCB
415-0611-901 DC Power Monitor/Distribution PCB
III. PROCEDURE:
A. Matrix 4 Motion Controller PCB (415-0247-005, 415-0247-006, 415-0247-007, 415-0247-008).
1. Test using ISA Mx4 /IOIF Test Harness (423-4410-001).
2. Reference Engineering Document 757-4002-046 for information pertaining to the
ISA Diagnostic Software operation.
B. DC I/O Node PCB (415-0601-902).

1. Test using ISA DCIO Test Harness (423-4410-004).
C. DC I/O Backplane PCB (415-0602-902).

1. The DCIO Backplane PCB (415-0602-902) should be tested with an ohmmeter to verify
that no unintended shorts occur on the board.
2. The procedure below should be followed:
a. Check that the following pins on connector J4 are shorted:
Pins 3 and 4
Pins 5 and 6
b. Check that there is no short between the following pins on connector J4:
Pin 1 and all other pins.

Pin 3 and all other pins (except Pin 4 as noted above).
3
D. Remote Jog Node PCB (415-0603-902).
1. Test using ISA Jog Test Harness (423-4410-003).
E. Console Interface Node PCB (415-0604-902).

1. Test using the following test harnesses:
a. ISA CIN Test Harness (423-4410-002).
b. ISA CIN Test PCB ASSY (415-0610-001).
c. ISA Jog Test Harness (423-4410-003).
F. CANbus Controller PCB (415-0605-902).

` 2. Reference Engineering Document 757-4002-046 for information pertaining to the
G. FDD Transceiver PCB (415-0606-902).

1. The FDD Transceiver PCB should be tested in the ISA Test Fixture with a set of known
good boards installed in the test fixture.
a. Turn power to the test fixture OFF if not already OFF.
b. Disconnect the power harness connected to J3 of the FDD Transceiver PCB
(415-0606-902).
c. Disconnect the 34 conductor ribbon cable from connector J1 of the FDD
Transceiver board.
d. Disconnect the 34 conductor ribbon cable from connector J2 of the FDD
Transceiver board. This cable connects the FDD Transceiver board to J11 of
the CIN PCB (415-0604-902).
e. Remove the retaining screw and then remove the FDD Transceiver board.
f. Place the FDD Transceiver board to be tested into the slot from which the
previous FDD Transceiver board was just removed. Be sure it is properly
seated into the motherboard.
g. Connect the 34 conductor ribbon cable from J11 of the CIN board to
connector J2 of the FDD Transceiver board.
h. Connect the 34 conductor ribbon cable from J21 of the motherboard to J1 of
the FDD Transceiver board.
i. Connect the FDD power harness from the DC Distribution board
(415-0611-901) to J3 of the FDD Transceiver board.
j. Power up the ISA Test Fixture.
k. At the MAIN MENU, select “Choose Tests . . .”
l. At the TEST SETUP MENU, choose “Select Boards . . .”
m. At the BOARD SELECTION MENU, select “PC/AT Peripherals,” then press
“ESC.”
n. At the TEST SETUP MENU, choose “Select Functions . . .”
o. At the BOARD FUNCTIONS MENU, choose “PC/AT Peripherals” then
press “Enter.”
p. Select the “Floppy Drive” test only.
q. “ESC” back to the MAIN MENU.
r. Place a floppy disk in the floppy disk drive and Run Selected Tests.
s. If finished, replace the original FDD Transceiver board in the ISA Test
Fixture, or repeat this procedure to test additional FDD Transceiver boards.
H. I/O Interface PCB (415-0607-902).

4
I. Honda Breakout PCB (415-0609-901).

1. The Honda Breakout PCB Assy. (415-0609-901) should be tested first with an
ohmmeter, and then in the ISA Test Fixture with a set of known good boards.
a. Using an ohmmeter, check that there is a short across the terminals of each
of the fuses (F1 and F2). See Figure 1 for locations of F1 and F2.
b. Turn power to the test fixture OFF if not already OFF.
c. Disconnect the 50 conductor ribbon cable (ISA/DSP Servo I/O Harness
423-4400-006) from the latching connector (J5) on the Honda Breakout
board.
d. Remove the two screws from the ISA/DSP Honda Breakout bracket on the
outside of the card rack.
e. Remove the Honda Breakout board assembly from the card rack.
f. Insert the Honda Breakout board assembly to be tested into the slot from
which the previous Honda Breakout board assembly was just removed.
g. Secure the Honda Breakout board assembly to the card rack with at least one
screw.
h. Connect the 50 conductor ribbon cable (ISA/DSP Servo I/O Harness
423-4400-006) to the latching connector (J5) on the Honda Breakout board
assembly.
i. Connect the ISA MX4/IOIF Test Harness (423-4410-001) to IOIF/J1,
IOIF/J2, IOIF/J3, MX4/J1, MX4/J2, MX4/J3, and MX4/J4.
j. Power up the ISA Test Fixture.
k. At the MAIN MENU, select “Choose Tests . . .”
l. At the TEST SETUP MENU, choose “Select Boards . . .”
m. At the BOARD SELECTION MENU, select “Matrix 4 #1”, the press “ESC.”
n. At the TEST SETUP MENU, choose “Select Functions . . .”
o. At the BOARD FUNCTIONS menu, choose “Matrix 4 #1.”
p. Select only the “DAC” and “Encoder” tests, then press “ESC.”
q. “ESC” back to the MAIN MENU and Run Selected Tests.
r. If finished, replace the original Honda Breakout board assembly in the ISA
Test Fixture, or repeat this procedure to test additional Honda Breakout
boards.
J. DC Power Monitor/Distribution PCB (415-0611-901).

1. Test using the DC Power Monitor/Distribution (DCD) Assembly Test Fixture.
a. With the power switch of the test fixture turned OFF, plug the harnesses of the
DC Power Monitor/Distribution PCB into the respective mating connectors on
the test fixture.
b. Plug the reference voltage M-N-L harness from the test fixture into the DC
Power Monitor/Distribution PCB.
c. Insert the test plug into J2 of the DC Power Monitor/Distribution PCB.
d. Turn the power switch of the test fixture ON.
e. ALL GREEN LEDs should be ON. If any LED is not illuminated, either the
wire’s connection is not made, or the wire is inserted in the wrong place.
f. Turn the potentiometer (knob on the test fixture) counter-clockwise until the
RED LED turns ON. The pointer on the knob should be aligned with the mark
on the test fixture.
g. Turn the potentiometer back to the FULL clockwise position.
h. Turn the power switch OFF and remove the DC Power Monitor/Distribution
PCB being tested.
5
6
R 757-4002-089 REV: A ECN #13636
02/21/96 CAD #D8468
SUBJECT: ULTIMAX 3 / ISA CONTROL PACKAGE BUILD

PROCEDURE
________________________________ _______ _______________________________ _______

Revisions:

Level:
02-21-96 A Release
I. INTENT:
To provide instruction on the assembly of ULTIMAX 3 / ISA Control Card Rack.
II. SCOPE:
Applies to Dual Screen BMC Card Rack. Build procedures for Single Screen and Knee Mill card rack
assemblies are identical, except that one or more of the following differences will apply.
1. Single Screen Card Rack uses a single VGA card instead of a dual VGA card.
2. DC I/O PCB (415-0601-901) may not be included on some card racks.
3. FDD Transceiver PCB (415-0606-902) may not be included on some card racks.
III. PROCEDURE:
A. Recording & Marking Printed Circuit Board Serial Numbers
1. Recording and marking the serial numbers for each of the printed circuit boards to be
installed in the ISA Control should be performed before actual assembly of the control
begins. Completing this recording and marking procedure first will save time and also
help prevent forgetting to record or mark the serial number on a circuit board. Follow
the instructions below.
2. Record serial numbers for the following circuit boards on the Commissioning
Report Form:
* ISA C.P.U. 415-0166-9**

* Dual VGA Graphics PCB 415-0220-*04
* Motion Control PCB 415-0247-*05
* DC I/O PCB 415-0601-*02
* DC I/O Backplane 415-0602-*02
* DC I/O Can Bus Cont. PCB 415-0605-*02
* ISA FDD Transceiver PCB 415-0606-*02
* I/O I/F PCB 415-0607-*02
3. Write the serial number on the following circuit boards in the space provided:
* DC I/O PCB 415-0601-*02

* I/O I/F PCB 415-0607-*02
4. Write the serial number on the top or front plate of the following circuit boards:
* DC I/O PCB 415-0601-*02

* I/O I/F PCB 415-0607-*02
5. Write the serial number on a small decal or label and place near the top (on the
solder side) on the following circuit boards:
* Dual VGA Graphics PCB (see note below) 415-0220-*04

NOTE: May use the serial number decal that is on the protective wrapping of the
Dual VGA Graphics PCB instead of making a label.
B. Power Supply
1. Remove fuse holder (center section) of power supply ON/OFF switch.
2. Insert four fuses into fuse holder slots and spare storage slots of fuse holder.
3. Reinsert fuse holder into power supply ON/OFF switch.
4. Insert the ON/OFF switch into the power supply cover with the switch towards the top
side of the cover. Secure the switch with two screws.
5. Connect the three wires from the ON/OFF switch to the three screws at the end of the
power supply as follows:
* Green/Yellow wire to terminal marked with Ground Symbol

* Blue wire to terminal marked with “N”
* Brown wire to terminal marked with “L”
6. Remove jumper on power supply from E1 to E2 and attach the three black wires
labeled E1, E2, and E3 to the posts on the power supply labeled E1, E2, and E3.
7. Attach harness (423-4400-014) to the power supply as follows:
* Blue wire to terminal marked “V4”

* Grey wire to terminal marked “RET”
* Brown wire to terminal marked “V2”
* Orange wire to terminal marked “V3”
* Yellow wires (3) to post next to R5
* Grey wires (2) to post nearest outer edge of the case
8. Place cover over power supply and attach with four screws (NOTE: two screws
on one side are longer than two screws on other side).
9. Place CAUTION decal on top of power supply cover at the same end as the
ON/OFF switch.
10. Plug the power supply’s harness into the card rack and attach the power supply to the
card rack using three screws and three washers.
C. Card Rack Assembly

1. Remove plastic wrap and card rack cover.
2. Place large decal (ISA Card Cage Label) on inside of cover with the bottom of the
decal towards the center of the cover (closest to the styrofoam pad).
3. Remove back panel of the card rack by removing four screws. Save these screws for
reinstallation of the cover.
4. Screw nylon standoffs (10) into the bottom of the card rack.
5. Be sure the pins on the microprocessor are straight, and insert the microprocessor into
the socket on the motherboard. Lock the microprocessor holder/socket and verify that
the microprocessor is secure.
6. Insert plastic retaining pin (keyslot standoff w/locking bayonet nose) into the hole in the
corner of the motherboard, then place the motherboard into the card rack so that the
retaining pin fits into the key slot in the bottom corner of the card rack.
7. Adjust the motherboard’s position so that the holes in the motherboard are aligned with
the nylon standoffs installed in step 4.
8. Secure the motherboard to the card rack using 10 screws. Do not tighten screws all the
way until all screws have been started in their holes. This will make it easier to properly
align the motherboard.
9. Insert the SIMM memory module into the first SIMM slot on the motherboard (the slot
nearest the center of the motherboard).
10. Insert the COM2 serial port harness (423-4400-007) into the lower COM port cutout
near the front of the card rack (red stripe should be down). Secure the port/harness with
two jack screws.
11. Connect the other end of this harness to header J19 on the motherboard. Be sure pin 1
is positioned properly.
12. Insert the COM1 serial port harness (423-4400-007) into the upper COM port cutout
two jack screws.
13. Connect the other end of this harness to header J20 on the motherboard. Be sure pin 1
is positioned properly.
14. Stick an adhesive backed tie mount to the side of the card rack adjacent to the COM
ports. Insert a tie wrap horizontally through the slot with the square end of the tie wrap
towards the COM ports. This tie wrap will be used in step 20.
15. Test the DC Power Monitor/Distribution PCB (415-0611-*01) by connecting all of the
DC Distribution board’s harnesses to the tester. Turn the power on and verify that all
green LEDs illuminate. If any LED is not illuminated, either the wire’s connection is
not made, or the wire is inserted in the wrong place. Turn the potentiometer counter-
clockwise until the red LED illuminates. The pointer on the knob should be aligned
with the mark on the test fixture. Disconnect the DC Distribution board from the tester
when finished.
16. Carefully bend the wiring harnesses toward the center of the DC Distribution board and
position the board so that connectors J1-J4 pass through the cutout in the side of the card
rack.
17. Secure the DC Distribution board to the card rack with six screws. A long screw should
be used for the hole in the upper right corner of the DC Distribution board. This hole is
marked with a ground symbol on the card rack exterior.
18. Place a washer, a nut, and a wingnut on the end of the long screw which extends
through
the wall of the card rack.
19. Run the harness from the DC Distribution board for the FDD and the power to the
motherboard along the bottom of the card rack over towards the COM ports.
20. Connect the power harness connectors to the motherboard and then tie wrap the harness
to the adhesive backed tie mount installed in step 14.
21. Connect the harness end of the ISA Parallel Port Harness (002-4403-006) to the
motherboard at header J18 (be sure pin 1 orientation is correct). Place the parallel port
bracket into the third slot from the front of the card rack (this leaves two open card rack
slots between the COM ports and the parallel port). Secure the bracket with a screw.
22. Insert the Floppy Drive Transceiver Board (415-0606-*02) into the two open card rack
slots between the COM ports and the parallel port. Secure the bracket with a screw.
23. Connect the FDD power harness (from the DC Distribution board) to the six pin
connector on top of the Floppy Drive Transceiver board.
24. Connect the ISA Hard Drive Harness (423-4400-003) to header J22 on the motherboard
(be sure pin 1 orientation is correct).
25. Connect the ISA Floppy Interconnect (423-4400-004) to header J21 on the motherboard,
then connect the other end to J1 of the Floppy Transceiver board (be sure pin 1
orientation is correct).
26. Mount the hard disk drive to the hard drive bracket using four screws, then place
bracket onto the two studs on the card rack wall and tighten the screw at the top of the
bracket.
27. Connect the ISA Hard Drive Harness (423-4400-003) which was connected to header
J22 on the motherboard in step 24 to the hard disk drive.
28. Connect the HDD power harness from the DC Distribution board to the hard disk drive.
29. Connect the power harnesses from the DC Distribution board to the cooling fans, and
also connect the two wire speaker harness to the “SPKR” header (J26) on the
motherboard.
30. Insert the Dual VGA Graphics PCB (415-0220-*04) into slot 7 (next to the SIMM slots)
on the motherboard. Secure the Dual VGA board’s bracket with a screw.
31. Insert the DC I/O CANbus Controller PCB (415-0605-*02) into slot 6 on the
motherboard. Secure the CANbus Controller board’s bracket with a screw.
32. Run the power harness from the DC Distribution board along the sides of the card rack
to the card rack extension where the DC I/O Backplane will be mounted (harness can be
inserted into the slot between the motherboard and the card rack).
33. Connect the power harness to connector J4 on the DC I/O Backplane.
34. Connect the ISA CANbus Internal DC I/O Harness (423-4400-008) to connector J6 of
the DC I/O Backplane board.
35. Mount the DC I/O Backplane board (415-0602-*02) to the card rack extension base
using nine screws.
36. Run the ISA CANbus Internal DC I/O Harness (423-4400-008) along the bottom of the
card rack toward the end of the rack with the cutouts. Fold the harness so that it fits
through the clip on the cornerpost, making sure that the red stripe of the harness is
toward the cutout end of the card rack.
37. Connect the ISA/DSP TTL I/O Harness (423-4400-002) to connector J6 (AXIS X, Y,
Z, S) of the I/O Interface PCB (415-0607-*02) and feed the harness through the ribbon
cable clamp located just below connector J3.
38. Connect the ISA CANbus Controller I/O Harness (423-4400-005) to connector J4 of the
I/O Interface PCB and feed the harness through the ribbon cable clamps located just
below connector J1.
39. Insert the I/O Interface board into the slot in the DC I/O Backplane nearest to the
motherboard. Secure the board by tightening the screws at each end of the front panel.
40. Insert the DC I/O PCB (415-0601-*02) into the middle slot of the DC I/O Backplane
and tighten the screws at each end of the front panel.
41. Peel the protective paper cover off the DC I/O blank slot cover and install it over the
rearmost DC I/O slot using two screws and two plastic screw guides. The side of the
slot cover from which the paper cover was removed is the top.
42. Reinstall the back panel of the card rack using the four screws set aside in step 3.
43. Move jumper JU2 on the Motion Controller PCB (415-0247-*05) to the “1-2” position.
44. Insert the Motion Controller board into slot 1 of the motherboard and secure it’s bracket
with a screw.
45. Insert the ISA/DSP Honda Breakout PCB (415-0609-901) in the rearmost cutouts at the
back of the card rack. The fifty pin connector from the back of the Honda Breakout
board should pass through the second cutout from the back of the card rack so that it is
adjacent to the Motion Controller board inside the card rack. Secure the Honda Breakout
board with two screws.
46. Connect the ISA/DSP Servo I/O Harness (423-4400-006) from the Honda Breakout
board to connector J6 of the Motion Controller board.
47. Install blank brackets in the three empty slots between the Motion Controller board and
the CANbus Controller board. Use a screw to secure each bracket.
CANbus Controller board.
49. Connect the ISA/DSP TTL I/O Harness (423-4400-002) to connector J3 of the Motion
Controller board.
50. Connect the ISA CANbus Internal DC I/O Harness (423-4400-008) to connector J6 of
the Motion Controller board.
51. Reinstall the card rack cover.
R 757-4002-090 CURRENT REV: B CAD #D8469
SUBJECT: PROCEDURE TO ZERO Mx4/DSP DACS USING Mx4PRO

SOFTWARE

Jeff Nolletti 3/6/96 Mike Caron 3/14/96
________________________________ _______ _______________________________ _______
Revisions:
A 13636 Release
B 13789 Add 3 Motion Control PCBs:
415-0247-006
415-0247-007
415-0247-008
I. INTENT:
To provide instruction on the procedures to zero the DACs on the Mx4/DSP/Motion Control PCB using
Mx4PRO software.
II. SCOPE:
Applies to the Mx4PRO software version 3.12 and the four Mx4/DSP/Motion Control PCBs:
415-0247-005 Mx4/DSP, X, Y, Z, S
415-0247-006 Mx4/DSP, a, b, c, d
415-0247-007 Mx4 cnC++, X, Y, Z, S
415-0247-008 Mx4 cnC++, a, b, c, d
III. PROCEDURE:
1. Connect the test harness from the PC/AT Mx4 Test Fixture (black box) to the Honda Breakout
board connectors (X, Y, Z and S axes).
2. Place the Mx4PRO test disk in the floppy disk drive.
3. Power up the test fixture (card rack).
4. At A:\>, press the “m” key, then press “Enter.”
5. At the MAIN MENU select Dynamic Move and press “Enter.”
6. At the DYNA. MENU, select Direct Dac and press “Enter.”
7. You will be prompted to select axis(es). Use the Arrow keys to move through the axis select
menu. Pressing the Space bar selects the axis. An “X” in the box indicates the axis has been
selected.
8. Press “Enter” when your selections have been made.
9. Once the axis(es) is chosen, you are prompted for a voltage level (in volts). Enter “0” for zero
volts and press the “Enter” key. The “Esc” key aborts.
10. Use a voltmeter (set to the millivolts scale) to measure the DAC output voltage at the PC/AT
Mx4 test fixture (black box). Verify that the measured value is the same as the value
programmed.
11. When finished, select DONE from the DYNA. MENU and then QUIT from the MAIN MENU.
R 757-4002-104 CURRENT REV: A CAD #D8489
SUBJECT: BUILD PROCEDURE FOR ULTIMAX 3 / ISA

CONTROL PACKAGE WITH PENTIUM
PROCESSOR MOTHERBOARD
________________________________ _______ _______________________________ _______

A 13789 Release
2
I. INTENT:
To provide instruction on the assembly of ULTIMAX 3 / ISA Control Card Rack with Hunter Industrial
Pentium processor motherboard.
II. SCOPE:
Applies to Dual Screen BMC Card Rack. Build procedures for Single Screen and Knee Mill card
rack assemblies are identical, except that one or more of the following differences will apply.
1. Single Screen Card Rack uses a single VGA card instead of a dual VGA card.
2. DC I/O PCB (415-0601-901) may not be included on some card racks.
3. FDD Transceiver PCB (415-0606-902) may not be included on some card racks.
III. PROCEDURE:
A. Record and mark printed circuit board serial numbers.

B. Assemble power supply.
C. Modifify cable kit.
D. Assemble card rack.
A. Record and mark printed circuit board serial numbers.
1. Recording and marking the serial numbers for each of the printed circuit boards to be
installed in the ISA Control should be performed before actual assembly of the control
begins. Completing this recording and marking procedure first will save time and also
help prevent forgetting to record or mark the serial number on a circuit board. Follow the
instructions below.
2. Record serial numbers for the following circuit boards on the Commissioning Report Form:
* Dual VGA Graphics PCB 415-0220-*04

* Motion Control PCB 415-0247-*07
* DC I/O PCB 415-0601-*02
* I/O I/F PCB 415-0607-*02
3. Write the serial number on the following circuit boards in the space provided:
* DC I/O PCB 415-0601-*02

* I/O I/F PCB 415-0607-*02
4. Write the serial number on the top or front plate of the following circuit boards:
3
* DC I/O PCB 415-0601-*02
* I/O I/F PCB 415-0607-*02
5. Write the serial number on a small decal or label and place near the top (on the solder side)
on the following circuit boards:
* Dual VGA Graphics PCB (see note below) 415-0220-*04

NOTE: May use the serial number decal that is on the protective wrapping of the Dual
VGA Graphics PCB instead of making a label.
B. Assemble power supply
1. Remove fuse holder (center section) of power supply ON/OFF switch.
2. Insert four fuses into fuse holder slots and spare storage slots of fuse holder.
3. Reinsert fuse holder into power supply ON/OFF switch.
4. Insert the ON/OFF switch into the power supply cover with the switch towards the top side
of the cover. Secure the switch with two screws.
5. Connect the three wires from the ON/OFF switch to the three screws at the end of the power
supply as follows:
* Green/Yellow wire to terminal marked with Ground Symbol

* Blue wire to terminal marked with “N”
* Brown wire to terminal marked with “L”
6. Remove jumper on power supply from E1 to E2 and attach the three black wires labeled E1,
E2, and E3 to the posts on the power supply labeled E1, E2, and E3.
7. Attach harness (423-4400-014) to the power supply as follows:
* Blue wire to terminal marked “V4”

* Gray wire to terminal marked “RET”
* Brown wire to terminal marked “V2”
* Orange wire to terminal marked “V3”
* Yellow wires (3) to post next to R5
* Gray wires (2) to post nearest outer edge of the case
8. Place cover over power supply and attach with four screws (NOTE: two screws on one side
are longer than two screws on other side).
9. Place CAUTION decal on top of power supply cover at the same end as the ON/OFF switch.
10. Plug the power supply’s harness into the card rack and attach the power supply to the card
rack using three screws and three washers.
4
C. Modify cable kit (007-3006-001)
1. The hard drive harness consists of a 17”-long 40-conductor ribbon and 3 connectors (two
with strain relief at the two ends; one in between, dividing the cable into 2 sections).
Cut the ribbon in the shorter section along the keyed edge of the middle connector.
Use the 11”-long section (left with 2 connectors), and throw away the 6”-long section.
2. The floppy drive harness consists of a 25”-long 34-conductor ribbon and 4 connectors (two
with strain relief at the two ends; two in between, dividing the cable into 3 sections).
Cut the ribbon in the middle section along the edge of the smaller connector. Use the 15”-
long section (with 2 smaller connectors), and throw away the shorter section.
3. No modification needed for the remaining 3 harnesses (all have DB connectors at one end).
D. Card Rack Assembly
1. Remove plastic wrap and card rack cover.
2. Place large decal (ISA Card Cage Label) on inside of cover with the bottom of the decal
towards the center of the cover (closest to the styrofoam pad).
3. Remove back panel of the card rack by removing four screws. Save these screws for
reinstallation of the cover.
4. Screw nylon standoffs (9) into the bottom of the card rack. (see Figure 1 for hole positions).
5.Insert plastic retaining pin (keyslot standoff w/locking bayonet nose) into the hole in the
corner of the motherboard, then place the motherboard into the card rack so that the
retaining pin fits into the key slot in the bottom corner of the card rack.
6. Adjust the motherboard’s position so that the holes in the motherboard are aligned with the
nylon standoffs installed in step 4.
7. Do not force the motherboard into the chassis by using excessive force.
8. Secure the motherboard to the card rack using 9 screws. Do not tighten screws all the way
until all screws have been started in their holes. This will make it easier to properly align
the motherboard.
9. Do not place too much torque on a mounting screw.
10. Insert the COM2 serial port harness (from the cable kit) into the lower COM port cutout near
the front of the card rack (red stripe should be down). Secure the port/harness with two jack
screws.
11. Connect the other end of this harness to header J10 on the motherboard. Be sure pin
1 is positioned properly.
12. Insert the COM1 serial port harness (from the cable kit) into the upper COM port cutout
two jack screws.
5
13. Connect the other end of this harness to header J11 on the motherboard. Be sure pin 1 is
positioned properly.
14. Stick an adhesive backed tie mount to the side of the card rack adjacent to the COM ports.
Insert a tie wrap horizontally through the slot with the square end of the tie wrap towards the
COM ports. This tie wrap will be used in step 20.
15. Test the DC Power Monitor/Distribution PCB (415-0611-*01) by connecting all of the DC
Distribution board’s harnesses to the tester. Turn the power on and verify that all green
LEDs illuminate. If any LED is not illuminated, either the wire’s connection is not made, or
the wire is inserted in the wrong place. Turn the potentiometer counter-clockwise until the
red LED illuminates. The pointer on the knob should be aligned with the mark on the test
fixture. Disconnect the DC Distribution board from the tester when finished.
16. Carefully bend the wiring harnesses toward the center of the DC Distribution board and
position the board so that connectors J1-J4 pass through the cutout in the side of the card
rack.
17. Secure the DC Distribution board to the card rack with six screws. A long screw should be
used for the hole in the upper right corner of the DC Distribution board. This hole is marked
with a ground symbol on the card rack exterior.
18. Place a washer, a nut, and a wingnut on the end of the long screw which extends through
the wall of the card rack.
19. Run the harness from the DC Distribution board for the FDD and the power to the
motherboard along the bottom of the card rack over towards the COM ports.
20. Connect the power harness connectors to the motherboard and then tie wrap the harness to
the adhesive backed tie mount installed in step 14.
21. Connect the harness end of the ISA Parallel Port Harness (from the cable kit) to the
motherboard at header J12 (be sure pin 1 orientation is correct). Place the parallel port
bracket into the third slot from the front of the card rack (this leaves two open card rack slots
between the COM ports and the parallel port). Secure the bracket with a screw.
22. Insert the Floppy Drive Transceiver Board (415-0606-*02) into the two open card rack slots
between the COM ports and the parallel port. Secure the bracket with a screw.
23. Connect the FDD power harness (from the DC Distribution board) to the six pin connector
on top of the Floppy Drive Transceiver board.
24. Connect the ISA Hard Drive Harness (made from Procedure C) to header marked IDE 1 on
the motherboard (be sure pin 1 orientation is correct).
25. Connect the ISA Floppy Interconnect (made from Procedure C) to header J9 on the
motherboard, then connect the other end to J1 of the Floppy Transceiver board (be sure pin 1
orientation is correct).
26. Mount the hard disk drive to the hard drive bracket using four screws, then place bracket
onto the two studs on the card rack wall and tighten the screw at the top of the bracket.
27. Connect the ISA Hard Drive Harness (made from Procedure C) which was connected to
header marked IDE 1 on the motherboard in step 24 to the hard disk drive.
6
28. Connect the HDD power harness from the DC Distribution board to the hard disk drive.
29. Connect the power harnesses from the DC Distribution board to the cooling fans, and also
connect the two wire speaker harness to the “SPKR” header (J16) on the motherboard.
30. Insert the Dual VGA Graphics PCB (415-0220-*04) into slot 7 (next to the SIMM slots) on
the motherboard. Secure the Dual VGA board’s bracket with a screw.
31. Insert the CANbus Controller PCB (415-0605-*02) into slot 3 on the motherboard. Secure
the CANbus Controller board’s bracket with a screw.
32. Run the power harness from the DC Distribution board along the sides of the card rack to the
card rack extension where the DC I/O Backplane will be mounted (harness can be inserted
into the slot between the motherboard and the card rack).
33. Connect the power harness to connector J4 on the DC I/O Backplane.
34. Connect the ISA CANbus Internal DC I/O Harness (423-4400-008) to connector J6 of the
DC I/O Backplane board.
35. Mount the DC I/O Backplane board (415-0602-*02) to the card rack extension base using
nine screws.
36. Run the ISA CANbus Internal DC I/O Harness (423-4400-008) along the bottom of the card
rack toward the end of the rack with the cutouts. Fold the harness so that it fits through the
clip on the cornerpost, making sure that the red stripe of the harness is toward the cutout end
of the card rack.
37. Connect the ISA/DSP TTL I/O Harness (423-4400-002) to connector J6 (AXIS X, Y, Z, S)
of the I/O Interface PCB (415-0607-*02) and feed the harness through the ribbon cable clamp
located just below connector J3.
38. Connect the ISA CANbus Controller I/O Harness (423-4400-005) to connector J4 of the I/O
Interface PCB and feed the harness through the ribbon cable clamps located just below
connector J1.
39. Insert the I/O Interface board into the slot in the DC I/O Backplane nearest to the
motherboard. Secure the board by tightening the screws at each end of the front panel.
40. Insert the DC I/O PCB (415-0601-*02) into the middle slot of the DC I/O Backplane and
tighten the screws at each end of the front panel.
41. Peel the protective paper cover off the DC I/O blank slot cover and install it over the
rearmost DC I/O slot using two screws and two plastic screw guides. The side of the slot
cover from which the paper cover was removed is the top.
42. Reinstall the back panel of the card rack using the four screws set aside in step 3.
43. Move jumper JU2 on the Motion Controller PCB (415-0247-*05) to the “1-2” position.
44. Insert the Motion Controller board into slot 1 of the motherboard and secure it’s
bracket with a screw.
7
45. Insert the ISA/DSP Honda Breakout PCB (415-0609-901) in the rearmost cutouts at the back
of the card rack. The fifty pin connector from the back of the Honda Breakout board should
pass through the second cutout from the back of the card rack so that it is adjacent to the
Motion Controller board inside the card rack. Secure the Honda Breakout board
with two screws.
46. Connect the ISA/DSP Servo I/O Harness (423-4400-006) from the Honda Breakout board to
connector J6 of the Motion Controller board.
47. Install blank brackets in the three empty slots between the CANbus Controller board and the
VGA board. Use a screw to secure each bracket.
CANbus Controller board.
49. Connect the ISA/DSP TTL I/O Harness (423-4400-002) to connector J3 of the Motion
Controller board.
50. Connect the ISA CANbus Internal DC I/O Harness (423-4400-008) to connector J6 of the
Motion Controller board.
51. Reinstall the card rack cover.
8
757-4002-105 REV: B CAD#D8490
R
SUBJECT: Setup Procedure for Hunter

Industrial Pentium Motherboard
____________________________ _______ ___________________________ _______

Originator Date Manager Date
2
RECORD OF CHANGES
Engineering Document CAD #D8490
Revision ECN # Revision Description Pg # Date Appd By Date

A 13789 Original Release MMZ 10-20-96 MFC 10-20-96
B 14352 Added jumper settings for the P166 WRS 7-21-98
processor
3
I. INTENT
To provide a procedure to allow for a standard production setup of the Hunter Industrial Pentium
processor motherboard. This document will provide information on the jumper configuration for the
board and proper setup of BIOS.
II. APPLICABILITY
Specific to the Hunter Industrial system board from American Predator Corp. (415-0166-908
mothere bd. only and 007-3003-001 Sub-assembly)
III. PROCEDURE
A. CMOS Setup
Due to the variations in manufacturing process, the CMOS setup of the motherboard may not be always
consistent with a set of values. So it needs to be reset to its defaults.
Before the motherboard is installed into the card rack, move JP9 from 1-2 (normal position) to 2-3 (reset
position). Then, wait for about 30 seconds, and move JP9 back to 1-2. See Figure 1 for jumper
locations.
B. Jumper Setup
Visually check all jumper settings to table below. Motherboard should come from the supplier with jumpers
set to this configuration.
Standard Production Jumper Settings
Jumper No. Function Setting Selected Pins

Covered
JP17 Standard I/O enable Enable 1-2
JP10 Mouse IRQ enable Disable 1-2
JP20 Parallel port IRQ selection IRQ 7 1-2
JP19 First serial port IRQ selection IRQ 4 1-2
JP18 Second serial port IRQ selection IRQ 3 1-2
JP 7 ∗ CPU Clock frequency selection 66 MHz 5-6
JP 2 ∗ CPU Clock speed selection 100 MHz CPU 1-2
JP26 ∗ CPU Clock speed selection 100 MHz CPU 1-2
JP 2 ∗ CPU Clock speed selection 166 MHz CPU 2-3
JP26 ∗ CPU Clock speed selection 166 MHz CPU 2-3
JP21 DMA configuration for EPP Disabled 1-2
JP22 DMA configuration for EPP Disabled 1-2
JP14 Display selection Color 2-3
4
JP28 Cache size 256 K 1-2
JP 9 CMOS reset Normal 1-2
Note: * JP2, JP7, and JP26 are pre-configured for the factory installed processor. These settings should not
be altered, even if they are different from the settings listed. Consult installation guide for alternating
settings, if it is required.
C. BIOS Setup
This motherboard uses WinBIOS setup, which has a graphical user interface. See the following table for
keystroke functions.
<Tab> Move to the next window or field.

Arrows Move to the next field to the right, left, above, or below.
<Enter> Select in the current field.
+ Increases a value.
- Decreases a value.
<Esc> Closes the current operation and return to previous level.
<PgUp> Return to previous page.
<PgDn> Advances to the next page.
<Home> Returns to the beginning of the text.
<End> Advances to the end of the text.
<Alt> <H> Access a help window.
<Alt> <Spacebar> Exit WinBIOS setup.
Press <DEL> during power-on memory test to start WinBIOS setup.
The WinBIOS setup main menu is organized into four sub-windows: Setup, Utilities, Security, and Default.
The settings not mentioned in this section remain the default settings. A complete standard production BIOS
setting are listed at the end of the setup procedure.
1. Firstly, press <Tab> key to make “Utility Window” active, then press <Enter> key to select it.
See the table above for keystroke functions.
Utility Window Choose Detect IDE
PIO Mode: Choose 0
Block Mode: Choose Off
LBA Mode: Choose Off
Note: All the IDE hard drives and drive parameters are detected and displayed automatically by selecting
the “Detect IDE” icon. By using this utility, the standard setup procedures for hard drives in the
5
Setup Window can be omitted. However, for certain hard drives, some parameters at the “Auto
Detection Status” screen must be changed to meet the user program requirements.
2. Secondly, press <Tab> key to make “Setup Window” active, then press <Enter> to select it.
Setup Window. Only three of the six setup sub-screens (Standard, Advanced, Chipset, Power
management, PCI/PnP, and Peripheral) need to be set:
1). Standard Setup
Date/Time: Enter current values through the displayed window.
2). Advanced Setup
BootUp Sequence: Choose A:, C:,CDROM
Mouse Support: Choose Disabled
System Keyboard: Choose Absent
Wait For F1 if Error: Choose Disabled
Hit Del Message Display: Choose Disabled
System BIOS Cacheable: Choose Disabled
C000, 16K Shadow : Choose Enabled
C400, 16K Shadow : Choose Enabled
3). Chipset Setup
IRQ12/M Mouse Function: Choose Disabled
Lastly, save the changes and exit the WinBIOS setup.
Reference documents:
a. Standard Production BIOS Settings (attached)

b. Figure 1: Jumper locations (attached)
c. Pentium Processor Motherboard Installation Guide (Engineering files)
6
Standard Production BIOS Settings
Sub-Window: Setup
Standard Setup
Pri Master Pri Slave

Type User Type Not Installed
LBA/Large Mode Off Sec Master
Block Mode Off Type Not Installed
32 bit Mode Off Sec Slave
PIO Mode 0 Type Not Installed
Floppy A 1.44 MB 3 1/2 Floppy B Not Installed
Date/Time Enter current date and time
Advanced Setup
Quick Boot Enabled Hit “Del” Message Disabled

Bootup Sequence A:,C:,CDROM Wait for “F1” if Error Disabled
Bootup Num-Lock On Internal Cache WriteBack
Floppy Drive Swap Disabled External Cache WriteBack
Floppy Drive Seek Disabled System BIOS Cacheable Disabled
Mouse Support Disabled C000, 16K Shadow Enabled
System Keyboard Absent C400, 16K Shadow Enabled
Primary Display VGA/EGA C800, 16K Shadow Disabled
Password Check Setup CC00, 16K Shadow Disabled
OS/2 Compatible Disabled D000, 16K Shadow Disabled
Chipset Setup
Memory Hole Disabled

DRAM Speed 70 ns
IRQ12/M Mouse Function Disabled
8 Bit I/O Recovery Time 1
16 Bit I/O Recovery Time 1
Power Management Setup
7
Power Management/APM Disabled
PCI/PnP Setup
Plug & Play Aware O/S No DMA Channel 7 ISA/EISA
PCI Burst Mode Enabled IRQ 3 ISA/EISA
PCI Concurrency Enabled IRQ 4 ISA/EISA
PCI Streaming Enabled IRQ 5 ISA/EISA
PCI Latency Timer 64 IRQ 7 ISA/EISA
PCI VGA Palette Snoop Disabled IRQ 9 ISA/EISA
PCI IDE BusMaster Disabled IRQ 10 ISA/EISA
DMA Channel 0 ISA/EISA IRQ 11 ISA/EISA
DMA Channel 1 ISA/EISA IRQ 14 PCI/PnP
DMA Channel 3 ISA/EISA IRQ 15 PCI/PnP
DMA Channel 5 ISA/EISA Reserved Memory Size Disabled
DMA Channel 6 ISA/EISA
Peripheral Setup
Onboard FDC Auto Parallel Port Mode Normal
Onboard Serial Port 1 Auto Parallel Port DMA N/A
Onboard Serial Port 2 Auto Parallel Port IRQ 7
Onboard Parallel Port Auto Onboard PCI IDE Primary
Sub-Window: Security
Supervisor Not Used Anti-Virus Disabled

User Not Used
Note: If a password has been entered, and later forgotten, a CMOS setup (as described in Section A) can
remedy the situation.
Sub-Window: Utility
Detect IDE Language English

PIO Mode 0
Block Mode Off
LBA Mode Off
Sub-Window: Default
Original No
Optimal No
8
Fail-Safe No
9
R
757-4002-125 CAD #D8515E
SUBJECT: Ultimax v2.xx Software Field Installation Procedure E1
Barry A. Van Paris 5/6/97 Michael Dupont 4/4/97

Procedure, Ultimax v2.00 Field Installation 757-4002-125 Rev. E Page 1

RECORD OF CHANGES
Engineering Document 757-4002-125 CAD #D8515E

By
A 13984 Original Release MAD 4/497
B 14009 Modified per field and production notes BVP 5/6/97 MAD 5/15/97
C 14055 Modified BMC30HTM Siemens &
BMC30M Yaskawa in table in step 21 on
page 7. Prefix & suffix incorrect. BVP 6/17/9 MAD 6/17/97
7
D 14185 Modified tables pertaining to machine
configuration and parameters disks due
to the new composite configuration and
parameters disks. Removed MCODE
harness modification section. Removed
entering positive number for a negative 0
inch position in the leadscrew map.
Added fields for logging spindle rpm. BVP 2/4/98
E 14376 Changed v2.00 to v2.xx in description BVP 9/1/98
(E1); Added 1 diskette to the Initial
Ultimax disk set (007-4123-008) (E2).
Added Hawk30/40 bed mill parameter
doc (E3); Added Hawk30/40 serial
number prefixes (E4) and REX files (E5);
Added Max4 *.HB8 files (E6); Added
BMC2416 & BMC6434 parameter docs to
contents list (E7).
Procedure, Ultimax v2.xx Field Installation 757-4002-125 Rev. E Page 2

I. INTENT
The purpose of this document is to provide instructions for field installation of the Ultimax 3 version 2.XX
software on ISA based Hurco machines.
II. SCOPE
This document is applicable to machines that already have an existing Ultimax v1.X version of software on the
control. The machine will be fully operational after this installation. The procedure is meant for a qualified
Hurco service person only. It is not meant for customer use. It is assumed that the control has a Pentium CPU
board installed.
This document divided into the following sections:
• Materials required
• Software Installation procedure
• Manual Hard Disk Setup
• V2.XX Hard Disk & File Structure
• Parameters
III. MATERIALS
The following is necessary for successful installation of the Ultimax v2.XX software:
• PC/AT keyboard
• 007-4123-009, Ultimax v2.XX Software Installation Kit (Binder issued by Hurco service.):
Contents:
Diskette Description Part Number Disks
E2
INITIAL ULTIMAX VERSION 2.XX PRODUCTION INSTALLATION DISKETTE 007-4123-008 3
DOS UTILITY DISKETTE 427-0004-009 1
One of the following required: Part Number Disks

ULTIMAX 3 MACHINE PARAMETERS/PRODUCTION COMPOSITE 427-0004-021 1
ULTIMAX 3 MACHINE PARAMETERS/FIELD COMPOSITE 427-0004-024 1
Document Description Part Number CAD

Number
LIST, V2.XX ULTIMAX 704-0020-027 DS0043
DOCUMENT, ULTIMAX V2.XX FIELD REFERENCE 757-4002-134 D8528
DOCUMENT, ULTIMAX PENTIUM FIELD REFERENCE 757-4002-135 D8529
PENTIUM FIELD INSTALLATION PROCEDURE FOR ULTIMAX 757-4002-130 D8523
SET-UP PROCEDURE FOR HUNTER INDUSTRIAL PENTIUM MOTHERBOARD 757-4002-105 D8490
MACHINE PARAMETERS - BMC 30SSM SIEMENS 757-4005-001 DP001
MACHINE PARAMETERS - BMC 30SSM YASKAWA 757-4005-002 DP002
MACHINE PARAMETERS - BMC 30M SIEMENS 757-4005-003 DP003
MACHINE PARAMETERS - BMC 30HT/M SIEMENS 757-4005-004 DP004
MACHINE PARAMETERS - BMC 30M YASKAWA 757-4005-005 DP005
MACHINE PARAMETERS - BMC 30HT/M YASKAWA 757-4005-006 DP006

MACHINE PARAMETERS - BMC 4020HT SIEMENS 757-4005-008 DP008
E3
MACHINE PARAMETERS – HAWK30/40 BEDMILLS 757-4005-012 DP0012
E7
MACHINE PARAMETERS – BMC2416 YASKAWA 757-4005-014 DP0014
E7
MACHINE PARAMETERS & PROCEDURES – BMC6434 YASKAWA 757-4005-015 DP0015
• (1) 3.5” formatted floppy diskette (for copying leadscrew map).

• Ultimax v2.XX Upgrade package:
Check the items you have, before beginning the procedure:

Description Part Number Serial Number
Prefix
√
ULTIMAX 3 VERSION 2.00/ULTIMAX CNC (EXECUTIVE) 007-4123-004 U3V2
ULTIMAX 3/CNC (EXECUTIVE) LANGUAGES 007-4123-005 ELAN
ULTIMAX 3/MACHINE LANGUAGES 007-0001-003 MLAN
OPTIKEY UTILITY DISKETTE/SECURITY MODIFIER SKOX200 007-4136-005 -
ULTIMAX 3 VERSION 2.00 & ABOVE CONTROL OPERATION ADDENDUM 704-0101-765 -
ULTIMAX 3 V2.XX PATCH UTILITY DISKETTE 007-4123-010 -
ULTIMAX3 V2.XX PATCH UTILITY DOCUMENT 757-4002-030 -
WIRE, 24AWG, BLUE (60”) 406-2008-001 -
FERRULE, 24AWG LIGHT YELLOW (8) 406-0965-014 -
CONTACT, FEMALE SILVER (2) 406-0811-010 -
TERMINAL BLOCK, CUSTOM #260 ASS’Y, 20 TERM W/END – STOPS & RAIL 406-4005-323 -
CABLE, 24 AWG 5 COND SHIELDED 406-1325-008 -
WIRE, 22 GA, SMALLER OD, GREY 406-2006-050 -
One of the following:

ULTIMAX 3 MACHINE CONFIGURATION / FIELD COMPOSITE 427-0004-025 FLDR
If CPU board upgrade:

ASSY, ISA PENTIUM CPU STD 007-3003-001T -

IV. SOFTWARE INSTALLATION PROCEDURE
NOTE 1: Connect the PC keyboard to the control. Steps 1 through 5 require PC keyboard interaction NOT console
key presses. The remaining steps require console key presses NOT PC keyboard presses.
NOTE 2: Diskette names will appear in capital letters and bold - be sure to match the diskette name exactly during
this procedure.
NOTE 3: Make a copy of this procedure before beginning. Initial each step on the copy and place the copy in the
machine folder.
________1. Make sure that the customers part program files are backed up. The following procedure will
destroy all data on the hard disk.
________2. Record the Tool Change Height, Max DAC Voltage for each axis , Spindle Motor Speed, Spindle
Speed and copy the Leadscrew Map to a floppy diskette. Do not copy the leadscrew map to the
v2.00 hard drive until step #44.
TC Height ____________mm
Max DAC Voltages:
(X)_______ (Y)_______ (Z)_______ (S)_______ (A)______ (B)_______
Spindle Motor Speed______________rpm Spindle Speed______________rpm
Leadscrew Map Copied Yes
________3. Complete hard disk setup. See Manual Hard Disk Setup section of this document. Follow these
steps to set up the hard disk.
________4. After the format is complete, place the disk 1 of the INITIAL ULTIMAX V2.xx PRODUCTION
INSTALLATION (007-4123-008) in the floppy drive and reset system.
________5. If the system asks to change the boot sector, enter “Y” and press ENTER. Allow the diskette to copy
files.
________6. When prompted, put in the next INITIAL ULTIMAX V2.xx PRODUCTION INSTALLATION
DISKETTE in the floppy drive.
________7. Boot the control with the Optikey OPTIKEY UTILITY DISKETTE/ SECURITY MODIFIER
SKCOX200 (007-4136-005) diskette in floppy drive to program the security device. Note: Skip this
step if replacing the hard drive of an Ultimax v2.XX system. Follow the instructions on the Optikey
screens. Remove the Optikey diskette when complete.

________8. If any options accompany this upgrade, repeat step 7 using the OPTIKEY UTILITY DISKETTES
furnished to load these options.
________9. Cycle Power to reset the system. The Ultimax v2.00 base system should run.
NOTE: DO NOT try to run machine using this executive.
________10. Place the ULTIMAX3 VERSION 2.XX/ULTIMAX CNC (EXECUTIVE) disk 1 (007-4123-004) in
floppy drive.
________11. Select Auxiliary Mode and select the “UPGRADE SYSTEM FILES”. Select the “YES” softkey to
copy the files. Insert the next diskette when prompted.
“YES” softkey.
________13. Insert the ULTIMAX 3 CNC (EXECUTIVE) LANGUAGES disk 1 (007-4123-005) in the floppy drive.
This will install the text languages for the Executive. Insert the next diskette when prompted.
“YES” softkey.
________15. Verify the machine serial number prefix and suffix. Insert the ULTIMAX 3 MACHINE
CONFIGURATION / FIELD COMPOSITE diskette (427-0004-025) supplied in the Ultimax v2.XX
Upgrade Package in the floppy drive. This will install the PLC system for use on all machine types.
“YES” softkey.
________17. Insert the ULTIMAX 3 MACHINE LANGUAGES diskette (007-0001-003) in the floppy drive. This
will install the text languages for the PLC system.
“YES” softkey.
________19. Insert the ULTIMAX 3 VERSION 2.XX PATCH diskette (007-4123-010), if present in upgrade
package in the floppy drive. This will install any updates to the system files.
“YES” softkey.
________21. Insert with the ULTIMAX 3 MACHINE PARAMETERS / PRODUCTION COMPOSITE diskette
(found in the Ultimax v2.XX Software Installation Kit 007-4123-009 binder) in the floppy drive. This
will install the parameters that PLC system will use for current production machines.
________22. Insert with the ULTIMAX 3 MACHINE PARAMETERS / FIELD COMPOSITE diskette (found in the
Ultimax v2.XX Software Installation Kit 007-4123-009 binder) in the floppy drive. This will install the
parameters that PLC system will use for nonproduction machines.
________23. Upon completion, the prompt “Do you have another set of system disks?” will appear. Select “NO”
________24. Cycle power to the control.
________25. After the system restarts, select Auxiliary Mode.
________26. Press the <ENTER> <100> <ENTER> keys, sequentially.

________27. Press the “MISCELLANEOUS SERVICES” softkey.
________28. Press the “SELECT MACHINE CONFIG DIRECTORY” softkey.
________29. Verify the machine type with the machine serial number prefix. Highlight the appropriate <machine
type>.MCD selection using the arrow keys and press <ENTER>. Use the following table to
determine the <machine type>:
<machine type> Description S/N Prefix Std Spindle

RPM
30SSMS BMC3017SSM with single or dual screen & Siemens B3SM 8000
spindle
30SSMY BMC30SSM with Yaskawa spindle B3SM 8000
30MS BMC3017M with Siemens drives B3M 8000
30MY BMC30M with Yaskawa drives B3M, QAM 8000
30HTMS BMC30HT/M with Siemens drives B3HM 8000
30HTMY BMC30HT/M with Yaskawa drives B3HM, QHT 8000
4020SSM BMC4020SSM with Siemens drives B42S 8125
4020HT BMC4020HT with Siemens drives B42M 6500
4050MY BMC4050M with Yaskawa drives B45 4000
E4
HAWK30 Hawk30SSM bedmill H30S 3900
E4
NOTE: Some machines may require that the spindle speed parameter be edited if a non-standard
spindle has been installed.
________30. The prompt “There are machine boot config files in the selected MCD. Do you want to copy these
to the configuration directory?” will appear. Select the “YES” softkey.
________31. Press the “EXIT” softkey after the copying is complete.
________32. The control will automatically reset. If the system does not restart, then cycle the machine power.
NOTE: If the hard drive is being replaced on a v2.XX system, follow steps a through e below.
________a) Select Auxiliary Mode after the system restarts.
________b) Select the “SYSTEM CONFIGURATION” softkey.
________c) Insert the ULTIMAX 3 VERSION 2.00 MACHINE CONFIGURATION diskette in drive
A: and select the “YES” softkey.
________d) Restart the control.
________e) Skip the remainder of this procedure.
________33. After the system restarts, go to the INTEGRATOR SUPPORT SERVICES hidden screen by
pressing <ENTER> <100> <ENTER> from the Auxiliary screen.

________34. Select the “CNC CONFIG PARAMETERS” softkey.
________35. Select the “SPINDLE” softkey then select the “PHYSICAL PARAMETERS” softkey and enter the
Max DAC Volts (that was recorded previously) for each axis.
________36. Press the “EXIT” softkey.
________37. If the machine is an SSM, then do steps a to d.
________a) Select the “GENERAL PARAMETERS SOFTKEY”.
________b) Cursor down to the POINTING DEVICE MODE field.
________c) Select the “ABSOLUTE” softkey.
________d) Press the “EXIT” softkey.
________39. Select the “INTEGRATOR CONFIG PARAMETERS” softkey.
________40. Select the “DOUBLE (F96) PARAMETERS” softkey then select the “JUMP TO PARAMETER
NUMBER” softkey. Type 30 then press <ENTER>. This will jump to the F96:30 register.
________41. The Tool Change Height recorded in step #2 must be converted to metric units (MM). This value
will always be negative (make sure you type the minus sign). Enter the tool change height recorded
in step #2.
________42. Select the “EXIT” softkey. Select the “YES” softkey when asked if the changes are to be saved.
________44. Boot DOS using the DOS Utility diskette found in the installation kit and copy the Max3 v1.XX
leadscrew map (LEADSCRW) to C:\ from the diskette that was made in step 2. Do this from the A:
prompt by typing:
COPY LEADSCRW C:\
________45. Reset the control by cycling power.
________46. Backup the configuration.
________a) Place the ULTIMAX 3 VERSION 2.XX/PARAMETER BACKUP diskette that

accompanied the Ultimax v2.XX upgrade package in the floppy drive.
________b) From the Auxiliary screen, select the “SYSTEM CONFIGURATION” softkey.
________c) Then select the “BACKUP MACHINE CONFIGURATION” softkey. The system will
copy the configuration files to the diskette.
________d) Store the diskette in a safe place.
________47. The version 2.XX installation is complete. Insert all diskettes provided with the Ultimax v2.XX
Upgrade Package in the machine folder provided and the diskette folder from the the previous
version of Ultimax. Discard the diskettes from the previous version.

V. MANUAL HARD DISK SETUP
1. Insert the DOS UTILITY DISKETTE (427-0004-009) into the Floppy Disk Drive.
2. Cycle the Machine Power Off and attach the AT keyboard harness.
3. Cycle the Machine Power On.
4. At the A> prompt, enter FDISK to display the FDISK options.
5. Select option 3, Delete Partition or Logical DOS Drive.
a) Select option 3, Delete Logical DOS Drive(s) in the Extended DOS Partition.
b) At the warning, enter D for the Drive letter to be deleted.
c) Enter the Volume Label (if there is no Volume Label, then just press Enter).
d) At the prompt “Are you sure?”, enter Y.
e) “All Logical Drives deleted in the Extended DOS partition” should be displayed when completed.
f) Press ESC. The prompt “No Logical Drives defined” should be displayed.
g) Press ESC to return to the main menu.
a) Select option 2, Delete Extended DOS Partition.
b) At the warning, enter Y to continue.
c) “Extended DOS Partition deleted” prompt should be displayed when completed.
d) Press ESC to return to the main menu.
a) Select option 1, Delete Primary DOS Partition.
b) At the warning, enter 1 for the Primary Partition to be deleted.
e) “Primary DOS Partition deleted” should be displayed when completed.
f) Press ESC to return to the main menu.
8. Press ESC to exit FDISK and reboot the Control.
9. Make sure that the CMOS setup is correct for that drive type (See Engineering Document 757-4002-105).
Use the auto hard disk setup of the CMOS if possible. DO NOT use the old 50 sector limitation settings
for the CMOS configuration. This will render the disk not usable for v2.XX. The CMOS settings should
match the settings on the hard disk label. If there is a PIO Mode in the IDE Hard Disk Setup, then set it to
0 (zero). Also, the LBA or Large Mode must be ON for v2.XX systems.
10. Reboot the control with the DOS UTILITY DISKETTE (427-0004-009) in the floppy disk drive.
12. Select option 1, Create DOS Partition or Logical DOS Drive.
a) Select option 1, Create the Primary DOS Partition.
b) At the prompt “Do you wish to use the maximum available size for a primary DOS partition and make
the partition active (Y/N)” enter N.
c) At the prompt “Enter partition size in Mbytes or percent of disk space (%) to create a primary DOS
partition”, enter 10 for 10Mbytes.
d) “Primary DOS partition created” should be displayed when completed.
e) Press ESC to return to the main menu.
a) Select option 2, Create the Extended DOS Partition.
b) At the prompt “Enter partition size in Mbytes or percent of disk space (%) to create an extended DOS
partition”, leave the default Mbytes displayed or set the percentage to 100% minus the percentage of
the primary DOS partition and press ENTER.
c) “Extended DOS partition created” should be displayed when completed.
d) Press ESC to advance to the next prompt.
e) At the prompt “Enter logical drive size in Mbytes or percent of disk space (%)”,leave the default
Mbytes displayed or set the percentage to 100% minus the percentage of the primary DOS partition
and press ENTER.

f) “All available space in the extended DOS partition is assigned to logical drives” should be displayed
when completed with 100% listed for Usage.
14. Select option 2, Set Active Partition.
a) At the prompt “Enter the number of the partition you want to make active”, enter 1.
b) “Partition 1 made active” should be displayed when completed.
c) Press ESC to return to the main menu.
15. Select option 4, Display Partition Information.
a) The following should be displayed as:
Partition Status Type Volume Label Mbytes System Usage
C:1 A PriDOS 10 Unknown 3%
2 ExtDOS 339 Unknown 97%
Note that Usage and Mbytes will be different depending upon the Hard Drive.
b) The logical drive information should be displayed as:
Drv Volume Label Mbytes System Usage
D 399 Unknown 100%
16. Press ESC to Quit FDISK and reboot the Control.
17. At the A> prompt, enter FORMAT C: /U /V:EXECUTIVE_1 to format the Hard Disk Drive C partition.
Verify that only 10M (approximately) is formatted.
18. At the A> prompt, enter FORMAT D: /U /V:PART_PROGS to format the Hard Disk Drive D partition.
19. For V2.xx systems, follow the procedures in the V2.XX Field Retrofit Kit.

VI. V2.XX HARD DISK & FILE STRUCTURE
The following is the hard disk directory tree along with a brief description of the files after the upgrade has been
completed.
Filenames in lower case indicate files that have read only and hidden file attributes.
C:\ root directory

INTCFG.SYS Contains integrator parameters.
LADDERS.TXT Script file of Ladder files to be loaded at startup.
LOGO.PCX Graphics screen logo, displayed at startup.
PREVIOUS.VER File created after an upgrade to indicate the previous version.
TOOLOFF.SET Tool Offset file.
bootsave.bin Old bootstrap saved in this file(system/hidden file).
execprog Version 2.XX Executive (system/hidden file).
hurco.ldr Bootloader file (system/hidden file).
loadfrag.bin New bootstrap file (system/hidden file).
LADDERS sub directory

1BASE000.REX The following (3) REX files are base ladders only allowing the
screens to be
2BASE000.REX used and allow upgrades. A machine tool cannot be operated with
these
3BASE000.REX ladders.
30SSMS.REX Dummy File; used to identify machine from Software Configuration
30SSMY.REX screen; one for each model; only one file will be on Drive C.
30MS.REX
30MY.REX
30HTMS.REX
30HTMY.REX
4020SSM.REX
4020HT.REX
4050MY.REX
5050MY.REX
HAWK30.REX E5
HAWK40.REX E5
AXOUT000.REX Auxiliary Output logic, i.e., Aux M-Codes
AMPL_000.REX Amplifier Logic; used for Fault checking, A/B axis enable, axis load
calculations.
AXTUN000.REX Axis Tune Cycle Support; interface to NAV/CNC side.
B30YIN.REX Input Mask; maps real Input points to internal bit locations; machine
B30SIN.REX specific file, only one file will be on Drive C.
BMC42IN.REX
BMC45IN.REX
KM34IN.REX E5
B30YOUT.REX Output Mask; maps real Output points to internal bit locations;
B30SOUT.REX machine specific file, only one file will be on Drive C.
BMC42OUT.REX
BMC45OUT.REX
KM34OUT.REX E5
BKGND000.REX Background fault checking for Low Air Pressure, Low Way Lube, and
Overload Faults.
CAL_000.REX Axis Calibration sequence.
CE_000.REX CE Support; Cycle Keyswitch, cycle doors, etc.
COOL_000.REX Coolant control and interface; used for Flood, Mist, and Washdown.
CYCLS000.REX LC Cycle handler; detects and responds to requests for unsupported

M-Codes.
INDEX000.REX Indexer logic.
JOG_000.REX Axis Jog; used for Rapid and Incremental, Rotary Axis Clamp and
Unclamp.
LEDTS000.REX Console LED Test logic.
LUBE_000.REX Lube system logic; not active for BMC machines with external lube
systems.
MCODE000.REX M-Code handler; detects and responds to requests for unsupported
M-Codes.
MSC_000.REX Machine State Control; PLC for Keyboard decoding, Mode Control,
Interrupt Cycle, etc.
MSTST000.REX Machine Setup and Test; PLC for Axis Balance, Spindle Test Cycle,
Keyboard Test, and CRT Degauss
PARK_000.REX Machine Park sequence logic.
PDEV_000.REX Pointer Device; used for “absolute pointers”, i.e. SSM Mouse.
PROBE000.REX Probe logic; support for Tool and Part Probing, calibration, etc.
QUAD_000.REX Quad-size DRO handler.
SPIN_000.REX Spindle logic; interfaces to Navigation for Spindle speeds, overrides,
tapping, and spindle orient; used for both Yaskawa and Siemens.
TCHGR000.REX Type 0 ATC support; ATC and ATC Diagnostics and screens.
TCHGR003.REX E5 Type 3 ATC support (No ATC – Hawks); ATC and ATC Diagnostics and
screens.
WRMUP000.REX Warmup cycle logic; controls sequence and error handling
IOTST000.REX IOIF & DCIO2 loop back testing
LANG sub-directory
DEFAULT.HBM Default font bitmap.
DEFAULTHQ.HBM Default quad size bitmap.
DEFAULT.HB8 E6 Default font bitmap for 800x600 video (Max4).
DEFAULTHQ.HB8 E6 Default quad size bitmap for 800x600 video (Max4).
ENGLISH.HRC CNC language resource file.
ENGLISH.HRL Machine language resource file.
FRENCH.HRC
FRENCH.HRL
GERMAN.HRC
GERMAN.HRL
ITALIAN.HRC
ITALIAN.HRL
CONFIG sub-directory
VER2_00 sub-directory
SYSFIX.SYS The following files contain integrator, system and user parameters.
SYSINT.SYS
TUNE.SYS
SERIAL.SYS
PROBE.SYS
SPINDLE.SYS
MCODE.SYS
NETWORK.SYS
<machine type>.MCD subdirectory - Contains ladders and config files specific to <machine type>
See page 7 for the existing machine types.

VII. PARAMETERS
Use this section to enter the current v1.XX as well as the v2.XX parameters from the secret screens. After the
v2.XX upgrade is complete, use this section to verify the new parameters were entered correctly.
• Axis Parameters
• Spindle Parameters
• Machine Parameters
• Tool Change Parameters
• Matrix4 Axis Tuning Parameters

Description V1.XX V2.XX V1.XX V2.XX V1.XX V2.XX
AXIS PHYSICAL PARAMETERS X Axis Y Axis Z Axis
Axis Pitch not used not used not used
Counts per Revolution CNC Configuration, CNC Configuration, CNC Configuration,

Physical Parameters Physical Parameters Physical Parameters
Distance per Revolution CNC Configuration, CNC Configuration, CNC Configuration,
In Position Tolerance CNC Configuration, CNC Configuration, CNC Configuration,
Calib: To Lim Sw Velocity Integrator Configuration Integrator Configuration Integrator Configuration
Parameters, F96:6 Parameters, F96:7 Parameters, F96:8
Calib: To Marker Velocity Integrator Configuration Integrator Configuration Integrator Configuration
Positive Limit Switch Signal Logic CNC Configuration, CNC Configuration, CNC Configuration,
Negative Limit Switch Signal Logic CNC Configuration, CNC Configuration, CNC Configuration,
Load Meter Bar One Value Integrator Configuration Integrator Configuration Integrator Configuration
Parameters, N95:220 Parameters, N95:222 Parameters, N95:224
Load Meter Overload Value Integrator Configuration Integrator Configuration Integrator Configuration
Parameters,N95:221 Parameters, N95:223 Parameters, N95:225
Fault Signal Logic Integrator Configuration Integrator Configuration Integrator Configuration
Maximum Travel CNC Configuration, CNC Configuration, CNC Configuration,
Vertical Parameters Vertical Parameters Vertical Parameters
Leadscrew Mapping Leadscrew Mapping Leadscrew Mapping Leadscrew Mapping
Maximum Feedrate CNC Configuration, CNC Configuration, CNC Configuration,

AXIS VERTICAL PARAMETERS X Axis Y Axis Z Axis
Coordinate Frame Sense not used not used not used
Machine Wiring Logic CNC Configuration, CNC Configuration, CNC Configuration,

Calibrate Home Position CNC Configuration, CNC Configuration, CNC Configuration,
Calibrate Limit Switch
Axis Usage not used not used not used

Description V1.XX V2.XX V1.XX V2.XX
AXIS PHYSICAL PARAMETERS A Axis B Axis
Rotary Resolution
Maximum RPM CNC Configuration, CNC Configuration,

Physical Parameters Physical Parameters
Clamp Mechanism Present Integrator Configuration Integrator Configuration

Parameters, N95:25 Parameters, N95:26
Clamp Signal Present Integrator Configuration Integrator Configuration

Clamp Signal Logic Integrator Configuration Integrator Configuration

Unclamp Mechanism Present not used not used
Unclamp Signal Present Integrator Configuration Integrator Configuration

Fault Signal Present Integrator Configuration Integrator Configuration

Fault Signal Logic Integrator Configuration Integrator Configuration

Machine Wiring Logic CNC Configuration, CNC Configuration,

Vertical Parameters Vertical Parameters
Limit Switch Present CNC Configuration, CNC Configuration,

Limit Switch to Marker Distance Integrator Configuration Integrator Configuration

Parameters, F96:4 Parameters, F96:5
Limit Switch Signal Logic
Backlash Compensation Leadscrew Mapping Leadscrew Mapping
In Position Tolerance CNC Configuration, CNC Configuration,

Calibrate to Limit Switch Velocity Integrator Configuration Integrator Configuration

Calibrate to Marker Velocity Integrator Configuration Integrator Configuration

Calibrate Home Position CNC Configuration, CNC Configuration,

Procedure, Ultimax v2.00 Field Installation 757-4002-125 Rev. D Page 16

AXIS VERTICAL PARAMETERS A Axis B Axis
Coordinate Frame Sense not used not used


Axis Usage not used not used

Description V1.XX V2.XX
SPINDLE PHYSICAL PARAMETERS
Counts per Revolution (Motor) CNC Configuration,
Physical Parameters
In Position Tolerance CNC Configuration,

Physical Parameters
Orient Mechanism Present CNC Configuration,

Physical Parameters
Clamp/Unclamp Present not used
High/Low Winding Present Integrator Configuration

Parameters, N95:18
Spindle High Winding Threshold RPM Integrator Configuration

Parameters, N95:19
Spindle Air Purge Time On Delay Integrator Configuration

Parameters, N95:20
Load Meter Bar One Value Integrator Configuration

Parameters, N95:226
Load Meter Overload Value Integrator Configuration

Parameters, N95:227
Spindle Control Type CNC Configuration,

Physical Parameters
Maximum DAC Volts CNC Configuration,

Physical Parameters
AMR Relay Present not used
Fault Signal Logic Integrator Configuration

Parameters, N95:3
Spindle Brake Enable Time not used
Minimum Tap RPM CNC Configuration,

Physical Parameters
Maximum Tap RPM CNC Configuration,

Physical Parameters
Orient Mechanism Type not used
Max RPM in High Gear CNC Cfg., Vert.

Parameters, Gear Table
Min RPM in High Gear CNC Cfg., Vert.


Max RPM in Low Gear CNC Cfg., Vert.
Min RPM in Low Gear CNC Cfg., Vert.

Maximum Programmable RPM
Minimum Programmable RPM
Switch to High Gear Breakover not used
SPINDLE VERTICAL PARAMETERS

Machine Wiring Logic CNC Configuration,
Vertical Parameters
Maximum Motor Speed CNC Configuration,

Vertical Parameters
Maximum Spindle Speed CNC Configuration,

Vertical Parameters

MACHINE PARAMETERS
Machine Type not used
Machine Class CNC Configuration

Parameters, General
Verify Chip Door Upon ESTOP Integrator Configuration

Parameters, N95:238
Serial Mouse Present not used
Swing Table Present not used
Alarm Light Present not used
Control Relay Panel Board Type not used
Maximum Prog. Contouring Feedrate CNC Configuration

Parameters, General
Jog Wheel Scale Factor Integrator Configuration

Parameters, F96:34, 36
Graphics Pointer Speed Integrator Configuration

Parameters, F96:202
Servo Drive Type Int. Cfg. Parameters,

N95:211, 213

TOOL CHANGE PARAMETERS
Tool Changer Present not used
Maximum ATC Magazine Count Integrator Configuration

Parameters, N95:57
ATC Type Integrator Configuration

Parameters, N95:58
Z Tool Change Position (Height) Integrator Configuration

Parameters, F96:30
Magazine Encoder Type Integrator Configuration

Parameters, N95:201
Magazine Encoder Logic Integrator Configuration

Parameters, N95:202
Non-adjacent Tool Decel Band Integrator Configuration

Parameters, N95:204
Adjacent Tool Decel Band Integrator Configuration

Parameters, N95:205
Magazine Stop Band Integrator Configuration

Parameters, N95:206
Gray Code Count Direction Integrator Configuration

Parameters, N95:207

MATRIX 4 AXIS TUNE X Axis Y Axis Z Axis

DIAGNOSTICS
Integral Servo Tuning, X Axis Servo Tuning, Y Axis Servo Tuning, Z
Axis
Proportional Servo Tuning, X Axis Servo Tuning, Y Axis Servo Tuning, Z
Axis
Feedforward Servo Tuning, X Axis Servo Tuning, Y Axis Servo Tuning, Z
Axis
Derivative Servo Tuning, X Axis Servo Tuning, Y Axis Servo Tuning, Z
Axis
Integral Limit Servo Tuning, X Axis Servo Tuning, Y Axis Servo Tuning, Z
Axis
Output Loop Gain Servo Tuning, X Axis Servo Tuning, Y Axis Servo Tuning, Z
Axis
Integral Bandwidth Servo Tuning, X Axis Servo Tuning, Y Axis Servo Tuning, Z
Axis
DAC Balance not used not used not used
DAC Balance Limit not used not used not used
Max Rapid Accel Servo Tuning, X Axis Servo Tuning, Y Axis Servo Tuning, Z
Axis
Max Contour Accel Servo Tuning, X Axis Servo Tuning, Y Axis Servo Tuning, Z
Axis
Maximum Abort Accel Servo Tuning, X Axis Servo Tuning, Y Axis Servo Tuning, Z
Axis
Following Error Halt Servo Tuning, X Axis Servo Tuning, Y Axis Servo Tuning, Z
Axis
Tap Deceleration not used not used not used
Z/S Tap Gain not used not used not used

MATRIX 4 AXIS TUNE Spindle

DIAGNOSTICS
Integral Servo Tuning, Spindle
Proportional Servo Tuning, Spindle
Feedforward Servo Tuning, Spindle
Derivative Servo Tuning, Spindle
Integral Limit Servo Tuning, Spindle
Output Loop Gain Servo Tuning, Spindle
Integral Bandwidth Servo Tuning, Spindle
DAC Balance not used
DAC Balance Limit not used
Max Rapid Accel Servo Tuning, Spindle
Max Contour Accel not used
Maximum Abort Accel Servo Tuning, Spindle
Following Error Halt Servo Tuning, Spindle
Tap Deceleration not used
Z/S Tap Gain Servo Tuning, Spindle

MATRIX 4 AXIS TUNE A Axis B Axis

DIAGNOSTICS
Integral Servo Tuning, A Axis Servo Tuning, B Axis
Proportional Servo Tuning, A Axis Servo Tuning, B Axis
Feedforward Servo Tuning, A Axis Servo Tuning, B Axis
Derivative Servo Tuning, A Axis Servo Tuning, B Axis
Integral Limit Servo Tuning, A Axis Servo Tuning, B Axis
Output Loop Gain Servo Tuning, A Axis Servo Tuning, B Axis
Integral Bandwidth Servo Tuning, A Axis Servo Tuning, B Axis
DAC Balance not used not used
DAC Balance Limit not used not used
Max Rapid Accel Servo Tuning, A Axis Servo Tuning, B Axis
Max Contour Accel Servo Tuning, A Axis Servo Tuning, B Axis
Maximum Abort Accel Servo Tuning, A Axis Servo Tuning, B Axis
Following Error Halt Servo Tuning, A Axis Servo Tuning, B Axis
Tap Deceleration not used not used
Z/S Tap Gain not used not used

R
757-4002-125 CAD #D8515F

Procedure, Ultimax v2.xx Field Installation 757-4002-125 Rev. F Page 1

RECORD OF CHANGES
Engineering Document 757-4002-125 CAD #D8515F

By
A 13984 Original Release MAD 4/497
Added fields for logging spindle rpm. BVP 2/4/98 DJS 2/5/98
E 14376 Changed v2.00 to v2.xx in description
contents list (E7). BVP 9/1/98 TLK 9/3/98
F 14462 Removed the reference to the alternate
language diskettes (F1-pg4); Added
Ultimax Utility diskette to kit contents (F2
– pg4);Removed reference to installing
CNC language disks in procedure (F3-
pg6); Removed the reference to
installing the Machine language disks in
procedure (F4- pg6); Added the
BMC2416 to the spindle speed table (F5
– pg7) BVP 11/20/98

I. INTENT
II. SCOPE
board installed.
• Parameters
III. MATERIALS
• PC/AT keyboard
Contents:
E2


Number

MACHINE PARAMETERS - BMC 4020HT SIEMENS 757-4005-008 DP008
E3
E7
MACHINE PARAMETERS – BMC2416 YASKAWA 757-4005-014 DP0014
E7
MACHINE PARAMETERS & PROCEDURES – BMC6434 YASKAWA 757-4005-015 DP0015

Check the items you have, before beginning the procedure: F1

Prefix
√
ULTIMAX 3 VERSION 2.00/ULTIMAX CNC (EXECUTIVE) 007-4123-004 U3V2
ULTIMAX 3 V2.XX PATCH DISKETTE 007-4123-010 -
ULTIMAX3 V2.XX PATCH DOCUMENT 757-4002-030 -
F2
ULTIMAX UTILITY DISKETTE 427-0004-023 U3UT
WIRE, 24AWG, BLUE (60”) 406-2008-001 -



this procedure.
machine folder.
Max DAC Voltages:
(X)_______ (Y)_______ (Z)_______ (S)_______ (A)______ (B)_______
files.

________9. Cycle Power to reset the system. The Ultimax v2.xx base system should run.
floppy drive.
copy the files. Insert the next diskette when prompted. F3
“YES” softkey.
Upgrade Package in the floppy drive. This will install the PLC system for use on all machine types.F4
“YES” softkey.
“YES” softkey.
“YES” softkey.

RPM
spindle
E4
E4
F5
2416Y BMC2416 with Yaskawa Servo Pack drives B24S, B24M 8000
________27. The prompt “There are machine boot config files in the selected MCD. Do you want to copy
these to the configuration directory?” will appear. Select the “YES” softkey.
________c) Insert the ULTIMAX 3 VERSION 2.00 MACHINE CONFIGURATION diskette in drive
A: and select the “YES” softkey.

in step #2.
prompt by typing:
COPY LEADSCRW C:\


and press ENTER.

D 399 Unknown 100%

completed.
C:\ root directory

bootsave.bin Old bootstrap saved in this file(system/hidden file).
execprog Version 2.XX Executive (system/hidden file).
hurco.ldr Bootloader file (system/hidden file).
loadfrag.bin New bootstrap file (system/hidden file).
LADDERS sub directory

1BASE000.REX The following (3) REX files are base ladders only allowing the
screens to be
2BASE000.REX used and allow upgrades. A machine tool cannot be operated with
these
3BASE000.REX ladders.
30SSMS.REX Dummy File; used to identify machine from Software Configuration
30SSMY.REX screen; one for each model; only one file will be on Drive C.
30MS.REX
30MY.REX
30HTMS.REX
30HTMY.REX
4020SSM.REX
4020HT.REX
4050MY.REX
5050MY.REX
HAWK30.REX E5
HAWK40.REX E5
AXOUT000.REX Auxiliary Output logic, i.e., Aux M-Codes
AMPL_000.REX Amplifier Logic; used for Fault checking, A/B axis enable, axis load
calculations.
AXTUN000.REX Axis Tune Cycle Support; interface to NAV/CNC side.
B30YIN.REX Input Mask; maps real Input points to internal bit locations; machine
B30SIN.REX specific file, only one file will be on Drive C.
BMC42IN.REX
BMC45IN.REX
KM34IN.REX E5
B30YOUT.REX Output Mask; maps real Output points to internal bit locations;
B30SOUT.REX machine specific file, only one file will be on Drive C.
BMC42OUT.REX
BMC45OUT.REX
KM34OUT.REX E5
BKGND000.REX Background fault checking for Low Air Pressure, Low Way Lube, and
Overload Faults.
CAL_000.REX Axis Calibration sequence.
CE_000.REX CE Support; Cycle Keyswitch, cycle doors, etc.
COOL_000.REX Coolant control and interface; used for Flood, Mist, and Washdown.
CYCLS000.REX LC Cycle handler; detects and responds to requests for unsupported

M-Codes.
INDEX000.REX Indexer logic.
JOG_000.REX Axis Jog; used for Rapid and Incremental, Rotary Axis Clamp and
Unclamp.
LEDTS000.REX Console LED Test logic.
LUBE_000.REX Lube system logic; not active for BMC machines with external lube
systems.
MCODE000.REX M-Code handler; detects and responds to requests for unsupported
M-Codes.
MSC_000.REX Machine State Control; PLC for Keyboard decoding, Mode Control,
Interrupt Cycle, etc.
MSTST000.REX Machine Setup and Test; PLC for Axis Balance, Spindle Test Cycle,
Keyboard Test, and CRT Degauss
PARK_000.REX Machine Park sequence logic.
PDEV_000.REX Pointer Device; used for “absolute pointers”, i.e. SSM Mouse.
PROBE000.REX Probe logic; support for Tool and Part Probing, calibration, etc.
QUAD_000.REX Quad-size DRO handler.
SPIN_000.REX Spindle logic; interfaces to Navigation for Spindle speeds, overrides,
tapping, and spindle orient; used for both Yaskawa and Siemens.
TCHGR003.REX E5 Type 3 ATC support (No ATC – Hawks); ATC and ATC Diagnostics and
screens.
WRMUP000.REX Warmup cycle logic; controls sequence and error handling
IOTST000.REX IOIF & DCIO2 loop back testing
LANG sub-directory
FRENCH.HRC
FRENCH.HRL
GERMAN.HRC
GERMAN.HRL
ITALIAN.HRC
ITALIAN.HRL
VER2_00 sub-directory
SYSINT.SYS
TUNE.SYS
SERIAL.SYS
PROBE.SYS
SPINDLE.SYS
MCODE.SYS
NETWORK.SYS

VII. PARAMETERS
• Axis Parameters





Rotary Resolution


















Physical Parameters

Physical Parameters

Physical Parameters

Parameters, N95:18

Parameters, N95:19

Parameters, N95:20

Parameters, N95:226

Parameters, N95:227

Physical Parameters

Physical Parameters

Parameters, N95:3

Physical Parameters

Physical Parameters





Vertical Parameters

Vertical Parameters

Vertical Parameters

MACHINE PARAMETERS

Parameters, General

Parameters, N95:238

Parameters, General


Parameters, F96:202

N95:211, 213


Parameters, N95:57

Parameters, N95:58

Parameters, F96:30

Parameters, N95:201

Parameters, N95:202

Parameters, N95:204

Parameters, N95:205

Parameters, N95:206

Parameters, N95:207


DIAGNOSTICS
Axis
Axis
Axis
Axis
Axis
Axis
Axis
Axis
Axis
Axis
Axis


DIAGNOSTICS


DIAGNOSTICS

R
757-4002-125 Rev G CAD #D8515G

Procedure, Ultimax v2.xx Field Installation 757-4002-125 Rev. G Page 1

RECORD OF CHANGES
Engineering Document 757-4002-125 CAD #D8515G

By
contents list (E7). BVP 9/1/98 TLK 9/3/98
– pg7) BVP 11/20/98 TLK 11/24/9
8

By
G 14547 Added Yaskawa Sigma drive parameter
diskette (G1); Added parameter
documents for rotary tilt tables with
Sigma drives, VTC40 machines, BMC30
& 4020 machines with Sigma drives (G2);
was 5050MY (G3); Was Yaskawa Servo
Pack – error (G4); Added machine
selections for BMC30, 4020 & 6434
machines with Yaskawa Sigma drives
(G5); Replaced list of ladder files with a
reference to the eng doc describing the
ladders diskettes (G6); Added alternate
language files and optional note (G7);
Added CANBUS.CFG and
V800X600.VGA files (G8);Was VER2_00
(G9); Added Max4 activation disk (G10);
Added steps for installing Max4
activation disk (G11); Added BM6434
mach paramas & passive backplane CPU
set up doc (G12) BVP 2/13/99

I. INTENT
II. SCOPE
board installed.
• Parameters
III. MATERIALS
• PC/AT keyboard
Contents:
E2

G1
YASKAWA SIGMA SERVO PACK PARAMETERS DISKETTE 007-4000-002 1

Number

MACHINE PARAMETERS – BMC 4020HT SIEMENS 757-4005-008 DP008
MACHINE PARAMETERS – BMC 4050M YASKAWA 757-4005-010 DP0010
E3
G12
MACHINE PARAMETERS – BMC6434 YASKAWA SIGMA DRIVES 757-4005-013 DP0013
E7
E7
SETTINGS FOR MACHINES WITH YASKAWA SIGMA DRIVES 757-4005-015 DP0015
G2
INSTALL PROCEDURE FOR ROTARY / TILT TABLES WITH SIGMA MOTORS 757-4005-016 DP0016
G2
MACHINE PARAMETERS - VTC40 757-4005-017 DP0017
G2
MACHINE PARAMETERS - BMC 30M YASKAWA SIGMA DRIVES 757-4005-020 DP0020
G2
MACHINE PARAMETERS - BMC 4020 YASKAWA SIGMA DRIVES 757-4005-021 DP0021
G12
FIC LMB-586PF P/B CPU BOARD SET UP PROCEDURE 757-4002-169 D8578

Check the items you have, before beginning the procedure: F1

Prefix
√
ULTIMAX 3 VERSION 2.XX/ULTIMAX CNC (EXECUTIVE) 007-4123-004 U3V2
F2
ULTIMAX UTILITY DISKETTE 427-0004-023 U3UT
WIRE, 24AWG, BLUE (60”) 406-2008-001 -
G10
ULTIMAX 4 CONSOLE ACTIVATION DISK (If an Ultimax 4 console is present) 007-4000-001 -



this procedure.
machine folder.
Max DAC Voltages:
(X)_______ (Y)_______ (Z)_______ (S)_______ (A)______ (B)_______
files.

________9. If the system has an Ultimax 4 console present, then boot the control with the ULTIMAX 4
CONSOLE ACTIVATION DISK (007-4000-001) in the floppy drive. This will copy the files
necessary for the Max4 console to function correctly. If the disk is run again, the Max4 files will be
removed from the system (reference: engineering document 704-0004-037). G11
________10. Remove the ULTIMAX 4 CONSOLE ACTIVATION DISK (007-4000-001) from the floppy drive
________11. Cycle Power to reset the system. The Ultimax v2.xx base system should run.
floppy drive.
copy the files. Insert the next diskette when prompted. F3
“YES” softkey.
Upgrade Package in the floppy drive. This will install the PLC system for use on all machine types.F4
“YES” softkey.
“YES” softkey.
“YES” softkey.


RPM
spindle
G3
(pre-v1.08 ladders)
G3
5050Y BMC5050M with Yaskawa drives B5 4000
E4
E4
F5 G4
2416Y BMC2416 with Yaskawa Sigma drives B24S, B24M 8000
G5
3017Y BMC3017 with Yaskawa Sigma drives B3M, B3SM 8000
G5
3017HY BMC3017HT with Yaskawa Sigma drives B3HM 8000
G5
4020Y BMC4020 with Yaskawa Sigma drives B42M, B42S 8000
G5
6434Y BMC6434 with Yaskawa Sigma drives B64T 8000
________c) Insert the ULTIMAX 3 VERSION 2.00 MACHINE CONFIGURATION diskette in

drive A: and select the “YES” softkey.

in step #2.
prompt by typing:
COPY LEADSCRW C:\



and press ENTER.

D 399 Unknown 100%

completed.
C:\ root directory

BOOTSAVE.BIN Old bootstrap saved in this file(system/hidden file).
EXECPROG Version 2.XX Executive (system/hidden file).
HURCO.LDR Bootloader file (system/hidden file).
LOADFRAG.BIN New bootstrap file (system/hidden file).
CANBUS.CFGG8 Canbus script file (used with Max4 consoles only)
V800X600.VGA G8 Makes the executive put the video card into 800x600 mode for Max4
consoles.
LADDERSG6 sub directory – contains ladder files (*.REX). Refer to engineering
document 704-0020-038 (DS0066) for the contents of this subdirectory.
LANG sub-directory
FRENCH.HRC Alternate language files (optional)G7
FRENCH.HRL
GERMAN.HRC
GERMAN.HRL
ITALIAN.HRC
ITALIAN.HRL
VER2_XX G8 sub-directory
SYSINT.SYS
TUNE.SYS
SERIAL.SYS
PROBE.SYS
SPINDLE.SYS
MCODE.SYS
NETWORK.SYS

VII. PARAMETERS
• Axis Parameters





Rotary Resolution


















Physical Parameters

Physical Parameters

Physical Parameters

Parameters, N95:18

Parameters, N95:19

Parameters, N95:20

Parameters, N95:226

Parameters, N95:227

Physical Parameters

Physical Parameters

Parameters, N95:3

Physical Parameters

Physical Parameters





Vertical Parameters

Vertical Parameters

Vertical Parameters

MACHINE PARAMETERS

Parameters, General

Parameters, N95:238

Parameters, General


Parameters, F96:202

N95:211, 213


Parameters, N95:57

Parameters, N95:58

Parameters, F96:30

Parameters, N95:201

Parameters, N95:202

Parameters, N95:204

Parameters, N95:205

Parameters, N95:206

Parameters, N95:207


DIAGNOSTICS
Axis
Axis
Axis
Axis
Axis
Axis
Axis
Axis
Axis
Axis
Axis


DIAGNOSTICS


DIAGNOSTICS

R
757-4002-130 CAD# D8523
Pentium Field Installation

Procedure for Ultimax,
For Version 2.xx
Scott Wrobleski
Originator Mgr. Control Systems Engineering
Date Date
RECORD OF CHANGES
Engineering Document 757-4002-130 CAD # D8523
Revision ECN # Revision Description Rev By Date Appd By Date

Pentium Field Installation Procedure, Ultimax 757-4002-130 Rev. A Page 2

I. INTENT
To provide a standardized method to retrofit and install Pentium Motherboard and

Processor assembly in existing machining centers.
II. APPLICABILITY
As required on all machines equipped with 486 based motherboard and CPU.
1) 757-4002-105, Setup Procedure for Hunter Industrial Pentium Motherboard.

2) Manufacturing Notice 3997 for Canbus Controller Modification.
3) Manufactuiring Notice 4057 for M-code wiring Modification.
IV. INDEX
Page 3 Kit Definition

Page 4 Installation Instructions
Page 6 Canbus Controller Modification
V. KIT DEFINITION
Pentium compatible motherboard and Pentium processor.
Description Part Number Quantity

Hunter Motherboard & CPU 007-3003-001 1

VI. INSTALLATION PROCEDURE
1. Be sure machine is running properly before beginning.

2. Cycle the Machine Power Off.
3. Locate the Card Rack and disconnect and label all harnesses.
Note: all harnesses will be reconnected to the same boards in the Card Rack.
4. Disconnect and label all harnesses to the Power Supply.
5. Remove the Card Rack from the Cabinet by removing the four bolts at each corner of the Card Rack
base.
6. At a flat table with plenty of workspace, remove the top cover of the Card Rack by loosening the four
spring screws.
NOTE: the following steps have the Card Rack positioned so that the Power Supply is to the left, the
I/O Interface and DC I/O flyer cards to the right, and the Card Rack connectors nearest you. PC
Slots are numbered one through seven, right to left. Use static strap when motherboard and cards.
7. Disconnect and label the harnesses to the DSP Board in slot 1 (the right-most PC board) of the Card
Rack.
8. Disconnect and label the harnesses to the CANbus Controller Board in slot 3 of the Card Rack.
9. Remove the Hard Drive by loosening the spring screw on the left-side of the Card Rack; disconnect
and label the Hard Drive power harness and disconnect and label the IDE Harness. Store the Hard
Drive in a safe place.
10. Disconnect and label the J6 harness from the DSP Board to the Breakout Board.
11. Remove the Breakout Board (covers slots 2 and 3) by removing the two screws.
12. Remove the DSP Board from slot 1(remove the hold-down screw and carefully pull board from slot).
13. Remove the CANbus Controller Board from slot 3 (remove the hold-down screw and carefully pull
board from slot).
14. Remove the VGA Card from slot 7 (remove the hold-down screw and carefully pull board from slot).
15. Remove Disk Drive.
16. Remove Parallel Port Connector.
17. Remove Speaker wire, the black wire should be to the right.
18. Disconnect and label all harnesses plugged into the CPU. Note that the two, 6-terminal power
harnesses are removed by pulling the connectors straight up and then tilting them forward (almost 90
degrees).
19. Remove the CPU motherboard (remove nine screws). May need to loosen all wires routed inside the
Card Rack. Lower right corner has guide that may hold board.
20. Inspect nylon spacers on Card Rack base and resecure if necessary.
21. Verify all jumper settings on Pentium CPU motherboard per Engineering Document 757-4002-105.
22. Install 3 nylon spacers.
23. Carefully install the Pentium CPU motherboard with the slots aligned to the bottom right (ten
screws). Reroute and secure all wires removed in previous step and secure board
24. Reconnect all harnesses to the Pentium CPU, using new harnesses provided where necessary.
25. Install serial port.
26. Install parallel port.
27. Install floppy drive card.
28. Install the VGA Card in slot 7 (note that Dual VGA cards will come very close to the Pentium CPU
Fan Assembly; if there is interference from the Fan Assembly, do not install in slot 7 but use slot 4
instead).

29. Install the Breakout Board with the connector through the slot 3 opening (or slot 2 if CANbus
Controller has to be in slot 3). Install the DSP Board in slot 1.
30. Install the DSP Board in slot 1.
31. Modify CANbus controller board. See Attached.
32. Install the CANbus Controller Board in slot 4 (or slot 3 if Dual VGA has to be in slot 4).
33. Reconnect the Breakout harness to J6 of the DSP Board.
34. Reconnect the Hard Drive power harness and the Hard Drive IDE harness to the Hard Drive.
35. Install the Hard Drive on the left-side of the Card Rack.
36. Reconnect the harnesses to the CANbus Controller Board.
37. Reconnect the harnesses to the DSP Board.
38. Move the J9 Jumper on the Pentium CPU to pins 2-3.
39. Reinstall the Card Rack inside the Control Cabinet (four bolts).
40. Reconnect all harnesses to the Power Supply and the Card Rack.
41. Cycle the Machine Power On for 10 seconds (allows the Pentium CPU BIOS to reset).
44. Attach an AT Keyboard to the DIN Keyboard Port of the Card Rack.
45. Cycle the Machine Power On. Press and hold the Delete key on the AT Keyboard to access the
CMOS BIOS setup utility (may require several attempts by cycling the Machine Power Off and On).
46. Verify and set all BIOS settings per Engineering Document 757-4002-105 with the following
exception:
In Standard Setup, do not set Pri Master Type to Auto. Need to manually set the Hard Drive’s
Cylinders and Heads as taken from the label on the Hard Drive. However, for V1.6x software,
Sectors should be set to 50.
47. Save and Exit the changes.
The system will reboot and should load the Ultimax Executive.

CanBus Controller Modification
This modification is necessary for all Pentium based systems to correct an ISA bus conflict, caused by
the I/F circuit responding to non-specific addressing.
Modification: U36, pin 1 is to be cut at the PCB and pulled out perpendicular to the side of the IC.
Using ¾ “ 30 GA. Wire (insulated wierwrap wire), solder one end to the floating pin 1 on
U36, and the other end to the via as shown below. Change the revision letter from B to C.
U36 U37
Ground
Verification: Continuity between gold finger A11(AEN) and U36 pin 1, and no continuity between
U36 pin 1 and ground.

R
757-4002-134 CAD #D8528B
SUBJECT: Ultimax Version 2.XX Field Service Reference
Barry A. Van Paris 5/5/97 Michael A. Dupont 5/15/97

RECORD OF CHANGES
Engineering Document 757-4002-134 CAD #D8528B

By
A 14009 Original Release BVP 5/5/97 MAD 5/15/97
B 14185 Changed descriptions due to the BVP 2/4/98
creation of composite configuration and
parameters disks, plus the deletion of
machine specific disks.
Document, Ultimax v2.00 Field Reference 757-4002-134 Rev. B Page

2
I. INTENT
The purpose of this document is to provide information for field service technicians on features and characteristics
of Ultimax 3 version 2.XX.
II. SCOPE
This document encompasses characteristics of the Ultimax 3 version 2.XX software and does not describe the
installation of the software.
• Ultimax v2.XX Diskette List

• Ultimax v2.XX Diskette Description
• Ultimax v2.XX Feature Summary
• Ultimax v2.XX Integrator Summary
• Error Logging

3
III. Ultimax v2.XX Diskette List
The following table represents the diskettes that are contained in the V2.xx Ultimax Upgrade Package (007-
4121-041). If upgrading from a pre-v2.00 system, the contents will be as follows:
EXECUTIVE DISKETTES
DISKETTE DESCRIPTION Part Number S/N Disks

Prefix
Ultimax 3 Version 2.xx CNC (Executive) 007-4123-004 U3V2 4
Ultimax 3 CNC (Executive) Languages 007-4123-005 ELAN 2
Ultimax 3 Machine Languages 007-0001-003 MLAN 1
Ultimax 3 Machine Configuration FIELD 427-0004-025 FLDR 1
COMPOSITE
Ultimax v2.xx Patch Disk 007-4123-010 - 1
Ultimax Utility Disk 427-0004-023 U3UT 1
OPTIKEY DISKETTES
DISKETTE DESCRIPTION Part Number Disks

Optikey Utility Diskette, Security Modifier 007-4136-005 1
SKCOX200
Optikey Utility Diskette, Software Option 007-4124-020 1
UltiPro

4
IV. Ultimax v2.XX Diskette Description
Executive Disk Set (007-4123-004 Ultimax 3 Version 2.XX, Ultimax CNC (Executive))
Diskettes containing the boot strap loader, CNC executive software and logo file for the start-
up graphics screen.
In the event of an executive software release for rapid response or major feature addition,
these disks will be shipped as part of the upgrade package.
Copies of these disks should be shipped with each control and accompany the completed
machine.
A parameter backup diskette is also included.
CNC Language Disk Set (007-4123-005 Ultimax 3, CNC (Executive) Languages)

Diskettes containing the text support for the CNC executive. These files are completely
independent from machine model or type.
These disks will be updated WITH the CNC Executive disks or when additional non-English
languages become translated and available for deployment.
Copies of these disks should be shipped with each control and accompany the completed
machine.
Machine Configuration PLC System (427-0004-025 Ultimax 3, Machine Configuration,

FIELD COMPOSITE)
Diskettes containing all PLC programs necessary to run a particular machine tool model.
Each machine model has its own set of ladders. Each ladder is under Engineering Document
control and carries a revision code in it. This disk will only change if bugs are found in the
logic for the machine control or a new ladder-driven feature is added to the machine.
This disk contains the ladders for all ISA based machine types.
There is a disk for machine production that contains ladders for current production machines
only and the field disk (427-0004-025) which contains ladders for all ISA based machines.
Machine Configuration Languages (007-0001-003 PKG, Ultimax 3, Machine Languages)

Diskettes containing error messages, text and screens that directly support the ladder logic.
These disks contain the current text reflecting the contents of the PLC programs. These disks
are typically paired-up with the current revision of ladder disks sets. They are maintained
separately from the PLC disks so that as new translations become available, they may be
distributed independent from the PLC disks.

5
Copies of these disks should accompany the machine as it leaves the contract manufacturer’s
facility.
Machine Configuration Parameters (Reference P/N 757-4005-001 to 757-4005-008, 757-

4005-010, 757-4005-011 Machine Configuration Parameters)
There are 2 diskettes containing default parameters for particular machine tool models. There
is a production parameters disk containing parameters for current production machines for use
at the contract manufacturers and a field parameters disk that contain the parameters for
noncurrent machine models. Both of these disks will be required by the service technician.
These disks are provided by Engineering to significantly reduce data entry errors – technicians
at the Contract Manufacturer’s site building the machines no longer have to type-in each
parameter as it appears on a document. Each machine model has its own parameters and
may differ depending upon particular implementation details for the model. Documentation in
the Engineering Department describes the parameter set for each machine model. The disks
reflect the contents of those documents.
These disks are provided to the contract manufacturers to simplify their work. These disks
should NOT accompany the completed machine.
ULTIMAX UltiPRO Option (007-4136-020 OPTIKEY UTILITY DISKETTE, SOFTWARE

OPTION,UltiPro)
Provides customers who machine parts using Hurco Basic NC or Industry Standard (Fanuc)
NC with a high performance navigation system that examines the angles between successive
line segments (G01 blocks) and automatically compensates the speed of the segments for
machine acceleration limits to allow for precise machining and cornering.
Highlights of the package follow:
High speed block processing rate of 1-millisecond which accommodates dense point data files.
A 400 block look ahead algorithm which provides sophisticated further acceleration control and
assures smooth, fast machining of complex NC parts and keeps velocity transitions within
acceleration limits of the machine.

6
V. Ultimax v2.XX Feature Summary
1. ULTI-PRO 1, features 400 block look-ahead and 1msec Block Transfer Rate (1000
Blocks/sec) to prevent gouging, counter-weight banging, etc.
2. Rapid Traverse Override - uses the Axis Override pot
3. New 3D-style Softkey Menus with Active and Inactive status
4. Full Color settings (and SET DEFAULT COLORS softkey)
5. Keyboardless Text Entry via pop-up window
6. Help active - context sensitive based on cursor position
7. Pop-up boxes for operator functions (bottom prompts are general information)
8. 24th Status Line for HD and FD activity, Units, Free Memory, and Time of Day
9. Units - can independently set Program Units, DRO Units, or Configuration Units
10. Storage Functions - added BEGIN OPERATION and DELETE ALL TAGGED FILES,
rearranged menus; select directories with Enter key
11. Manual Mode - added Calibration Status instead of UNCAL in Part display; added
Washdown control; can deselect an axis jog
12. Auto Mode - added Program Run-time clock and quad-size DRO
13. Review Mode - added segment numbers to Contour blocks and Hole operations; added
ability to access Tool Setup
14. Chord Error - expanded resolution to 0.000001in or 0.00001mm
15. Input Mode - display Available Program Memory
16. M-Code Data Block in Conversational - four M-code Inputs and four M-code Outputs
17. Program Compatibility with V1.xx Ultimax 3
18. Low lube level & loss of air pressure warnings have been modified. If the machine is
running in Auto mode and a low lube level or loss of air pressure is detected, the
control will go into Interrupt Cycle mode. The machine tool will no longer terminate the
program and disable COR. This feature will allow the program to be easily resumed
after the warning condition has been corrected.

7
VI. Ultimax v2.XX Integrator Summary
1. M-Code Data Block in Conversational - 0-255 M-codes can be created by Integrator,

includes Definition and Time to Complete (for Estimated Run-time calculations)
2. Automatic Data Log - for Navigation errors only
3. Customizable Graphics screen logo
4. Diagnostics - 100 screen access from Auxiliary to all Integrator/Service functions
a) CNC CONFIG PARAMETERS - machine setup parameters

i) XAXIS, Y AXIS, Z AXIS, SPINDLE
a) PHYSICAL PARAMETERS
b) VERTICAL PARAMETERS
ii) GENERAL PARAMETERS
a) M CODE TABLE
b) INTEGRATOR CONFIG PARAMETERS

i) DOUBLE (F96) PARAMETERS - Floating Point parameters (for system
values)
ii) INTEGER (N95) PARAMETERS - Integer parameters (for logic states)
c) MACHINE SETUP AND TEST - Axis and Spindle Setups

i) SPINDLE ORIENT DIAGNOSTICS
ii) SPINDLE TEST CYCLE
iii) AXIS BALANCE ADJUSTMENT
iv) T/C DIAGNOSTICS
d) LEADSCREW MAPPING - Linear and Rotary Axis Mapping; data entry

requires actual position
i) X AXIS, Y AXIS, Z AXIS, A AXIS
ii) LOAD DATA FROM DISK
iii) STORE DATA ON DISK
e) CONTROL DIAGNOSTICS
i) INPUT/OUTPUT TESTS
ii) PORT TESTS
iii) CONSOLE TESTS
iv) CONTINUOUS DISK TEST
f) SERVO TUNING - no overshoot count, within tolerance, or at position; no

min/max rigid tap setup
i) X AXIS, Y AXIS, Z AXIS, SPINDLE, A AXIS

8
g) MISCELLANEOUS SERVICES - Logic Controller Debugger Port, Screen
Capture capability, D Drive display, Axis FIFO Data Logging, reload Ladder
Files
i) SELECT MACHINE CONFIGURATION DIRECTORY
ii) RELOAD LADDER FILES
5. CNC Configuration - Version, Options, Ladder information (displays name of file,

revision, description, and date)

9
VII. Error Logging
Error logging has been added to the v2.XX system. Specific data that engineering can use to
help determine the cause of certain bugs is stored in files on drive D:. These files can be
copied to a floppy after the problem has occurred. It is recommended that these files are
copied immediately after the bug has occurred to ensure that the data for that bug is in the
files.
The files are as follows:
NAVERR01.DAT
NAVERR02.DAT
NAVERR03.DAT
NAVERR04.DAT
NAVERR05.DAT

10
R 757-4002-166 Revision D CAD #D8577
SUBJECT: HARD DRIVE PARAMETERS FOR CMOS SETUP
_ Wesley Shelton _ 10-20- _ Fred Gross _ 10/2/9

98 8
RECORD OF CHANGES
By By
A 14372 Original Release FWG 10-2-98
III. A. Added LMB680 Doc.
V.A. Changed Ultipath to Ultipath/Newall
B 14732 Clamped to 400 MB. WRS 5-13-99 FWG 8-10-99
V.B. Added LMB-680 CHS Limitations
V.C. Added Quantum Fireball EL & EX
C 14825 Changed from 2.11 (C1) pg 4. BVP 11-8-99 FWG 11-10-99
D 14891 V.C. Added Quantum CX, KA, LCT(LA, LB) PES 2-1-2000
757-4002-166 Page 2 of 5 CAD#D8577

I. INTENT
To provide a standard document that shows the proper Hard Drive Parameters for CMOS Setup in all
combinations of hard drives, motherboards, and software
II. SCOPE
This document is applicable to all combinations of hard drives, motherboards, and software supported as of
5/29/98.
III. SUPPORTING DOCUMENTS
A. The following chart shows the part number and CAD number for the CMOS setup document for each of the
mother bds. used in controls.
MOTHER BOARD DOC. PART # CAD #

Multibus “386” 757-4002-057 D8430
Multibus “486” 757-4002-137 D8532
486iVL (Whitesburg) 757-4002-066 D8442
486BL (Blue Lightening) 757-4002-054 D8299
APC “486” (Predator 747) 757-4002-117 D8507
APC Pentium (Hunter) 757-4002-105 D8490
FIC LMB-586PF 757-4002-169 D8578
FIC LMB-680 757-4002-232 D8644
IV. PROCEDURE
A. Determination Of Proper CHS (Cylinders, Heads, Sectors) Values.
1. Document the maximum capacity for the software to be installed. (From Chart A)
2. Document the maximum capacity for the mother bd. being used. (From Chart B)
3. Document the maximum capacity for the hard drive to be used. (From Chart C)
4. Document the CHS values that correspond to the lowest Maximum Capacity value selected in
Steps 1-3 above.
B. Notes
1. If the maximum capacity value selected in Step A-4 is larger than 500 MB the LBA mode must be
used.
2. All Ultimax software requires that PIO mode be set to 0 and Block mode be turned OFF.
C. Enter CHS Values Into BIOS
1. Use the chart in Step III (Supporting Documents) above to determine the procedure needed to enter
the CHS values determined in Step A-4 into the BIOS.
757-4002-166 Page 3 of 5 CAD#D8577

D. See the following documents for proper partitioning, formatting, and loading of the hard drive.
1. Field Service – 757-4002-125 “Ultimax V2.XX Software Field Installation Procedure” (CAD#
D8515).
2. Production – 757-4002-124 “Eng. Doc. Ultimax V2.00 Software Production Installation Procedure”
(CAD# D8514).
V. CHARTS
A. Software Limitations For Hard Drive Parameters
VERSION CYL HDS SECS MAX CAPACITY

MAX 3 ISA & MB VER. 1.22 – 1.30 1024 16 18 144MB
MAX 3 ISA & MB VER 1.40 1024 16 22 176MB
MAX3 ISA & MB VER 1.50 – 1.64 1024 16 50 400MB
MAX3 ISA VER 1.71 & 2.00 – present C1 3303 16 63 1626MB
MAX 32 VER 1.00 – 1.64 1024 16 50 400 MB
Ultipath / Newall 1024 16 63 504 MB
B. Bios Limitations For Hard Drive Parameters
MOTHER BOARD CYL HDS SECS MAX CAPACITY

Multibus “386” 1024 16 50 400MB
Multibus “486 1024 16 50 400MB
486iVL (Whitesburg) 1024 16 50 400MB
486BL (Blue Lightning) 1024 16 50 400MB
APC 486 (Predator 747)* None None None None
APC Pentium (Hunter)* None None None None
FIC (LMB-586PF)* None None None None
FIC (LMB-680)* None None None None
*Note: Mother bds. with no CHS limitations require LBA mode if the hard drive is
to be set up for over 500MB.
C. Hard Drive Parameters
MAX
HD MFG. MODEL CYL HDS SECS WPC LZ
CAPACITY
Conner CFS210A 685 16 38 0 685 213 MB
Conner CFS425A 839 16 62 0 1024 426 MB
Quantum ELS42AT 968 5 17 0 968 43 MB
Quantum ELS85AT 977 10 17 0 97 85 MB
Quantum ELS127AT 919 16 17 0 919 127 MB
Quantum ELS170AT 1011 15 22 0 1011 170 MB
Quantum MV270AT 944 14 40 821 821 270 MB
Quantum Fireball EL 5300 15 63 0 5300 2.5 GB
Quantum Fireball EX 6256 15 63 0 6256 3.2 GB
Quantum Fireball EX 10602 15 63 0 10602 5.1 GB
Quantum QM306400CX-A 14158 9 63 0 14159 6.4 GB
Quantum QM309100KA-A 16383 16 63 0 16384 9.1 GB
Quantum QML04300LA-A 8912 15 63 0 8913 4.3 GB
Quantum QML05100LB-A 10585 15 63 0 10586 5.1 GB
757-4002-166 Page 4 of 5 CAD#D8577

WPC LZ MAX
HD MFG. MODEL CYL HDS SECS
CAPACITY
Seagate
Seagate ST3243A
ST351A\X 1024
820 12
6 34
17 1002
26 1002
561 214 MB
42 MB
Seagate ST3145A 1001 15 17 821 821 130 MB
Seagate ST3243A 1024 12 34 1002 1002 214 MB
Seagate ST3290A 1001 15 34 1024 1024 260 MB
Seagate ST3630A 1223 16 63 1002 1002 631 MB
Seagate ST31720A 3303 16 63 3304 3304 1.7 GB
Seagate ST32122A 4096 16 63 4097 4097 2.1 GB
Sandisk 3D35B-40 612 4 32 65535 611 40 MB
757-4002-166 Page 5 of 5 CAD#D8577

LEADSCREW COMPENSATION PROCEDURE
VERSION 2.XX SOFTWARE
VERSION 2.XX MAPPING IS ENTERED INTO PLUS AND MINUS FIELDS, VERSUS THE
FORWARD AND REVERSE FIELDS WHICH WERE USED IN ALL PRIOR SOFTWARE
VERSIONS.
LEADSCREW MAPPING CAN BE ACCESSED BY SELECTING THE AUXILLIARY KEY, ENTER,

100, ENTER. THIS WILL ACCESS THE INTEGRATOR/SERVICE FUNCTIONS. BY SELECTING
THE LEADSCREW MAPPING SOFTKEY AND THEN THE MANUAL DATA ENTRY SOFTKEY,
COMPENSATION CAN BE ENTERED INTO THE SELECTED AXIS FOR LEADSCREW ERROR
AND REVERSAL(BACKLASH) CORRECTION. EACH ENTRY MUST BE ENTERED IN AS AN
ACTUAL MEASURED VALUE.
AXES MAPPING DIRECTIONS
X AND Y AXES: PLUS MAP STARTS AT THE CALIBRATION ZERO

POINT TO THE MAXIMUM END OF TRAVEL.
MINUS MAP STARTS AT THE MAXIMUM END OF

TRAVEL, BACK TO THE ZERO POINT.
Z AXIS: MINUS MAP STARTS AT THE ZERO CALIBRATION

POINT TO THE MAXIMUM MINUS END OF TRAVEL.
PLUS MAP STARTS AT THE MAXIMUM NEGATIVE END

OF TRAVEL TO THE ZERO START POINT.
THE “ENTER OFFSET” FUNCTIONS IN THE PLUS DIRECTION OF X AND Y AXES, AND THE
MINUS DIRECTION OF THE Z AXIS ARE NOT TO BE
USED FOR BACKLASH COMPENSATION. THIS FIELD IN THESE AXES DIRECTIONS IS
RESERVED TO ALTER THE LEADSCREW ERROR COMPENSATION BY A COMMON
AMOUNT IN EACH INCREMENT IN
THE MAPPING. **LEADSCREW COMPENSATION** IS ENTERED IN AS
ACCUMULATIVE ERROR. “ENTER OFFSET” IN THESE FIELDS ONLY
IF THE ENTIRE PATTERN NEEDS TO SHIFT BY ONE COMMON AMOUNT.
**THE MAX KEYPAD CAN BE USED AS A CACULATOR TO ENTER THE LEADSCREW AND
BACKLASH COMPENSATION. ADD OR SUBTRACT THE ERROR AMOUNT FROM EACH
MAPPING LOCATION VALUE, AND ONCE ENTER IS SELECTED THE COMPENSATION WILL
BE DISPLAYED CORRECTLY FOR VERSION 2.XXX.
9/5/97
T.CLOUD
R
757-4002-191 CAD # D8602
SUBJECT: PS/2 AND 24V POWER SUPPLY SETUP PROCEDURE
Wes Shelton 11/11/98 Fred Gross 12/28/98

RECORD OF CHANGES
Engineering Document
757-4002-191 CAD # D8602
Rev. ECN # Revision Description Rev By Date Appd By Date

A 14399 Original Release WRS 11/11/98
B 14884 Revised III.B.4.b Vmax From 12.20 PES 2/15/2000
757-4002-191 CAD# D8602

Page 2 of 4
I. INTENT
To provide a standardized procedure for the adjustment of the PS/2 (Martek Power Switch) and 24V (Cosel)
power supplies used with ISA Control.
II. SCOPE
Specific to PS/2 power supply (413-0008-024), the 24V power supply, (413-0008-025), the PS/2 power supply
assembly (007-3027-001), and the PS/2 power supply retrofit assembly (007-3027-002T).
III. PROCEDURE
A. Unloaded Power Supply Check
1. Connect the power supply to a switched AC source. (A switched AC source is required since the
assembly does not have an integrated switch of its own).
2. Switch on the AC power.
3. Ensure the unloaded DC voltages meet the following specs:

Power Supply Output Vmin Vmax
413-0008-024 +5V 4.5 5.5
+12V 10.8 13.2
-12V -13.2 -10.8
413-0008-025 +24V 21.6 26.4
4. Switch off the AC power.
B. Loaded Power Supply Assembly Check
1. Lay the power supply or power supply assembly next to a fully loaded card cage (With the PS/2
adjustment pot access hole facing up) and connect the DC power connectors to the DC
distribution board.
2. Connect CIN board and floppy drive to the card cage.
3. Connect a 3-ohm 50W load resistor to 12V supply at the CIN.
4. PS/2 Power Supply
a. Switch on AC power.
b. With non-conductive tool, adjust power supply voltages to meet the following specs
(See Fig. 1 for pot locations and voltage test points):
+5V 5.07 5.10 5.13
+12V 12.00 12.10 12.50
-12V -13.2 -12.00 -11.4
5. 24 Volt Power supply
a. With non-conductive tool, adjust power supply voltages to meet the following specs:
757-4002-191 CAD# D8602

Page 3 of 4
+24V 22.8 24.0 26.4
Figure 1
DC Distribution Bd.
415-0611-901
757-4002-191 CAD# D8602

Page 4 of 4
757-4002-196
R
757-4002-196 CAD # D8607
SUBJECT:
PS/2 Power Supply Assembly Build Procedure
_Phil Stewart______________________ 12/15/98 ___Fred Gross___________________ 12/28/98

Page 1 of 4
757-4002-196 CAD #
D8607
757-
4002-196
RECORD OF CHANGES
Engineering Document CAD Number

757-4002-196 D8607
Revisions:
Revision ECN # Revision Description Page # Date Approved Date

By
B 14564 Changed quantity of Item #16 from 3 in 3 4/13/99
III.A.4, added “Crimp terminal…”
sentence to the end of III.A.5.
Modifications reflect changes to print
007-3027-001, -002 (CN 8859).
Page 2 of 4
757-4002-196 CAD #
D8607
757-
4002-196
I. INTENT:
To provide a standardized procedure for the assembly of the 007-3027-001 PS/2
Power Supply Assembly.
II. SCOPE:
Applies to MAX 4 / Passive Backplane Contol Package (007-3002-0XX, CN
8779). Also applies to ULTIMAX 3 and other ISA Control Packages on a retrofit
basis. Refer to drawing of 007-3027-00X (CN 8859) in conjunction with this
assembly procedure. Also refer to 757-4002-191 (CN D8602) PS/2 and 24V
Power Supply Setup Procedure.
III. PROCEDURE:
A. Power Supply Assembly:
1. Obtain power supply cover (ITEM # 7) from the 007-3027-001 (or –002)
(CN 8859) kit.
2. Attach the 24V power supply (ITEM # 9) to the cover using the 5 M3
screws (ITEM # 3), then tighten.
3. Attach the PS/2 power supply (ITEM # 8) to the cover end using 4 6-32
screws (ITEM # 2).
4. Locate the PS/2 Power Supply Harness (ITEM # 10), 1 M4 x 6 screw

(ITEM # 4), 1 M4 x 8 screw (ITEM # 5), and 1 M4 lockwasher (ITEM # 16).
Use the M4 x 8mm screw and 1 M4 lockwasher to secure the two ground
ring terminals (one from the PS/2 Power Supply, one from the PS/2 Power
Supply Harness) to the upper power supply mounting tab. Install one
screw, then the two ring terminals, and one M4 lockwasher on the M4 x
8mm screw before installing on the power supply tab. Use the M4 x 6mm
screw to secure the lower power supply mounting tab. Tighten all screws.
5. Connect the four wires from the PS/2 Power Supply to the PS/2 Power
Supply Harness. Connect the two terminals from the PS/2 Power Supply
Harness with the white wire to the terminals from the PS/2 Power Supply
with the blue and the white wires. Connect the two terminals from the
PS/2 Power Supply Harness with the black wire to the terminals from the
PS/2 Power Supply with the black and the brown wires. Crimp terminals
on the four wires from the PS/2 power supply to grip the mating lugs as
needed. Connectors must not pull apart easily.
Page 3 of 4
757-4002-196 CAD #
D8607
757-
4002-196
6. Plug the 4 position connector on the PS/2 Power Supply Harness (ITEM #
10) from the previous step into the AC input CN1 mating connector on the
24V Power Supply. Note the rib on the side of the harness connector
must engage the keeper on the mating connector of the 24V Power
Supply.
7. Locate the 423-4400-020 (ITEM # 11) + 24V to DC Power Monitor /
Distibution Harness. Plug the 6 position harness connector into the
mating CN2 connector on the 24V Power Supply. Note the rib on the side
of the harness connector must engage the keeper on the mating
connector on the 24V Power Supply.
Page 4 of 4
757-4002-196 CAD #
D8607
757-4002-197
R
757-4002-197 CAD # D8608
SUBJECT:
ISA/PCI Passive Backplane Card Cage Build Procedure
__Phil Stewart__________________ 12/28/98 __Fred Gross_________________ 12/28/98

Page 1 of 11
757-4002-197 CAD #
D8608
757-
4002-197
RECORD OF CHANGES

757-4002-197 D8608
Revisions:
Revision ECN # Revision Description Page Date Approved Date

# By
B 14646 Updated many details throughout the 2-11 5/5/99
document found to be incomplete or in
need of correction since initial release.
Rearranged items in III.C.7 through
III.C.50 to reflect changes in assembly
sequence since original release on
ECN 14399.
Page 2 of 11
757-4002-197 CAD #
D8608
757-
4002-197
I. INTENT:
To provide a standardized procedure for the assembly of the 007-3002-011,
007-3002-015, 007-3002-012, and 007-3002-016 (CN 8779) ISA/PCI Passive
Backplane Card Cage Assemblies.
II. SCOPE:
Applies to ISA/PCI Passive Backplane Card Cage Assembly 007-3002-0** (CN
8779). Also refer to 757-4002-191 (CN D8602) PS/2 and 24V Power Supply
Setup Procedure, and 757-4002-196 (CN # D8607) PS/2 Power Supply Assy
Procedure.
Build procedures for Machining Center and Bed Mill card cage assemblies are
identical, except that one or more of the following differences will apply (REF:
CN 8779):
1. Single Screen Card Cages (-011, -015) use a single VGA card instead of
a dual VGA card.
2. DC I/O PCB (415-0601-002) is not included on –015 and –016 card
cages.
3. FDD Transceiver PCB (415-0606-902) is now included on -015 card
cages. Previously, the SSM C/C FDD Signal Harness (002-4403-012, CN
3111) was used when the FDD Transceiver PCB was not used (Ref.:ECN
14549).
Additional documents applicable to this assembly:

753-2000-002 (CN D8030), Sensitive Component Handling Procedure, ESD.
III. PROCEDURE:
NOTE: Proper ESD precautions shall be observed throughout all of this assembly
procedure as set forth by the ESD document listed above. Failure to do so will cause
irreparable damage to electronic components.
A. Recording and marking Printed Circuit Board Serial Numbers:

1. Recording and marking the serial numbers for each of the printed
circuit boards to be installed in the ISA/PCI Passive Backplane Card
Cage should be performed before actual assembly of the control
begins. Completing this recording and marking procedure first will
save time and also help prevent forgetting to record or mark the serial
number on a circuit board. Record all PCB serial numbers on the
Commissioning Report, even if the part number or description is not
listed in the following steps. Follow the instructions below.
Page 3 of 11
757-4002-197 CAD #
D8608
757-
4002-197
2. Record serial numbers for the following circuit boards on the
Commissioning Report Form (not all boards will be included in all
assemblies):
* Passive Backplane C.P.U. 415-0166-913

* Passive Backplane 415-0166-911
* PCI VGA Video, S3 1M 415-0220-006
* Dual PCI VGA PCB 415-0220-007
* Motion Control PCB 415-0247-007
* DC I/O PCB 415-0601-002
* DC I/O Backplane 415-0602-
902
* DC I/O Can Bus Cont. PCB 415-0605-002
* ISA FDD Transceiver PCB 415-0606-902
* I/O I/F PCB 415-0607-002
3. Write the serial number on the following circuit boards in the space
provided:
* DC I/O PCB 415-0601-002

* DC I/O Backplane 415-0602-
902
* I/O I/F PCB 415-0607-002
4. Write the serial number on the top or front plate of the following circuit
boards:
* DC I/O PCB 415-0601-002

* I/O I/F PCB 415-0607-002
5. Write the serial number on a small decal or label and place near the
top (on the solder side) on the following circuit boards:
* Dual VGA Graphics PCB 415-0220-007

* PCI VGA Video, S3 1M 415-0220-006
B. Assemble PS/2 Power Supply:
1. Refer to drawing 007-3027-00* (CN # 8859), and 757-4002-196 (CN #

D8607) for additional power supply assembly information. The Item#’s
Page 4 of 11
757-4002-197 CAD #
D8608
757-
4002-197
listed in this section are found on the 007-3027-00* print.
2. Obtain power supply cover (ITEM # 7) from the kit.
3. Attach the 24V power supply (ITEM # 9) to the cover using the 5 M3
screws (ITEM # 3), then tighten.
4. Attach the PS/2 power supply (ITEM # 8) to the cover end using 4 6-
32 screws (ITEM # 2).
5. Locate the PS/2 Power Supply Harness (ITEM # 10), 1 M4 x 6 screw

(ITEM # 4), 1 M4 x 8 screw (ITEM # 5), and 1 M4 lockwasher (ITEM #
16). Use the M4 x 8mm screw and 1 M4 lockwasher to secure the two
ground ring terminals (one from the PS/2 Power Supply, one from the
PS/2 Power Supply Harness) to the upper power supply mounting tab.
Install one M4 screw, then the two ring terminals, and one M4
lockwasher on the M4 x 8mm screw before installing on the power
supply tab. Use the M4 x 6mm screw to secure the lower power supply
mounting tab. Tighten all screws.
6. Connect the four “AC” wires from the PS/2 Power Supply to the PS/2
Power Supply Harness, refer to “Detail A” on print 007-3027-00* (CN
8859). Connect the two terminals from the PS/2 Power Supply
Harness with the white wire to the terminals from the PS/2 Power
Supply with the blue and the white wires. Connect the two terminals
from the PS/2 Power Supply Harness with the black wire to the
terminals from the PS/2 Power Supply with the black and the brown
wires. Crimp terminals on the four wires from the PS/2 power supply to
grip mating lugs as needed. Connectors must not pull apart easily.
7. Plug the 4 position connector on the PS/2 Power Supply Harness

(ITEM # 10) from the previous step into the AC input CN1 mating
connector on the 24V Power Supply. Note the rib on the side of the
harness connector must engage the keeper on the mating connector
of the 24V Power Supply.
8. Locate the 423-4400-020 (ITEM # 11) + 24V to DC Power Monitor /

Distibution Harness. Plug the 6 position harness connector into the
mating CN2 connector on the 24V Power Supply. Note the rib on the
side of the harness connector must engage the keeper on the mating
connector on the 24V Power Supply.
C. Card Cage Assembly:
Page 5 of 11
757-4002-197 CAD #
D8608
757-
4002-197
1. Remove plastic wrap and card cage cover.
2. Place large decal (ISA Card Cage Label) on inside of cover with the
bottom of the decal towards the center of the cover (closest to the
styrofoam pad).
3. Remove back panel of the card cage extension by removing four

screws. Save these screws for reinstallation of the Back Panel.
4. The card cage will require screwing 10 nylon standoffs into the bottom
of the card cage. Nine of the standoffs match the holes in the passive
backplane. The remaining standoff is installed in the hole under the
position where the LED’s are mounted on the passive backplane.
(Note: some of the first production card cages will need a 110-0129-
013 plastic keyslot standoff w/locking bayonet nose retaining pin
inserted into the corner hole near the ISA/EISA connecter on the
passive backplane. This will require placing the passive backplane
into the card rack so that the retaining pin fits into the key slot in the
bottom corner of the card cage. This configuration will only require
nine standoffs).
5. Adjust the passive backplane’s position so that the holes in the pas-
sive backplane are aligned with the nylon standoffs installed in step 4.
6. Secure the passive backplane to the card rack using 9 6-32 screws
(item 23). Do not tighten screws all the way until all screws have been
started in their holes. This will make it easier to properly align the
passive backplane.
7. Test the DC Power Monitor/Distribution PCB (415-0611-002) by

connecting all of the DC Distribution board’s harnesses to the tester.
Turn the power on and verify that all green LEDs illuminate. If any LED
is not illuminated, either the wire’s connection is not made, or the wire
is inserted in the wrong place. Turn the potentiometer counter-
clockwise until the red LED illuminates. The pointer on the knob
should be aligned with the mark on the test fixture. Disconnect the DC
Distribution board from the tester when finished.
8. Carefully bend the wiring harnesses toward the center of the DC

Distribution board and position the board so that connectors J1-J4
pass through the cutout in the side of the card cage.
9. Secure the DC Distribution board to the card cage with six screws.
The long screw and one lockwasher (Items 45 and 46) should be used
for the hole in the upper right corner of the DC Distribution board.
Page 6 of 11
757-4002-197 CAD #
D8608
757-
4002-197
This hole is marked with a ground symbol on the card cage exterior.
Use 5 screws (Item 38) for the remaining mounting holes and tighten.
10. Place a washer, a nut, and a wingnut on the end of the long screw
which extends through the wall of the card cage.
11. Run the harness from the DC Distribution board for the Floppy Drive
Transceiver Board and the power to the passive backplane (P/B)
along the bottom of the card cage over to the passive backplane
power connector below the hard disk drive mounting position.
12. Stick an adhesive backed tie mount to the side of the card cage
behind the hard drive mounting area adjacent to the P/B power
connector. Insert a tie wrap horizontally through the slot with the
square end of the tie wrap away from the DC Distribution board.
Connect the power harness connectors to the passive back-plane and
then tie wrap the harness to the adhesive backed tie mount.
13. Connect the power harnesses from the DC Distribution board to the
cooling fans, and also dress the two wire speaker harness to the
service loop bundle and secure with a tie wrap.
14. Install the D-body parallel port connector into the open position in the
Floppy Drive Transceiver Board bracket. After removing the two
screws, place the D-body parallel port connector into the opening in
the Floppy Drive Transceiver Board bracket. Parallel port connector
orientation must match the Floppy Drive Transceiver connector
orientation. Secure the connector with the two screws and two
washers.
15. Connect the FDD power harness (from the DC Distribution board) to
the six pin connector on the bottom (as installed) of the Floppy Drive
Transceiver board.
16. Insert the Floppy Drive Transceiver Board (415-0606-902)/ parallel

port connector/ bracket combination into the first two open card cage
slots adjacent to the PS/2 power supply. Secure the bracket with a
screw.
17. Mount the hard disk drive to the hard drive bracket using four screws.
18. Connect the ISA Hard Drive Harness to the hard disk drive. Pin 1 of
the cable (red stripe) must align with pin 1 of the hard disk drive
connector. Use the cable included with the CPU board. It may be
Page 7 of 11
757-4002-197 CAD #
D8608
757-
4002-197
necessary to trim one end of the cable off (if the cable has three
connectors). Trim the connector and cable off the end of the cable with
two connectors in closest proximity. The finished cable will be about
10 inches long with two connectors.
19. Connect the HDD power connector on the harness from the DC
Distribution board to the hard disk drive.
20. Place the hard disk drive/bracket assembly onto the two studs on the
interior card cage wall and tighten the screw at the top of the bracket.
21. Connect the ISA Floppy Harness to J1 on the Floppy Transceiver

board. Pin 1 of the cable (red stripe) must align with pin 1 of the pcb
connector. Use the cable included with the CPU board. It may be
necessary to trim one end of the cable off if the cable has three or five
connectors. Trim off only the cable end with the “twisted” conductors.
The finished cable will be about 9 inches long with two connectors.
22. Insert the Single or Dual VGA Graphics PCI PCB (415-0220-00*) into
slot 9 (PCI slot 2, next to the Floppy Drive Transceiver Board) on the
passive backplane. Secure the VGA board’s bracket with a screw.
23. Run the power harness from the DC Distribution board along the sides
of the card rack to the card cage extension where the DC I/O
Backplane will be mounted (harness can be inserted into the slot
between the passive backplane and the card cage).
24. Be sure the pins on the microprocessor are straight, and after aligning
pin one of the microprocessor with pin one of the CPU socket, insert
the microprocessor into the socket on the CPU board. Lock the
microprocessor holder/socket and verify that the microprocessor is
secure. Install the heatsink/fan assembly. Be sure that the heatsink is
aligned with the top of the CPU before securing the hold down clips.
The heatsink is offset from the center of the hold down clip mounting
hardware. This offset must match the offset of the microprocessor chip
in the socket for proper contact of the heatsink to the top of the
microprocessor (to prevent overheating). After checking alignment of
the heatsink/fan on the CPU, remove and apply thermoconductive
compound grease to the bottom surface of the heatsink. Install the
heatsink/fan assembly on the CPU and secure with the mounting clip
hardware.
25. Insert the two SIMM memory modules into the first and second SIMM
slots on the CPU board (these slots are nearest the center of the CPU
board).
Page 8 of 11
757-4002-197 CAD #
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757-
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26. Set up the CPU board as specified by document 757-4002-232 (CN

D8644).
27. Install the CPU board assembly into the first available dual ISA/PCI
slot (slot seven) directly adjacent to the PCI connectors on the passive
backplane.
28. Connect the harness end of the ISA Parallel Port Harness to the CPU
board “Printer” header. Orient pin one of the harness connector with
pin one of the CPU board header.
29. Connect the ISA Hard Drive Harness from the hard disk drive to
header “IDE1” on the CPU board. Orient pin one of the harness
connector with pin one of the CPU board header.
30. Connect the ISA Floppy Harness to header “FDD” on the CPU board.
Orient pin one of the harness connector with pin one of the CPU board
header.
31. Connect the power harness of step 23 to connector J4 on the DC I/O

Backplane.
32. Connect the ISA CANbus Internal DC I/O Harness (423-4400-008) to

connector J6 of the DC I/O Backplane board.
33. Mount the DC I/O Backplane board (415-0602-902) to the card cage
extension base using nine screws.
34. Insert the ISA CANbus Controller PCB (415-0605-002) into slot 5 on
the passive backplane. Secure the CANbus Controller board’s bracket
with a screw.
35. Insert the I/O Interface board into the slot in the DC I/O Backplane
nearest to the passive backplane. Secure the board by tightening the
screws at each end of the front panel.
36. Insert the DC I/O PCB (415-0601-002) into the middle slot of the DC
I/O Backplane and tighten the screws at each end of the front panel.
37. Peel the protective paper cover off the DC I/O blank slot cover and
install it over the rearmost DC I/O slot using two screws and two
plastic screw guides. The side of the slot cover from which the paper
cover was removed is the top.
Page 9 of 11
757-4002-197 CAD #
D8608
757-
4002-197
38. Run the ISA CANbus Internal DC I/O Harness (423-4400-008) along
the bottom of the card cage toward the end of the cage with the
cutouts. Fold the harness so that it fits through the clip on the
cornerpost, making sure that the red stripe of the harness is toward
the cutout end of the card cage.
39. Connect the ISA/DSP TTL I/O Harness (423-4400-002) to connector

J6 (AXIS X, Y, Z, S) of the I/O Interface PCB (415-0607-002) and feed
the harness through the ribbon cable clamp located just below
connector J3.
40. Connect the ISA CANbus Controller I/O Harness (423-4400-005) to

connector J4 of the I/O Interface PCB and feed the harness through
the ribbon cable clamps located just below connector J1.
41. Reinstall the back panel of the card rack extension using the four
screws set aside in step 3.
42. Move jumper JU2 on the Motion Controller PCB (415-0247-007) to the
“1-2” position.
43. Insert the Motion Controller board into slot 1 of the passive backplane
and secure it’s bracket with a screw.
44. Insert the ISA/DSP Honda Breakout PCB (415-0609-901) in the

rearmost cutouts at the back of the card rack. The fifty pin
connector/cable from the back of the Honda Breakout board should
pass through the second cutout from the back of the card cage so that
it is adjacent to the Motion Controller board inside the card cage.
Secure the Honda Breakout board with two screws.
45. Connect the ISA/DSP Servo I/O Harness (423-4400-006) from the
Honda Breakout board to connector J6 of the Motion Controller board.
46. Install blank brackets in all the empty slots between the Motion
Controller board and the CPU board. Use a screw to secure each
bracket.
47. Connect the ISA CANbus Controller I/O Harness (423-4400-005) to

connector J3 of the CANbus Controller board.
Page 10 of 11
757-4002-197 CAD #
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757-
4002-197
48. Connect the ISA/DSP TTL I/O Harness (423-4400-002) to connector
J3 of the Motion Controller board.
49. Connect the ISA CANbus Internal DC I/O Harness (423-4400-008) to

connector J6 of the Motion Controller board.
50. Reinstall the card cage cover.
51. Install the PS/2 Power Supply assembly.
A. Locate the power supply mounting pins on the outside of the hard
disk drive mounting panel at the base.
B. Align the three slots on the bottom of the power supply with the
respective pins (screw heads) at the bottom of the card cage.
C. Connect the two six pin connectors to the connector on the DC I/O
PCB. The black wires on one connector must be adjacent to the
black wires on the other connector after installation.
D. Plug the two pin connector into the mating two pin connector on
the DC Power Monitor/Distribution PCB, and seat.
E. Secure the wires from both harnesses to the side panel using a tie
wrap. Thread the tie wrap through the formed metal loop directly
adjacent to the twelve pin connector on the DC Power
Monitor/Distribution PCB. Check that all wires are inside of the tie
wrap, and then fasten and tighten. Cut off the excess tie wrap.
F. Lift the power supply, then set down on the pins while maintianing
the alignment from step B. above.
G. Hold the power supply against the side panel and install the item #
43 (109-5031-002) screw and the item #37 (110-0066-006)
lockwasher in the center mounting hole at the top of the power
supply. Locate and install the other screw and lockwasher in the
mounting hole on the right side of the power supply. Locate and
install the item #40 (109-5031-001) screw and the item #35 (110-
5001-002) flat washer in the top left mounting hole. Tighten all
screws.
Page 11 of 11
757-4002-197 CAD #
D8608
Max4 Activation Diskette
R
Part No. : 704-0004-037

Drawing No. : D8601B
Revision : B
Drawn By : Barry Van Paris
Approved By :
ECN No. : 14547 Date: 2/19/99
Description:
The Max4 Activation diskette (007-4000-001) is used to allow the Ultimax software to configure itself to
communicate with the new Max4 console. The diskette is a DOS bootable diskette. If the control is
booted with this diskette, the AUTOEXEC.BAT file will automatically copy two files from the diskette to the
root directory of the control’s hard disk. These two files are CANBUS.CFG and V800X600.VGA. The
CANBUS.CFG file is a script file that reconfigures the Canbus I/O to communicate with the Max4 console.
V800X600.VGA informs Ultimax to put the video card into 800x600 mode for the new flat panel displays.
Rev A
V1.00 Initial release.
Rev B
V1.01 Changes made so when the control is booted again with the diskette in the control, the two files
will be removed from the control hard disk. This will make Ultimax configure itself for a Max3
console. Now distributors or selling divisions can remove a Max4 console and replace it with a
SSM console and easily reconfigure the software to communicate with Ultimax. Hopefully this
will reduce calls to field service and engineering when doing this switch. Now, each time the
control is booted with this diskette, it will toggle between Max3 and Max4 console support.
Rev C
V1.01 Made this document a CODE TYPE 3 in structure under the 007-4000-001 diskette so it will be
called out as reference only and not included with the product. No changes were made to the
diskette.
757-4002-286 CAD #D8703
SUBJECT: ULTIMAX CONTROL KIT SERIAL NUMBER

IDENTIFICATION
EDIT THE ORIGINATORS AND REVIEWED & APPROVED.
ORIGINATOR: REVIEWED AND APPROVED:

David Skrzypczak 12/1/00 Fred Gross 12/1/00
Name Date Name Date
Page 1
1.0 RECORD OF CHANGES
Engineering Document 757-4002-286 CAD#8703
Rev.ECN # Revision Description Pg. # Date By Appvl.
A 15135 Original Issue. 11/17/00 WRS FWG
B 15204 Added B to tables 4.4.7.1 and 4.4.7.2. 5 2/01/01 PES FWG
Page 2
2.0 PURPOSE
2.1. INTENT
This document will provide instructions on how to complete and implement the Control Kit Serial
Number on Ultimax 4 and Ultimax 3/SSM Controls. It will also be used to track major revisions to
the Control Kit for traceability by Service and Quality.
2.2. GUIDELINES FOR REVISIONS

The Control Kit Serial Number will provide a letter designation for Revisions of the Control Kit’s
primary components, the Card Cage and the Console. The Revision letter shall be updated to the next
consecutive letter for:
2.2.1. Any sub-assembly structure changes to the primary components of the Control Kit.
Example: 1) PCB. part number changes (Not necessarily revision changes)
2) A change in form, fit, or function of a component.
2.2.2. A revision to a component of the Control Kit that affects Quality or Performance.
3.0 CONTROL KIT LABELS
3.1. CONTROL KIT DISKETTE LABELS

Control Kit Diskette Labels are to be of a standard size to fit on a 3.5in floppy diskette using a white
background with black lettering: Arial font, Regular Font Style, 10 Size. Each Control Kit Diskette
Label will be uniquely identified by Software ID, Part Number, Serial Number, and Disk Number of
the total number of Diskettes and will contain the Hurco logo.
ULTIMAX Product Type

Executive V2.16
Software ID
R
Integration V1.11
Part No. 007-4123-015 Part Number

Control Kit S/N U3S01001030A Serial Number
Disk 1 of 3
Disk Number
3.2. CONTROL KIT CONTAINER LABELS

Control Kit Container Labels will be on 8.5in x 11in or A4 paper size, white paper printed in
landscape with black lettering: Arial font, Bold Font Style, 48 Size. Each Control Kit Container Label
will be uniquely identified by Product Type, Software ID, Serial Number, and Box Number of the total
number of Boxes and will contain the Hurco logo.
ULTIMAX Product Type

R
EXECUTIVE V2.16 Software ID

INTEGRATION V1.11
CONTROL KIT S/N U3S01001030A

Page 3
BOX 1 OF 2
Serial Number
Box Number
3.3. CONTROL KIT ASSEMBLY LABELS
Control Kit Assembly labels will be on a 0.5in x 4in (15mm x 100mm) material (lexan, polycarbonate,
polyester, or other similar type material), white background with black lettering: Arial font, Regular
Font Style, 12 Size. The Control Kit Assembly Labels will contain a Hurco logo and the Serial
Number. Two Control Kit Assembly Labels will be required for each Control Kit.
Control Kit S/N: U3S01001030A

R
4.0 CONTROL KIT LABEL FORMAT
4.1. PRODUCT TYPE: ULTIMAX
4.2. SOFTWARE ID FORMAT:

Executive V2.xx
Integration V1.xx
Use the Software ID indicated on the Ultimax Software Release Document (reference Ultimax
Software Release and Build Document, 757-4002-176).
4.2.1. V2.xx – Executive Software Version

Example: V2.15
4.2.2. V1.xx – Integration Software Version

Example: V1.10
4.3. PART NUMBER FORMAT:

Use the following Part Numbers for the corresponding Software ID.
Software ID Part #
V2.00 through V2.15/V1.10 007-4123-004
V2.16/V1.11 or greater 007-4123-015
4.4. SERIAL NUMBER FORMAT: PPP - Y1 F XXX MM Y2 R
4.4.1. PPP The prefix identifying the Control type.

Values: U3S for Ultimax 3/SSM.
U4M for Ultimax 4.
4.4.2. Y1 The decade of the year of manufacture.

Example: 0 for 2000.
Page 4
4.4.3. F The factory designation.
F Factory
0 Hurco Manufacturing Company
1 Hurco Automation Ltd.
4.4.4. XXX Serial Number of Control Kit per month. This number will increment for
every Control Kit manufacturer in the current month. It will be reset to
001 for the first Control Kit of each type of every month.
Example: 001 for 1st Ultimax 3/SSM Control Kit of the month, 002 for
2nd Ultimax 3/SSM Control Kit of the month, etc.
4.4.5. MM The month of manufacture for the Control Kit

Values: 01 for January 05 for May 09 for September
02 for February 06 for June 10 for October
03 for March 07 for July 11 for November
04 for April 08 for August 12 for December
4.4.6. Y2 The last digit of the year of manufacture.

Example: 0 for 2000, 1 for 2001, etc.
4.4.7. R The suffix identifying major Control revisions. From the appropriate table
below, select the Revision letter that describes the Control Kit
Example: A for initial release.
4.4.7.1. Ultimax 3/SSM Table for Suffix:

R Ultimax 3/SSM Suffix Description
A Initial Release
007-3002-011: ISA/PCI Passive Backplane CPU, Single VGA,
Card Cage Assy, Rev G
007-3008-004/005: SSM Operator Panel Assy, Rev B
B 007-3002-011,-015: ISA/PCI Pass B/P CC Assy. Rev.J; Add 415-
0605-003; per ECN 15134.
4.4.7.2. Ultimax 4 Table for Suffix:

R Ultimax 4 Suffix Description
A Initial Release
007-3002-012: ISA/PCI Passive Backplane CPU, Card Cage
Assy, Rev G
007-3004-005: Dual TFT Flat Panel Console Assy, Rev C
B 007-3002-012,-016: ISA/PCI Pass B/P CC Assy. Rev.J ; Add
415-0605-003, 415-0220-008; per ECN 15134
Page 5
Page 6
4.5. SERIAL NUMBER EXAMPLES
4.5.1. The first Ultimax 3/SSM manufactured by Hurco Automation Ltd in March, 2000.
PPPP - Y1 F XXX MM Y2 R
Example: U3S - 0 1 001 03 0 A
Initial Release.
Year of manufacture, 2000.
Month of manufacture, 03 for March
Serial # of Control Kit per month, 01 for first.
For Hurco Automation Ltd, 1
Decade of the year of manufacture, 2000.
Ultimax 3/SSM Control Kit.
4.5.2. The first Ultimax 4 manufactured by Hurco Automation Ltd in March, 2000.
PPPP - Y1 F XXX MM Y2 R
Example: U4M - 0 1 001 03 0 A
Initial Release.
Year of manufacture, 2000.
Month of manufacture, 03 for March
Serial # of Control Kit per month, 001 for first.
For Hurco Automation Ltd, 1
Decade of the year of manufacture, 2000.
Ultimax 4 Control Kit.
5.0 RESPONSIBILITY AND LABEL PLACEMENT
5.1. It shall be the responsibility of the Control Manufacturer to ensure that the Control Kit Diskette Labels,
the Control Kit Container Labels, and the Control Kit Assembly Labels are completed for all Ultimax
Control Kits per the guidelines in this document.
5.2. The Control Mfr. is also responsible for the uniformity of serialized Control Kits.
5.2.1. Control Kit Assemblies (e.g. Card Cage, Console) should be tested and serialized as a set.
5.2.2. Ensure that the Control Kit Container and all of the components(e.g. Control Kit Assemblies,
Diskettes) inside have matching serial numbers .
5.3. PLACEMENT OF DISKETTE IDENTIFICATION LABELS

The Control Kit Diskette Labels are to be placed on each of the Ultimax diskettes. Three labels are to
Page 7
be provided for Disk 1 of 3, for Disk 2 of 3, and for Disk 3 of 3 of the Ultimax diskettes.
5.4. PLACEMENT OF CONTROL KIT CONTAINER LABELS

The Control Kit Container Labels are to be placed on the outside of each of the shipping containers,
Box 1 of 2 and Box 2 of 2. Eight labels are to be provided and will be affixed to all four sides of each
box with transparent, adhesive tape across the front of the label.
5.5. PLACEMENT OF CONTROL KIT ASSEMBLY LABELS

The Control Kit Assembly Labels are to be placed on the cover of the Control Card Rack (see Figure
1) and on the inside of the rear cover of the Control Console (see Figure 2 for Ultimax 3/SSM and
Figure 4 for Ultimax 4). Two labels will be provided for each Control Kit.
Figure 1: Placement of Control Kit Assembly Label on Control Card Rack
Page 8
Figure 2: Placement of Control Kit Assembly Label on Ultimax 3/SSM Rear Cover
Figure 3: Placement of Control Kit Assembly Label on Ultimax 4, Inside Rear Cover
Page 9
R 757-4002-266 CAD # D8683
SUBJECT: PROCEDURE, MAX 4 CONTROL PCB TEST
Wesley Shelton 9-18-00

757-4402-266
RECORD OF CHANGES

757-4002-266 D8683
Revisions:
Revision ECN # Revision Description Rev Date Approved Date

By By
757-4002-266 Page 2 of 2 CAD#D8683

757-4402-266
I. INTENT:
To provide a standardized procedure for the proper testing of all the PCBs in a Max 4 control (PCBs
inside the console and the card cage).
II. SCOPE:
This procedure applies to the following devices.
Part Number Description Part Number Description

1 415-0220-006 Pcb Assy, PCI VGA Video, S3 12 415-0605-002 Pcb Assy, Isa CANBUS
1M Controller Cfg’d
2 415-0220-007 Pcb Assy, Dual PCI VGA 13 415-0628-001 Pcb Assy, FPN Console Jog
Video
3 426-0056-019 Hard Drive,ISA Std. 3.5" IDE 14 415-0626-001 Pcb Assy, Detented Jog Node
2.0GB or Larger
4 415-0606-902 Pcb Assy, ISA FDD 15 415-0625-001 Pcb Assy, Console
Transceiver Pushbutton Interconnect
5 415-0166-913 Pcb Assy, LMB 680P CPU 16 807-0013-005 Keyboard, Program Entry
Passive Backplane
6 415-0601-002 Pcb Assy, CANBUS DC I/O 17 807-0013-004 Keyboard, Machine Function
Node
7 415-0607-002 Pcb Assy, ISA I/O Interface 18 807-0006-002 Touchscreen, 4-Wire Resistive
Configured
8 415-0247-007 Pcb Assy, MX4 CNC++, 19 416-0252-005 Encoder, Trackball
X,Y,Z,S
9 415-0250-902 Pcb Assy, 4MB SIMM, 1Mx32 20 007-0022-003 Assy, FPD PCI?TFT 12.1”
Non-Parity LCD 800X600 W/Backlight
10 415-0250-903 Pcb Assy, 8MB SIMM, 2Mx32 21 426-0056-007 Disk Drive, 3.5” FD 1.44M
Non-Parity
11 415-0250-904 Pcb Assy, 16MB SIMM, 4Mx
32 Non-Parity
III. SUPPORTING DOCUMENTS

Part Number Description Document Number
757-4002-221 Procedure, TFT FPD Configuration and Test for Service D8633
757-4002-232 Procedure, Formosa LMB-680 P/B CPU Board Setup D8644
757-4002-166 Procedure, Hard Drive Parameters for CMOS Setup D8577
IV. PROCEDURE:
A. Component Installation
1. Visually inspect the device to be tested for any physical damage (i.e. burnt traces, cracked or burnt chips).
If any damage is found do not insert it into the test fixture.
2. Ensure that the fixture power is off.
3. Substitute the Device Under Test (DUT) for the known good device in the fixture (See Appendix A). Only test
one DUT at a time. One device can effect how another works and give erroneous results.
757-4002-266 Page 3 of 3 CAD#D8683

757-4402-266
B. Diagnostic Selection
1. The following table shows the proper section(s)of this procedure needed to test the DUT. Find the Device to
be tested in the list and then go to the corresponding section as indicated.
Part Number Description (DUT) Diagnostic Section

415-0628-001 Pcb Assy, FPN Console Jog Section C (Resident Diag.) P.3
415-0220-006 Pcb Assy, PCI VGA Video, S3 1M Section C (Resident Diag.) P.3
415-0220-007 Pcb Assy, Dual PCI VGA Video Section C (Resident Diag.) P.3
415-0626-001 Pcb Assy, Detented Jog Node Section C (Resident Diag.) P.3
415-0625-001 Pcb Assy, Console Pushbutton Interconnect Section C (Resident Diag.) P.3
807-0013-005 Keyboard, Program Entry Section C (Resident Diag.) P.3
807-0013-004 Keyboard, Machine Function Section C (Resident Diag.) P.3
807-0006-002 Touchscreen, 4-Wire Resistive Section C (Resident Diag.) P.3
416-0252-005 Encoder, Trackball Section C (Resident Diag.) P.3
007-0022-003 Assy, FPD PCI TFT 12.1” LCD 800X600 W/Backlight Section C (Resident Diag.) P.3
415-0605-002 Pcb Assy, ISA CANBUS Controller Cfg’d Section C (Resident Diag.) P.3
Section E (ISATest) P.7
426-0056-019 Hard Drive,ISA Std. 3.5" IDE 2.0GB or Larger Section D (QAFE) P.5
415-0606-902 Pcb Assy, ISA FDD Transceiver Section D (QAFE) P.5
415-0166-913 Pcb Assy, LMB 680P CPU Passive Backplane Section D (QAFE) P.5
415-0250-902 Pcb Assy, 4MB SIMM, 1Mx32 Non-Parity Section D (QAFE) P.5
415-0250-903 Pcb Assy, 8MB SIMM, 2Mx32 Non-Parity Section D (QAFE) P.5
415-0250-904 Pcb Assy, 16MB SIMM, 4Mx 32 Non-Parity Section D (QAFE) P.5
426-0056-007 Disk Drive, 3.5” FD 1.44M Section D (QAFE) P.5
415-0601-002 Pcb Assy, CANBUS DC I/O Node Section E (ISATest) P.7
415-0607-002 Pcb Assy, ISA I/O Interface Configured Section E (ISATest) P.7
415-0247-007 Pcb Assy, MX4 CNC++, X,Y,Z,S Section E (ISATest) P.7
2. If the specified tests do not perform as indicated in the procedure the DUT fails.
C. Control Resident Diagnostics
1. Applicable Test Selection
a. The following chart is to determine the steps of this section needed to properly test the DUT.
Part Number Description (DUT) Steps to

follow
415-0628-001 Pcb Assy, FPN Console Jog 2–6
415-0220-006 Pcb Assy, PCI VGA Video, S3 1M 2, 7
415-0220-007 Pcb Assy, Dual PCI VGA Video 2, 7
415-0626-001 Pcb Assy, Detented Jog Node 2-5
415-0625-001 Pcb Assy, Console Pushbutton Interconnect 2-5
807-0013-005 Keyboard, Program Entry 2-5
807-0013-004 Keyboard, Machine Function 2,4,5
807-0006-001 Touchscreen, 8-Wire Resistive 2,4
807-0006-002 Touchscreen, 4-Wire Resistive 2,4
757-4002-266 Page 4 of 4 CAD#D8683

757-4402-266
416-0252-005 Encoder, Trackball 2,4

007-0022-003 Assy, FPD PCI?TFT 12.1” LCD 800X600 W/Backlight 2, 7
2. Boot Ultimax
a. Ensure there is not a floppy in the floppy drive .
b. Turn the test fixture power on and allow the Ultimax software to boot.
c. Press the Auxiliary button on the Program Entry Keyboard.
d. To enter the Interactive Diagnostics Main Menu press “Enter,” then type 100 and press “Enter” again.
3. COR Circuit Test
a. Make sure all E-Stops are released. Press the Power On button. The pushbutton lamp and the COR
LED (on the simulator box) should light up.
b. Press the Start button. The AER LED (on the simulator box) should light up.
c. Now press the Console E-stop. The COR LED, AER LED, and Power On lamp should all turn off.
Repeat steps 2 and 3, then press the Detented Jog E-stop. Again verify that the COR LED, AER LED,
and Power On lamp all turn off.
4. Input Device Test
a. From the Main Menu press F5 (Control Diagnostics), then F3 (Console Tests), then F1 (Keyboard Test).
Press each key on the keyboards in the following chart to cause the appropriate indicator on the screen
to be highlighted (for example, pushing the “Enter” key causes the word Enter on the screen to be
highlighted). If the key is pressed a second time the highlight will turn off.
KEYBOARD NO. OF KEYS

Detented Jog 6
Program Entry * 35
Machine Function 12
*Note: To test the F or the ALT key, the key must be pressed and held while a number key (1-8 only) is
pressed. Two things will happen: the appropriate indicator will be highlighted (The F key indicator is the
word “Control”), and the number pressed will change its highlight state.
b. Press each of the pushbuttons. The appropriate indicators will be highlighted as the keys did in step 4.
To unhighlight the Motion Hold or either E-Stop button, release the button, then press it again.
c. Press the appropriate area on the touchscreen to highlight the F1-F8 indicators. When the touch screen
is pressed an X, Y coordinate will appear on the screen where it says “Touch X: Y:”. Touch the 4
corners of the touchscreen. The coordinates should indicate the following X and Y coordinates (+/-10
counts).
CORNER X Y
Upper Left 6 245
Lower Left 6 6
Upper Right 245 245
Lower Right 245 6
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757-4402-266
d. Spin the Jog Wheel and verify the count on the screen changes where it says “Incremental.”
Rotation Count
CW Positive
CCW Negative
e. Spin the Trackball and verify the count on the screen changes on both “Cursor X” and “Cursor Y.”
Direction Count Direction Count

Left Negative UP Negative
Right Positive Down Positive
f. Turn each potentiometer and verify the count on the screen changes on the appropriate indicators. A
clockwise turn will count up toward 255 and a counter clockwise turn will count down toward 0.
g. Rotate the rotary switch. Only the selected axis will be highlighted on the screen.
h. Press the F8 area of the touchscreen twice to exit this test.
5. LED Test
a. From the Main Menu press F5 (Control Diagnostics), then F3 (Console Tests), then press F5 (LED
test). The control will illuminate each LED in sequence and then turn them on all at once. There are a
total of 18 LEDs to be cycled through.
b. Press F8 to exit this test.
6. Continuous Disk Test.
a. From the Main Menu press F5 (Control Diagnostics), then F3 (Console Tests), then press F4
(Continuous disk test).
b. Put a formatted blank disk into the floppy disk drive.
c. Press F2 to continue with the test.
d. The results will be displayed on the screen. The loop count and number of Passes should be the same.
e. Let the test run for a loop count of 10.
f. Press F8 to exit.
7. Video Tests
a. From the Main Menu press F5 (Control Diagnostics), then F3 (Console Tests), then press F2 (Text
Test). The screen should completely fill up with text.
b. Press F8 (Exit). With the screen displaying the text F8 will not be visible but if the area where F8 is
normally displayed is pressed it will still respond.
c. Press F3 (Crosshatch Test). The screen should fill with a pattern of squares and a circle in the center.
d. Press F8 (Exit). With the screen displaying the text F8 will not be visible but if the area where F8 is
757-4002-266 Page 6 of 6 CAD#D8683

757-4402-266
e. Press F4 (Color Bar). The screen will display several vertical lines of different colors. The following
represents what color each of these bars represent.
Lt. Blue
Orange
Lt Blue
Yellow
Green
Green
White
White
Black
Black
Violet
Violet
Blue
Blue
Red
Red
f. Press F8 (Exit). With the screen displaying the text F8 will not be visible but if the area where F8 is
D. QAFE Diagnostics
1. Start QAFE software.
a. Insert the Diagnostic Boot Disk into the floppy drive.
b. Turn on the power to the fixture.
c. At the A:\ prompt type Q and Enter unless the DUT is the Hard Drive (426-0056-019). For the Hard Drive
type Qa and Enter
2. QAFE Options setup.
a. Keys for menu navigation and item selection.
↵ (Enter) = Select Item, Run Test Module or Run Test

↑ (Up Arrow) = Move Cursor Up
↓ (Down Arrow) = Move Cursor Down
F1 = Help
ESC = Go Back to Previous Menu
b. On the Main Menu select Diagnostics and press Enter.
c. On the Diagnostics Menu select Options and press Enter.
d. The Hault on Error, Beep on Error and Pause Between Tests options can be toggled on or off by
selecting the desired option and pressing Enter. The results are displayed on the message bar at the
bottom of the screen. These should be set as follows.
Option Result to be displayed

Hault on Error HaultOnError
Beep on Error BeepOnError
Pause Control NoPause
e. The last option to be set is the Lap Count. Select Lap Count and press Enter. Enter the desired number
of laps each set of tests is to be executed.
3. Module Test setup.
a. From the Main Menu select Diagnostics and press Enter.
b. From the Diagnostics Menu select Module Tests and press Enter.
757-4002-266 Page 7 of 7 CAD#D8683

757-4402-266
c. The following are additional keys for navigation and selection in the Module Test Menu.
Tab = Move to Test Group (or Move to Parameters)

Space Bar = Toggle Modules/Tests On/Off (♦) = ON ( )= OFF
F10 = Local Menu
+ = Next Unit Number (i.e. COM1, Com2, etc.)
- = Previous Unit Number
d. Toggle the appropriate modules on or off as needed to meet the requirements indicated in the following
chart to properly test the DUT.
Part Number Description (DUT) Modules Needed

426-0056-019 Hard Drive,ISA Std. 3.5" IDE 2.0GB or Larger Hard Disks
415-0606-902 Pcb Assy, ISA FDD Transceiver Floppy Disks
System Board
Memory
Hard Disks
415-0166-913 Pcb Assy, LMB 680P CPU Passive Backplane Floppy Disks
Keyboard
COM Ports
LPT Port
415-0250-902 Pcb Assy, 4MB SIMM, 1Mx32 Non-Parity Memory
415-0250-903 Pcb Assy, 8MB SIMM, 2Mx32 Non-Parity Memory
415-0250-904 Pcb Assy, 16MB SIMM, 4Mx 32 Non-Parity Memory
426-0056-007 Disk Drive, 3.5” FD 1.44M Floppy Disks
e. Use the default Test Group selection for all modules except COM Ports and LPT Port modules.
1) COM Port and LPT Port Test Group setup.
a) Select the module in which the Test Group selection needs to be changed and press the Tab
Key to enter into the Test Group Menu.
b) Use the Space Bar and Arrow Keys to toggle all of the tests on except Printer and Modem
options, which should be turned off.
c) When in the COM Ports Test Group the + Key must be use to setup COM 2. When COM 2 is
setup press the – Key to return to COM 1.
d) Once the Test Group is setup press the ESC Key to return to the Modules Menu.
2) If the COM ports and LPT port are to be tested ensure that the loopback harnesses are installed.
f. Select Run ALL Selected and press Enter to start the testing.
E. Loopback Tests (ISATest)
1. Start ISATest Software
757-4002-266 Page 8 of 8 CAD#D8683

757-4402-266
a. Insert the Diagnostics Boot Disk into the floppy drive.
b. Turn on the power to the fixture.
c. At the A:\ prompt type ” I ” and Enter.
2. ISATest Operation
a. Keys for menu navigation and item selection.
↵ (Enter) = Select Menu, Toggle Options

↑ (Up Arrow) = Move Cursor Up
↓ (Down Arrow) = Move Cursor Down
ESC = Go Back to Previous Menu
b. From the Main Menu select Choose Tests and press Enter.
c. From the Test Setup Menu select Loop Count and press Enter. The Loop Count is used to allow the
test to run a predetermined number of times.
1) Enter the number of loops and press Enter.
d. From the Test Setup Menu select Select Boards and press Enter.
1) From the Board Selection menu select the board that is to be tested and deselect all other boards.
A check mark next to the board indicates selected and no check mark next to the board indicates
deselected.
2) Press the ESC Key twice to return to the Main Menu.
e. From the Main Menu select Run Select Tests and press Enter to begin the tests.
1) A screen will appear that shows the results of the tests. This screen only shows a PASS or FAIL.
2) Once the selected number of loops has completed the screen will show Test Complete at the top. If
there are any failures the F key can be press and a list of those failures will be displayed.
757-4002-266 Page 9 of 9 CAD#D8683

757-4402-266
APPENDIX A
ITEM PART NUMBER DESCRIPTION

1 007-0022-003 ASSY FPD,12.1"LCD 800x600 W/B PCI/TFT
2 007-3002-012 ASSY,ISA/PCI PASS,DUAL-VGA M/C
3 - ASSY, GREEN PUSHBUTTON
3.1 404-3677-001 SWITCH, P/B MOMENTARY, 2 MAKE
3.2 404-4121-003 FRONT RING, SWITCH
3.3 404-4161-012 LENS CAP, FLUSH GREEN
3.4 404-9200-001 DIFFUSER, FLUSH WHITE
3.5 411-0001-015 LAMP, 24V SLIDE BASE
4 - ASSY, YELLOW PUSHBUTTON
4.1 404-3677-001 SWITCH, LOW LEVEL MAINTAINED 2 MAKE
4.3 404-4161-012 LENS CAP, EXTENDED YELLOW
4.4 404-9200-001 DIFFUSER, EXTENDED WHITE
4.5 411-0001-015 LAMP, 24V SLIDE BASE
5 - ASSY, RED PUSHBUTTON
5.3 404-4161-011 LENS CAP, EXTENDED RED
5.4 404-9200-001 DIFFUSER, EXTENDED WHITE
5.5 411-0001-015 LAMP, 24V SLIDE BASE
6 - ASSY, GREEN PUSHBUTTON(POWER ON)
6.2 404-3677-028 ADAPTER, FLUSH MOUNT SERIES 14 PB SWITCH
6.3 404-4161-012 LENS CAP, FLUSH GREEN
6.4 404-9200-004 DIFFUSER, WITH LEGEND (FLAT WHITE)
6.5 411-0001-015 LAMP, 24V SLIDE BASE
7 - ASSY, E-STOP SWITCH
7.1 404-7502-005 ACTUATOR, SLIM E-STOP SWITCH
7.2 404-7502-006 CONTACT BLOCK, SLIM E-STOP SWITCH
8 - ASSY, SMALL E-STOP SWITCH
757-4002-266 Page 10 of 10 CAD#D8683

757-4402-266
8.1 404-7502-008 ACTUATOR, SMALL MUSHROOM E-STOP SWITCH

8.2 404-7502-009 CONTACT BLOCK, SMALL MUSHROOM E-STOP SWITCH
9 415-0625-001 PCB ASSY, CONTROL PANELINTERCONNECT
10 415-0626-901 PCBA,DETENTED JOG NODE
11 415-0628-901 PCBA,FLAT PANEL NODE,MAX4
12 416-0252-005 ENCODER,TRACKBALL
13 - HARNESS,FPD POWER_A
14 423-4401-173 HARNESS,MACHINE FUNCTION TO FPN/J7_B
15 423-4401-174 HARNESS,FDD SIGNAL_A
16 423-4401-175 HARNESS,TRACKBALL_B
17 423-4401-176 HARNESS,FDD POWER_B
18 423-4401-177 HARNESS,PROGRAM ENTRY KEYBOARD_B
19 423-4401-178 HARNESS,E-STOP CONSOLE_C
20 423-4401-179 HARNESS,E-STOP 2"_C
21 423-4401-180 HARNESS,REMOTE JOG MAX 4_D
22 423-4401-186 HARNESS,CPI TO FPN_A
23 426-0056-B07 DISK DRIVE,3.5" FDD 1.44MB
24 807-0006-001 TOUCHSCREEN,4-WIRE RESISTIVE_B
25 807-0013-004 KEYBOARD,MACHINE FUNCTION_A
26 807-0013-005 KEYBOARD,PROGRAM ENTRY_A
27 807-0013-006 KEYBOARD,REMOTE JOG_A
28 - SIMULATOR, CRP
29 - HARNESS, DC POWER
30 - HARNESS, CANBUS
ITEM PART NUMBER DESCRIPTION
31 - HARNESS, FDD CARD CAGE TO FPN
32 - HARNESS, VAG CARD TO TFT
33 - RS-232 TESTER
34 - PRINT TESTER
35 - HARNESS, ISA LOOPBACK TEST
757-4002-266 Page 11 of 11 CAD#D8683

757-4402-266
24
21
8
20
27
757-4002-266 Page 12 of 12 CAD#D8683

757-4402-266
9 3 4 6
29
18
22 28
8
10
11
13
14
17
15
26
23
25
19
16
2
33
34
35
31
30
32
757-4002-266 Page 13 of 13 CAD#D8683

757-4402-266
757-4002-266 Page 14 of 14 CAD#D8683

757-4002-206 CAD# D8618
SUBJECT: PROCEDURE, FLAT PANEL DISPLAY CONFIGURATION

FOR SERVICE.
__Jeff Nolletti________________________ 01/14/99 _________________________ _______

1
757-4002-206 D8618
RECORD OF CHANGES

By
2
757-4002-206 D8618
I. INTENT
To provide instructions for DIP switch configuration of tested Hurco 12.1”
Flat Panel Display Assemblies 007-0022-001T and 007-0022-002T.
Hurco part number 007-0022-001T is intended to be used in Max 4

systems with an ISA Dual VGA video board (415-0220-004). Customers
having an ISA video board and a 007-0022-001 flat panel display should
order part number 007-0022-001T as a flat panel display replacement.
Hurco part number 007-0022-002T is intended to be used in Max 4

systems with a PCI Dual VGA video board (415-0220-007). Customers
having a PCI video board and a 007-0022-002 flat panel display should
order part number 007-0022-002T as a flat panel display replacement.
II. SCOPE
Applies only to Hurco 12.1” Flat Panel Display Assemblies
007-0022-001T and 007-0022-002T.
III. PROCEDURE
A. Disassembly of Flat Panel Display
NOTE: The following procedure is intended to be performed with the

flat panel display power disconnected. High voltage is present inside
the flat panel display when it is powered. ESD prevention procedures
should be followed (Ref. CN D8030, Sensitive Component Handling
Procedure, ESD).
1. Carefully remove the video ribbon cable connector from the mating
connector on the rear of LCD at the left end (Item 1, Figure 1).
Move the ribbon cable connector away from the back of the LCD
panel towards the metal chassis to remove.
2. Remove the four LCD mounting screws and save for reinstallation
of the LCD (Item 2, Figure 1).
3. Flip LCD (display only) over to the right so it is lying face down on
the bench as shown in Figure 2. USE CAUTION so that the short
pink and white wires from the backlight inverter board to the LCD
are not damaged.
3
757-4002-206 D8618
4
757-4002-206 D8618
5
757-4002-206 D8618
B. DIP Switch Configuration
1. Determine whether the flat panel display is to be configured for

an ISA (–001T) or PCI (–002T) control system. The only difference
between a –001T and a –002T is the DIP switch configuration.
2. Locate the three small DIP switches labeled DIPSW1, DIPSW2

and DIPSW3 on the lower right corner of the large circuit board
(see Figure 2).
3. Set the three DIP switches on the bottom of the large circuit board
as indicated in Table 1.
Assy. Switch Pos. Pos. Pos. Pos. Pos. Pos. Pos. Pos.
1 2 3 4 5 6 7 8
-001T DIPSW1 OFF OFF OFF ON ON OFF ON OFF
(ISA) DIPSW2 ON ON OFF OFF ON OFF OFF OFF
DIPSW3 ON ON ON ON OFF ON OFF OFF
-002T DIPSW1 OFF OFF OFF ON OFF ON ON OFF

(PCI) DIPSW2 ON ON ON ON OFF OFF OFF OFF
DIPSW3 ON ON ON ON OFF ON OFF OFF
Table 1 ON = switch to the left
OFF = switch to the right
C. Reassembly of Flat Panel Display
1. Verify that the two white plastic light bars on the back of the LCD
have not come loose. If they have, secure them with tape
(Kapton or packaging tape will work).
2. Flip the LCD back into its normal position, being careful not to
damage the short pink and white wires.
3. Align the mounting holes and slots with the standoffs on the sheet
metal chassis and secure the LCD with the four screws removed in
Part A, Step 2.
4. Reconnect the video ribbon cable connector to the mating

connector on the rear of the LCD at the left end (Item 1, Figure 1).
6
757-4002-206 D8618
Be sure that the ribbon cable connector seats fully into the mating
connector on the back of the LCD or video problems will result.
D. Electrical Test of Flat Panel Display
1. Connect the flat panel display to a suitable power source and an

appropriate Ultimax 4 control card cage or test fixture. Part
number 007-0022-001T should be connected to an ISA Dual VGA
board (415-0220-004) and part number 007-0022-002T should be
connected to a PCI Dual VGA board (415-0220-007).
2. Boot the control with Ultimax software. Check that the displayed
image is not distorted in any way.
3. Use the Hurco “crosshatch” test to confirm that the video image is
properly oriented on the display. The crosshatch grid should be
centered on the screen and the sides, top and bottom should not be
cropped or cut off. The keystrokes required to activate the
crosshatch test are as follows:
a. Alt-A (puts the control in Auxiliary Mode). The “Auxiliary” key

may be used if the Program Entry Keyboard is connected
instead of an AT keyboard.
b. Press “Enter” then “1”, “0”, “0” and “Enter” again.
c. Press “F5” (for Control Diagnostics).
d. Press “F3” (for Console Tests).
e. Press “F3” (for the Crosshatch Test).
f. To exit the crosshatch test, press “F8.”
4. Power down the system when testing is complete and remove the
flat panel display.
7
Hurco Manufacturing Company
HURCO DS0062-1.DOC
Flat Panel Node Firmware
January 14, 1999
Description: EPROM, FLAT PANEL NODE V2.0

Drawing No.: 450-3001-969 REV.: A
CAD No.: DS0062 ECN No.: 14490
Drawn By: Jeff Nolletti Approved By: _______________

---------------------------------------------------------------------------------------------------------
Flat Panel Node Firmware V2.0
Product ROM Size Part Number Rev.

Flat Panel Node 32Kx8 450-3001-969 A
Description:
This document set contains all the data necessary to program an EPROM for the
Flat Panel Node 415-0628-901. Program 27C256 part using DS0062-2.hex.
Create and affix label per specification below. This document also contains Max
4 CANbus mapping information.
Bill Of Materials:
Qty Hurco P/N Description Item

1 450-3001-948 EPROM, BLANK 27C256 1
1 703-0010-001 LABEL, EPROM BLANK 2
File Descriptions:
File Name File Description Offset

Type Require
d
DS0062-1.DOC Winword Firmware Release Document n/a
DS0062-2.DOC Winword Max 4 CANbus Map Document n/a
DS0062-3.HEX HEX Programming File none
DS0062-4.ZIP ZIP Firmware Source Code Files n/a
Label:
FPN V2.0
450-3001-969 REV A
CS=(checksum)
Ultimax 4 CANbus Map DS0062-2.DOC
FWG 01/11/98
Node Assignments
Node # Ultimax 3 Ultimax 4

0x00 CONTROLLER_NODE CONTROLLER NODE
0x01 DCIO_NODE_1 DCIO_NODE_1
0x04 REMOTE_JOG_NODE RJN2_REMOTE_JOG_NODE
0x04 REMOTE_JOG_LEDS_NODE -
0x05 REMOTE_JOG_KEYS_NODE DCIO_NODE_4
0x06 REMOTE_JOG_OVERRIDES_NODE DCIO_NODE_5
0x07 REMOTE_JOG_ENCODER_NODE DCIO_NODE_6
0x08 CONSOLE_JOG_LEDS_NODE CIN2_CONSOLE_JOG_NODE
0x09 CONSOLE_JOG_KEYS_NODE -
0x0a CONSOLE_JOG_OVERRIDES_NODE -
0x0b CONSOLE_JOG_ENCODER_NODE -
0x0c CONSOLE_INTERFACE_NODE CIN2_CONSOLE_NODE
0x0c CONSOLE_DISCRETES_NODE -
0x0d CONSOLE_KEYS_AND_LEDS_NODE CIN2_TOUCHSCREEN_NODE
0x0e AT_KEYBOARD_NODE -
0x0f CONSOLE_TRACKBALL_NODE -
0x10 LOCAL_IO_NODE LOCAL_IO_NODE
0x11 ANALOG_NODE_1 ANALOG_NODE_1
p. 1 of 9
FWG 01/11/98
0x04 – Detented Jog Node

1. Reset identifier: “J”
2. I/O Definitions
Signal Device I/O Type Node.Byte.Bit Key Code(s)
x1 LED Led bit-wise output 0x04.0.0 -
X Axis Select 1 of 6 rotary switch bit-wise input 0x04.0.0 -
Y Axis Select 1 of 6 rotary switch bit-wise input 0x04.0.1 -
Z Axis Select 1 of 6 rotary switch bit-wise input 0x04.0.2 -
a Axis Select 1 of 6 rotary switch bit-wise input 0x04.0.3 -
b Axis Select 1 of 6 rotary switch bit-wise input 0x04.0.4 -
Jog+ Key Momentary pushbutton bit-wise input 0x04.0.5 -
Jog- Key momentary pushbutton bit-wise input 0x04.0.6 -
Embedded switch bit-wise input 0x04.0.7 -

Estop
x1 Key momentary pushbutton bit-wise input 0x04.1 0x71
x10 Key Momentary pushbutton bit-wise input 0x04.1 0x72
m+ Key Momentary pushbutton bit-wise input 0x04.1 0x56
Key Mode Constant 8-bit value 0x04.2 0x80
Manual Potentiometer 8-bit input register 0x04.3 -

Override
Jog Encoder Quadrature encoder low byte of 16-bit 0x04.4 -

Low Byte register
Jog Encoder Quadrature encoder high byte of 16-bit 0x04.5 -

High Byte register
p. 2 of 9
FWG 01/11/98
0x08 – Console Jog / Flat Panel Node

1. Reset identifier: “I”.
2. I/O Definitions
Jog- Key Momentary pushbutton bit-wise input 0x08.0.6 -
Embedded Estop Switch bit-wise input 0x08.0.7 -
Key Mode Constant 8-bit input 0x08.2 0x80
Manual Override Potentiometer 8-bit input register 0x08.3 -

Low Byte register

High Byte register
p. 3 of 9
FWG 01/11/98
0x0c – Flat Panel Node

2. I/O Definitions
Eestop – Console switch bit-wise input 0x0c.0.0 -
Start Button momentary pushbutton bit-wise input 0x0c.0.1 -
Motion Hold Button latching pushbutton bit-wise input 0x0c.0.2 -
Stop Button momentary pushbutton bit-wise input 0x0c.0.3 -
Power On Button momentary pushbutton bit-wise input 0x0c.0.4 -
Start Lamp 24V lamp bit-wise output 0x0c.0.0 -
Motion Hold Lamp 24V lamp bit-wise output 0x0c.0.1 -
Stop Lamp 24V lamp bit-wise output 0x0c.0.2 -
LCD Backlight Enable - Text LCD input bit-wise output 0x0c.0.3 -
LCD Backlight Enable - Grax LCD input bit-wise output 0x0c.0.4 -
Interrupt Cycle Lamp led bit-wise output 0x0c.1.0 -
Aux Mode LED led bit-wise output 0x0c.1.1 -
Review Mode LED led bit-wise output 0x0c.1.2 -
Input Mode LED led bit-wise output 0x0c.1.3 -
Manual Mode LED led bit-wise output 0x0c.1.4 -
Test Run Mode LED led bit-wise output 0x0c.1.5 -
Single Cycle Mode LED led bit-wise output 0x0c.1.6 -
Auto Mode LED led bit-wise output 0x0c.1.7 -
Spindle Off LED led bit-wise output 0x0c.2.0 -
Spindle On LED led bit-wise output 0x0c.2.1 -
ATC Manual Mode LED led bit-wise output 0x0c.2.2 -
ATC Auto Mode LED led bit-wise output 0x0c.2.3 -
Coolant Auto Mode LED led bit-wise output 0x0c.2.4 -
Flood Coolant LED led bit-wise output 0x0c.2.5 -
Mist Coolant LED led bit-wise output 0x0c.2.6 -
Key Code matrix scan code 8-bit input register 0x0c.1 -
Key Mode ctrl or alt combinations 8-bit input register 0x0c.2 0x81 = Alt + Key
0x82 = Ctl. + Key
0x83 = Ctl. + Alt. + Key
Trackball X quadrature input 8-bit input register 0x0c.3 -
Trackball Y quadrature input 8-bit input register 0x0c.4 -
p. 4 of 9
FWG 01/11/98
0x0c – Flat Panel Node (cont’d)

2. I/O Definitions (cont’d)
Signal Device I/O Type Node.Byte.Bit Key

Code(s)
Feed Override potentiometer 8-bit input register 0x0c.5 -
Rapid Override potentiometer 8-bit input register 0x0c.6 -
Spindle Override potentiometer 8-bit input register 0x0c.7 -
0x0d – Touchscreen Node / Flat Panel Node

2. I/O Definitions
Signal Device I/O Type Node.Byte.Bit Data Values
Touchscreen 1 X Coordinate is proportional to 8-bit input 0x0d.0 Range: 0 – 255

activated screen position. register
Touchscreen 1 Y Coordinate is proportional to 8-bit input 0x0d.1 Range: 0 – 255

Touchscreen 2 X Coordinate is proportional to 8-bit input 0x0d.2 Range: 0 – 255

Touchscreen 2 Y Coordinate is proportional to 8-bit input 0x0d.3 Range: 0 – 255

Pen Status Indicates a Touch (Pen 8-bit input 0x0d.4 0x00 = Pen Up
Down) or non-touch (Pen register 0x04 = Pen Down
Up)
Control Register Address Determines the touch 8-bit output 0x0d.0 0x00 = TS1
screen to which the Control register 0x01 = TS2
Registers are applied.
Sample Count The number of samples 8-bit output 0x0d.1 Default = 8

from which the register Min = 1
microprocessor calculates a Max = 8
valid Pen Down condition. A value of zero will be
This is a global parameter ignored by the node.
that affects both TS1 and
TS2 regardless of the
Control Register Address
selected.
Repeat Time The amount of time 8-bit output 0x0d.2 Default = 5 (50 msec)
(x10msec) between register Min = 1 (10 msec)
consecutive transmissions, Max = 100 (1 sec)
effective during a Drag A value of zero will be
operation. This parameter ignored by the node.
is global and may be set via
TS1 or TS2.
p. 5 of 9
FWG 01/11/98
0x0d – Touchscreen Node / Flat Panel Node (cont’d)

Rejection Threshold Screen presses are rejected 8-bit output 0x0d.3 Default = 5
if the Sample Set Delta register A value of zero will be
(Max-Min) is less than the ignored by the node.
Rejection Threshold. Lower
Rejection Threshold values
provide more accurate
decoding, while higher
values result in a quicker
response. This global
parameter may be set via
the Control Register
Address (TS1 or TS2).
Noise Floor If the average of the Sample 8-bit output 0x0d.4 Default = 5
Set is greater than the Noise register A value of zero will be
Floor value, it may be ignored by the node.
considered as a valid screen
decode. This parameter is
global – set by either TS1 or
TS2 Control Register
Address.
Drag Threshold Determines the delta 8-bit output 0x0d.5 Default = 5

needed before a new register Drag Mode Off = 0x0ff
coordinate is sent. This Non-zero values will be
local parameter may be set ignored.
independently for TS1 and
TS2.
Cursor Latch Mode If Cursor Latch Mode is on, 8-bit output 0x0d.6 Off = 0 (VRTX)
the screen will transmit the register On = 1 (Windows)
last touched coordinate
upon release. If Latch Mode
is off, the node will transmit
a (0,0) when the screen is
released.
p. 6 of 9
FWG 01/11/98
Key Codes
0x04 - Detented Jog Node
Device Up/Down Key Code at Key Code at

Node.Byte 0x04.1 Node.Byte 0x04.2
x1 down 0x71 0x80
x10 down 0x72 0x80
x100 down 0x73 0x80
Store Position down 0x56 0x80
0x08 – Console Jog Node / Flat Panel Node

x1 down 0x71 0x80
x10 down 0x72 0x80
x100 down 0x73 0x80
p. 7 of 9
FWG 01/11/98
Key Codes (cont’d)

* = discrete input, not part of matrix
RL SL Device Up/Down 0x0c.1 0x0c.2 Repeat

* * Interrupt Cycle down 0x5d 0x80 No
* * Spindle Off down 0x2f 0x80 No
0 0 Softkey 1 down 0x20 0x80 No
1 6 Softkey 15 down 0x7a 0x80 No
1 7 Softkey 16 down 0x7b 0x80 No
2 0 Input down 0x38 0x80 No
2 1 Review down 0x39 0x80 No
2 2 Aux. Down 0x3a 0x80 No
2 3 Help down 0x51 0x80 No
2 4 Delete down 0x58 0x80 Yes
2 5 Insert down 0x57 0x80 No
2 6 Auto Mode down 0x2a 0x80 No
2 7 Single Mode down 0x2b 0x80 No
3 0 Divide down 0x40 0x80 No
3 1 Multiply down 0x44 0x80 No
3 2 Minus down 0x48 0x80 No
3 3 Plus down 0x4b 0x80 No
3 4 End down 0x5a 0x80 Yes
3 5 Home down 0x59 0x80 Yes
3 6 Test Mode down 0x2c 0x80 No
3 7 Manual Mode down 0x2d 0x80 No
4 0 Clear down 0x4d 0x80 No
4 1 Seven down 0x3d 0x80 Yes
4 2 Eight down 0x3e 0x80 Yes
4 3 Nine down 0x3f 0x80 Yes
4 4 Page Down down 0x5c 0x80 Yes
4 5 Page Up down 0x5b 0x80 Yes
4 6 Tool Changer down 0x28 0x80 No
Auto
Manual
p. 8 of 9
FWG 01/11/98

5 0 (available) - - - -
5 1 Four down 0x41 0x80 Yes
5 2 Five down 0x42 0x80 Yes
5 3 Six down 0x43 0x80 Yes
5 4 Down Arrow down 0x53 0x80 Yes
5 5 Left Arrow down 0x54 0x80 Yes
5 6 Auto Coolant down 0x30 0x80 No
5 7 Mist Coolant down 0x31 0x80 No
6 0 (available) - - - -
6 1 One down 0x45 0x80 Yes
6 2 Two down 0x46 0x80 Yes
6 3 Three down 0x47 0x80 Yes
6 4 Rt. Arrow down 0x55 0x80 Yes
6 5 Up Arrow down 0x52 0x80 Yes
6 6 Flood Coolant down 0x32 0x80 No
6 7 Spindle On down 0x2e 0x80 No
7 0 (available) - - - -
7 1 Zero down 0x49 0x80 Yes
7 2 Enter down 0x4e 0x80 Yes
7 3 Decimal down 0x4a 0x80 No
7 4 Graph. Select down 0x3c 0x80 No
7 5 Graph. Draw down 0x3b 0x80 No
7 6 (available) - - - -
7 7 (available) - - - -
p. 9 of 9
Hurco Manufacturing Company
HURCO DS0076-1.DOC
Flat Panel Node Firmware
December 17, 1999
Description: EPROM, FLAT PANEL NODE V2.2

Drawing No.: 450-3001-978 REV.: A
CAD No.: DS0076 ECN No.: 15033
Drawn By: Phil Stewart 8/10/00 Approved By: __________ ________

---------------------------------------------------------------------------------------------------------
Flat Panel Node Firmware V2.2
Product ROM Size Part Number Rev.
Flat Panel Node 32Kx8 450-3001-978 A
Description:
This document set contains all the data necessary to program an EPROM for the
Flat Panel Node 415-0628-901. Program 27C256 part using DS0076-2.hex.
Create and affix label per specification below. This document also contains Max 4
CANbus mapping information.
V2.2 differs from V2.1 (450-3001-976) in the setting for Delta1_Touch hex value.
The Delta1_Touch hex value for V2.1 was 0005, and is changed to 0017 (Rejection
Threshold, page 8 of 450-3001-978, CN DS0076-2). This change addresses the
problem with slow or no response in the upper right corner of the 4 wire touch
screen. This change enables the 4 wire touch screen to respond in a like manner to
the 8 wire touch screen. The 415-0628-901 Flat Panel Node PCB Assembly print
changed from Rev. G to Rev. H. V2.2 supports both the 8 wire and the 4 wire touch
screen, while V2.1 will support only the 8 wire touch screen reliably.
Bill Of Materials:
Qty Hurco P/N Description Item
1 450-3001-948 EPROM, BLANK 27C256 1
1 703-0010-001 LABEL, EPROM BLANK 2
File Descriptions:
File Name File Type Description Offset
Required
DS0076-1.DOC Winword Firmware Release Document n/a
DS0076-2.DOC Winword Max 4 CANbus Map Document n/a
DS0076-3.HEX HEX Programming File none
DS0076-4.ZIP ZIP Firmware Source Code Files n/a
Label: (Note: Checksum calculated by BP Microsystems BP-1200 Programmer with default

buffer value set to 00).
FPN V2.2
450-3001-978 REV A
CS = 001BF44C
FWG 12/17/99
SOFTWARE DOCUMENT
R
450-3001-978 CAD # DS0076-2
SUBJECT:
ULTIMAX 4 CANbus MAP
_Phil Stewart___________________ 8/15/2000 ______________________________ _______

450-3001-978 p. 1 of 11 CAD # DS0076-2

FWG 12/17/99
RECORD OF CHANGES
Software Document Number CAD Number

450-3001-978 DS0076-2
Revisions:

By
450-3001-978 p. 2 of 11 CAD # DS0076-2

FWG 12/17/99
Node Assignments
Node # Ultimax 3 Ultimax 4

0x00 CONTROLLER_NODE CONTROLLER NODE
0x04 REMOTE_JOG_NODE RJN2_REMOTE_JOG_NODE
0x04 REMOTE_JOG_LEDS_NODE -
0x05 REMOTE_JOG_KEYS_NODE DCIO_NODE_4
0x06 REMOTE_JOG_OVERRIDES_NODE DCIO_NODE_5
0x07 REMOTE_JOG_ENCODER_NODE DCIO_NODE_6
0x08 CONSOLE_JOG_LEDS_NODE CIN2_CONSOLE_JOG_NODE
0x09 CONSOLE_JOG_KEYS_NODE -
0x0a CONSOLE_JOG_OVERRIDES_NODE -
0x0b CONSOLE_JOG_ENCODER_NODE -
0x0c CONSOLE_INTERFACE_NODE CIN2_CONSOLE_NODE
0x0c CONSOLE_DISCRETES_NODE -
0x0d CONSOLE_KEYS_AND_LEDS_NODE CIN2_TOUCHSCREEN_NODE
0x0e AT_KEYBOARD_NODE -
0x0f CONSOLE_TRACKBALL_NODE -
0x10 LOCAL_IO_NODE LOCAL_IO_NODE
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0x04 – Detented Jog Node

1. Reset identifier: “J”
2. I/O Definitions
X Axis 1 of 6 rotary switch bit-wise input 0x04.0.0 -

Select
Y Axis 1 of 6 rotary switch bit-wise input 0x04.0.1 -

Select
Z Axis 1 of 6 rotary switch bit-wise input 0x04.0.2 -

Select
a Axis 1 of 6 rotary switch bit-wise input 0x04.0.3 -

Select
b Axis 1 of 6 rotary switch bit-wise input 0x04.0.4 -

Select
Jog- Key momentary pushbutton bit-wise input 0x04.0.6 -
Embedded switch bit-wise input 0x04.0.7 -

Estop
x1 Key momentary pushbutton bit-wise input 0x04.1 0x71
Key Mode Constant 8-bit value 0x04.2 0x80
Manual Potentiometer 8-bit input register 0x04.3 -

Override

Low Byte register

High Byte register
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0x08 – Console Jog / Flat Panel Node

2. I/O Definitions
Jog- Key Momentary pushbutton bit-wise input 0x08.0.6 -
Embedded Switch bit-wise input 0x08.0.7 -

Estop
Key Mode Constant 8-bit input 0x08.2 0x80
Manual Override Potentiometer 8-bit input register 0x08.3 -

Low Byte register

High Byte register
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2. I/O Definitions
Eestop – Console switch bit-wise input 0x0c.0.0 -
Start Button momentary pushbutton bit-wise input 0x0c.0.1 -
Motion Hold Button latching pushbutton bit-wise input 0x0c.0.2 -
Stop Button momentary pushbutton bit-wise input 0x0c.0.3 -
Power On Button momentary pushbutton bit-wise input 0x0c.0.4 -
Start Lamp 24V lamp bit-wise output 0x0c.0.0 -
Motion Hold Lamp 24V lamp bit-wise output 0x0c.0.1 -
Stop Lamp 24V lamp bit-wise output 0x0c.0.2 -
LCD Backlight Enable - Text LCD input bit-wise output 0x0c.0.3 -
LCD Backlight Enable - Grax LCD input bit-wise output 0x0c.0.4 -
Interrupt Cycle Lamp led bit-wise output 0x0c.1.0 -
Aux Mode LED led bit-wise output 0x0c.1.1 -
Review Mode LED led bit-wise output 0x0c.1.2 -
Input Mode LED led bit-wise output 0x0c.1.3 -
Manual Mode LED led bit-wise output 0x0c.1.4 -
Test Run Mode LED led bit-wise output 0x0c.1.5 -
Single Cycle Mode LED led bit-wise output 0x0c.1.6 -
Auto Mode LED led bit-wise output 0x0c.1.7 -
Spindle Off LED led bit-wise output 0x0c.2.0 -
Spindle On LED led bit-wise output 0x0c.2.1 -
ATC Manual Mode LED led bit-wise output 0x0c.2.2 -
ATC Auto Mode LED led bit-wise output 0x0c.2.3 -
Coolant Auto Mode LED led bit-wise output 0x0c.2.4 -
Flood Coolant LED led bit-wise output 0x0c.2.5 -
Mist Coolant LED led bit-wise output 0x0c.2.6 -
Key Code matrix scan code 8-bit input register 0x0c.1 -
Key Mode ctrl or alt combinations 8-bit input register 0x0c.2 0x81 = Alt + Key
0x82 = Ctl. + Key
0x83 = Ctl. + Alt. + Key
Trackball X quadrature input 8-bit input register 0x0c.3 -
Trackball Y quadrature input 8-bit input register 0x0c.4 -
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Signal Device I/O Type Node.Byte.Bit Key

Code(s)
Feed Override potentiometer 8-bit input register 0x0c.5 -
Rapid Override potentiometer 8-bit input register 0x0c.6 -
Spindle Override potentiometer 8-bit input register 0x0c.7 -
0x0d – Touchscreen Node / Flat Panel Node

2. I/O Definitions
Touchscreen 1 X Coordinate is proportional 8-bit input 0x0d.0 Range: 0 – 255

to activated screen register
position.
Touchscreen 1 Y Coordinate is proportional 8-bit input 0x0d.1 Range: 0 – 255

position.
Touchscreen 2 X Coordinate is proportional 8-bit input 0x0d.2 Range: 0 – 255

position.
Touchscreen 2 Y Coordinate is proportional 8-bit input 0x0d.3 Range: 0 – 255

position.
Pen Status Indicates a Touch (Pen 8-bit input 0x0d.4 0x00 = Pen Up
Down) or non-touch (Pen register 0x04 = Pen Down
Up)
Control Register Address Determines the touch 8-bit output 0x0d.0 0x00 = TS1
screen to which the register 0x01 = TS2
Control Registers are
applied.
Sample Count The number of samples 8-bit output 0x0d.1 Default = 8

from which the register Min = 1
microprocessor calculates Max = 8
a valid Pen Down A value of zero will
condition. This is a global be ignored by the
parameter that affects node.
both TS1 and TS2
regardless of the Control
Register Address
selected.
Repeat Time The amount of time 8-bit output 0x0d.2 Default = 5 (50 msec)
(x10msec) between register Min = 1 (10 msec)
consecutive Max = 100 (1 sec)
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transmissions, effective A value of zero will

during a Drag operation. be ignored by the
This parameter is global node.
and may be set via TS1 or
TS2.
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0x0d – Touchscreen Node / Flat Panel Node (cont’d)

Rejection Threshold Screen presses are 8-bit output 0x0d.3 Default = 0x17
rejected if the Sample Set register A value of zero will
Delta (Max-Min) is less be ignored by the
than the Rejection node.
Threshold. Lower
Rejection Threshold values
provide more accurate
decoding, while higher
values result in a quicker
response. This global
parameter may be set via
the Control Register
Address (TS1 or TS2).
Noise Floor If the average of the 8-bit output 0x0d.4 Default = 5

Sample Set is greater than register A value of zero will
the Noise Floor value, it be ignored by the
may be considered as a node.
valid screen decode. This
parameter is global – set
by either TS1 or TS2
Control Register Address.
Drag Threshold Determines the delta 8-bit output 0x0d.5 Default = 5

needed before a new register Drag Mode Off =
coordinate is sent. This 0x0ff
local parameter may be set Non-zero values will
independently for TS1 and be ignored.
TS2.
Cursor Latch Mode If Cursor Latch Mode is on, 8-bit output 0x0d.6 Off = 0 (VRTX)
the screen will transmit the register On = 1 (Windows)
last touched coordinate
upon release. If Latch
Mode is off, the node will
transmit a (0,0) when the
screen is released.
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FWG 12/17/99
Key Codes
0x04 - Detented Jog Node

x1 down 0x71 0x80
x10 down 0x72 0x80
x100 down 0x73 0x80
0x08 – Console Jog Node / Flat Panel Node

x1 down 0x71 0x80
x10 down 0x72 0x80
x100 down 0x73 0x80
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FWG 12/17/99

* = discrete input, not part of matrix

* * Interrupt Cycle down 0x5d 0x80 No
* * Spindle Off down 0x2f 0x80 No
1 6 Softkey 15 down 0x7a 0x80 No
1 7 Softkey 16 down 0x7b 0x80 No
2 0 Input down 0x38 0x80 No
2 1 Review down 0x39 0x80 No
2 2 Aux. Down 0x3a 0x80 No
2 3 Help down 0x51 0x80 No
2 4 Delete down 0x58 0x80 Yes
2 5 Insert down 0x57 0x80 No
2 6 Auto Mode down 0x2a 0x80 No
2 7 Single Mode down 0x2b 0x80 No
3 0 Divide down 0x40 0x80 No
3 1 Multiply down 0x44 0x80 No
3 2 Minus down 0x48 0x80 No
3 3 Plus down 0x4b 0x80 No
3 4 End down 0x5a 0x80 Yes
3 5 Home down 0x59 0x80 Yes
3 6 Test Mode down 0x2c 0x80 No
3 7 Manual Mode down 0x2d 0x80 No
4 0 Clear down 0x4d 0x80 No
4 1 Seven down 0x3d 0x80 Yes
4 2 Eight down 0x3e 0x80 Yes
4 3 Nine down 0x3f 0x80 Yes
4 4 Page Down down 0x5c 0x80 Yes
4 5 Page Up down 0x5b 0x80 Yes
4 6 Tool Changer Auto down 0x28 0x80 No
Manual
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5 0 (available) - - - -
5 1 Four down 0x41 0x80 Yes
5 2 Five down 0x42 0x80 Yes
5 3 Six down 0x43 0x80 Yes
5 4 Down Arrow down 0x53 0x80 Yes
5 5 Left Arrow down 0x54 0x80 Yes
5 6 Auto Coolant down 0x30 0x80 No
5 7 Mist Coolant down 0x31 0x80 No
6 0 (available) - - - -
6 1 One down 0x45 0x80 Yes
6 2 Two down 0x46 0x80 Yes
6 3 Three down 0x47 0x80 Yes
6 4 Rt. Arrow down 0x55 0x80 Yes
6 5 Up Arrow down 0x52 0x80 Yes
6 6 Flood Coolant down 0x32 0x80 No
6 7 Spindle On down 0x2e 0x80 No
7 0 (available) - - - -
7 1 Zero down 0x49 0x80 Yes
7 2 Enter down 0x4e 0x80 Yes
7 3 Decimal down 0x4a 0x80 No
7 4 Graph. Select down 0x3c 0x80 No
7 5 Graph. Draw down 0x3b 0x80 No
7 6 (available) - - - -
7 7 (available) - - - -
450-3001-978 p. 12 of 11 CAD # DS0076-2

757-4002-221 CAD# D8633
SUBJECT: PROCEDURE, TFT FPD CONFIGURATION

AND TEST FOR SERVICE.
____________________________________ _______ _________________________ _______

1
757-4002-221 D8633
RECORD OF CHANGES

By
2
757-4002-221 D8633
I. INTENT
To provide instructions for On-Screen Display (OSD) menu configuration
and testing of Hurco 12.1” TFT Flat Panel Display (FPD) Assemblies.
On-screen display configuration varies depending on whether the system

the display will be installed into is ISA or PCI. ISA systems will have an
ISA Dual VGA video board (415-0220-004) and PCI systems will have a
PCI Dual VGA video board (415-0220-007).
II. SCOPE
Applies only to Hurco 12.1” TFT Flat Panel Display Assemblies. This
procedure applies to creation of “T” or tested assemblies and to
reconfiguration of displays in the field.
III. PROCEDURE
A. Calibration
1. Calibration of the FPD assembly shall consist of configuring the

parameters in the on-screen display (OSD). The OSD is accessed
as follows:
a. Press the “MENU” button on the keypad at the top of the flat
panel display.
b. Press the “MODE” button on the keypad to select the desired

mode to change. The selected mode is highlighted.
c. Press the “UP” or “DOWN” button as appropriate to change the

mode values/settings.
d. Set the modes as shown in the table on the following page.
2. Proper configuration of the OSD should be verified visually.

Additionally, the Hurco “crosshatch” test should be used to verify
that the image is centered on the display. None of the edges of
the crosshatch pattern should be clipped or cropped by the edges
of the display. See Item 3b in the Electrical Test section for
instructions to run the Hurco “crosshatch” test.
3
757-4002-221 D8633
Modes (PCI) Settings (ISA) Settings
Brightness 128* 128*

Contrast 100 72
R-Contrast 100 72
G-Contrast 100 72
B-Contrast 100 72
H-Position 160 73
V-Position 21 26
Clock 128 128
Phase 10 10
Expension Normal Normal
Graphic/Text Text Text
Center User Setting** User Setting**
Reset User Setting** User Setting**
* Potentiometer setting overrides brightness setting.

** Do not change this setting.
B. Electrical Test of Flat Panel Display
1. Connect the flat panel display to a suitable power source and an

appropriate Ultimax 4 control card cage or test fixture. ISA
configured displays should be connected to an ISA Dual VGA
board (415-0220-004) and PCI configured displays should be
connected to a PCI Dual VGA board (415-0220-007).
2. When all connections have been made, the system should be

powered up. Check for proper operation of 640 x 480 mode
during the power-on self test. The display should change
automatically to 800 x 600 mode following the self test
(indicated by an increase in text size). Check also for
backlight enable functionality (backlight should turn off and on
three times) during the boot sequence.
3. Upon completion of the boot sequence, the following items

should be checked:
4
757-4002-221 D8633
a. Brightness potentiometer: check that brightness can be

adjusted linearly between the LOWEST and HIGHEST
settings.
b. Check that the displayed image is not distorted in any way.

Use the Hurco “color bar” and “crosshatch” tests to confirm
this. The keystrokes required to activate these tests are
as follows:
1. “Auxiliary” or Alt-A (puts the control in Auxiliary Mode).
2. Press “Enter” then “1”, “0”, “0” and “Enter” again.
3. Press “F5” (for Control Diagnostics).
4. Press “F3” (for Console Tests).
5. Press “F3” (for the Crosshatch Test) or press “F4” (for

the Color Bar Test) as appropriate.
6. To exit either test, press “F8.”
NOTE: If the screen blanks during either of these tests,

press any key to restore the displayed image.
c. Check the display carefully for bubbles, scratches, pinholes,

dents, bright spots, black spots or other defects or foreign
particles on its surface. If any of these defects are present,
the display shall be deemed unacceptable and be rejected.
The Hurco “color bar” and “crosshatch” tests should be used for
this inspection.
d. Check that the crosshatch pattern’s edges are not clipped or

cropped by the edges of the display. If the crosshatch pattern’s
edges are clipped or cropped, verify that the OSD configuration
is correct and that the proper video board (ISA/PCI) is being used.
5
R
757-4002-232 CAD # D8644
SUBJECT: PROCEDURE, FORMOSA LMB-680 P/B CPU BOARD SETUP
Wesley Shelton 4/26/99

757-4402-232
RECORD OF CHANGES

757-4002-232 D8644
Revisions:
Revision ECN # Revision Description Rev Date Approved Date

By By
I. INTENT:
757-4002-232 Page 2 of 7 CAD#D8644

757-4402-232
To provide a standardized procedure for the proper set up of the BIOS and jumper settings on the
Formosa LMB-680P Industrial CPU Board.
II. SCOPE:
Specific to the FIC LMB-680P Pentium CPU Board.
III. PROCEDURE:
A Jumper Configuration
1. Remove the CPU Board from its packaging and visually inspect it for any damage.
2. Configure the jumpers as follows.
a. JP2 - Battery and Clear CMOS (Internal)
b. JP4 - CPU Vcc3 I/O Voltage Select (P54C)
c. JP1 – Bus Core Ratio Select (2.5X)
d. JP3 – CPU Core Voltage Select (3.3V)
757-4002-232 Page 3 of 7 CAD#D8644

757-4402-232
e. JP5 – Watchdog Timer (Disabled)
f. JP12 – Power LED & Key-lock (No Connection)
g. JP8 – CPU Clock (66.6 MHz)
h. JP11 – PS/2 Mouse Support (Disabled)
i. JP6 – Base I/O Port Address Select (136h, 536h)
j. JP7 – Serial Port Setup (CN8 = COM1, CN11 = COM2)
B CMOS SETUP
1. Use the following table for the keystroke functions needed to modify the CMOS settings.
Arrows Move to the next field to the right, left, above, or below
Enter Enters a sub-menu from the main menu
PgUp / + Increase the numeric value or Change the selected field
PgDn / - Decrease the numeric value or Change the selected field
F1 Help
F10 Save and Exit
ESC Main Menu = Quit w/o saving or Exit menu
Sub-menu = Exit sub-menu and return to main menu
2. Enter the CMOS setup screen.
757-4002-232 Page 4 of 7 CAD#D8644

757-4402-232
a. Power on the card cage.

b. When the prompt “Press DEL to enter SETUP” appears at the bottom of the screen, press
the DEL key.
c. The CMOS setup utility main menu should appear on the screen.
3. Standard CMOS Setup.
a. Set the Primary Master hard drive parameters as follows. For a list of the approved hard
drives and their proper parameters see document 757-4002-166.
1) If the hard drive is less than 500MB or if the software is older and has cylinder and
sector restriction less than 500 MB:
a) Enter into the “Standard CMOS Setup” screen.

b) Change the Primary Master Type parameter to User.
c) Change the Primary Master Mode to Normal.
d) Set the cylinders, heads and sectors from the list in document 757-4002-166
(CAD# 8577).
2) If the hard drive is greater than 500MB and the software has no restriction under
500MB then the LBA mode must be used.
a) Enter into the “Standard CMOS Setup” screen.

b) Change the Primary Master Type parameter to User.
c) Change the Primary Master Mode to Normal.
d) Set the cylinders, heads and sectors from the list in document 757-4002-166.
e) Change the Primary Master Mode to LBA. The values in the cylinders, heads,
and sectors may change. These new numbers are derived by the CMOS and
will still work OK.
b. Primary Slave and both Secondary drives should be set to NONE.
c. The following table is a list of the remaining parameters for the Standard CMOS Setup.
Date Set to current date

Time Set to current time
Drive A: 1.44M, 3.5 in.
Drive B: None
Video: EGA / VGA
Halt On: All, But Keyboard
d. Press the ESC key until the Main menu appears.
4. BIOS Features Setup
Virus Warning Disabled

CPU Internal Cache Enabled
External Cache Enabled
Quick Power on Self Test Disabled
Boot Sequence A, C, SCSI
Swap Floppy Drive Disabled
Boot Up Floppy Seek Disabled
Boot Up NumLock Status On
Boot Up System Speed High
Gate A20 Option Normal
Typematic Rate Setting Disabled
Typematic Rate (Chars/Sec) 6
757-4002-232 Page 5 of 7 CAD#D8644
757-4402-232
Typematic Delay (Msec) 250

Security Option Setup
IDE Second Channel Control Disabled
PCI / VGA Palette Snoop Disabled
OS Select For DRAM > 64 MB Non-OS2
Video BIOS Shadow Enabled
C8000-CBFFF Disabled
CC000-CFFFF Disabled
D0000-D3FFF Disabled
D4000-D7FFF Disabled
D8000-DBFFF Disabled
DC000-DFFFF Disabled
5. Chipset Features Setup
DRAM Auto Configuration Disabled

DRAM Timing Control Normal
Sustained 3T Write Disabled

2 Bank PBSRAM 3-1-1-1
Read Pipeline Disabled
Write Pipeline Disabled
Cache timing Fast
Video BIOS Cacheable Disabled

System BIOS Cachable Disabled
Memory Hole At 15 MB Addr. Disabled
OnChip USB Disabled
6. Power Management Setup
Power Management Disabled

Note: All other items are disabled when Power Management is disabled
7. PNP/PCI Configuration
PNP OS Installed No
Resources Controlled By Auto
Reset Configuration Data Disabled
CPU to PCI Write Buffer Enabled

PCI Dynamic Bursting Enabled
PCI Master 0 WS Write Enabled
PCI Peer Concurrency Disabled
PCI Delay Transaction Disabled
PCI IRQ Actived By Edge

PCI IDE IRQ Map To PCI-Auto
Primary IDE INT # A
Secondary IDE INT# B
8. Integrated Peripherals
OnChip IDE First Channel Enabled

OnChip IDE Second Channel Disabled
757-4002-232 Page 6 of 7 CAD#D8644

757-4402-232
IDE Prefetch Mode Disabled

IDE HDD Block Mode Disabled
IDE Primary Master PIO Mode 0
IDE Primary Slave PIO Auto
IDE Primary Master UDMA Disabled

IDE Primary Slave UDMA Disabled
Onboard FDC Controller Enabled

Onboard UART 1 Auto
Onboard UART 2 Auto
Onboard UART 2 Mode Standard
Onboard Parallel Port 378 / IRQ7

Parallel Port Mode Normal
9. Once all of the above parameters are set ESC back to the main menu.
10. Press F10, the “Y” key and then the “Enter” to exit and save the new parameters.
757-4002-232 Page 7 of 7 CAD#D8644

757-4002-233
R
757-4002-233 CAD #D8647
SUBJECT:
Hard Disk Drive Test Procedure
_ ___________ _ ___ _ __ ___________ _ _
Page 1 of 6
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757-4002-233
Page 2 of 6
757-4002-233 CAD #
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757-4002-233
RECORD OF CHANGES

757-4002-233 D8647
Revisions:

By
Page 3 of 6
757-4002-233 CAD #
D8647
757-4002-233
I. INTENT:
This document is to provide instruction for testing of the 426-0056-019 Hard Disk
Drive.
II. SCOPE:
This Hard Disk Drive (HDD) is used on the ISA CARD CAGE ASS’Y.(CN 8779),
as well as other assemblies. The part number of the HDD after successful
completion of this procedure will be 426-0056-019T. The 426-0056-019T hard
disk drive will not work for Ultipath applications. This procedure is different from
the procedure used to test the hard disk drive that is used for Ultipath Control
Package Test Procedure (757-4002-122, CN D8512). Use part number 007-
0019-002T tested hard disk drive for Ultipath applications.
Additional information can be found in document number 757-4002-166 (CN
D8577).
Additional documents applicable to this assembly:
753-2000-002 ( CN D8030 ), Sensitive Component Handling Procedure, ESD.
III. PROCEDURE:
NOTE: Proper ESD precautions shall be observed throughout all of this assembly
procedure as set forth by the ESD document listed above. Failure to do so will
cause irreparable damage to electronic components.
1. Use a test fixture suitable for the hard disk drive being tested. A working
007-3002-015 (CN8779) ISA chassis with a floppy disk drive, a keyboard,
and a monitor attached will work well.
2. Disconnect and remove the installed hard disk drive from the test fixture.
Install the hard disk drive to be tested - Unit Under Test (UUT).
3. Power up the test fixture. Press <DELETE> or the appropriate keys to
enter the CMOS setup screen. Note the CMOS settings for drive C: hard
disk drive so that they may be restored after the completion of step 18.
For hard disk drives 1.7G or larger, set CMOS values for drive C: hard
disk drive to: Cylinders: 3305, Heads: 16, Sectors: 63. For hard disk
drives larger than 400M and smaller than 1.7G in size, set CMOS values
to: Cylinders: 1024, Heads: 16, Sectors: 50. Refer to document 757-4002-
166 for the CMOS hard disk drive settings for hard disk drive sizes
smaller than 400M. Save these settings and exit CMOS setup. Remove
power.
4. The UUT hard disk drive will have all software erased when the next two
steps are performed. Make sure that the UUT drive does not contain any
Page 4 of 6
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D8647
757-4002-233
information that needs to be retained. If you are unsure – do not continue

with this procedure.
5. Power up the test fixture and boot with the Hard Disk Setup disk (p/n 427-
0004-008 for 400M to less than 1.7G, p/n 427-0004-010 for 1.7G or
larger) in drive A: floppy disk drive. If the UUT drive being tested is any
other size, the appropriate Hard Disk Setup disk must be used.
6. After the A: prompt appears, type “D” and press <ENTER>. This will
delete any existing hard disk drive partitions. Remove power.
7. Power up the test fixture. After the A: prompt appears, type “P” and
<ENTER>. This will partition the hard disk drive.
8. After the partition is successfully installed, type “F” and <ENTER> to

format the UUT. This will format drive C: and D: in approximately 5
minutes.
9. After the format is complete, place a disk having Scandisk on it in drive a:.
10. Type “scandisk C:” and then press <ENTER>.
11. After scandisk completes on drive C:, check the results for any bad
sectors or other faults.
12. Type “scandisk D:” and then press <ENTER>.
13. These three program steps will test all available sectors on drives C: and
D:.
14. After scandisk completes on drive D:, check the results for any bad
sectors or other faults. If there are a small number of bad sectors or other
minor problems , go to step 15. If there are a large number of bad sectors,
reject the UUT drive and return to the manufacturer if it is in warranty. If
the UUT drive has no problems or errors, go to step 17.
15. If any fault is found on either drive C: or D:, repeat steps 4 through 14. If
after the second test on the same drive there are still errors of any kind,
reject the UUT drive as in the previous step.
16. After successful completion of all of the preceding steps, remove power.
Power up the test fixture again and boot with the Hard Disk Setup disk
(p/n 427-0004-010, ST31720) in drive A: floppy disk drive.
17. After the A: prompt appears, type “D” and press <ENTER>. This will
delete any existing hard disk drive partitions. Remove power.
Page 5 of 6
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757-4002-233
18. This completes the testing of the 426-0056-019T Hard Disk Drive.
Page 6 of 6
757-4002-233 CAD #
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R
757-4002-135 REV B CAD #D8529
SUBJECT: Ultimax Pentium Field Reference Documents
Barry A. Van Paris 5/5/97 Michael Caron 5/15/98

Originator Date Mgr, Control Systems Engineering Date
RECORD OF CHANGES
Engineering Document 757-4002-135 REV B CAD #D8529

By
A 14009 Original Release BVP 5/5/97 MFC 5/15/97
B 14799 Added Mfg notice 4138 and drawing CAD
#8779 for 007-3002-011 power supply.
BVP 10/14/99
Document, Ultimax Pentium Field Reference 757-4002-135 Rev. B

Page 2
I. INTENT
The purpose of this document is to provide information for field installation of the Ultimax Pentium CPU board on ISA
based Hurco machines. This information is to supplement the Pentium installation procedure.
II. SCOPE
This document is applicable to machines with ISA card racks.
III. Documents
The following documents are included:
• 007-3002-001 thru 004 (CAD #8451) ASSY, ISA/P CARD CAGE

• 415-0247-007 thru 008 (CAD #8455) PCB ASSY, MX4 CNC++
• 007-3003-001 (CAD #8456) ASSY, ISA PENTIUM CPU STD
• 007-3002-011 (CAD #8779) ASS'Y,C/C,ISA/PCI PASS B/P,M/C SING.VGA
Document, Ultimax Pentium Field Reference 757-4002-135 Rev. B

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Document, Ultimax Pentium Field Reference 757-4002-135 Rev. A Page
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757-4002-151
15 Jan 98 CAD #D8555
SUBJECT: LASER MEASUREMENT OF LINEAR POSITIONING

(FOR V2.00 OR GREATER)
DAVID J. SKRZYPCZAK
________________________________ _______ _______________________________ _______
REV. A
ECN #14168

2 of 15 757-4002-151
CONTENTS PAGE
I. INTENT................................................................................................................ 4
II. APPLICABILITY and BACKGROUND............................................................... 4
III. EQUIPMENT ....................................................................................................... 4
IV. SPECIFICATIONS/ACCEPTANCE CRITERIA .................................................. 5

A. ACCURACY............................................................................................. 5
B. REPEATABILITY .................................................................................... 5
V. FACTORS IN THE ASSESSMENT OF POSITIONAL ACCURACY.................. 5

A. POSITIONAL UNCERTAINTY (P) ......................................................... 5
B. POSITIONAL SCATTER (Ps) .................................................................. 5
C. POSITIONAL DEVIATION (Pa).............................................................. 5
D. REVERSAL ERROR (U) .......................................................................... 5
VI. MEASUREMENT PROCEDURE ........................................................................ 6

A. MACHINE SETUP ................................................................................... 6
B. LASER EQUIPMENT SETUP.................................................................. 6
C. PART PROGRAM SETUP........................................................................ 7
D. AXIS PREPARATION.............................................................................. 8
E. TWO-PASS LASER MEASUREMENT.................................................... 9
F. LEAD SCREW COMPENSATION DATA ENTRY ................................. 9
G. FOUR-PASS LASER MEASUREMENT .................................................. 10
VII. ACCURACY AND REPEATABILITY CERTIFICATION .................................. 12

A. TWO-PASS LASER MEASUREMENT ANALYSIS................................ 12
1. LEADSCREW EVALUATION........................................................ 12
2. BACKLASH EVALUATION........................................................... 13
3. GRAPHICAL PLOT EVALUATION............................................... 13
B. FOUR-PASS LASER MEASUREMENT ANALYSIS .............................. 13
C. SAVING LEAD SCREW COMPENSATION DATA................................ 14
D. RE-LASER CRITERIA ............................................................................. 15
3 of 15 757-4002-151
I. INTENT
A. To establish an accepted standard for:

1. measuring the positional accuracy of an unloaded machine tool by direct, linear
measurement on the machine
2. providing for the software compensation of geometrical deviations.
B. This standard is to be used to verify:

1. geometrically correct construction
2. no excessive leadscrew backlash
3. machine positional accuracy normalized to 20°C (68°F) is achievable.
II. APPLICABILITY and BACKGROUND

This procedure is applicable to all Machining Centers with an ISA Control using V2.00 software
or greater. This is the only procedure to be used by Quality Control for the confirmation and
acceptance of machine positioning accuracy and repeatability. Accuracy and repeatability will be
measured through the use of a LASER Interferometer Measurement System using linear
displacement.
During linear displacement measurements, the LASER accuracy can be affected by environmental
variations as well as differences in beam length between the reference point and the target
position; excessive variations of either can result in a significant error in the data. The setup of
the LASER system must be adjusted for proper wavelength of the measurement beam and must
also compensate for the ambient and material temperature, barometric pressure, and humidity
based on the correct coefficient of expansion for the material being measured.
The LASER Interferometer Measurement System will normalize the data based on the
environmental characteristics to a material temperature of 20°C (68°F).
V2.00 or greater software differs from previous versions of software in the entry of the
Leadscrew Mapping in that the error data is entered as the full dimension from the Part Zero (or
Target).
III. EQUIPMENT
A. LASER Interferometer Measurement System (Hewlett-Packard or equivalent)

1. Computer with I/O ROM
2. Printer/Plotter ROM
3. Printer/Plotter
4. Metrology software (Pullman & Associates, Model 11085A or HP 55286A or
equivalent)
5. Associated cabling
B. Adapter Plate AD-1
C. Hurco LASER Program Diskette (704-2000-004)
4 of 15 757-4002-151
IV. SPECIFICATIONS/ACCEPTANCE CRITERIA
These specifications are based on full travel of the axis and are normalized to a Leadscrew
material temperature of 20°C (68°F) by the LASER equipment.
A. ACCURACY
The positional Uncertainty (P) value calculated after completion of the qualifying 4 pass
(per VDI/DGQ 3441) is not to exceed 0.010 mm (0.0004 inches).
P < 0.010 mm
(P < 0.0004 in)
B. REPEATABILITY
The Positional Scatter (Ps) added to the Reversal Error (U) calculated after completion of
the qualifying 4 pass (per VDI/DGQ 3441) is not to exceed 0.005 mm (0.0002 inches).
Ps + U < 0.005 mm
(Ps + U < 0.0002 in)
V. FACTORS IN THE ASSESSMENT OF POSITIONAL ACCURACY

Reference "Verein Deutscher Ingenieure/Deutsche Gesellschaft fur Qualitat 3441", Statistical
Testing of the Operational and Positional Accuracy of Machine Tools, VDI/DGQ 3441.
A. POSITIONAL UNCERTAINTY (P)

The total deviation on the selected test axis taking into account the characteristic values
determined in the individual positions: Positional Deviation, Reversal Error, and
Positional Scatter. It includes both system and random deviations.
B. POSITIONAL SCATTER (Ps)

Represents the effect of random deviations in each position on the selected test axis. It is
expressed to a specified degree of probability.
C. POSITIONAL DEVIATION (Pa)

As a system deviation, it is the maximum difference of the mean values of all measuring
positions on the selected test axis.
D. REVERSAL ERROR (U)

As a system deviation, it represents the difference obtained from the mean values in both
directions of travel for each position on the selected test axis.
5 of 15 757-4002-151
VI. MEASUREMENT PROCEDURE
A. MACHINE SETUP
1. Verify that the Way Lube is at an adequate level to complete the measurement of
the axis.
2. Install all way covers with all fasteners and the full enclosure with all fasteners.
3. Verify that the machine has been leveled, the servos have been setup, and the
geometries are to specification.
4. Be sure that the temperature of the table (and the leadscrew) have stabilized. The
machine should be idle for a minimum of 8 hours to be sure that the table and
leadscrew temperature have achieved equilibrium.
5. Initial Control setup for default units, distance, and zero map:
a) Select Auxiliary mode.
b) Access the Integrator Support Services by entering the following sequence:
Enter 100 Enter
c) Select the LEADSCREW MAPPING softkey.
d) Select the X AXIS softkey.
e) At the Leadscrew Mapping Enable prompt, select the YES softkey.
f) At the prompt for Leadscrew Mapping Interval, enter 25.4 mm. Note: at
the bottom of the Text Display, check that the CFG Units are Metric.
g) Select the PLUS MAP DATA ENTRY softkey.
h) Select the SET MAP TO ZERO COMPENSATION softkey.
i) Select the TOGGLE PLUS AND MINUS MAP softkey.
j) Select the SET MAP TO ZERO COMPENSATION softkey.
k) Select the EXIT softkey.
l) Repeat steps d) through k) for YAXIS and Z AXIS.
m) Select the STORE DATA ON DISK softkey.
n) Select the HARD DRIVE softkey.
o) Select the EXIT softkey (to return to Integrator Support Services).
p) Select the EXIT softkey (to return to Auxiliary).
B. LASER EQUIPMENT SETUP

1. Obtain all necessary equipment to perform the measurement on the selected axis.
2. Mount Adapter Plate to the mill table. Using a Square, ensure that the Plate is
mounted square with the table, making certain that the Plate position permits
mounting of the Interferometer with adequate clearance to the Retro-reflector with
the table at the end of travel.
3. Mount the Interferometer to the mounting plate. Place the Reflector assembly
over the unused port of the Interferometer.
a) For X and Y axes: mount to a rod in the Tool holder and insert the Tool
holder into the Spindle. The Assembly should be no more than 150 mm
(6 in) off the table surface.
b) For Z axis: mount on a magnetic base and attach to a machined surface on
the front of the machine ram.
4. Attach the assembly to the Adapter Plate and use a Square to align it to the Plate.
Ensure that the orientation of the Interferometer is correct by aligning the direction
of the arrows on the Interferometer with the selected test axis.
6 of 15 757-4002-151
5. Jog the selected axis to its "home" limit switch then jog the axis away by
approximately 5 mm (0.25 in).
6. Position the Retro-reflector to be horizontally in line with the Interferometer on
the sides parallel to the selected axis by using a Square and by positioning the table
in the planes perpendicular to the selected axis.
7. At their closest point, the Interferometer and Retro-reflector should be about
25 mm (1 in) apart.
8. Position and level the tripod with the LASER Head attached.
9. Connect the cabling between the Head, the Display, the Compensator, and the
Computer.
10. Mount the Temperature Sensor as close as possible to the Ball Screw of the
selected axis.
11. Mount the Air Sensor on the outside of the full enclosure at the same height as the
optics mounted on the table. For Hewlett-Packard sensors, be sure to orient the
Air Sensor with the arrow pointing upward.
12. Perform the LASER alignment by following the LASER System Users Guide.
Alignment must be carefully done to minimize cosine errors. Ensure that the Beam
strength is at maximum for the entire travel of the selected axis.
CAUTION: DO NOT LOOK INTO THE LASER BEAM;
EYE DAMAGE MAY RESULT.
13. Load the Metrology software into the PC. Linear Calaibration measurements will
be normalized to a machine temperature of 20°C (68°F).
a) Select the program Linear Measurement.
b) Enter the proper values for Material Compensation. The Coefficient of
Thermal Expansion for Electrolytic Iron is:
6.5 or 0.0000065 PPM/°F; 11.7 or 0.0000117 PPM/°C.
c) Set the units for Target and Error display to Metric.
d) Set the error range as follows
Axis Length Error Range
1000.0 mm (39.37 in) or less 0.150 mm (0.0060 in)
Greater than 1000.0 mm (39.37 in) 0.200 mm (0.0080 in)
e) For Hewlett-Packard systems, the Temperature and Barometer setttings
are automatic. However, the Humidity needs to be manually set to 75%.
f) For Renishaw systems, the EC-10 Unit needs to be set in the Enabled
condition to capture the environmental data. Also, the Short Term
Averaging needs to be enabled by simultaneously depressing the “Alt” and
the “1” key at the PC.
C. PART PROGRAM SETUP

1. Insert the LASER Program Disk (704-2000-004) into the Floppy Drive of the
Control.
2. At the Control, select Auxiliary mode.
3. If necessary, select the CHANGE EDITOR softkey to change to the NC Editor.
4. Select the STORAGE FUNCTIONS softkey.
5. Select the SELECT CURRENT STORAGE UNIT softkey.
6. Select the FLOPPY DRIVE A softkey.
7. Select the READ PROGRAM softkey and select the appropriate program for the
axis to be measured.
7 of 15 757-4002-151
LASER PROGRAM DISK 704-2000-004
BMC 30 Series X Axis – 30_X.HNC
BMC 30 Series Y Axis – 30_Y.HNC
BMC 30 Series Z Axis – 30_Z.HNC
These programs position the selected axis in 25.4 mm (1 in) increments at a
feedrate of 2500 MMPM (approximately 100 IPM) with a five second pause at
the end of each move until the axis limit is reached. An additional move of 6 mm
(0.25 inch) occurs at the end of each direction of travel for the backlash move.
8. Select Manual mode.
9. Select the TOOL IN SPINDLE softkey.
10. Enter "1" for the Tool In Spindle.
11. Select Input mode.
12. Select the PART SETUP softkey.
13. With the LASER aligned at 0 position, select the STORE MACHINE POSITION
softkey for Part Zero X and Y.
14. Use the Enter key to advance the cursor to the Z Top (+) display and again select
the STORE MACHINE POSITION softkey.
D. AXIS PREPARATION
Do not begin the Axis Preparation unless the selected axis has been idle for at least eight
hours; "idle" is defined as not executing a RUN PROGRAM involving the selected axis.
Axis Preparation should be executed before every Two-Pass LASER measurement.
1. At the Control, select Auto mode.
2. Select the RUN PROGRAM softkey.
3. Press the Start push button to begin execution of the program. The machine will
make a 6mm backlash move at the start, move 25.4 mm, pause for 5 seconds, and
then move another 25.4 mm until the travel limit is reached. This will be followed
by a 6.0 mm backlash move at the end of the axis travel. Then the 25.4 mm
movements will continue in the opposite direction with 5 second pauses.
4. Run the program for two complete back-and-forth cycles (four unidirectional
passes).
5. With the machine returned to Part 0.000, depress the Motion Hold pushbutton.
E. TWO-PASS LASER MEASUREMENT

1. After completing the Axis Preparation and with the table returned to the Part
display 0.000 for the selected axis (after the initial backlash move), select the Reset
button at the LASER Display or PC.
2. Set the LASER equipment to complete a two-pass data run.
8 of 15 757-4002-151
3. Release the Motion Hold pushbutton to begin executing the program again.
4. For automatic data capture, the LASER equipment will automatically record the
error during the five second pause. Be sure that the axis is “settled” when the
data is recorded by the LASER equipment. "Settle" is defined as no greater than
0.00001 inch fluctuation of the LASER Display.
5. Allow the data to be collected for the two passes and stop the program after the
machine returns to Part Zero.
NOTE: Do not record data of the axis backlash moves (the short moves at the
beginning and end of the axis travel limits).
F. LEADSCREW COMPENSATION DATA ENTRY

1. For X and Y axes (enter all data in METRIC units)
Enter 100 Enter
d) Select the X AXIS or Y AXIS softkey.
e) Select the PLUS MAP DATA ENTRY softkey to display the Plus
Direction Map (as determined from the calibration point).
f) Enter the Error Data from the First Pass into the Plus Direction Map. To
enter the Error Data for each data point, use the calculator functionality of
the Control to add or subtract the Error Data from the default (or no
compensation) value.
Example: for the +25.40000 mm data point with a default error value of
+25.40000 and an Error value of - 0.00100 mm to be entered, position the
cursor in the Error column and press the minus key followed by the Error
value and then press the Enter key. The final result in the Error column
will be +25.39900.
g) If there are more increments in the Plus Direction Map then there are Error
Data points then you must enter the Error Data of the last data point for all
remaining increments to complete the Map.
h) When complete with entering the First Pass data points, select the
TOGGLE PLUS AND MINUS MAP softkey to display the Minus
i) Enter the Second Pass data points in the Minus Direction Map (use the
same procedures as in steps f and g).
j) Select the EXIT softkey.
k) Select the STORE DATA ON DISK softkey.
l) Select the HARD DRIVE softkey.
m) Select the EXIT softkey (to return to Integrator Support Services).
2. For Z axis (enter all data in METRIC units)
Enter 100 Enter
d) Select the Z AXIS softkey.
e) Select the MINUS MAP DATA ENTRY softkey to display the Plus
9 of 15 757-4002-151
IMPORTANT: For Z Axis, the First Pass data points are entered in the
Minus Direction Map and the Second Pass data points are entered in the
Plus Direction Map.
f) To enter the Error Data for each data point, use the calculator functionality
of the Control to add or subtract the Error Data from the default (or no
compensation) value.
Example: for the - 25.40000 mm data point with a default error value of
- 25.40000 and an Error value of - 0.00100 mm to be entered, position the
cursor in the Error column and press the minus key followed by the Error
value and then press the Enter key. The final result in the Error column
will be - 25.40100.
g) If there are more increments in the Minus Direction Map then there are
Error Data points then you must enter the Error Data of the last data point
for all remaining increments to complete the Map.
h) When complete with entering the First Pass data points, select the
TOGGLE PLUS AND MINUS MAP softkey to display the Plus Direction
Map (as determined from the calibration point).
i) Enter the Second Pass data points in the Plus Direction Map (use the same
procedures as in steps f and g).
j) Select the EXIT softkey.
k) Select the STORE DATA ON DISK softkey.
l) Select the HARD DRIVE softkey.
m) Select the EXIT softkey (to return to Integrator Support Services).
G. FOUR-PASS LASER MEASUREMENT

1. If the axis has been idle for more than one hour, repeat the Axis Preparation.
2. Select Auto mode followed by the RUN PROGRAM softkey and press the Start
pushbutton. This assumes that the proper Part Program is still loaded in memory
and that the Tool In Spindle and Part Setup data has not changed since the Two-
Pass Laser Measurement.
3. With the table returned to the Part display 0.000 for the selected axis (after the
initial backlash move), press the Motion Hold pushbutton.
4. Set the Error Range at the PC to 0.020 mm (0.0008 in).
5. Select the Reset button at the LASER Display or PC.
6. Set the PC to complete a four-pass data run.
7. Release the Motion Hold pushbutton to begin executing the program again.
8. For automatic data capture, the LASER equipment will automatically record the
error during the five second pause. Be sure that the axis is “settled” when the
data is recorded by the LASER equipment. "Settle" is defined as no greater than
0.00001 inch fluctuation of the LASER Display.
9. Allow the data to be collected for the four passes and stop the program after the
machine returns to Part Zero.
NOTE: Do not record data of the axis backlash moves (the short moves at the
beginning and end of the axis travel limits).
10 of 15 757-4002-151
VII. ACCURACY AND REPEATABILITY CERTIFICATION
A. TWO-PASS LASER MEASUREMENT ANALYSIS (analysis of Leadscrew Map)

1. LEADSCREW EVALUATION
a) If the error of any of the First Pass data points exceeds the following values
then the axis map has failed; return the machine to Manufacturing for
rework of the axis.
Axis Length Maximum Error of 1st Pass
1000.0 mm (39.37 in) or less 0.050 mm (0.0020 in)
b) If the error of any of the Second Pass data points exceeds the following
values (the First Pass error plus the maximum Backlash) then the axis map
has failed; return the machine to Manufacturing for rework of the axis.
Axis Length Maximum Error of 2nd Pass
1000.0 mm (39.37 in) or less 0.100 mm (0.0040 in)
c) Point-to-point evaluation (this evaluation tests for a “sawtooth” error

graph):
(1) For every data point, subtract the Error value of every Inch
increment from the one preceding it.
(2) If the difference between any two increments is greater than the
Repeatability specification then advance to the next comparison and
determine if the difference is also greater than the Repeatability
BUT in the opposite direction.
(3) If two consecutive comparisons both exceed the Repeatability
specification in opposite directions then the axis has failed; return
the machine to Manufacturing for rework of the axis.
Example 1: For a Repeatability specification of 0.005 mm:

Target (mm) Error (mm) Comparison Test (mm)
+ 0.00000 +0.00000
+ 25.40000 - 0.00102 +0.00000 – (- 0.00102) = +0.00102
+ 50.80000 - 0.00432 - 0.00102 – (- 0.00432) = +0.00330
+ 76.20000 - 0.00559 - 0.00432 – (- 0.00559) = +0.00127
+101.60000 - 0.00838 - 0.00559 – (- 0.00838) = +0.00279
+127.00000 - 0.01245 - 0.00838 – (- 0.01245) = +0.00407
+152.40000 - 0.00686 - 0.01245 – (- 0.00686) = - 0.00559
+177.80000 - 0.01397 - 0.00686 – (- 0.01397) = +0.00711
+203.20000 - 0.01778 - 0.01397 – (- 0.01778) = +0.00381
The axis has failed because the difference between the +127.0 mm and
+152.4 mm data points exceeds the Repeatability specification AND the
difference between the +152.4 mm and +177.8 mm data points also
exceeds the Repeatability specification but IN THE OPPOSITE
DIRECTION.
11 of 15 757-4002-151
Example 2: For a Repeatability specification of 0.0002 in:
Target (in) Error (in) Comparison Test (in)
+0.000000 +0.000000
+1.000000 - 0.000040 +0.00000 – (- 0.00004) = +0.00004
+2.000000 - 0.000170 - 0.00004 – (- 0.00017) = +0.00013
+3.000000 - 0.000220 - 0.00017 – (- 0.00022) = +0.00005
+4.000000 - 0.000330 - 0.00022 – (- 0.00033) = +0.00011
+5.000000 - 0.000490 - 0.00033 – (- 0.00049) = +0.00016
+6.000000 - 0.000270 - 0.00049 – (- 0.00027) = - 0.00022
+7.000000 - 0.000550 - 0.00027 – (- 0.00055) = +0.00028
+8.000000 - 0.000700 - 0.00055 – (- 0.00070) = +0.00015
The axis has failed because the difference between the +5.0 in and +6.0 in
data points exceeds the Repeatability specification AND the difference
between the +6.0 in and +7.0 in data points also exceeds the Repeatability
specification but IN THE OPPOSITE DIRECTION.
2. BACKLASH EVALUATION
a) Subtract the Error value of the last data point of the First Pass from the
first data point of the Second Pass.
b) Subtract the Error value of the first data point of the First Pass from the
last data point of the Second Pass.
c) If the absolute value of either calculation is greater than 0.050 mm (0.0020
in) then the axis has failed; return the machine to Manufacturing for rework
of the axis.
3. GRAPHICAL PLOT EVALUATION

The graph of the First Pass data points and the graph of the Second Pass data
points should be roughly parallel. If the plots diverge or converge excessively or if
the plots intersect then the axis has failed; return the machine to Manufacturing for
rework of the axis.
B. FOUR-PASS LASER MEASUREMENT ANALYSIS
1. If the Four-Pass LASER measurement completed successfully, allow the PC to

compute the Positional Accuracy.
2. The axis is certified if BOTH the Accuracy and Repeatability specifications are met
(see Section IV). The Graph of the Error data should be very near the Zero Error
axis of the Graph.
3. If the Repeatability specification fails then review the Graph to see if there is a
solitary point (or two) which are abnormal. If so, verify that an entry error for that
data point did not occur by comparing the data in the Leadscrew Map (both
directions) at that data point with the original Two-Pass LASER Measurement
data points.
12 of 15 757-4002-151
4. If the Accuracy specification fails then review the Graph to see if all Four Passes
overlap each other. If not, a mechanical adjustment may be required. Also, verify
that the leadscrew temperature has stabilized and has not changed during the
execution of the Four-Pass run. Note that a temperature change of 1°C (2°F) will
result in leadscrew growth of 0.003 mm (0.00012 in) for every 10 inches of travel.
5. If adjustments are made to the Leadscrew Map then rerun the Four-Pass LASER
Measurement.
6. If mechanical adjustments are made to the axis then the entire Measurement
Procedure must be rerun for that axis (see Re-LASER Criteria)
7. If adjustments cannot bring the machine within specification then return the
machine to Manufacturing for rework of the axis.
C. SAVING LEADSCREW MAPPING COMPENSATION DATA
1. After an axis has been certified, document the Leadscrew Map data and print the
Environment Data.
a) Use the Leadscrew Error Compensation data sheets (see Appendix) to
enter the Error data from the Plus and Minus Direction Maps for that axis.
Be sure to document the Machine Serial Number, the LASER Operator’s
Name, and the Date.
b) At the PC, print the Environment Data Printout for that axis. Be sure that
the name of the LASER operator, the date, the axis letter, and the Machine
Serial Number are all entered into the PC before printing.
c) Store the Leadscrew Compensation data sheets and the Environment Data
Printout in the Machine Diskette and Document Folder.
2. After all three axes have been certified, locate the Machine Configuration Backup
diskette and backup the Leadscrew Map to the diskette.
b) Access the Integrator Support Services by entering the following:
Enter 100 Enter
d) Select the STORE DATA ON DISK softkey.
e) Insert the Machine Configuration Backup diskette into the Floppy Disk
Drive.
f) Select the FLOPPY DRIVE softkey to copy the Leadscrew Map to the
Machine Configuration Backup diskette.
g) When complete, remove the Machine Configuration Backup diskette from
the Floppy Disk Drive.
h) On the label of the Machine Configuration Backup diskette, write (with
indelible ink) “Leadscrew copied” followed by the date and the LASER
operator’s initials.
i) Store the Machine Configuration Backup diskette in the Machine Diskette
and Document Folder.
3. Place the Machine Diskette and Document Folder inside the Control Cabinet.
13 of 15 757-4002-151
D. RE-LASER CRITERIA
An axis (or axes) must have the LASER Measurement Procedure rerun if the following
changes occur:
1. LIMIT SWITCHES ADJUSTED

If a Limit Switch is moved by 10 mm (0.400 in) or more then the axis is to be
recertified.
2. AXIS MECHANICAL ADJUSTMENTS

a) Axis Motor Belt adjustments require that the axis be recertified.
b) Motor/Encoder Assembly replacement requires that the axis be recertified.
c) Gib adjustments require that the axis be recertified.
d) Insufficient Way Lube flow requires that the axis be recertified.
3. MACHINE MECHANICAL ADJUSTMENTS

a) Machine Levelling adjustments require that all axes be recertified.
b) Machine Geometry adjustments require that all axes be recertified.
c) Removal and reattachment of the full enclosure/surround require that all
axes be recertified.
14 of 15 757-4002-151
LEADSCREW ERROR COMPENSATION MAP
Machine Serial Number_______________ Axis___________
Inch Metric Plus Minus Inch Metric Plus Minus

0.00 0.0 33.00 838.2
1.00 25.4 34.00 863.6
2.00 50.8 35.00 889.0
3.00 76.2 36.00 914.4
4.00 101.6 37.00 939.8
5.00 127.0 38.00 965.2
6.00 152.4 39.00 990.6
7.00 177.8 40.00 1016.0
8.00 203.2 41.00 1041.4
9.00 228.6 42.00 1066.8
10.00 254.0 43.00 1092.2
11.00 279.4 44.00 1117.6
12.00 304.8 45.00 1143.0
13.00 330.2 46.00 1168.4
14.00 355.6 47.00 1193.8
15.00 381.0 48.00 1219.2
16.00 406.4 49.00 1244.6
17.00 431.8 50.00 1270.0
18.00 457.2 51.00 1295.4
19.00 482.6 52.00 1320.8
20.00 508.0 53.00 1346.2
21.00 533.4 54.00 1371.6
22.00 558.8 55.00 1397.0
23.00 584.2 56.00 1422.4
24.00 609.6 57.00 1447.8
25.00 635.0 58.00 1473.2
26.00 660.4 59.00 1498.6
27.00 685.8 60.00 1524.0
28.00 711.2 61.00 1549.4
29.00 736.6 62.00 1574.8
30.00 762.0 63.00 1600.2
31.00 787.4 64.00 1625.6
32.00 812.8
Laser Operator_________________________ Date________________

HURCO MANUFACTURING
ULTIMAX Software Upgrade Procedure
R
704-0004-033 Rev B CAD # D8556

5/28/98
Important
This procedure is to be used only if the existing software on the machine tool is v2.00 or
higher. If this is not the case, please contact your local Hurco representative for the correct
software upgrade.
ULTIMAX Executive software resides on the hard disk and is upgraded by loading new
software from a set of 3 1/2" floppy diskettes shipped to you in this package. During the
upgrade process, all part programs stored on the hard disk are completely safe and are
retained in their directories. Be sure to save your part program to the hard drive and then
erase it in the control memory before doing the upgrade.
Disk Sets
Disks Part Number Description Disk Set
3 007-4123-013 Ultimax 3 Version 2.XX / Ultimax CNC (Maint. Executive) 1
2 007-4123-005 Ultimax 3 CNC (Executive) Languages 2
1 007-0001-003 Ultimax 3 Machine Languages 3
1 427-0004-025 Ultimax V2.XX Field Composite Ladders 4
1 007-4123-010 Ultimax V2.XX Patch (May Not Be Supplied) 5
*Ultimax 3 CNC (Executive)/Machine Configuration diskette (1 of 1) is not an upgradable disk. See procedure
below for its use.
* XX is the revision level for the Ultimax software. (ie: v2.XX could mean v2.00 to 2.99)
704-0004-033 Rev A Page 1

UPGRADE PROCEDURE
1. Power on the machine tool.
2. Select the Auxiliary mode.
3. Select the “UPGRADE SYSTEM FILES” softkey
4. Insert disk #1 from the first disk set from the table above into the floppy drive.
5. Select the “YES” softkey to start the upgrade. Pressing the “NO” softkey aborts the
upgrade. A blinking reverse video message "Insert EXECUTIVE_1" is displayed on the
CRT before the diskette is read. If this message does not disappear, ensure that the
diskette in the floppy drive is DISK 1 of the set.
6. The upgrade may be aborted by pressing the EXIT softkey.
NOTE: Selecting “ABORT” or removing the upgrade master diskette before copying is
completed does not corrupt the previous executive software.
7. The copy operation starts immediately upon insertion of the correct diskette. As each file
is copied from the Executive diskette onto the Hard Disk Drive, it is listed on the screen.
When all files are copied, a blinking reverse video message "Insert EXECUTIVE_2" is
displayed.
8. If additional diskettes are part of disk set being copied, the blinking reverse video message
is repeated. When prompted, continue to load Executive diskettes for that disk set until the
message “Do you have another set of system disks?” appears.
9. Remove the last diskette of that disk set from the floppy drive and select the “YES” softkey.
10. Repeat steps 4 through 9 with each disk set in the table above until all the sets are
installed.
11. After the last disk set has been copied and the prompt “Do you have another set of system
disks?” appears, select the “NO” softkey in answer to the prompt.
12. Remove the diskette from the Floppy Disk Drive.
13. Insert the ULTIMAX UTILITY DISKETTE (427-0004-023) into the floppy drive.
14. Cycle machine power.
15. This is an automatic utility and will display messages as it runs.
16. When this utility is finished, the message “Parameter update complete” will appear.
17. Remove the diskette from the floppy drive.
18. If an Optikey diskette package is sent with this upgrade then follow the furnished
“OPTIKEY INSTALL INSTRUCTIONS” document (704-0004-026, D8436).
704-0004-033 Rev A Page 2

19. Remove any diskettes from the floppy drive.
20. Cycle the Machine Power Off and On and verify the Executive Software Version at the top
of the screen in Input mode matches the version received. If these versions do not match,
try the upgrade again.
21. Insert the ULTIMAX 3 CNC (EXECUTIVE)/MACHINE CONFIGURATION diskette into the
Floppy Disk Drive and select Auxiliary mode (the disk can be found in the disk folder
normally kept in the machine power cabinet).
a) Select the “SYSTEM CONFIGURATION” softkey. Then select the “BACKUP CONFIG
AND MACHINE FILES" softkey to update the configuration to the diskette.
b) It will take approximately 10 minutes to backup and verify the configuration files.
Remove the ULTIMAX 3 CNC (EXECUTIVE)/MACHINE CONFIGURATION diskette
from the floppy disk drive when “BACKUP WAS SUCCESSFUL.” is displayed.
22. Store all of the diskettes in the disk folder and return to the power cabinet.
23. The software upgrade is now complete.
704-0004-033 Rev A Page 3

HURCO MANUFACTURING
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704-0004-033 Rev D CAD # D8556D

12/3/98
Important
software upgrade.
Disk Sets
*3 007-4123-013 Ultimax Version 2.XX / Ultimax CNC (Maint. Executive) 1
**1 427-0004-023 Ultimax Utility Diskette (May Not Be Supplied) N/A
*Ultimax 3 CNC (Executive)/Machine Configuration diskette (1 of 1) is not an upgradable disk (Disk Set 1). See
procedure below for its use.
**ULTIMAX UTILITY DISKETTE (427-0004-023) is not an upgradable disk (May not be supplied). See procedure
below for its use.
XX is the revision level for the Ultimax software. (ie: v2.XX could mean v2.00 to 2.99)
If there are any questions or problems with this upgrade, please contact Hurco Technical Support at (317)
298-2635 for assistance.
704-0004-033 Rev D Page 1

UPGRADE PROCEDURE
displayed.
installed.
13. If supplied, insert the ULTIMAX UTILITY DISKETTE (427-0004-023) into the floppy drive,
otherwise skip to step #18.
704-0004-033 Rev D Page 2

20. Cycle the Machine Power Off and On.
21. When prompted to insert the machine configuration diskette, press the Alternate Control
Back ( ALT CTRL for SSM) keys simultaneously to skip the backup.
22. Verify the Executive Software Version at the top of the screen in Input mode matches the
version received. If these versions do not match, try the upgrade again.
22. Insert the ULTIMAX CNC (EXECUTIVE)/MACHINE CONFIGURATION diskette found in

this package into the Floppy Disk Drive and select Auxiliary mode.
Remove the ULTIMAX CNC (EXECUTIVE)/MACHINE CONFIGURATION diskette
23. Store all of the diskettes in the disk folder and place in the power cabinet.
704-0004-033 Rev D Page 3

HURCO MANUFACTURING
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704-0004-033 Rev E CAD # D8556E

3/12/99
Important
software upgrade.
Disk Sets
*3 007-4123-013 Ultimax Version 2.XX / Ultimax CNC (Maint. Executive) 1
**1 427-0004-023 Ultimax Utility Diskette (May Not Be Supplied) N/A
*Ultimax 3 CNC (Executive)/Machine Configuration diskette (1 of 1) is not an upgradable disk (Disk Set 1). See
procedure below for its use.
**ULTIMAX UTILITY DISKETTE (427-0004-023) is not an upgradable disk (May not be supplied). See procedure
below for its use.
XX is the revision level for the Ultimax software. (ie: v2.XX could mean v2.00 to 2.99)
If there are any questions or problems with this upgrade, please contact Hurco Technical Support at (317)
298-2635 for assistance.
704-0004-033 Rev D Page 1

UPGRADE PROCEDURE
displayed.
installed.
13. If supplied, insert the ULTIMAX UTILITY DISKETTE (427-0004-023) into the floppy drive,
otherwise skip to step #18.
704-0004-033 Rev D Page 2

21. When prompted to insert the machine configuration diskette, press the keys below
simultaneously to skip the backup.
Alternate Control Back for Dual screen Ultimax 3 controls
ALT CTRL for SSM controls
alt F for Dual screen Ultimax 4 controls
22. Insert the ULTIMAX CNC (EXECUTIVE)/MACHINE CONFIGURATION diskette found in

this package into the Floppy Disk Drive and select Auxiliary mode.
Remove the ULTIMAX CNC (EXECUTIVE)/MACHINE CONFIGURATION diskette
23. Store all of the diskettes in the disk folder and place in the power cabinet.
704-0004-033 Rev D Page 3

MAX IV ISA
D8565 757-4002-158 Flat Panel Display Calibration, Burn - In And Functional Test Procedures
D8576 757-4002-168 Dual Flat Panel Control Kit Test Procedure
D8579 757-4002-170 MAX4 Console, Machine Tool Manufacturing Installation
D8580 757-4002-171 MAX4 PCB Test Procedure
D8581 757-4002-172 Procedure, MAX4 Print and Document Holder Installation
D8582 757-4002-173 Procedure, MAX4 Keyboard Drawer Installation
D8578 757-4002-169 Setup Procedure For The FIC LMB - 586PF P/B CPU Board /Rev B /Rev C
D8584 757-4002-175 Max 4 Demo Console Calibration, Burn - In and Functional Test Procedures
D8591 757-4002-181 Max 4 Demo Console Component Test Procedure
D8593 757-4002-184 Max 4 Console Master HDD Setup Procedure
D8602 757-4002-191 PS/2 Power Supply Setup Procedure
D8607 757-4002-196 PS/2 Power Supply Assembly Build Procedure
D8608 757-4002-197 ISA / PCI Passive Backplane Card Cage Build Prosedure
D8601B 704-0004-037 MAX 4 Activation Diskette
D8703 757-4002-286 Ultimax Control Kit Serial Number Identification
D8683 757-4002-266 Procedure, Max 4 PCB Test
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D8618 757-4002-206 Procedure, Flat Panel display, Configuration For Service.
DS0062 450-3001-969 Flat Panel Node Firmware V2.0
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DS0076-1 Flat Panel Node Firmware, Ver. 2.2
DS0076-2 Ultimax 4 Canbus Map
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D8633 757-4002-221 Procedure, TFT FPD Configuration and Test For Service
D8644 757-4002-232 Procedure, Formosa LMB680 P/B CPU Board Setup
MAX IV ISA
D8647 757-4002-233 Hard Disk Drive Test Procedure

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ULTIPATH
D8497 757-4002-111 Parameters for Ultipath Software, Version 1.0

D8559 704-0004-034 Ultipath Software Upgrade Procedure
D8512 757-4002-122 Ultipath Control Package Test Procedure
D8513 757-4002-123 Ultipath Machine I/O Test Procedure
D8550 757-4002-148 Ultipath Servo Tranducer Probe Test Procedure
D8551 757-4002-149 Ultipath Hard Drive Test
D8552 757-4002-150 Ultipath Servo Setup
D8507 757-4002-117 Ultipath CMOS Setup
D8511 757-4002-121 Ultipath Machine Kit Test Procedure
D8537 757-4002-139 Ultipath Diagnostic Software Operation
D8573 704-0004-036 V1.21 for Ultipath CNC Customer Information
ENGINEERING DOCUMENT 757-4002-111 Revision A CAD # D8497
SUBJECT: Parameters for ULTIPATH Software Version 1.0
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A 14010 Original Issue (filename D8497A.DOC) 08 JAN 97
I. INTENT
To provide documentation of the default parameter values used by the executive software.
II. APPLICABILITY
Applicable to the UltiPath Chevalier 2 Axis Machine.
III INDEX
page 2 Chevalier 2 Axis Machine
_________________________________________ _________ _________________________________________ _________

Originator Date Product Line Supervisor Date
Chevalier 2 Axis Machine
** MACHINE CONFIGURATION ** <enter>, /74159, <enter>
** AXIS MOTOR ** Motor 1 Motor 2 Motor 3 Motor 4

Counts per Revolution 4,000 4,000 1,000 1,000
Maximum DAC Voltage 10 10 10 10
DAC Direction NEG POS POS POS
Encoder Direction NEG POS POS POS
** PHYSICAL AXIS ** X Axis Y Axis Z Axis ** PHYSICAL AXIS ** S Axis

Physical Actuator Motor 1 Motor 2 Motor 3 Physical Actuator Motor 4
Axis Units Metric Metric Metric Axis Units Inch
Distance/Revolution 2.5 mm 2.5 mm 10 mm Distance/Revolution 0.25 in
Minimum Travel Limit -1 mm -1 mm -254 mm Spindle Control Type Contact
Maximum Travel Limit 864 mm 356 mm 254 mm Maximum Motor Speed 2000 RPM
Positive Limit Switch Phys X+ Phys Y+ Phys Z+ Maximum Spindle Speed 2000 RPM
Negative Limit Switch Phys X- Phys Y- Phys Z- Maximum Acceleration 100,000 R/min2
Maximum Feedrate (Z+) 5080 mm/min 5080 mm/min 5080 mm/min
(Z-) n/a n/a 5080 mm/min
Maximum Acceleration 2540000 mm/min2 2540000 mm/min2 2540000 mm/min2
Leadscrew Mapping Yes Yes Yes
Calibration Home Position 431.8 mm 177.8 mm 0 mm
** COORDINATE FRAME ** Vertical Horizontal ** MACHINE PARAMETERS **

X Coordinate X Physical X Physical Machine Class Vertical
Coord. Frame Sense Positive Positive Manual Z Control Enable
Y Coordinate Y Physical Z Physical Joystick Control Table
Coord. Frame Sense Positive Positive System Friction (λ) 100
Z Coordinate Z Physical Y Physical PathFree Sticky Factor 50
Coord. Frame Sense Positive Positive PathFree Tolerance 0.01
Mechanical Limit Switches Disable
UltiPath Software Version 1.0 Parameters 757-4002-111 Rev. A 2

Software Upgrade Procedure
704-0004-034 Rev A CAD # D8559
5/13/98
Important
Your Executive software resides on the hard disk and is upgraded by loading new software
from a set of 3 1/2" floppy diskettes shipped to you in this package. During the upgrade
process, all part programs stored on the hard disk are completely safe and are retained in their
directories. Be sure to save your part program to the hard drive before doing the
upgrade.
UPGRADE PROCEDURE
1. The software in your control can be upgraded from floppy diskettes using the Upgrade
function. To access the Upgrade function, select the Working Parameters softkey from the
top level menu. Perform the Upgrade by placing Disk 1 in the floppy drive and selecting the
Upgrade softkey. If you select the Upgrade softkey without having a diskette in the drive,
the control will display a warning message.
704-0004-034 Rev A Page 1

2. After the Upgrade process has begun, the window shown below will be displayed. Press
the ENTER key if you want to continue the upgrade. Use the cursor keys select the Cancel
button and press ENTER if you want to cancel the upgrade.
3. As the upgrade process continues, the screen will display the progress bar shown below.
The control will prompt you when to insert the next diskette into the drive. After changing
the diskette, press the ENTER key to continue with the upgrade.
4. The following prompt will be displayed after the upgrade has successfully completed.
Remove the diskette from the floppy drive and turn the control power off and back on to
restart your control using the upgraded software version.
704-0004-033 Rev A Page 2

ULTIMAX Ver 2.xx Reference Guide
DS0064 704-0020-036 ULTIMAX Utility Diskette Reference

DS0065 704-0020-037 ULTIMAX Parameter Diskette Reference
DS0066 704-0020-038 ULTUMAX Ver. 2.xx Ladder Logic Reference
DS0067 704-0020-039 ULTIMAX Initial Install Disk Set Reference
D8522 757-4002-129 ULTIMAX Ver. 2.xx Software Controls Mfg. Installation Procedure
D8515 757-4002-125 ULTIMAX Ver. 2.xx Software Field Installation Procedure
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D8530 704-0020-030 ULTIMAX Ver. 2.xx Software Patch Utility Rev. K
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D8544 757-4002-145 ULTIMAX v2.xx Machine type Selection Procedure
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D8554 704-0020-033 Ver. 2.14 and LC 1.09 ERRATA Sheets
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D8556 704-0004-033 ULTIMAX Ver. 2.xx Upgrade Procedure.
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704-0020-036 Rev D CAD #DS0064
SUBJECT: Ultimax Utility Diskette Reference
Barry A. Van Paris 2/12/99 Tim Kaufman

Originator: B. Van Paris Date Mgr, Real Time Systems Date
RECORD OF CHANGES
Engineering Document: 704-0020-036 CAD #DS0064

By By
A 14547 Original Release BVP 2/12/99
B 14653 Release v1.03 RMN 5/6/99 DEO 5/17/99
C 14687 Release v1.04 RMN 7/19/99 DEO 8/3/99
D 14799 Release v1.05 RMN 10/15/99
Ultimax Utility Diskette Reference

704-0020-036 Rev. D Page 2
I. INTENT
DISK, ULTIMAX UTILITY.
II. SCOPE
• Description of the Ulltimax Utility diskette

• How to configure the diskette
• Where the utility diskette can be obtained
• Revision history of the utility diskette
III. UTILITY DISKETTE DESCRIPTION

The 427-0004-023 Ultimax Utility diskette is used to update machine parameters on a customer’s Ultimax control.
Parameters that will be modified specified by the INTCFG.SYS file of the Machine Configuration Directory for each
specified machine (*.MCD). Any new parameters, with modified parameter descriptions or modified values can be
set using this diskette. Using this diskette when upgrading software will insure that the machine parameters on the
customer’s machine will be up to date with the latest parameter documents.
This diskette is DOS bootable and will automatically run the utility program when booted.
Parameters on the utility disk will be copied to the INTCFG.SYS file only if the existing parameter description is
"….." or "RESERVED FOR ICP".
IV. HOW TO CONFIGURE THE UTILITY DISKETTE
1. Use an existing 427-0004-023 diskette as a guide to configuring the new utility diskette.
2. Delete all of the Machine Configuration Directories (*.MCD) on the floppy diskette.
3. Create the Machine Configuration Directories (*.MCD) on the floppy that parameter changes are required.
Reference the 757-4002-125 Ultimax Field Install document for MCDs for each machine type.
4. Using any ASCII text editor, create an INTCFG.SYS file containing only the parameters to be added or
modified. Use an existing INTCFG.SYS file as a template.
5. Create an INTCFG.SYS file for each of the machines that require parameter changes.
6. When booted, the utility program will copy these values and descriptions in the INTCFG.SYS files on the
diskette to the corresponding INTCFG.SYS files on the hard disk of the control.
7. Boot a control with this diskette and check the INTCFG.SYS files on the control for the proper changes.
8. If the changes are correct, give the diskette to the engineer responsible for maintaining the Makedisk stations
to make the necessary production changes

704-0020-036 Rev. D Page 3
Example:
The Calibration to Marker Pulse Velocity parameter for the X & Y axes is to be changed to 200 mmpm on
a BMC30M with Siemens servo drives.
1. Create the directory on the floppy disk: 30MS.MCD
2. Create an INTCFG.SYS file containing the following text:
F96:12=CAL TO MARKER VEL (MMPM) X = 200.0000000000

F96:13=CAL TO MARKER VEL (MMPM) Y = 200.0000000000
3. Save the file to the 30MS.MCD directory of the diskette.
V. UTILITY DISKETTE AVAILABILITY

Ultimax customer upgrade kits will contain the 427-0004-023 utility diskette. The use of this diskette is referenced
in the customer upgrade instructions 704-0004-033
VI. UTILITY DISKETTE REVISION HISTORY

A 14168 Changed the limit switch to calibration from (IN) and .3543 to (MM) and
(V1.00) 9.00 for all machine types that were in inches.
B 14434 Modified the following parameter descriptions and their default values
(V1.01) for all machine types:
F96:205=PROBE IN SPIND. JOG VEL (MMPM)
F96:209=VELOCITY MODE SCALE FACTOR
F96:210=MAX SPIN SPD (NON CE DOOR SW)
F96:211=HAWK30/40 LO BELT G0 RATIO
F96:212=HAWK30/40 LO BELT G0 MIN RPM
F96:213=HAWK30/50 LO BELT G0 MAX RPM
F96:214=HAWK30/40 LO BELT G0 TAP ACCEL
F96:215=HAWK30/40 LO BELT G1 RATIO
F96:216=HAWK30/40 LO BELT G1 MIN RPM
F96:217=HAWK30/40 LO BELT G1 MAX RPM
F96:218=HAWK30/40 LO BELT G1 TAP ACCEL
F96:219=HAWK30/40 HI BELT G0 RATIO
F96:220=HAWK30/40 HI BELT G0 MIN RPM
F96:221=HAWK30/50 HI BELT G0 MAX RPM
F96:222=HAWK30/40 HI BELT G0 TAP ACCEL
F96:223=HAWK30/40 HI BELT G1 RATIO
F96:224=HAWK30/40 HI BELT G1 MIN RPM
F96:225=HAWK30/40 HI BELT G1 MAX RPM
F96:226=HAWK30/40 HI BELT G1 TAP ACCEL
N95:60=AXIS CLAMP OUTPUT INVERT A
N95:61=AXIS CLAMP OUTPUT INVERT B

704-0020-036 Rev. D Page 4
N95:65=MOUSE SCALE FACTOR
N95:66=MOUSE MAXIMUM DELTA PER SCAN
N95:150=(ATC 5) NUM OF POCKETS TO SKIP
N95:151=(ATC 5) TOOL IN POCKET #1
N95:200=ATC DISABLE
N95:230=CE (0-OFF:1-MACH CTR:2-HAWKS)
N95:250=AUX. OUTPUT CONFIRM ENABLE
N95:251=SPINDLE BREAKOVER RPM (HAWK5)
N95:252=SPIN BREAK ENABLE TIME (HAWK5
N95:253=HAWK LOW BELT LOW GEAR SCALE
N95:254=HAWK HIGH BELT LOW GEAR SCALE
N95:255=MAX 4 LOW RANGE MULTIPLIER
N95:256=MAX4 MID RANGE MULTIPLIER
N95:257=MAX4 HIGH RANGE MULTIPLIER
N95:258=HAWK30/40 CURR BELT POSITION
N95:259=HAWK30/40 SPINDLE GEARS
C 14547 Added the following 2 parameters to all current and past machine
(V1.02) types:
F96:208=LRG TOOL ROTAT DEBOUNCE (SEC)
N95:228=WASHD MPLEX TIME/ENBLE (S/100)

704-0020-036 Rev. D Page 5
D 14653 Added four new parameters (applicable to Max IV consoles only):
(V1.03) N95:140=MAX 4 JOG ENHANCE
F96:150=MAX 4 JOG ENH. MIN VEL
F96:151=MAX 4 JOG ENH. MAX VEL
F96:152=MAX 4 JOG ENH. CONSTANT
F96:153=MAX 4 JOG ENH. FACTOR
Diskette will now copy parameters on the utility disk to the
INTCFG.SYS file only if the existing parameter description is "….." or
"RESERVED FOR ICP"
E 14687 Added seven new parameters for future feature development
(V1.04) F96:140=X AXIS FIXTURE POSITION (MM)
F96:141=Y AXIS FIXTURE POSITION (MM)
F96:142=Z AXIS FIXTURE POSITION (MM)
F96:143=X AXIS ACCESS POSITION (MM)
F96:144=Y AXIS ACCESS POSITION (MM)
F96:145=X AXIS DISTANCE TO CLEAR (MM)
F96:146=Y AXIS DISTANCE TO CLEAR (MM)
Changed default value for N95:254 “HAWK HIGH BELT LOW GEAR
SCALE” to =630
F 14799 Added support parameters for TPS system.
(1.05) N95:143=TPS TRACKING (do not edit)
N95:144=TPS TRACKING (do not edit)
VII. DISKETTE CONTENTS
Files
MSDOS.SYS
IOSYS.SYS
COMMAND.COM
AUTOEXEC.BAT
SETPARAM.EXE
DRVSPACE.BIN
Machine Configuration Directories and parameter files (INTCFG.SYS) as needed

704-0020-036 Rev. D Page 6
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704-0020-037 Rev D CAD #DS0065
SUBJECT: Ultimax Parameter Diskette Reference
Barry A. Van Paris 2/15/99 Dan Ornelas

Originator: B. Van Paris Date Mgr, Machine Integration Systems Date
RECORD OF CHANGES

By By
B 14687 Modifications for modified Max 4 RMN 7/21/99 DEO 8/3/99
handwheel jogging, support for future
tool load fixture. Support VTC-40 and
Hawk-5 machines. Modified
MCODE.SYS file for estimated runtime.
C 14799 Added TPS tool tracking parameters. RMN 10/15/99 GT 8/12/99
D 14872 Added Alt. Washdown “Left Side ON” RMN 4/25/00
and “Side-to-Side OFF” time
parameters. Added CE Access Code
storage parameters.
Ultimax Parameter Diskette Reference

704-0020-037 Rev. D Page 2
I. INTENT
and 427-0004-024 production and field service parameter diskettes.
II. SCOPE
• Description of the Ulltimax parameter diskettes

• Loading Parameters with the diskettes
• How to configure the diskette
• Machine Configuration Directory (MCD) naming convention
• Where the parameter diskette can be obtained
• Revision history of the parameter diskette
III. PARAMETER DISKETTE DESCRIPTION

There are currently two parameter diskettes. The first being 427-0004-021 and the second 427-0004-024. Both of
these diskettes represent the latest data on the the parameter documents 757-4005-xxx (DPxxxx). When any of
these documents are modified, the respective parameter files on these diskettes will need updating. Each of these
diskettes are described below.
NOTE: These diskettes are not product disks and are not to be sold or sent to customers. The disks are a
Hurco tool and are not to be distributed outside Hurco. When a new revision of these disks is released,
the old disk should be returned to the Hurco SQA department or destroyed (see Ultimax Parameter
Release Document – UPRD).
The 427-0004-021 Ultimax production parameter diskette is used to load machine parameters on an Ultimax
control at Hurco controls production or machine contract manufacturer. Loading these default parameters prevents
entering parameter data manually, thus increasing productivity, reducing errors and insuring the latest parameters
are being used. Parameters that are used are represented as files placed in a Machine Configuration Directory for
each specified machine (*.MCD).
This diskette should contain parameters for current production only. Since there are many older machine types with
similar designators, it would cause confusion at machine set up when selecting a machine type. Therefore, when a
machine type is no longer produced, its parameters should be removed from this diskette and placed on the field
parameter diskette.
The 427-0004-024 Ultimax production parameter diskette is used to load machine parameters on an Ultimax
control at a customer’s site by a Hurco representative. Loading these default parameters prevents entering
parameter data manually, thus increasing productivity, reducing errors and insuring the latest parameters are being
used. Parameters that are used are represented as files placed in a Machine Configuration Directory for each
specified machine (*.MCD).
This diskette should contain parameters for obsolete production only. When a machine type is no longer produced,
its parameters should be removed from the production diskette and placed on this diskette.

704-0020-037 Rev. D Page 3
Both of these diskettes are included in the 007-4123-009 Ultimax v2.xx Field Installation notebook. Using both of
these diskettes, the parameters for all current and obsolete machine types supported by Ultimax v2.xx software is
available to Hurco field engineers.
IV. LOADING PARAMETERS WITH THE DISKETTES
1. Power up the control.

2. Select Auxiliary mode by pressing the AUX mode key.
3. Press the MORE soft key.
4. Press the UPGRADE SYSTEM FILES soft key.
5. Insert the appropriate parameter diskette into the floppy drive.
6. Press the YES soft key.
7. The parameter files will be copied to the hard disk of the control.
8. When asked if there are any more files to upgrade, press the NO soft key.
9. Reset the control when prompted.
10. After the control restarts, select Auxiliary mode by pressing the AUX key.
11. Press <ENTER> <100> <ENTER>.
NOTE: If the tool change height (F96:30 TOOL CHANGE POSITION) has already been determined, record this
value before continuing.
12. Press the MISCELLANEOUS SERVICES soft key.

13. Press the SELECT MACHINE CONFIG DIRECTORY soft key.
14. Highlight the Machine Configuration Directory (MCD) that corresponds with the machine type that is being
configured using the arrow keys (see engineering documents 757-4002-124 or 757-4002-125 to match serial
number to MCD)
15. Press <ENTER>.
16. The new parameter files will be copied the working area of the hard disk (\CONFIG\VER2_XX).
17. The control will now reset itself.
18. Enter the tool change height after the control restarts (see documents 757-4002-124 or 757-4002-125).
V. HOW TO CONFIGURE THE PARAMETER DISKETTE
1. Create the Machine Configuration Directories (*.MCD) on DOS formatted floppy for each machine type.
Reference the 757-4002-124 or 757-4002-125 Ultimax Field Install document for MCDs for each machine type.
These MCD names must match the MCD names on the respective Machine Configuration diskette set (ladders
diskette set – see 007-0071-044 or 427-0004-025).
2. Copy the correct and tested files listed below to each of their respective Machine Configuration Directories
(MCDs):
INTCFG.SYS
MCODE.SYS
SPINDLE.SYS
SYSFIX.SYS
TUNE.SYS
3. When completed, the disk to the engineer responsible for maintaining the Makedisk stations to make the
necessary production changes

704-0020-037 Rev. D Page 4
VI. MACHINE CONFIGURATION DIRECTORY (MCD) NAMING CONVENTION
The Machine configuration diskettes (production and field) will contain Machine Configuration Directories (MCDs) that
contain specific information about each machine type.
Machine configuration naming format is to be as follows:
Machine Type Special Designator .MCD
MMMMMMDD.MCD
i.e. 3017Y.MCD Describes the BMC3017 machine with Yaskawa Sigma servo drives with no
special designator.
where:
Machine Type reflects the X & Y travel, servo drive type, spindle configuration or other major characteristic. Up to six (6)
characters can be used for the machine type.
Special Designator is to be used to specify a special option or characteristic of an existing machine type that would
constitute a different identification file. This characteristic can be up to two (2) characters long.
NOTE: The name of the MCD and the identification (dummy) file should be the same for consistency.
VII. PARAMETER DISKETTE AVAILABILITY

Ultimax v2.xx Field upgrade kits will contain the 427-0004-021 and 427-0004-024 parameter diskette. In addition,
upon release of new parameters, these two diskettes will be delivered to each selling division to duplicate along with
the Ultimax Parameter Release Document (UPRD).

704-0020-037 Rev. D Page 5
VIII. PARAMETER DISKETTE REVISION HISTORY
427-0004-021 Production Parameter Diskette

B 14687 Added new Int Cfg parameters (N95:140, F96:150-153) for use with
remote jog firmware v1.01+ to improve Max 4 console jog operation.
Added new Int Cfg parameters (F96:140-146) for future implementation
of tool loading fixture. Modified Alternate Servo Tuning parameters
(TUNE.SYS) for use with remote jog firmware v1.01+ and modified
ladder logic functionality. Modified Standard Tuning parameters for
YSM machines for improved cutting performance. Added support for
VTC-40 machines. Modified MCODE.SYS file to improve generic times
for tool changes, spindle orient, rotary & tilt axis clamp and unclamp to
be used for vastly more accurate estimated run time calculation.
C 14799 Added new Int Cfg parameters (N95:143-149) for use with newly
implemented TPS system. These parameters are for tracking tool
status and are not intended to be edited. Set default values for 6434
machines, parameters F96:145, F96:146.
D 14872 Added new Int Cfg parameters (N95:248, 249) for use with modified
logic for “alternating washdown coolant”, these parameters dictate
Left Side “ON” time, and Side-to-Side “OFF” time, respectively.
Added new Int Cfg parameters (N95:260 – N95:263) for use with CE
Access Code. These parameters store the 4-digit keycode values (this
is NOT the keypad values 0-9)

704-0020-037 Rev. D Page 6
427-0004-024 Field Parameter Diskette
B 14687 Added new Int Cfg parameters (N95:140, F96:150-153) for use with
remote jog firmware v1.01+ to improve Max 4 console jog operation.
Added new Int Cfg parameters (F96:140-146) for future implementation
of tool loading fixture. Modified Alternate Servo Tuning parameters
(TUNE.SYS) for use with remote jog firmware v1.01+ and modified
ladder logic functionality. Modified Standard Tuning parameters for
YSM machines for improved cutting performance. Added support for
VTC-40 and Hawk 5(kneemill) machines. Modified MCODE.SYS file to
improve generic times for tool changes, spindle orient, rotary & tilt
axis clamp and unclamp to be used for vastly more accurate estimated
run time calculation.
C 14799 Added new Int Cfg parameters (N95:143-149) for use with newly
implemented TPS system. These parameters are for tracking tool
status and are not intended to be edited. Set default values for 6434
machines, parameters F96:145, F96:146.
D 14872 Added new Int Cfg parameters (N95:248, 249) for use with modified
logic for “alternating washdown coolant”, these parameters dictate
Left Side “ON” time, and Side-to-Side “OFF” time, respectively.
Added new Int Cfg parameters (N95:260 – N95:263) for use with CE
Access Code. These parameters store the 4-digit keycode values (this
is NOT the keypad values 0-9)

704-0020-037 Rev. D Page 7
IX. DISKETTE CONTENTS
Files
Machine Configuration Directories (*.MCD) as needed with files below:
INTCFG.SYS
MCODE.SYS
SPINDLE.SYS
SYSFIX.SYS
TUNE.SYS

704-0020-037 Rev. D Page 8
R
704-0020-039 Rev A CAD #DS0067
SUBJECT: Ultimax Initial Install Disk Set Reference
Barry A. Van Paris 2/16/99 Tim Kaufman

Originator: B. Van Paris Date Mgr, Real Time Systems Date
RECORD OF CHANGES

By By
Ultimax Initial Disk Set Reference

704-0020-039 Rev. A Page 2
I. INTENT
The purpose of this document is to describe the functionality and to provide a revision history for the 007-4123-
008 Ultimax Initial Install diskette.
II. SCOPE
• Description of the Ultimax Utility disk set

• Where the disk set can be obtained
• Revision history of the disk set
• Disk set contents (filenames)
III. ULTIMAX INITIAL INSTALL DISK SET DESCRIPTION

The 007-4123-008 Ultimax Initial Install disk set contains a fixed version of the Ultimax executive. This
executive will be the vehicle for which a released version of Ultimax executive and ladders can be easily
installed. The initial install disk set is used in controls production and in the field for loading Ultimax software on
a new hard disk.
This disk set is DOS bootable and will automatically install the initial Ultimax executive when booted.
For instructions how to use this diskette, reference engineering documents 757-4002-125 field Ultimax install
procedure or 757-4002-129 controls production Ultimax install procedure.
NOTE: This disk set is for Hurco use only. It is a tool to load released Ultimax software and should NOT be
used to run a machine tool. The Ultimax Initial Install disk set is not to be sold or distributed to customers.
IV. ULTIMAX INITIAL INSTALL DISK SET AVAILABILITY

Ultimax v2.xx Field Installation kits (notebooks) will contain an Ultimax Initial Install disk set for field installation
of Ultimax software on a blank hard disk. Hurco controls manufacturers will also possess this disk set for
installation of the Ultimax software product on new production controls.
The software contained on this disk set need only operate an Ultimax console. Therefore, this disk set will only
be updated when there is a console or card cage hardware requirement.
V. ULTIMAX INITIAL INSTALL DISK SET REVISION HISTORY

A 14009 Original release – Ultimax v2.00
B 14376 Updated Ultimax executive to v2.11 to support Max4 consoles.

704-0020-039 Rev. A Page 3
VI. DISK SET CONTENTS
The files contained on this disk set are:
Files Type
AUTOEXEC.BAT FILE
COMMAND.COM FILE
EXECPROG.001 FILE
HURCO.LDR FILE
IO.SYS FILE
MSDOS.SYS FILE
MAKEBOOT SUBDIRECTORY
-> MAKEBOOT.EXE FILE
-> LOADFRAG.BIN FILE
->BOOTSECT.BIN FILE
Disk 2
AUTOEXEC.BAT FILE
EXECPROG.002 FILE
INTCFG.SYS FILE
LADDERS.TXT FILE
LOGO_800.PCX FILE
LOGO.PCX FILE
LADDERS SUBDIRECTORY
->1BASE000.REX FILE
->2BASE000.REX FILE
->3BASE000.REX FILE
CONFIG\VER2_11 SUBDIRECTORY
->MCODE.SYS FILE
->NETWORK.SYS FILE
->PROBE.SYS FILE
->SERIAL.SYS FILE
->SPINDLE.SYS FILE
->SYSFIX.SYS FILE
->SYSINT.SYS FILE
->TUNE.SYS FILE
Disk 3
AUTOEXEC.BAT FILE
CANBUS.CFG FILE
COMBINE.EXE FILE
V800X600.VGA FILE
LANG SUBDIRECTORY
->DEFAULT.HBM FILE
->DEFAULTQ.HBM FILE
->DEFAULT.HB8 FILE
->DEFAULTQ.HB8 FILE
->ENGLISH.HRC FILE
->ENGLISH.HRL FILE
NOTE: The AUTOEXEC.BAT file needs to be on all diskettes so the operator is not prompted to put disk number one
into the floppy drive to continue the batch file. The AUTOEXEC.BAT file needs to be identical on all
diskettes.

704-0020-039 Rev. A Page 4
R
757-4002-129 Rev F CAD #D8522F
SUBJECT: Ultimax v2.xx Software Controls Manufacturing

Installation Procedure

Originator: B. Van Paris Date Mgr. Ultimax Products Group Date
RECORD OF CHANGES
Engineering Document: 757-4002-129 CAD #D8522F

By By
B 14137 Fixed errors: (B1) removed composite BVP 11/24/97 MAD 11/24/97
ladders diskette; (B2) part number was
007-0071-001; (B3) Added “Keep at
workstation”;(B4) added “Product disks
to send with control”.; (B5) Added text to
remove disks from floppy drive; (B6)
elaborated on the CMOS setup.
C 14168 Need to reboot by cycling power to avoid BVP 1/15/98 MAD 1/22/98
an error (C1).
D 14376 Added a diskette to the 007-4123-008 BVP 9/1/98 TLK 9/3/98
Initial Ultimax Software set (D1);
Changed part number for Machine
Configuration diskette. (D2)
E 14662 Removed language disks from list of BVP 11/20/98 TLK 11/24/98
contents for Ultimax upgrade kit (E1 –
pg3); Removed reference to installing
CNC and Machine language disks from
procedure (E2– pg6); Added continue
sentence for remaining diskettes for
initial Ultimax set(E3 – pg5); Added
continue sentence for remaining
diskettes for ladder disk set(E4 – pg6);
F 14547 Added the Max4 console activation disk
(F1); Added steps for using the Max4
activation diskette (F2); was “place a
copy in the machine folder” (F3);
removed “currently ST31720” (F4); used
to be set per label on HDD (F5); Added
reference to 757-4002-169 doc (F6) BVP 2/16/99
Ultimax v2.xx Software Controls Manufacturing Installation Procedure

757-4002-129 Rev. F Page 2
I. INTENT
The purpose of this document is to provide instructions for production installation of the Ultimax version 2.XX
software on ISA based Hurco Ultimax CNC controls. No machine-model or type specific information is
assumed in these instructions.
II. SCOPE
This document is applicable to Ultimax CNC controls that are being built and commissioned for the first time.
The Ultimax CNC will be fully operational after this installation but NO MACHINE TYPE or PERSONALITY will
be configured at the end of these procedures. The procedure is meant for qualified Hurco electronics assembly
personnel only. It is not meant for customer use. It is assumed that the control has a Pentium CPU board
installed.
III. MATERIALS
• PC/AT keyboard
• 007-4123-007, Ultimax v2.XX Production Software Installation Kit: (Keep at workstation) B3
Contents:
B1
HARD DISK SETUP DISKETTE (ST3630) 427-0004-008 1

HARD DISK SETUP DISKETTE (ST31720) 427-0004-010 1
D1
D2
DISK, PARAMETERS COMPOSITE ULTIMAX V2.XX 427-0004-021 1
• Ultimax v2.XX Software diskettes: (Product disks to send with control) B4
Check the items you have, before beginning the procedure. These items are created on the makedisk
stations by entering the corresponding part numbers in response to the Makedisk program prompts. If the
following part numbers are not part of the work order, contact material planning for the controls area. Only
qualified users can create software on the makedisk stations. If you are not a current user, see the SQA
department for user access to Makedisk.
E1
Description Part Number Serial
Number
√
Prefix
ULTIMAX VERSION 2.XX/ULTIMAX CNC (EXECUTIVE) 007-4123-004 U3V2
OPTIKEY UTILITY DISKETTE/SKCOX200 PKG, PROD #0 PROD 007-4137-008 -
B2
DISK, LADDERS COMPOSITE ULTIMAX V2.XX 007-0071-044 PLDR
F1
ULTIMAX 4 CONSOLE ACTIVATION DISK (If an Ultimax 4 console is present) 007-4000-001 -
After checking off the items in the above list, the following software installation procedure can be started.

757-4002-129 Rev. F Page 3
NOTE 1: Connect the PC keyboard to the control. Steps 1 through 4 require PC keyboard interaction, NOT
console key presses. The remaining steps require console key presses NOT PC keyboard presses.
this procedure.
NOTE 3: Make a copy of this procedure before beginning. Initial each step on the copy and retain a copy with the
control documentation F3.
________1. Check the hard disk label and determine the model _________. If a HARD DISK SETUP diskette is
not available for the particular model of hard disk in the machine (see installation kit), DO NOT use
one for another type drive. See Manual Hard Disk Setup at the end of this document. Then skip to
step #8.
________2. Power up control with the HARD DISK SETUP diskF4 in drive A:.
________3. After the A: prompt appears, type “D” and press <ENTER>. This will delete the existing hard disk
partitions.
________4. Reboot the control by cycling powerC1 and make sure that the CMOS setup is correct for that drive
type. Use the auto hard disk detect of the CMOS if possible. DO NOT use the old 50 sector
limitation settings for the CMOS configuration (as with Ultimax v1.64). This will render the disk not
usable for v2.xx.systems The CMOS settings should be cylinders: 3305; heads:16; sectors:63F5.
If there is a PIO Mode in the IDE Hard Disk Setup, then set it to 0 (zero). Also, the LBA or Large
Mode must be set to ON. B6 Reference document 757-4002-169 for changing these settings on the
passive backplane CPU board.F6
________5. After saving the CMOS settings, reboot the control by cycling powerC1 with the HARD DISK SETUP
diskette in drive A:.
________6. After the A: prompt appears, type “P” and <ENTER> to partition the drive.
________7. After the partition is successfully installed, type “F” <ENTER> to format the drive. This will format
drive C: and D:. It will take approximately 5 minutes. The hard disk setup is now complete.
________8. After the format is complete, place Disk 1 of the INITIAL ULTIMAX V2.xx PRODUCTION
INSTALLATION (007-4123-008) disk set in the floppy drive and reset system. This will start the
Ultimax software installation.
files.
DISKETTE in the floppy drive. Continue inserting diskettes as prompted. E3
________11. After file copying is complete, be sure that the security device is connected to control. Boot the
control with the Optikey OPTIKEY UTILITY DISKETTE/ SKCOX200 PKG, PROD #0 PROD (007-
4137-008) diskette in floppy drive to program the security device. Remove the Optikey diskette
when complete.

757-4002-129 Rev. F Page 4
________12. If any options accompany this installation, repeat step 11 using the OPTIKEY UTILITY DISKETTES
________13. Remove disk from floppy drive and Cycle Power to reset the system. The Ultimax v2.xx base
system should run.
________14. Place the ULTIMAX VERSION 2.XX/ULTIMAX CNC (EXECUTIVE) disk #1 (007-4123-004) in floppy
drive.
________15. Select Auxiliary Mode and select the “UPGRADE SYSTEM FILES” softkey. Select the “YES”
softkey to copy the files. Insert the next diskette when prompted.
“YES” softkey. E2
________17. Insert with the ULTIMAX V2.XX COMPOSITE LADDERS (007-0071-044)D2 diskette in the floppy
drive. This will install the ladder files that PLC system will use. Continue to insert disks for this set
as prompted. E4
“YES” softkey.
________19. Insert with the ULTIMAX V2.XX COMPOSITE PARAMETERS (427-0004-021) diskette in the floppy
drive. This will install the parameter files that PLC and CNC system will use.
________21. Remove any disks from the floppy drive. B5 Cycle power to the control.
________26. Highlight the TESTSET.MCD selection using the arrow keys and press <ENTER>.
________28. Press the “EXIT” softkey after the copying is complete. The control will automatically reset. If the
system does not restart, then cycle the control power.
________29. The diskettes indicated on the work order are to placed in the machine folder.
________30. The control is now ready to be tested on the test fixture.
________31. If the system is to get an Ultimax 4 console, there will be a diskette in the CONTROL KIT, MAX 4
DSM (007-3005-003) or if an upgrade KIT,DSM CONSOLE UPGRADE (007-3005-013). This disk
is the ULTIMAX 4 CONSOLE ACTIVATION DISK (007-4000-001). F2

757-4002-129 Rev. F Page 5
________32. Boot the control with the ULTIMAX 4 CONSOLE ACTIVATION DISK (007-4000-001) in the floppy
drive. This will copy the files necessary for the Max4 console to function correctly. If the disk is run
again, the Max4 files will be removed from the system (reference: engineering document 704-0004-
037). F2
________33. Remove the ULTIMAX 4 CONSOLE ACTIVATION DISK (007-4000-001) from the floppy drive. F2

757-4002-129 Rev. F Page 6

757-4002-129 Rev. F Page 7
and press ENTER.
D 399 Unknown 100%

757-4002-129 Rev. F Page 8
R
757-4002-125 Rev L CAD #D8515

Procedure, Ultimax v2.xx Field Installation 757-4002-125 Rev. L Page 1

RECORD OF CHANGES

By
entering positive number for a negative
0 inch position in the leadscrew map.
Added Hawk30/40 bed mill parameter doc
(E3); Added Hawk30/40 serial number
prefixes (E4) and REX files (E5); Added
Max4 *.HB8 files (E6); Added BMC2416 &
BMC6434 parameter docs to contents
list (E7). BVP 9/1/98 TLK 9/3/98
– pg7) BVP 11/20/98 TLK 11/24/98

By
G 14547 Added Yaskawa Sigma drive parameter
diskette (G1); Added parameter
documents for rotary tilt tables with
Sigma drives, VTC40 machines, BMC30
& 4020 machines with Sigma drives
(G2); was 5050MY (G3); Was Yaskawa
Servo Pack – error (G4); Added
machine selections for BMC30, 4020 &
6434 machines with Yaskawa Sigma
drives (G5); Replaced list of ladder files
with a reference to the eng doc
describing the ladders diskettes (G6);
Added alternate language files and
optional note (G7); Added
CANBUS.CFG and V800X600.VGA files
(G8);Was VER2_00 (G9); Added Max4
activation disk (G10); Added steps for
installing Max4 activation disk (G11);
Added BM6434 mach paramas &
passive backplane CPU set up doc BVP 2/13/99 TLK 2/13/99
(G12)
H 14687 1.) Added content for Hawk5 RMN 7/7/99 DEO 7/22/99
2.) Added content for VTC40
J 14799 1.) Added content for BMC 6434 CAT -50 RMN 10/15/99 GT 10/25/99
K 14872 1.) Removed Initial Ultimax (007-4123- BVP 4/17/00 DEO 6/7/00
008) diskette pg 4.
2.) Removed Ultimax Utility diskette
(427-0004-023), Ultimax 4 Activation
diskette (007-4000-001) and Ultimax
Machine Configuration (ladders)
diskette (007-0071-044) pg5
3.) Changed the installation procedure
for the new install diskettes.
Eliminates the Ultimax Initial and
Max4 Activation diskettes pg6
4.) Added INTEGRAT.VER file pg 12
5.) Changed from 10MB to 20MB for the
system partition since Ultimax now
supports up to 40MB. This gives
more room for language and other
system files. Pg 10
6.) Added content for BMC 6434 w/ 40
station ATC.

By
L 14992 1.) Added reference to parameter RMN 6/8/00
documents for new machine models.
2.) Added reference to machine type
data for new machine models.

I. INTENT
The purpose of this document is to provide instructions for field installation of the Ultimax version 2.XX software on
ISA based Hurco machines.
II. SCOPE
control. The machine will be fully operational after this installation. The procedure is meant for a qualified Hurco
service person only. It is not meant for customer use. It is assumed that the control has a Pentium CPU board
installed.
• Parameters
III. MATERIALS
• PC/AT keyboard
Contents:
Diskette Description J1 K1 Part Number Disks

G1
YASKAWA SIGMA SERVO PACK PARAMETERS DISKETTE 007-4000-002 1

Number


MACHINE PARAMETERS – BMC 4020HT SIEMENS 757-4005-008 DP008
E3
G12
E7
E7
SETTINGS FOR MACHINES WITH YASKAWA SIGMA DRIVES 757-4005-015 DP0015
G2
INSTALL PROCEDURE FOR ROTARY / TILT TABLES WITH SIGMA MOTORS 757-4005-016 DP0016
G2
MACHINE PARAMETERS - VTC40 757-4005-017 DP0017
G2
MACHINE PARAMETERS - BMC 30M YASKAWA SIGMA DRIVES 757-4005-020 DP0020
G2
MACHINE PARAMETERS - BMC 4020 YASKAWA SIGMA DRIVES 757-4005-021 DP0021
H1
MACHINE PARAMETERS – HAWK 5 757-4005-026 DP0026
J1
MACHINE PARAMETERS – BMC 6434 (CAT-50) YSM DRIVES 757-4005-024 DP0024
K6
MACHINE PARAMETERS – BMC 6434 (CAT-50, 40st. ATC) YSM DRIVES 757-4005-028 DP0028
L1
MACHINE PARAMETERS – BMC 50 (YASKAWA SIGMA II DRIVES) 757-4005-029 DP0029
L1
L1
L1
MACHINE PARAMETERS – BMC 4020E (YASKAWA SIGMA II DRIVES) 757-4005-034 DP0034
FIC LMB-586PF P/B CPU BOARD SET UP PROCEDURE G12 757-4002-169 D8578

Check the items you have, before beginning the procedure: F1 H3
Description K2 Part Number Serial

Number
√
Prefix
ULTIMAX UPGRADE DISKETTE 007-4123-016, - U3V2
017
OPTIKEY UTILITY DISKETTE/SECURITY MODIFIER SKOX2__ 007-4136-005 -
WIRE, 24AWG, BLUE (60”) 406-2008-001 -


IV. SOFTWARE INSTALLATION PROCEDURE K3
NOTE 1: Connect the PC keyboard to the control. Steps 3 and 41 require PC keyboard interaction NOT console key
presses. The remaining steps require console key presses NOT PC keyboard presses.
this procedure.
machine folder.
________2. Record the Tool Change Height, Max DAC Voltage for each axis , Spindle Motor Speed, Spindle Speed
and copy the Leadscrew Map to a floppy diskette. Do not copy the leadscrew map to the v2.00 hard
drive until step #41.
Max DAC Voltages:
(X)_______ (Y)_______ (Z)_______ (S)_______ (A)______ (B)_______
________3. Complete hard disk setup. See Manual Hard Disk Setup section of this document. Follow these steps
to set up the hard disk. H4
________4. Insert disk #1 from the ULTIMAX UPGRADE DISKETTE (007-4123-016, -017) set into the floppy drive
and cycle power to the machine tool.
________5. The control will reset and the Ultimax Installation Utility will start. Follow the instructions on the screen.
________6. Insert the proper diskettes (by part number) into the floppy drive when prompted.
*** NOTE: DO NOT remove the current diskette from the floppy drive until prompted to put in the next
diskette.
________7. After the installation utility installs the files, there will be a prompt to insert the OPTIKEY UTILITY
DISKETTE/ SECURITY MODIFIER SKCOX2__ (007-4136-005) diskette to complete the upgrade. This
must be a valid and unused Optikey security modifier diskette for the version of Ultimax being installed.

________8. When prompted, insert the ULTIMAX PATCH DISKETTE (007-4123-010) into the floppy drive.
________9. When prompted, insert the ULTIMAX MACHINE PARAMETERS/PRODUCTION COMPOSITE diskette
(427-0004-021) into the floppy drive.
________10. When prompted, insert the the ULTIMAX MACHINE PARAMETERS/FIELD COMPOSITE diskette (427-
0004-024) into the floppy drive.
________11. Before the installation utility completes, it will require that the ULTIMAX UPGRADE DISKETTE (007-
4123-016, -017) #1 be reinserted into the floppy drive.
________12. After a successful upgrade, the installation utility will prompt you to insert the Optikey diskette. Reset
the control with the OPTIKEY UTILITY DISKETTE/ SECURITY MODIFIER SKCOX2__ (007-4136-005)
diskette in floppy drive to program the security device. Follow the instructions on the Optikey
installation instructions (704-0004-026). Remove the Optikey diskette when complete. H7
________13. If any options accompany this upgrade, install these options using the OPTIKEY UTILITY DISKETTES
________14. After the installation and all options are installed, remove any diskettes from the floppy drive.
________15. Cycle the Machine Power Off and On.
________16. Verify the Executive Software Version at the top of the screen in Input mode matches the version
received. If these versions do not match, try the upgrade again.
________14. Select Auxiliary Mode.
type>.MCD selection using the arrow keys and press <ENTER>. Use the following table to determine
the <machine type>:

RPM
spindle
G3
(pre-v1.08 ladders)
5050Y G3 BMC5050M with Yaskawa drives B5 4000
H1
KM5SSM Hawk 5 kneemill H5M, H5SSM 3800
E4
E4
F5 G4
2416Y BMC2416 with Yaskawa Sigma drives B24S, B24M 8000
G5
3017Y BMC3017 with Yaskawa Sigma drives B3M, B3SM 8000
G5
3017HY BMC3017HT with Yaskawa Sigma drives B3HM 8000
G5
4020Y BMC4020 with Yaskawa Sigma drives B42M, B42S 8000
G5
6434Y BMC6434 with Yaskawa Sigma drives B64T 8000
H2
VTC40 VTC40 Travelling column (vert) with Siemens drives VTC4 8000
J1
64C50Y BMC6434 CAT-50 with Yaskawa Sigma drives B65T 6000
K6
6434HY BMC6434 CAT-50, 40 station ATC (YSM drives) * 8000
L2
BMC24 BMC 24 with Yaskawa Sigma II drives * 10000
BMC30 L2 BMC 30 with Yaskawa Sigma II drives * 10000
L2
BMC50 BMC 50 with Yaskawa Sigma II drives * 10000
L2
4020E BMC 4020E with Yaskawa Sigma II drives * 10000
* Unresolved at time of document release.
________27. The prompt “There are machine boot configuration files in the selected MCD. Do you want to copy
these to the configuration directory?” will appear. Select the “YES” softkey.

________c) Insert the ULTIMAX MACHINE CONFIGURATION diskette in drive A: and select the
“RESTORE MACHINE CONFIGURATION” softkey and then the “YES” softkey.
________d) After the configuration is successfully restored, reset the control.
________30. After the system restarts, go to the INTEGRATOR SUPPORT SERVICES hidden screen by pressing
<ENTER> <100> <ENTER> from the Auxiliary screen.
________32. Select the “SPINDLE” softkey then select the “PHYSICAL PARAMETERS” softkey and enter the Max
DAC Volts (that was recorded previously) for each axis.
________38. The Tool Change Height recorded in step #2 must be converted to metric units (MM). This value will
always be negative (make sure you type the minus sign). Enter the tool change height recorded in
step #2.
prompt by typing:
COPY LEADSCRW C:\

________a) Place the SYSTEM CONFIGURATION diskette that accompanied the Ultimax v2.XX
upgrade package in the floppy drive.
________c) Then select the “BACKUP MACHINE CONFIGURATION” softkey. The system will copy
the configuration files to the diskette.
________44. The version 2.XX installation is complete. Insert all diskettes provided with the Ultimax v2.XX Upgrade
Package in the machine folder provided and the diskette folder from the previous version of Ultimax.
Discard the diskettes from the previous version.

9. Make sure that the CMOS setup is correct for that drive type (See Engineering Document 757-4002-105). Use
the auto hard disk setup of the CMOS if possible. DO NOT use the old 50 sector limitation settings for the
CMOS configuration. This will render the disk not usable for v2.XX. The CMOS settings should match the
settings on the hard disk label. If there is a PIO Mode in the IDE Hard Disk Setup, then set it to 0 (zero).
Also, the LBA or Large Mode must be ON for v2.XX systems.
b) At the prompt “Do you wish to use the maximum available size for a primary DOS partition and make the
partition active (Y/N)” enter N.
partition”, enter 20 for 20Mbytes. K5
partition”, leave the default Mbytes displayed or set the percentage to 100% minus the percentage of the
primary DOS partition and press ENTER.
e) At the prompt “Enter logical drive size in Mbytes or percent of disk space (%)”,leave the default Mbytes
displayed or set the percentage to 100% minus the percentage of the primary DOS partition and press
ENTER.

f) “All available space in the extended DOS partition is assigned to logical drives” should be displayed when
completed with 100% listed for Usage.
a) The following should be displayed as: K5
D 380 Unknown 100%
17. At the A> prompt, enter FORMAT C: /U /V:EXECUTIVE_1 to format the Hard Disk Drive C partition. Verify
that only 20M (approximately) is formatted. K5

completed.
C:\ root directory

PREVIOUS.VER K4 File created after an upgrade to indicate the previous version.
BOOTSAVE.BIN Old bootstrap saved in this file(system/hidden file).
EXECPROG Version 2.XX Executive (system/hidden file).
HURCO.LDR Bootloader file (system/hidden file).
LOADFRAG.BIN New bootstrap file (system/hidden file).
CANBUS.CFGG8 Canbus script file (used with Max4 consoles only)
V800X600.VGA G8 Makes the executive put the video card into 800x600 mode for Max4
consoles.
INTEGRAT.VER K4 Contains version data for ladder and language files.
LADDERS G6 sub directory – contains ladder files (*.REX). Refer to engineering document
704-0020-038 (DS0066) for the contents of this subdirectory.
LANG sub-directory
FRENCH.HRC Alternate language files (optional)G7
FRENCH.HRL
GERMAN.HRC
GERMAN.HRL
ITALIAN.HRC
ITALIAN.HRL
VER2_XX G8 sub-directory
SYSINT.SYS
TUNE.SYS
SERIAL.SYS
PROBE.SYS
SPINDLE.SYS
MCODE.SYS
NETWORK.SYS

VII. PARAMETERS
• Axis Parameters





Rotary Resolution



Procedure, Ultimax v2.xx Field Installation 757-4002-125 Rev. K Page 18



Physical Parameters
Physical Parameters
Physical Parameters

Parameters, N95:18
Parameters, N95:19
Parameters, N95:20
Parameters, N95:226
Parameters, N95:227
Physical Parameters
Physical Parameters

Parameters, N95:3

Physical Parameters
Physical Parameters



Vertical Parameters
Vertical Parameters
Vertical Parameters

MACHINE PARAMETERS

Parameters, General
Parameters, N95:238

Parameters, General
Parameters, F96:202
N95:211, 213


Parameters, N95:57
Parameters, N95:58
Parameters, F96:30
Parameters, N95:201
Parameters, N95:202
Parameters, N95:204
Parameters, N95:205
Parameters, N95:206
Parameters, N95:207


DIAGNOSTICS
Integral Servo Tuning, X Axis Servo Tuning, Y Axis Servo Tuning, Z Axis
Proportional Servo Tuning, X Axis Servo Tuning, Y Axis Servo Tuning, Z Axis
Feedforward Servo Tuning, X Axis Servo Tuning, Y Axis Servo Tuning, Z Axis
Derivative Servo Tuning, X Axis Servo Tuning, Y Axis Servo Tuning, Z Axis
Integral Limit Servo Tuning, X Axis Servo Tuning, Y Axis Servo Tuning, Z Axis
Output Loop Gain Servo Tuning, X Axis Servo Tuning, Y Axis Servo Tuning, Z Axis
Integral Bandwidth Servo Tuning, X Axis Servo Tuning, Y Axis Servo Tuning, Z Axis
Max Rapid Accel Servo Tuning, X Axis Servo Tuning, Y Axis Servo Tuning, Z Axis
Max Contour Accel Servo Tuning, X Axis Servo Tuning, Y Axis Servo Tuning, Z Axis
Maximum Abort Accel Servo Tuning, X Axis Servo Tuning, Y Axis Servo Tuning, Z Axis
Following Error Halt Servo Tuning, X Axis Servo Tuning, Y Axis Servo Tuning, Z Axis


DIAGNOSTICS


DIAGNOSTICS

R
704-0020-030 Rev K CAD #D8530
SUBJECT: Ultimax v2.XX Software Patch Utility List
5/13/97
List, Ultimax v2.XX Patch Utility 704-0020-030 Rev. J Page 1

RECORD OF CHANGES

By By
B 14547 Added information on v1.01 through
v1.06. BVP 2/16/99
C 14578 Added information for v1.07 for new
MSC_000.REX for a Hawk bed mill
problem. BVP 3/5/99
D 14653 Added information for v1.08 for new RMN 5/6/99 DEO 5/11/99
MSC_000.REX, JOG_000.REX and
YSM output files.
E 14687 Added information for v1.09 as part of RMN 8/10/99 DEO 8/19/99
2.14 / 1.09I software release.
Added 0074123.010, for Instalit disk ID.
F 14799 Changed labeling from v1.xx to Rev_A. RMN 10/15/99 GT 10/25/99
Added information for v1.10 as part of
2.15/1.10I software release.
G 14872 Added information for v1.11 as part of RMN 4/25/00 DEO 6/7/00
2.16/1.11I software release.
H 14992 Added information for v1.12i RMN 6/8/00 DEO 6/30/00
Integration-only software release
(Rev_C).
J 15059 Added information for 2.17/1.13i BVP 10/18/00 DEO 11/2700
software release (Rev_N). Changed to
Rev N to match the version in the
system to reduce confusion.
K 15226 Added information for 2.20/1.13i BVP 3/1/01
software release
List, Ultimax v2.XX Patch Utility 704-0020-030 Rev. K Page 2

I. INTENT
The purpose of this document is to provide a list of features that are released on the Patch Utility diskette (007-4123-
010).
II. SCOPE
This patch utility will be used to upgrade Ultimax v2.XX systems between software releases. Each patch diskette will
be released using a manufacturing notice. All of the fixes and enhancements in each patch will be incorporated
into the next software release. This will provide an easy and quick way to respond to customers and still maintain
a manageable method of tracking the software fixes and enhancements.
Included on this diskette is a file named PX_XX.TXT. X_XX will be the revision of the patch diskette. This diskette will
contain a brief description of the changes on the patch diskette. PX_XX.TXT can be viewed with any ASCII editor.
III. LIST OF FEATURES FOR V1.00
A. Ladder Modifications
The following table describes the ladders that are modified and the changes to those ladders. All of these
ladder files have been update to v1.01 and should be revised on the ECN of the next Ultimax v.2xx software
release.
File Name Description
B30SIN, B30SOUT v1.01 Modified I/O mapping. Includes Auxiliary M-code, Siemens Reset
bit, Probe I/O rearrangement, and Jog direction reverse logic.
B30YIN, B30YOUT v1.01 Modified I/O mapping. Includes Auxiliary M-code, Probe I/O
rearrangement, and Jog direction reverse logic.
BMC42IN, v1.01 Modified I/O mapping. Includes Auxiliary M-code, Siemens Reset
BMC42OUT bit, Probe I/O rearrangement, and Jog direction reverse logic.
MSC_000 v1.01 Modification to TIS screen to accommodate type-0, 1, and 2
ATC’s. Fixed minor bug where after a manual mode ATC cycle with a
tool insert, the Tool In Spindle prompt field remained *** after operator
did insert and pressed Start P.B.. Rapid Override Enable / Disable
modifications.
SPIN_000 Modified Spindle override to be +/- rpm defined by N95:216 (defaults to
+/- 640 if parameter value = 0). Corrected spindle speed clamping for
minimum and maximum motor and tool RPM values.
TCHGR002 Added “anti-bit” for chip enclosure door, increased FLL length to 35
(from 20) for error clearing, corrected selector switch rotate bug, and
implemented Rapid Override disable for ATC cycle Z up and down
movement. Modified Diagnostics Z axis moves to include unclamp /
clamp sequence when ATC magazine is in right position.

ENGLISH.HRL Adds fields on Auto Run screen for override percentages, adds softkey
for enable / disable Rapid Override, removes Spindle Orient softkey
from ATC diagnostics screen.

B. Additions to Integrator Configuration Parameters
The following changes are description changes only. These descriptions should be given to the following
parameters. Although, if these descriptions are not changed, the functionality of the control will not be
affected.
Parameter Parameter Tag Description Default

Number Value
N95:215 SPINDLE OVERRIDE Specifies the range +/- range 0
RANGE in RPM that the spindle speed
may be overridden. A value of
200 would yield a range of +/-
200 RPM. A value of 0 will
default to +/- 640 RPM. The
“step value” will equal
parameter value divided by 32.
N95:216 ATC RAPID OVERRIDE When set =1 allows the Z axis 0
ENABLE movement during an ATC
cycle to be overridden. This
parameter is effective only
when the Disable Rapid
Override parameter is
disabled.
N95:217 DISABLE RAPID When set=1, the Rapid 0
OVERRIDE override value will always be
100% regardless of feedrate
override pot setting and when
set=0 the rapid override will be
0 to 100% depending on
feedrate override pot setting.
This parameter can be toggled
via softkey from the Auto Run
screen. Auto Run screen also
now has DRO fields to display
current feedrate and override
percentages. When this
parameter is toggled, it’s state
is retained, even after machine
shutdown and powered up.
N95:218 JOG DIRECTION When enabled (set =1) the 0
REVERSE Rapid Jog buttons and
incremental handwheel
controls will be reversed. This
parameter is intended primarily
for the Japanese market.

IV. LIST OF FEATURES FOR V1.01
This disk contains the following files:
B30SIN.REX 6/6/97 v1.02 input map

BMC42IN.REX 6/6/97 v1.02 input map
AMPL_000.REX 6/6/97 v1.01 Servo Amp logic
MSTST000.REX 6/6/97 v1.01 Machine Setup and Test
JOG_000.REX 6/19/97 v1.01 Axis Jog Logic
TCHGR002.REX 6/6/97 v1.02 Type-2 ATC Logic
CAL_000.REX 6/9/97 V1.01 Calibration Logic
Also included is the following revised language file:
ENGLISH.HRL 5/29/97
Specifically fixed / changed:
- Input mapping for Siemens spindle machines modified to read

all fault signals.
- Incremental (handwheel) jogging uses velocity-mode for smoother

operation. Can now jog past software travel limits.
- Rotary "B" Axes supported.
- Minor bugs in Spindle Test cycle corrected (no longer requires

that axes be calibrated).
- Toolchanger manual remove/insert sequence refined. Support for

Servo Fault/Reset corrected.
The following ladder files were modified for Ultimax v2.01 RRB 1:
AMPL_000.REX
B30SIN.REX
B30SOUT.REX
B30YIN.REX
B30YOUT.REX
BMC42IN.REX
BMC42OUT.REX
CAL_000.REX
JOG_000.REX
MSC_000.REX
MSTST000.REX
SPIN_000.REX
TCHGR002.REX
ENGLISH.HRL
P1_01.TXT

V. LIST OF FEATURES FOR V1.02
No software changes were made to v1.02 for Ultimax v2.10. The description file was only changed. The following ladder
files were modified:
P1_02.TXT
VI. LIST OF FEATURES FOR V1.03

The ladder TCHGR000.REX fixes problems seen with the type 0 tool changer
ATC board. The fix allows the ATC to work with a new design ATC board.
The problem was during CCW magazine moves, there was no braking and the
magazine would drift CCW and finally create an ATC fault. Also, the pressing
of the Magazine Rotate pushbutton will now reset the COR off timer.
The ladder IOTST000.REX has a timer fix that previously caused the DCIO
loopback test not to function.
This was before the release of Utimax v2.11.
IOTST000.REX
TCHGR000.REX
P1_03.TXT
VII. LIST OF FEATURES FOR V1.04

P1_04.TXT
VIII. LIST OF FEATURES FOR V1.05

P1_05.TXT

IX. LIST OF FEATURES FOR V1.06
P1_06.TXT
X. LIST OF FEATURES FOR V1.07
The ladder MSC_000.REX fixes a problem seen only on Hawk 5/30/40 with v2.13.
Specifically, when the F8 "RUN PROGRAM" softkey is pressed, the machine
does nothing. The problem fixes a requirement for the spindle to be
clamped (which obviously doesn't apply to Hawk machines).
3/5/99 Patch Disk v1.07
P1_07.TXT
LADDERS\MSC_000.REX
XI. LIST OF FEATURES FOR V1.08
The JOG_000.REX contains new logic for improved Max IV handwheel jog operation. The improved jog operation
requires updated firmware with 10 msec update rates. The MSC_000.REX contains the change in v1.07 as well as logic
changes to force program abort on Hawk CE machines if the door is opened while the program is running. Output files
were modified to move auxiliary M-code outputs to IOIF and spindle unclamp to DCIO1.
File Version Description Time Date

jog_000.rex 1.06 MAX IV JOG PATCH 15:45 04/15/1999
msc_000.rex 1.08 MACHINE STATE CTRL. 1:08 04/12/1999
2416yout.rex 1.02 OUTPUT MAPPING 14:57 03/25/1999
30ysmout.rex 1.01 3017 YSM OUTPUT MAP 15:06 03/25/1999
42ysmout.rex 1.01 4020 YSM OUTPUT MAP 15:10 03/25/1999
6434yout.rex 1.01 OUTPUT MAPPING 15:12 03/25/1999
p1_08.txt Descriptive Text File
XII. LIST OF FEATURES FOR V1.09
No software changes were made to v1.09 for Ultimax v2.14. The description file only was changed, and ID file added.
P1_09.TXT
0074123.010 (new)

XIII. LIST OF FEATURES FOR Rev_A
NOTE: Labeling of patch version is being changed from p1_xx to Rev_x to prevent confusion between integration
release and patch release.
No software changes were made to v1.10 for Ultimax v2.15. The description file only was changed. The following ladder
REV_A.TXT
0074123.010
XIV. LIST OF FEATURES FOR Rev_B
REV_B.TXT
0074123.010
XV. LIST OF FEATURES FOR Rev_C

REV_C.TXT
0074123.010
XVI. LIST OF FEATURES FOR Rev_N

REV_N.TXT
0074123.010
Note: The revision and description were changed to rev N to match the system. The difference of versions was causing
confusion.
XVII. LIST OF FEATURES FOR Rev_P


REV_P.TXT
0074123.010
XVIII. Patch Utility Installation Procedure
________1. Insert the ULTIMAX 3 VERSION 2.XX PATCH diskette into the floppy drive.
________2. Select Auxiliary Mode and select the “UPGRADE SYSTEM FILES”. Select the “YES” softkey to copy
the files.
________3. Upon completion, the prompt “Do you have another set of system disks?” will appear. Select the “NO”
softkey.
________4. Reset the system by cycling the power.
List, Ultimax v2.XX Patch Utility 704-0020-030 Rev. K Page

10
R
757-4002-145 Rev F CAD #D8544
SUBJECT: Ultimax v2.xx Machine Type Selection Procedure
Michael Dupont
RECORD OF CHANGES

By By
B 14547 Added MCDs for machines with Yaskawa
Sigma drives and VTC40. Removed the
Siemens drive machines from the table.
Also, added the serial number graphic
(B1); Added the old Yaskawa, new
Yaskwaw and Siemens drive machines
to table along with the serial number
graphic. This table was blank. (B2). BVP 2/18/99
Added the machine revision field to the
table for better machine identification
(B3)
C 14687 1) Added MCD’s for field retrofit of Hawk RMN 7/19/99 DEO 7/22/99
5 kneemill.
D 14799 1) Added MCD’s for BMC6434 50-Taper RMN 10/22/99 GT 10/25/99
(64C50Y)
E 14872 1) Added MCD’s for BMC6434 40-Taper RMN 4/25/00 DEO 6/7/00
with 40 station ATC (6434HY)
F 14992 1) Added MCD’s for BMC 24, 30, 50. RMN 6/8/00

757-4002-145 Rev. F Page 2
I. INTENT
The purpose of this document is to provide instructions for the selection of the proper machine type when installing the
Ultimax control on a machine tool equipped with version 2.00 or above. This procedure can also be used to
reselect a machine type if the incorrect type has been selected.
II. SCOPE
The procedure is meant for qualified Hurco machine tool assembly and field service personnel only. It is not meant for
customer use.
This document is divided into the following sections:
• Prerequisites
• Production machine type selection procedure
• Reselecting a machine type
• Field retrofit machine type selection procedure
III. PREREQUISITES
The following is necessary for successful selection of the correct machine type:
1) Ultimax control successfully installed on machine tool.

2) Successful installation of the v2.00 or greater Ultimax software (ref. 757-4002-129)
3) Serial number of machine tool.

757-4002-145 Rev. F Page 3
IV. PRODUCTION MACHINE TYPE SELECTION PROCEDURE
________1. Power up the control.
________2. After the Input screen appears, select Auxiliary Mode.
________6. Verify the machine type with the machine serial number prefix and suffix. Highlight the appropriate
<machine type>.MCD selection using the arrow keys and press <ENTER>. Use the following table to
Serial number
PPPP - Y1 F D XX MM Y2 R Z
<machine type> Description S/N Prefix S/N Suffix

HAWK30 Hawk30 bed mill H3 N/A
3017Y BMC3017 with Yaskawa Sigma drives B3SM, B3M B
3017HY BMC3017HT with Yaskawa Sigma drives B3HM B
4020Y BMC4020 with Yaskawa Sigma drives B42S, B42M B
5050Y BMC5050 with Yaskawa drives B5M B
6434HY BMC6434 CAT-40 40-station ATC (YSM) * *
6434Y BMC6434 with Yaskawa Sigma drives B64T B
D1
64C50Y BMC6434 CAT-50 with YSM drives B65T B
F1
BMC24 BMC24 with Yaskawa Sigma II drives * *
F1
F1
F1
4020Y BMC 4020E with Yaskawa Sigma II drives * *
VTC40 VTC40 with Siemens drives VTC4 C
* Unresolved at time of document release.
________7. The prompt “There are machine boot config files in the selected MCD. Do you want to copy these to the
configuration directory?” will appear. Select the “YES” softkey.
________9. Following procedures for setting up servo drives and tool changer, enter the MAXIMUM DAC VOLTS and
TOOL CHANGE POSITION.

757-4002-145 Rev. F Page 4
V. RESELECTING MACHINE TYPE
________1. Apply power to the control.
________2. After the Input screen reappears, select Auxiliary mode.
________4. Press the “CNC CONFIG PARAMETERS” softkey.
________5. Press the “SPINDLE” softkey.
________6. Cursor down using the arrow keys to the MAXIMUM DAC VOLTS field.
________7. Write down the maximum DAC voltage _________________.
________9. Press the “EXIT” softkey again.
________10. The prompt “The current CNC configuration file(s) will be overwritten. OK to continue?” will be
displayed. Press the “YES” softkey in response.
________11. The INTEGRATOR SUPPORT SERVICES SCREEN will now be displayed.
________12. Press the “INTEGRATOR CONFIG PARAMETERS” softkey.
________13. Press the “DOUBLE (F96) PARAMETERS” softkey.
________14. Press the “JUMP TO PARAMETER NUMBER” softkey.
________15. Type 30 and press <ENTER> or press the <PAGE DOWN> key until F96:30 is displayed.
________16. Write down the tool change position ___________________.
________20. Now the INTEGRATOR SUPPORT SERVICES screen will be displayed.
________21. Follow the procedure described in MACHINE TYPE SELECTION section above starting at step 4 to
select the new machine type. Use the logged values for the specified fields or use new values if
necessary.

757-4002-145 Rev. F Page 5
VI. FIELD RETROFIT MACHINE TYPE SELECTION
Serial number
<machine type> Description S/N Prefix Mach RevB3 S/N Suffix

30SSMY BMC30SSM with Yaskawa spindle B3SM Thru F A
30MY BMC30M with Yaskawa drives B3M, QAM Thru F B
30HTMY BMC30HT/M with Yaskawa drives B3HM, QHT Thru F B
30SSMS BMC30SSM with Siemens spindle B3SM Thru F D
30MS BMC30M with Siemens drives B3M Thru F C
30HTMS BMC30HT/M with Siemens drives B3HM Thru F C
4020SSM BMC4020SSM with Siemens drives B42S Thru F C
4020HT BMC4020HT with Siemens drives B42M Thru F C
4050MY BMC4050 with Yaskawa drives B45M Thru C B
5050MY BMC5050 with Yaskawa drives B5M Thru B B
(pre-v1.08 ladders)
HAWK30 Hawk30 bed mill H3 N/A N/A
2416Y BMC2416 with Yaskawa Sigma drives B24S B B
3017Y BMC3017 with Yaskawa Sigma drives B3SM, B3M E B
3017HY BMC3017HT with Yaskawa Sigma drives B3HM E B
4020Y BMC4020 with Yaskawa Sigma drives B42S, B42M E B
5050Y BMC5050 with Yaskawa drives B5M C B
(v1.08 ladders & later)
6434HY BMC6434 CAT-40 40-station ATC (YSM)
6434Y BMC6434 with Yaskawa Sigma drives B64T A B
D1
64C50Y BMC6434 CAT-50 with YSM drives B65T A B

757-4002-145 Rev. F Page 6
VTC40 VTC40 with Siemens drives VTC4 A C
C1
KM5SSM Hawk5 knee mill H5M, H5SM Thru B N/A
B2
NOTE: Some SSM machines may have been converted to dual screen. Use the SSM machine type.
________7. The prompt “There are machine boot config files in the selected MCD. Do you want to copy these to
the configuration directory?” will appear. Select the “YES” softkey.
________14. Type the maximum DAC voltage and press <ENTER>.
________23. Type the tool change position using metric units (mm) and press <ENTER>.

757-4002-145 Rev. F Page 7
________29. Now the control will display the Auxiliary screen. The machine is now functional.

757-4002-145 Rev. F Page 8
R
704-0020-033 Rev C CAD #D8554
SUBJECT: Interactive Software Products

Ultimax Software ERRATA
Ultimax CNC Version 2.14
Ultimax LC Version 1.09
Michael A. Dupont 1/15/98 David J. Skrzypczak 1/22/98

Originator: Michael Dupont Date Date
Information contained herein is the property of Hurco Companies, Inc. No reproduction or disclosure of this information shall be made by the
recipient to any other person or organization without the prior written consent of Hurco Companies, Inc.
Page 1
RECORD OF CHANGES

By By
A Initial Revision MAD 1/18/98 DJS 1/22/98
B 14547 Changed ISNC to an option on
page 10 (B1); Added the
v2.11/v.106, v2.12/v1.07 and BVP 2/16/99
v2.13/v1.08 fixes and
enhancements
C 14687 Added the v2.14/v1.09I fixes and RMN 8/8/99
enhancements. BVP
Page 2
Part Number: 704-0020-033 REV. C
CAD Number: D8554
HURCO MANUFACTURING
Interactive Software Products
Release to Manufacturing
Ultimax Software Release Errata Sheet

Product: ULTIMAX CNC / LC
Software Version: 2.14 / 1.09
Maintenance
Feature Enhancement
In the continuing effort to provide high quality software products, the Interactive Software
Products Division of Hurco Companies, Inc. is announcing the release of the Version 2.14 CNC
Software System and Version 1.09 of the Logic Control System on Hurco Machine Tools
Products equipped with the Ultimax CNC.
This package requires the following CNC configuration:

•Ultimax CNC with ISA-type controller (486 or above)
•8-Megabytes of RAM
This document contains the FULL list of corrections and enhancements incorporated into this
release of software. THIS LIST IS INTENDED FOR HURCO PERSONNEL ONLY and
discretion should be exercised when discussing these issues with non-Hurco personnel.
Page 3
The following documents describe some of the features, enhancements and differences between this new system and the
current v1.6x and 1.7x UltiMax-3 software systems.
Version 1.6x/1.7x Version 2.00

Internal Structure
OPERATOR INTERFACE
Help System NO YES - full support for
context-sensitive help
messages. Need to add text
to adequately support this
feature.
Foreign Language YES - using compiled ‘C’ YES - using script file and
Support text strings (simple off-line Windows-based off-line
tool available) - requires language translation tool -
HURCO Software NO HURCO Software
Engineering involvement Engineering involvement
required
Alternate Character Limited YES - using UNICODE
Sets encoding and character
bitmaps
DISPLAY SYSTEM
Window Manager NO YES - allows for features
like pop-up error messages,
etc.
Graphics Screen YES - FIXED. Must be YES - Custom. Integrator
LOGO modified by Hurco Software may define using PC-Paint or
Engineering other package that generates
a .PCX file.
CONTROL
CONFIGURATION
Setup Screens YES - series of secret YES - one secret entry point
support screens for servo to menu-driven configuration
tuning and other machine screens
model parameters
Integrator variables NO YES - 500 Floating point and
500 Integer values for
integration-specific
assignment
Page 4
Lead Screw Mapping YES - fixed on one inch YES - programmable interval
intervals with variable length data
table for each axis to
accommodate extended axis
travels
Rotary Axis Mapping NO YES
Vertical Machine YES YES
Support
Horizontal Machine NO - requires customized YES - standard
Support executive software
Universal Machine NO - requires customized YES - standard
Support executive software
Flexible Kinematic NO - requires customized YES - standard
definitions executive software
Spindle Gearing or YES - limited support for YES - Full support for 25
Winding Support dual winding motors gear ranges and ratios or
spindle motor windings
Integrator Definable NO YES - Hooks supplied for
Test/Diagnostic integrator to define test
Routines routines in ladder logic.
I/O SYSTEM Structured ‘C’ language Software PLC Using industry

accepted off-line
development tools
Easy customization NO - requires a HURCO YES - direct support for
for machine options software engineer to write additional ‘M-codes.’
‘C’ code Ladder logic permits easy
customization and machine
option additions
Language script file allows
easy customization of
screens to indicate status of
newly defined options
Modular I/O Control NO - Compiled, linked and YES - Ladder Logic modules
Software Structure located system that must be may be developed
fully managed by HURCO independently and
Software Engineering interchanged in a highly
modular fashion to allow
“LEGOTM” approach to
system construction
Reassignable I/O NO - must be managed by YES - all I/O assignments
Page 5
Point Addresses HURCO Software may be adjusted in Ladder
Engineering Logic
Off-line I/O NO YES - integrated debugger
Monitoring allows inspection and limited
modification of Logic
Controller I/O, bit, integer
and floating point data table
values. Attach control to any
TTY-type terminal via the
serial interface.
OTHER STRUCTURAL Eliminated conditional

BENEFITS: compiles - simplifies code
maintenance
Fully documented interface
between Logic Controller
and CNC
Completely isolated CNC
code and machine specific
code allows for feature
enhancements independent of
machine type
Code structure lends itself to
quick turn around of features
like Networking
Changes in I/O intensive
functions occur in ¼ the time
required for the same feature
in Version 1.6x/1.7x system
Logic Controller capable of
commanding motion so that
functions like jogging or
calibration may be fully
defined according to the
application
commanding display of error
messages
commanding display of pop-
up messages for immediate
Page 6
operator notification
Data Dictionary makes
internal data visible to screen
script file
Page 7
Version 1.6x/1.7x Version 2.00
Customer Features and Benefits
NAVIGATION
Profiling - 1 NO YES - Senses changes
in angle and attempted
acceleration breaches.
Slows line segments so
that machine
acceleration limits are
not exceeded. Revised
lookahead algorithm
smoothly handles
transitions in speed.
Look Ahead YES - 2-look ahead YES - 3-look ahead
algorithms. algorithms.
Approximately 55 Approximately 400
blocks blocks
High Block Throughput NO YES - 3msec on ‘486-
66;
Less than 1msec on
Pentium-100
OPERATOR INTERFACE
Inch/Metric Digital Read-out NO - DRO units tied to YES - DRO units
(DRO) program units completely independent
from program units -
indication on bottom
status line shows units
currently in effect
Memory Available Display NO - inconsistent YES - constant update
reporting of free of available memory on
memory bottom status line
Disk Activity Icons NO - only indication of YES - FDD and HDD
disk activity is LED’s disk icons on bottom
on console status line indicate disk
activity
NC File Status ICONS NO YES - indications on
bottom status line to
indicate whether an NC
Page 8
file is being read or
written in the
background.
Time of Day Indication NO YES - bottom status
line indicates time-of-
day in 24hour format
Program Run Time Indication NO YES - On AUTO-RUN
screens
QUAD-Size DRO NO YES - AUTO-RUN
screens have a softkey
selection for toggling
between standard and
QUAD-size DRO
3-Dimensional Softkey NO - HURCO-standard YES - softkeys appear
Separators “stick figure” lines to be 3-dimensional
between softkeys buttons that also
change state when a
softkey is pressed
(gives visual feedback
when a key is pressed).
Inactive softkeys
“greyed-out” using
user-selectable color.
Review Screen Enhancements Numbering of sub-
blocks for contours and
holes operations.
Provision for jumping
immediately to tool
blocks in Tool Setup
from Review Mode
Page 9
PART PROGRAMMING Version 1.6x/1.7x Version 2.00
HURCO NC YES YES
INDUSTRY STANDARDB1 YES – must order 1.7x YES - must be ordered
(FANUC) NC (ISNC) OPTION software package as an OPTION
ISNC Requires Keyboard YES - 1.7x systems NO - pop-up window
allows full operation of
ISNC option without
requiring expense of
keyboard (pop-up can
be disabled by user
configuration
parameter).
M-Function Support for machine NO - fixed set of M- YES - expandable M-
control functions Codes code set that can be
defined in ladder logic
and called-up equally
by NC or
Conversational
programming
Probe Stylus Offset Calibration NO YES - provision for
calibrating part probe
to account for stylus
irregularities.
Reorganization of Probe Setup NO - Special function YES - Probing for part
routines under Manual Mode and tool are handled
under the Part and Tool
Setup screens rather
than under Manual
Mode.
Chord Error Precision Expanded to 5-decimal
places under metric, 6-
decimal places under
inch
Page 10
STORAGE FUNCTIONS Version 1.6x/1.7x Version 2.00
Streamlined Key NO YES - for example,
Sequences pressing the [ENTER]
key on a directory
name moves to the
directory under the
cursor
Optimized Storage NO YES - most frequently
Functions Layout used operations on
top-level menu
Expanded Tagged File NO YES - can now delete
Operations tagged files
MANUAL FUNCTIONS
ATC diagnostics YES YES - enhanced
diagnostics indicate
relay states for more
comprehensive view
of machine condition
Manual Mode NO YES
Washdown
Deselect Current Jog YES - Not intuitive - YES - Supports
Axis must select another original means of
axis, perform a manual deselecting axis.
operation that Second depression of
deselects jogging or the axis select key
exit Manual Mode deselects the current
jog axis.
MACHINE OPERATION
Rapid Feedrate NO YES - allows override
Override below 100% of
nominal active rapid
traverse rate during
AUTO-RUN program
operation
Data Logging NO YES - comprehensive
data logging helps
isolate problems
through stored image
Page 11
of navigation and other
system data. Provides
diagnostic information
to aid Engineering and
Field Service
No COR shut off when NO YES -
low lube level or loss When in Auto mode
of air pressure sensed. and low lube level or
loss of air pressure is
sensed, the control
will go into Interrupt
Cycle mode
automatically. When
the lube is refilled or
air pressure is
restored, the program
can be resumed where
it was interrupted.
Page 12
MAXOEM V2.10 CNC BUG FIXES/ENHANCEMENTS
This document lists the changes from the V2.00 released system to the released V2.10 version dated 1-
15-98. It also includes changes to the languages files which are dated 1-9-98.
Track Number Bug Fix or Enhancement

Fixed a problem where changing the ‘MONITOR TYPE’ parameter on a single
screen console did not change the default graphics colors. It only changed the
default text colors.
SPR-M4M-433 Added support for the backspace key in the NC search and replace fields. When
in NC mode, you couldn’t delete unwanted text from the search field with the
PC keyboard.
SPR-M4M-435 Modified the NC String Search menu to say “REPLACE YES” and “REPLACE
NO” instead of “YES” and “NO”. An operator may punch YES upon
completion of the string search and not want it replaced with anything.
SPR-M4M-446 Allowed the operator to replace the current NC search string when it is on the
search string before the enter key is used to invoke the replace function.
Previously, you could only replace the next string.
SPR-M4M-428 Added an error message to be displayed if less than 8MB of memory is detected
during system initialization. After the message is displayed the system will also
lock up. The V2.00 system requires 8MB RAM and systems with less than that
will have problems when loading in programs and displaying them on the
graphics screen.
Gene Adair’s List Fixed a problem where if you format a floppy disk to 1.44MB and then without
removing it, try to format it again to 720K the control immediately responds
with FORMAT COMPLETE. The format disk routine was modified so that it
forces the floppy disk to mount and therefore allows the floppy to be formatted
properly.
Added support for the surface finish quality parameter. This parameter allows
the user to select a surface finish which ultimately controls how much slow
down is imposed upon the part program by the interpreter. The slow down is
used to prevent machine shocks in the system which is a detriment to surface
finish. This addresses the concerns about the V2.00 system running slower than
the V1.x systems when the V1.x surface finish was acceptable. It also gives the
user more control over the Profiling option. Please refer to the
q:\maxoem\document\nav\pro_parm.doc for additional details.
Deleted the language and logo files from the backup/restore configuration and
machine files. The language files were too big and caused an out of disk space
error when backing up the files. Sooner or later, this utility should
span disks but for now, there is plenty of space if the language files are not
included.
Information contained herein is the property of Hurco Companies, Inc. No reproduction or disclosure of this information shall be made by the recipient to any
other person or organization without the prior written consent of Hurco Companies, Inc.
Page 13
Made changes to prevent a stuttering effect which registered multiple program
numbers into the subprogram list when entering a program number in the
editor. Fixed a bug which prevented a program number from being registered
if the file began with the program number instead of a tape start character.
These changes were merged from the V1.72 system.
Fixed a bug where polar coordinates had to be in metric units. This change was
merged from the V1.72 system.
Modified a calculation in the lookahead algorithm to optimize the value of the
start feedrate and stop feedrate when there is a feedrate slower than a calculated
trapezoidal feedrate. In some parts, this may slightly improve the system
throughput. This defect was found in the part program sent to us by Quality Die
& Mold.
Fixed a problem in the copy file prim routine where the end of file wasn't
handled properly when overwriting a file with a smaller length. This problem
was found when doing upgrades from a bigger executive to a smaller
executive. When the new executive was loaded, it had a checksum error.
Fixed a problem where the changing of the configuration parameter units did not
update the config units display at the bottom of the screen.
Changed the language descriptor table so that a language that did not have both
language files did not stay in the table. This fixed a problem where a language
could be selected from the alternate language list but it is already known that
both the HRC & HRL files do not exist on the hard drive.
Clarified the information in the text entry help window.
Added support for the UltiNet networking option.
Added support for the NC vacant variable selection. The operator can now
enable/disable vacant variable testing. On the NC Parameters screen, the field
on the lower right hand side, “ALLOW VACANT VARIABLES”, can now be
used to enable/disable vacant variable testing. If this field is set to “YES” and
the operator attempts to use a vacant variable, an error message occurs. If this
field is set to “NO”, the variable assumes an initial value of 0 and no error
message appears. This change was merged from the V1.72 system.
Fixed a problem where line numbers and program numbers could be on the same
line but according to the FANUC dialect they can not be on the same line. To
fix this problem, if a line number has already been entered, and a program
number is then entered, the line number is deleted. This change was merged
from the V1.72 system.
Page 14
Cleaned up the access to certain NC pointer variables. These variables need
protection because they are accessed by multiple tasks and a task switch could
occur in the middle of their reads and writes. The method used to protect the
integrity of these variables was the disabling and then re-enabling of interrupts.
Unfortunately, these variables were not always being protected before being
accessed. To ensure that these parameters are always protected, they are now
accessed through read/write interface routines similar to the shared database.
The interface routines use the lock task/unlock task which is a better mechanism
than the interrupts. This clean up could potentially fix some NC problems that
are very hard to duplicate.
Modified the CCDK and ANSI-C libraries to use a memory manager interface
routine instead of a direct call to the memory manager. The new interface
routines allow the libraries to remain constant while the memory manger
undergoes renovations to support multiple heaps. (The multiple heaps should fix
the memory fragmentation problem).
SPR-M4M-405 Made some improvements to the recovery restart display in an effort to clarify
the information. When recovery restart was used with hole blocks the
information on the screen regarding operation number and hole number was
confusing. It was reported that on part Intro8, which has 12 holes, Recovery
Restart thinks there are only 2 holes. The 2 was actually referring to the 2nd
hole operation number. After that parameter is selected then the control will ask
for the correct hole number (1 to 12).
Fixed a problem where a system lockup would occur when reading a
conversational part program that contained a special insert datablock.
Removed the call to process a DXF accept key automatically after selecting a
circle. This gives the operator a chance to see the highlighted contour before
accepting the selection. This change was merged from the V1.72 system.
Fixed a problem where a DXF error was not being generated if a frame contour
was not closed. Also fixed a problem where valid frames were being set as
invalid as a result of using the end point tolerance to determine if a line segment
was horizontal. Also, mill frame chained contours are now displayed in normal
line style and color instead of being displayed as a milled contour. This change
was merged from the V1.72 system.
Implemented the correct usage of the backspace key from the keyboard.
Previously, the backspace key was treated like the console’s clear key when
editing conversational part programs.
Fixed a problem where the date/time of the files copied during a system upgrade
contained the date/time of when it was copied to the hard drive instead of the
date/time of the original file on the upgrade floppy disk.
Page 15
Fixed a problem where a RMX disk could not always be accessed properly.
The error 'the device name was not found' was reported because the system
thought that the disk was a DOS disk instead of a RMX disk. RMX disks need
to be mounted every time so that the proper status can be returned to
the caller.
Changed the memory manager to support two heaps. The first heap is for
system usage and the second heap is for part program and initialization usage.
By using two heaps, we can eliminate the interaction of these two different
types of mallocs and thereby prevent memory fragmentation problems.
The memory debug flag which controlled the display of the entire free
memory in the system has been modified so that it can specify the following
displays: 1. no memory display
2. display part heap memory only
3. display system heap memory only
4. display part and system heap memory
Fixed a problem where the dwells during a part program were not delaying
properly. The problem was due to the incorrect casting of a double to a
dword. This problem was identified by the chip breaker cycle which is
supposed to delay 2 revolutions of the spindle during a drill block.
Fixed a problem where the system did not properly process aborts during a
tap. The solution required both CNC and ladder changes. Now, taps can be
aborted right before the tap cycle begins. Also, if the operator aborts during the
middle of the tap, the tap will complete and then abort.
Added support for the display of the rigid tap tuning data and also for the
display of the axes following error and position counts. Both these displays are
enabled by their respective flags on the Miscellaneous Services Screen in the
secret Integrator Support Services. The rigid tap display will appear on the
Auto Run Screen during a rigid tap and stay displayed until the end of the
program. The following error display will appear on the Manual Mode and
Auto Run screens and stay displayed until a mode change. The following error
display is a replacement for the display that is currently controlled by the N95:59
integrator configuration parameter.
Changes were made to provide a prompt to delete the current NC file when
trying to load another NC file from the hard drive. The operator is also
prompted to delete the current file before serial loading a new file.
062597-4 Fixed a problem where the digitize mode does not work correctly in NC mode
because the NC interpreter buffers NC blocks. A change has been made to
disable NC block buffering in digitize mode. This change was merged from the
V1.72 system.
Page 16
Added support for the display of the required block lookahead of a NC program.
If the user does a check for errors from Auto Prep mode and then selects the
help key, a popup box will be displayed that lists the number of blocks that are
required for lookahead purposes.
Fixed an accuracy problem with the V2.00 system. The ‘Distance Per
Revolution’ parameter was entered in inch mode without enough accuracy. For
a 12mm ball screw, the equivalent inches is 0. 472440944 but the value entered
in the configuration screen was 0.4724. This directly affected the conversion
factor from inches to encoder counts and therefore the overall accuracy of the
machine. In addition to reentering the correct value on the screen, the number
of decimal places displayed in the distance per rev fields was increased.
062497-1 Fixed a DXF problem where the radius was set to a -1 in a mill frame and it
should have been set to 0.0.
Several cases have been reported that the autosave file becomes corrupt so
changes were made to try to bullet proof the autosave process. This includes
adding the program critical region semaphore to places that didn't have it before
and suspending the autosave task to ensure that it doesn't run at certain times.
Four problems associated with rotary have been fixed.
1. The part position display did not get updated when the store machine
position was selected on a rotary axis.
2. The rotary part setup was wrong when the machine position was negative
and the store machine position was selected. For example, when the A axis
machine position was at -5 degrees (displays show 355 degrees), the part
position display showed 5 degrees. It should have displayed -5 degrees or
355 degrees.
3. The part position displayed showed 360.0 instead of 0.0 when the A axis had
a negative machine position and the store machine position was selected.
4. A following error would occur after a tool change if the current rotary
machine position was negative.
Fixed a problem where the spindle would turn on and the tool would crash into
the part during a NC tap cycle in Dry Run Mode. Also fixed a problem where
the spindle always turned on when running a NC program in Dry Run mode.
A change was made to speed up the freeing of NC memory. There is a popup
message displayed with this activity along with a forced delay of 500 msec to
ensure that the operator saw the popup. Now, the delay is only executed when
the freeing up of memory takes less than 500 msec.
Page 17
Made correction to how the headers and the single cycles were put in the Axis
Fifo. The NC block on the Auto Run screen is now the next block to be
executed.
062597-2 Fixed a problem where a small peck depth on a rigid tap caused the spindle
speed to be adjusted below the min tap rpm and a Logic Controller error was
generated instead of an interpreter error. Now the error, unable to tap with
given parameters, is displayed by the interpreter.
Fixed a problem where the cutter comp lead in was not specifying a
feedrate to navigation.
The reset of NC variables is now performed when switching to NC mode. Not
all variables are reset. This is also where the variables are read in from a file for
the mill. The variables are no longer read in when the program is interpreted.
This approach was used so that changes that the operator makes on the NC
variables screen will be retained when the program is interpreted and not written
over.
The operator is now prompted to delete current file before serial loading
a new file or before loading a new NC file from the hard drive. This is to help
the operator who is used to just having one NC file in memory at a time.
Support has been added for work offsets for the a and b axes.
Made a change so that feedrates without a decimal point can be treated as
units of x.x. This is handled by a parameter on the NC parameter screen.
Also made some corrections to the G53 (machine coordinate sys) command.
Reworked the display of the NC parameters page and added a screen to display
the NC variables.
Made some changes to properly handle the overrides when determining the
automatic slowdown feedrate. This resulted from some machine shocks that
were found when running a program with the overrides disabled or when
running a program at 150% override.
Optimized the lookahead algorithm in the case where a fast line does not
always have to be clamped to the slowest line in front of it. This was found by
observing a rapid move after a contouring move (w/no decel inbetween)
and the rapid move was moving very slowly.
Fixed a problem where a contouring move right before a rapid move was not
always set to a decel. This could have potential problems in the contouring
task where contouring moves and rapid moves have different rules for
overrides and acceleration rates.
Added support for ethernet media type parameter.
Added call to close the FTP connection after copy all tagged files
from local drive to network. I was leaving the connection open with
no way to close it down.
Added support for lower case characters to support UNIX workstations.
Page 18
061797-2 Fixed a problem where a conversational program was executed during NC
mode. This was a result of having a separate edit and run program when
switching to NC mode and the run program was not formally deleted.
090997-4 Changed the intcfg editor to default the cursor to the value fields. The user can
use the left/right arrow keys to get to the label fields.
090997-2 090997-7 Vertical and Horizontal machines no longer invalidate the leadscrew map when
the calibrate home position or travel limits have changed. Universal machines
still require that restriction.
072397-1 Added support to prompt the operator if he really wants to renumber the
NC sequence numbers and warn him that gotos are not updated.
072397-8 Control locks up when deleting files in memory. Instead of disabling the
new/select/locate/delete file softkeys when the NC loader was active, those
softkeys are enabled and the user is given a message to abort the load if those
softkeys are selected. Also, instead of disabling the erase program/all softkeys
when the NC loader/saver was active, those softkeys are enabled and the user is
given a message to abort the load if those softkeys are selected. This helps the
user to understand what he has to do before performing those functions.
072397-7 Program stops running when Mem Avail reaches zero. Fixed a problem where
the fifo depletion handler couldn't get out of its loop when there wasn't enough
part program memory available to load in additional program blocks and
therefore couldn't fill up the Axis FIFO. Now the fifo depletion handler and
ncloader coordinate this particular scenario. This included adding two new flags
and changing the eof stuffed flag to a count.
062397-4 Fixed a problem where the G54 work offset values were not retained when
they were set with a store machine position button. Also fixed a problem
where the store machine position did not work for all tool offsets. Also
modified the display of the tool offsets to be more consistent with other displays
in the system.
081497-1 Running a NC program at F100, F150 was slower than F70. Optimized the
splitting of the line into the slow part and the fast part. I was keeping the entire
line slow when there wasn't enough distance in the fast part to accelerate from
the slowdown feedrate to the program feedrate. Now, I will accelerate to an
intermediate feedrate if there isn't enough distance to accelerate to the program
feedrate.
090497-1 090497- Fixed two problems with rotary contour datablocks. The first was that the
2 feedrates were not being updated when asked to and the second was that z end
was not being updated when asked to.
081997-1 NC program runs at a slower feedrate on the second run in ISNC. Fixed a
problem where the NC interpreter was not keeping the rotary feedrate radius
parameter up to date. This in turn, caused a bad interp inches per degree
parameter to be used by contouring. Contouring responded by forcing a much
slower feedrate to be used in the program. Now the rotary feedrate radius and
interp inches per degree parameter are always set properly.
080197-2 When switching between tool setup and part setup rapidly, sometimes the
display mixes information. Fixed a timing problem where a LC display could be
intermixed on the screen with a CNC display. The status task now checks the
Page 19
machine mode and only displays a LC display when the machine is not in idle
mode. In the process, I cleaned up the status module to make it more C++ like.
The global data has been replaced with function calls to operate on the internal
data and to make the status module perform some function.
Changed the error message relating to a checksum failure of the system's
code space so that it was more meaningful to the operator.
090997-5 Made changes for the feed/speed optimization feature. The contour
programmed feedrate is now stuffed into the Axis FIFO and stored in the nav
database. When the operator, presses the feed/speed softkeys, the appropriate
spindle speed and axis feedrate is read and incorporated into the feed/speed
message that gets passed through the system from the LC to opint.
Made somes changes to the kneemill auto speed controller. This includes
tapping support and DDAC support for a no servo controlled spindle.
Arctan2: Another decimal place to the filtering of the x value to fix a problem
that showed up with a dxf arc. The arc was quite small the change in x was
smaller than the filter we placed in the routine.
DXF: Added some bytes to the buffer for reading lines out of the dxf file
when checking for the SECTION keyword. It was not reading past a line
that exceeded 29 bytes and therefore it would not find the SECTION keyword
and would consider the file not a dxf file.
NC Editor: Hide the cursor when scrolling the nc program and inserting a block.
The cursor was not clearing when it landed on the E of the End of
buffer statement.
Review: Fixed a problem for mold datablocks where the tool search did not
work.
Page 20
Added support for the console demo unit for training and made changes to
support the max4 console hardware. This also includes support for a 800 x 600
pixel CRT.
090997-6 Added support for the servo tuning diagnostic utility.
Moved the DXF option to the main Aux menu and the Change Language
function to the second Aux menu. This puts the more commonly used functions
on the main screen.
Changed the mask to allow the System Configuration function on the Auxiliary
screen when the system is in Auto Run mode (i.e. concurrent programming).
Also masked off the network and floppy functions on the System Configuration
screen during Auto Run mode. The network stuff may cause a reboot which
would be bad during concurrent programming and the operator shouldn't be
doing the backup/restore stuff during concurrent programming because those
functions take a long period of time (longer during concurrent programming).
Added support for the displaying rotary feedrate in rpm. If a rotary axis and
only a rotary axis is moving during manual or manual setup mode, the display
will be in rpm instead of ipm/mmpm.
Removed the read-only, system, hidden attributes from the executive and
loader during an upgrade. This is a carry over from the old Max3 days that
doesn’t make sense any longer to do.
Changed the displaying of the security key messages to report errors so that
they don't get erased before the operator actually sees the message.
102997-1 Changed method of file display to sort vertically instead of horizontally.
Left the old code in place (conditioned) in case we are asked to make
this a user selectable feature. Changed the tool offset and nc parameters to
arrange their data in columns going down and then across. Changed the tool
offset and nc parameters to arrange their data in columns going down and then
across.
093097-10 Added support for point and shoot file copy. Works just like tagged file
functions except the operator may also enter a new file name.
082897-3 Changed the way the compiler error messages are cleared. They are not cleared
when going from idle mode to a machine mode (manual/auto/single/test) and
also cleared when going from manual mode to auto/single/test.
Optimized the restarting of the lookahead algorithm. Previously, when I
needed to restart, I went all the way back to the beginning. Now, I only
restart 1 or 2 entries as appropriate. In anticipation of the sliding
window, it was necessary to reduce the amount of time in the lookahead
algorithm.
092397-6 Fixed a fatal internal contouring error for rotary programs. The system
???? was doing some ultipro calculations that should not have been done.
Page 21
Made changes to display prompts on all the NC editor screens.
The NC editor cursor is hidden when scrolling the nc program and inserting a
block. The cursor was not clearing when it landed on the E of the End of
buffer statement.
Made changes to support Renishaw probing. Now can use null variable on
the right of an equation, can use LTABS in an equation and can write to
#2500-#2906 and #5601-#5603 variables.
Added functions update_work_offsets, update_graphics_work_offsets, and
added support for G84.2 and G84.3 for fanuc rigid tapping.
080597-1 Fixed a memory manager problem that was ultimately traced back to the
method of shutting down the interpreter. The scenario was that a NC program
was run, then the operator switched to conversational and later switched
back to NC. When the operator tried to execute the next NC program, a
'invalid free pointer' memory manager error was generated and the system
locked up. The root of the problem was that when the 1st NC program
completed, the interpreter was not shut down, and the switching of editor modes
causes some NC control structure data to be reset. Unfortunately, the reset NC
data is part of the data used during the 1st NC program. When the 2nd NC
program was initiated the 1st NC program shuts down but couldn't because it's
data was reset behind its back. To fix the problem, the interpreter is shut down
in a more timely manner (when aux/review/input is pressed and not in auto run
mode).
Page 22
111797-1 DXF - Reading and erasing a DXF program generates a 47 Kbyte memory leak.
093097-4 DXF - Autosave while a DXF file is being read can corrupt some DXF
locations.
061197-2 Mirroring - Mirror Image problem in conversational. At block 4 corner radius
R1.00 was not there on acutal cut (image side).
NC - ISNC M25 (Tool Home) in G90 (Absolute) can generate out of limits
error.
090997-3 NC, Units - Conversational, switch to NC. Units conversion does not occur
with Toolset/Partset.
080197-4 NC, Units - Units conversion problems for Ref. Pt. XYZ and Tool Len.
Tolerance
111397-1 Rotary/Interrupt - A axis does not reposition after Interrupt Cycle and the A axis
had been jogged.
102997-1 Added a parameter and support to select file list method, sort vertically
or sort horizontally for Storage Functions.
111897-1 Printing - Allow program to be printed to a text file.
Corrected z end calculation for helix's with sweep angle's > 360.
Page 23
LC - Increased the size of Bfile91 from 20 to 25. The tool changer parameter
for table safety was using the 21st element of that array and it was overwriting
the N95 servo drive data.
Networking - Changes to support reading and writing part programs from
network drives. This includes conversational as well as NC programs. Also
added support for exporting part program as text file to the network.
NC - Program Control Failure error message when graphing NC program that
spans memory.
NC - Fixed incompatibility problem with Hurco dialect use of dwell. "G04/50"
was not being interpreted properly.
Window Manager - The 800 x 600 changes neglected the unblank_screen flag
passed to write unicode string which prevented the text screen from blanking.
Added unblank override back in.
Updated the range word table with the maximum spindle speed as set by
the configuration parameter.
111797-2 Serial Communication - Run program while downloading will generate a “out of
limits” error. Fixed the problem where the same block was being executed twice
and added a parameter to the function get_current_nc_block to indicate when
there are no more nc blocks to run.
102797-2 DXF - File locks up control. Increased the number of free list entries from 2000
to 4500 for the part heap. This fixes a DXF problem where a DXF file needed
4000 entries in order to completely free the program.
Page 24
Changed the language file copyright from 1997 to 1998. Also changed the
coolant terminology from Coolant System #1 (Flood)/Coolant System #2 (Mist)
to Primary Coolant System (Flood)/Secondary Coolant System.
Fixed a digitize problem that was created while fixing another SCR concerning
serial communications.
Comprehensive list of ladder changes for v2.10 release (1/98)

New
functionality:
Support for the Tuning Move Cycle

I/O loopback testing support (requires IOTST000.REX and it’s inclusion in
ladders.txt file)
New configuration parameters N95:60, 61 (invert clamp output logic for axis A,
B resp.) (useful for Tsudakoma tables).
Added Spindle Clamp and Unclamp softkeys to ATC & Machine Diagnostics
screens.
New files for BMC 4050/5050 input and output mapping (BMC45IN.REX and
BMC45OUT.REX, resp.)
New files for type-0 ATC system (4050/5050) TCHGR000.REX
Modified
functionality:
ATC &Machine Diagnostics now utilize multiple pages of softkeys, adding -

MORE- and EXIT keys. Pending (selected function “armed”) can be aborted by
a second press of the same softkey, the -MORE- key, the EXIT key, or a mode
change. Pressing another functional softkey cancels the pending operation and
arms the newly selected one.
Rotate magazine button now valid during Interrupt mode.
CE logic modified so as to accommodate manual tool insertion and removal
steps. While prompted to perform manual insert/removal, the door locks will be
de-activated. At the conclusion of the manual insert/removal the doors must be
closed before resuming, at which time the door locks will re-activate.
Warmup cycle modified so as to wait for spindle at speed before initiating X, Y
axis motion (required for KM5 implementation).
Way Lube and Low Air warnings that force Interrupt mode have been changed
to operator-cleared popup messages. This is to correct condition in which an
brief or intermittent condition forced Interrupt cycle, but was quickly rectified
and cleared the popup message (operator had no indication of why Interrupt
cycle was effected).
Page 25
Calibration logic changed to treat F96:0-2 “Limit Switch to Marker Distance”
(X, Y, Z respectively) as millimeter dimensions (previously parameters were set
as inch). Note: When upgrading a previously installed v2.x system the F96:0-2
parameters must be changed to mm and the description of the parameter re-
typed to indicated mm dimensioning. If the previous inch value is retained, a
“Marker pulse not found” error message will occur during calibration.
Calibration routine aborts when a mode change is detected.
Mode change no longer “breaks” spindle orientation (operation now the same as
Ultimax 1.6x).
Washdown coolant can now be turned on from Auto Run screen softkey while
in Auto-prep mode (i.e. prior to pressing Start button to initiate program) as
well as from Manual Function Setup and while executing a part program. Note:
a mode change will shut off washdown coolant - this includes transition from
Auto Prep to Auto Run (when Start button is pressed) and transitions from/to
Auto/Interrupt, Auto/Manual modes.
Rapid move overrides no longer valid (Z axis ) during ATC cycles, Park cycle,
and Tool Up operation. Rapid override is valid during auto run in conjunction
with Rapid Override enable/disable softkeys - operation has been “tempered” by
eliminating possible transitions from enable to/from disabled with override pot at
low value such as 10% (i.e. 10% to 100% transition, 100% to 10% transition).
When this transition occurs, a stepping action occurs so as to ramp the override
percent up or down and prevent abrupt changes.
LC initiated popup messages moved to lower portion of screen to minimize
instances where popup box obscures data display.
Quad-Size DRO display modified to accommodate 10-99K spindle speeds.
Previously range allowed 0-9999 RPM.
Modified Table Safety Move to disregard rapid override setting (unless
specifically allowed by config parameter N95:216) and to correctly use Rapid
Traverse SDB velocity value (rather than previously incorrect, Z Retract
Velocity).
Data Table sizes optimized (should slightly reduce amount of memory required
by LC).
Problems
corrected:
ATC cycle no longer aborted during mode change. This addresses the problem
of Part Setup to Tool Setup mode changes while an ATC cycle is in process.
Fixed ATC aborts. Including, magazine rotate not being disabled on an abort
(previous releases were not correctly clearing bits).
Support added for concurrent mode abort bug (see CNC errata).
Fixed bug involving Spindle Test Cycle and Spindle Orient Diagnostics, where
SOR couldn’t be enabled (thus spindle didn’t run, or orient in the case of
Siemens equipped spindle drives). This bug popped up in rrb1 or rrb2.
Corrected recurring “Press Start to Orient and Lock the Spindle” message
Page 26
during tool probe operation.
Fixed Orient Spindle abort scenarios from main Manual screen.
Manual Function Setup now allows operator to enter negative (CCW) spindle
speeds.
Fixed bug in ATC with Table Safety Move (previously undocumented) where if
the X & Y axes were already in safety position, the TC cycle would pause
indefinitely.
Fixed another bug in ATC with Table Safety Move (previously undocumented)
where a Y axis Fault would be reported erroneously (fixed in executive
software).
Listed below are new ladder files associated with v2.10 release:
2.10 Project Name: Version:

(Q4 ’97)
AMPL_000.REX 1.03
AXTUN000.REX 1.01
BKGND000.REX 1.01
(new !) BMC45IN.REX 1.00
(new !) BMC45OUT.REX 1.00
CAL_000.REX 1.03
CE_000.REX 1.02
COOL_000.REX 1.02
(new !) IOTST000.REX 1.00
JOG_000.REX 1.03
MSC_000.REX 1.03
MSTST000.REX 1.03
PARK_000.REX 1.01
QUAD_000.REX 1.01
SPIN_000.REX 1.03
(new !) TCHGR000.REX 1.00
TCHGR002.REX 1.04
WRMUP000.REX 1.02
Page 27
This document lists the changes from the V2.10 released system to the V2.11 version dated 5-20-98.
New SCRs in this build include:
??? – Conversational Probe move moves slow in metric
SCR Build Bug Fix or Enhancement

Num Date
307 3-30-98 Fixed SCR 307 which was a problem with the A axis leadscrew map not
working. The root of the problem was that the A axis travel limit was defaulted
to zero in an earlier version and was later changed to default to 360 degrees. For
the machines with the earlier default, bootcfg has been modified to automatically
upgrade the travel limit to the correct value.
360 3-2-98 Hawk – Frequent occurrences of Motion Control Queue Runout while tapping.
Made the response for the tap reverse cycle optional. For the Hawk machines,
which are no servo controlled spindles, the waiting for the tap reverse response
was causing a queue runout error from the navigation system. To fix the
problem, navigation no longer waits for a response on the tap reverse cycle.
361 3-16-98 Made an enhancement to support jogging with the Max4 console. This
enhancement adds a second set of tuning params to the system and allows the LC
to program the 'standard' tuning params or the 'alternate' tuning params.
Upgraded the boot config directory to ver2_11. There were so many
changes to the network, tune, and mcode files that data would be loss when
going back and forth between the v2.10 and v2.11 systems. To solve this
problem, each version will have its own config directory.
365 3-16-98 Fixed a problem where spindle starts CCW when it was programmed for CW.
366 3-16-98 Fixed a problem where ISNC G86 turns off coolant and does not re-activate
coolant for next bore location.
374 3-30-98 Fixed SCR 374 which inserted lowercase letters into a NC program when mode
keys were pressed in certain screens.
376 3-16-98 Fixed G53 which did not move at rapid speed and Z did not move to machine
position.
381 3-2-98 Console – Several soft keys for the training console units are shown as inactive
but should be shown as active. They were shown as inactive because they were
checking to see if a Matrix4 board was present or not. Changed the code to
enable the soft keys, regardless if the Matrix4 board is present or not. However,
if the soft keys are pressed and a Matrix4 board is not present, then the normal
processing of the soft key is not performed.
383 3-2-98 Storage Functions – Version 2 can read only one MaxII file at a time. Cannot
access file tag operations. Changed some soft key masks to enable file tag
operations with RMX (MaxII) diskettes.
384 3-16-98 Changed the NC so that it didn’t automatically turn the spindle on after a tool
change. This was a result of problems with the gun drill.
385 3-2-98 Profiling – Program exhibits some bumping. Added the sliding window to the
lookahead algorithm. Redefined the G61/G64 precision cornering codes so that
G64 doesn’t stop at all and G61 stops at a >44 degree angle change. Also made a
Page 28
Num Date
change so that the header commands (tool change, coolant, M code) force the
previous line to decelerate. This helps prevent the UltiPRO from automatically
slowing down a line unnecessarily when there is a header command in between
two lines that are set to do not decelerate. Also found that the part zero update
is really a valid look through for the run program look ahead but is was treated as
a header command. Changed the part zero update so that it is an axis command
and a valid look-through for the Axis FIFO previews.
388 3-2-98 Autosave – Corrupt saveprog.hd3 locks up the control. Fixed a problem with
reading corrupt part programs. The control would appear to lock up due to an
infinite loop. I fixed the infinite loop and removed the initial_checksum_test
because it used some of the same routines and would loop forever just like when
reading the part program.
398 3-16-98 Probing – support for multi-axis probing support. The navigation layer has been
modified to support multiple axis probing instead of only probing one axis at a
time. Further development is needed to complete this SCR. While working on
this SCR, a problem was found in conversational probing. An erroneous move to
z start z was made when probing x. This move has been deleted.
399 3-2-98 Probing – Add support for 1 or 2 touch parameter. Two new probing m codes
(M41,M42) were added for this function. Also reserved some m codes for future
CNC use. While working on this SCR, a problem was found in the editing of the
M code table. If all the m codes on the screen were reserved, the system locked
up because no keys were being accepted by the operator.
400 3-2-98 Display – Scrolling on Max4 console generates unreadable text. Fixed 800x600
scrolling. Also, stopped reading from splane... since its shared by the text and
graphics screens, it may contain invalid data.
402 3-30-98 Fixed SCR 402 which was about the rapid overrides. When the overrides were
adjusted radically, the axis rumbled and bumped. Implemented an
acc/dec for overrides when at speed.
404 3-16-98 Fixed the random problems when reading or writing NC programs. The
and problems ranged from system lock-ups, memory manager errors, softkeys not
434 appearing, editor changing modes, etc. The root of the problem was an index
that was undefined for NC disk reads/writes. This index was used to update a
structure which would overwrite other global data in the system, randomly,
depending upon the value of the index.
411 3-16-98 Fixed problem with century wrap around when setting the current year.
412 4-30-98 Made changes for SCR 412 which provided a new way for the LC to manage the
gear table instead of the CNC. The Hawk machine needed two gear tables which
we previously only supported with a universal machine. This the Hawk wasn't a
universal machine, a parameter was added to the system to specify who was in
charge of managing the gear table, the CNC or the LC.
413 3-16-98 Created an edit screen for inputting data to the HOSTS file. The HOSTS file is
then used whenever the machine wants to connect to another host.
414 3-16-98 Added a parameter for setting the networking subnet mask.
415 3-16-98 Added a parameter for each Ultinet server user to specify initial working dir.
416 3-16-98 Made all Ultinet parameters accessible from one location.
Page 29
Num Date
418 3-16-98 Fixed problem with missing border when copying a file to the sameDirectory.
427 3-30-98 Fixed SCR 427 which complained that the backup/restore function took
too long and filled up the floppy disk. Changed the backup/restore function to
copy only the files that the machine actually uses. The unused MCD and ladder
files are no longer copied. Also added a popup window to show the user what
files are currently being copied.
429 3-16-98 Redefined the behavior of the UltiPRO option. The Version 2.10
UltiPRO option becomes obsolete and its behavior now becomes the Version
2.11 standard behavior. A new option (UltiPRO II) has been added that includes
the sliding window and the redefined G61/G64.
435 3-30-98 Fixed issues related to SCR 435, which involved G84 for using the Q
parameter, removing possible use of Z for G84 in fanuc, and fixed G73 to work
correctly for Hurco, which it did not before, and fixed G74.
436 3-30-98 Fixed a problem with reading UltimaxII programs that was saved from floppy to
the hard drive.
438 3-16-98 Fixed a problem where serial downloads gave a memory manager error. This
was related to some networking changes that broke the serial stuff.
439 4-29-98 Created a new logo file that works on the Max4 console.
441 4-27-98 Fixed SCR 441 which dealt with console label differences between the Max3 and
Max4 consoles. The control key is now shown as control/f and the clear
key is now shown as clear/c.
445 3-30-98 Fixed a console problem where the diagnostic floppy drive test softkey was not
active.
446 3-30-98 Ultinet screen refresh needed.
447 3-30-98 Cleaned up handling of network timeouts. Changed some network timeout
messages and network fault messages to be more detailed. Added support for an
asynchronous receipt of an escape key.
449 3-2-98 Max 4 console support. Auto-detects max3 or max4 console and sets up
hardware accordingly. If a CANbus configuration script file exists, it's settings
then override that configuration.
450 3-16-98 Fixed a problem where the skip coordinates variables could not be
written to and fixed a problem with the use of the NE operation with null
variables.
451 3-16-98 Made change so that 5061 through 5064 can be modified on the nc
variables screen.
452 4-13-98 Added declarations to support leaving the backlight enable turned on for Max4
consoles.
453 4-13-98 Removed call to destroy_all_windows from reboot_control. This was causing a
lock up with max4 consoles and is not necessary for a warm boot.
454 3-30-98 Changed file mask to disable "COPY FILE" softkey for RMX diskettes.
458 3-30-98 Restored executive system messages 24-28. These are used by opcntr
which calls report_error with a variable which is probably why these were
thought to be unused (SCR #458). The result was an empty box on the bottom
of the screen when these errors occurred.
461 3-30-98 Added support for displaying remote host name and IP when in storage
Page 30
Num Date
functions and connected to network (new SCR to be written).
468 4-29-98 The spindle override lockout was not working on the Hawk 40 machine because
of a check for spindle control type which has been removed.
471 4-29-98 Memory manager errors will lock up system in some window manager functions.
473 4-13-98 Fix for SCR #473 - problem found with symbolic links by GH Tool. Needed to
check for "L" attribute and convert it to a directory in IFX format.
474 4-13-98 Added check for properly configured ethernet card on systems with the ethernet
option. This is primarily used to indicate cards which have not had the plug and
play capability disabled.
475 4-13-98 Fixed a problem where floppy drive not mounted when selected through Ultinet
server. This was a change to the fusion library.
478 4-30-98 Changes for SCR #478 - new parameter for single/dual vga.
479 4-29-98 Machine locks up when attempting to invoke Manual mode, while using new
english.hrl file.
481 4-30-98 Change for SCR #481 - moved bsp386sx to code low. This module has a
real mode interrupt handler which must reside below 1 megabyte.
482 4-27-98 Fixed SCR 482 which dealt with sluggish rotary moves as the Z axis moves
toward the center of the cylinder. Found out that the contouring inches per
degree parameter was being used to calculate the contouring acceleration rate
where as the rapid inches per degree parameter should have been used. As the Z
moved toward the center the contouring accel rate was extremely low, thus
giving the motion a sluggish behavior. Also fixed the units of the rotary feedrate
radius when a radius of zero was detected.
491 4-13-98 Fixed a problem with the return plane where the status was retained from one
autorun pass to the next. This caused invalid error messages because the r plane
retained the value from the end of the last program.
495 4-30-98 Connecting to network locks up the control.
522 5-12-98 The variables #5021, #5022, and #5023 could not be read from in an equation.
523 5-12-98 Added support for a parameter to determine whether the probe has touched the
part within an NC macro. The variable #3020 is used as a flag and is set to true
when the probe touches during a probe move.
524 5-12-98 Fixed a problem where the wrong position values were used during the probing
algorithm when the probe did not actually touch the part.
528 5-14-98 Changed the default color parameters so that they looked better on a Max4
console.
529 5-19-98 Fixed a problem where a helix of exactly 360 degrees with cutter comp enabled
was generating an extra helical move.
??? 5-20-98 Fixed a problem where the initial Z move down in conversational part program
moves very slow in metric mode. The problem was that the feedrate was not
being converted from metric to inch.
Page 31
V1.06 (V2.11) LC BUG FIXES/ENHANCEMENTS
SCR Bug Fix or Enhancement

Num
75 Popup message that announces spindle fault also suggests to operator to reset servos.
78 Operator should be prompted 1) at beginning of program, 2) when a gear range change is
needed, 3) when resuming from interrupt mode.
392 Previously, COR off was inactive during Auto and Interrupt modes. When machine is in
Auto mode, the COR-Off timer is inactive and set=0. When machine goes into Interrupt
mode, COR-Off timer is activated and begins timing. If COR-Off timer expires in Interrupt
mode, COR will shut off and operator will NOT be able to resume his program.
419 Behaviour seen is correct for an ATC but not a manual TC. When operator aborts with
Motion Hold + Spindle Off (or via a STOP button), the program and TC abort without
updating the Tool In Spindle number.
443 The direction signal is not cleared with the enable signal. Rather, the direction signal is set
when the enable signal is set.
459 Corrected problem so correct prompt blocks and softkey labels are displayed.
460 On Max-4 consoles the Rapid Detent field has been removed from the prompt block.
469 When spindle is requested to turn on, originally we DAC'ed the spindle drive and waited until
the "agree" signal was true for .7 sec, then flagged the spindle as being "at speed". Since the
"agree" signal on the specified drive is (effectively) unusable, we are not using a time delay
based on the commanded motor speed, ignoring the "agree" signal, based upon the accel rate
that the spindle drive is configured for.
470 Corrected permissive logic.
472 Use Position-mode motion. This is the same as what is used for the Max IV jog action. RE-
FIX of 05/11/98: Use of position-mode moves exclusively (in Max III) is not acceptable. Use
a token position move when axis is selected, after a rapid jog and handwheel is used, or when
handwheel direction is changed then continue motion using velocity moves. This takes
advantage of P-mode leadscrew comp AND V-mode jog smoothness.
520 Modified LC (MSC_000.REX) to call correct prompt block, hence menu with proper
softkeys.
Ladder File (*.REX) Release Summary
V2.11 Ladder File Name: Version: Date Time
AXTUN000.REX 1.02 5/19/98 2:11AM

IOTST000.REX 1.02 5/19/98 2:11AM
JOG_000.REX 1.04 5/19/98 2:11AM
KM34IN.REX 1.01 5/19/98 2:11AM
KM34OUT.REX 1.01 5/19/98 2:11AM
LEDTS000.REX 1.01 5/19/98 2:11AM
MSC_000.REX 1.04 5/19/98 2:11AM
MSTST000.REX 1.04 5/19/98 2:11AM
PROBE000.REX 1.01 5/19/98 2:11AM
SPIN_000.REX 1.04 5/19/98 2:11AM
Page 32
V2.11 Ladder File Name: Version: Date Time
(new !) SPIN_001.REX 1.00 5/19/98 2:11AM

(new !) SPIN_003.REX 1.00 5/19/98 2:11AM
TCHGR000.REX 1.02 5/19/98 2:11AM
TCHGR002.REX 1.05 5/19/98 2:11AM
(new !) TCHGR003.REX 1.00 5/19/98 2:11AM
WRMUP000.REX 1.03 5/19/98 2:11AM
Page 33
This document details the changes from the V2.11 released system to the V2.12 build dated 10-27-98.
This is the fifth build of the Version 2.12 system.

Num
428 When selecting “All Planes” leaves pixel droppings on the bottom of the graphics screen.
440 Max 4 console – The csimon loader does not detect the motion hold button.
492 800x600 mode only works with colorgraphics video boards. The system was modified to
support new PCI bus video card.
516 Added functions to calculate x, y, and z program values and fixed. (ISNC G55-G59) – This is
the same problem reported in SCR 636.
535 Z move down to Z start point, spindle is not on if you have not pressed cycle start button.
This was for Hawk machines only.
537 February 29 displays “Invalid Day of Month” for both leap years and non-leap years.
538 Year remained at 2000 (1/1/0) after rollover to 2001.
542 Can’t use the entire capacity of the new 2.0GB hard drives. Must use smaller number of
cylinders to use the hard drive. The IFX workspace was too small for the new 2.0 Gigabyte
hard drive. It was increased from 80,000 to 90,000 bytes to solve the problem.
550 Able to jog axes in any mode under certain circumstances. This was a problem where the jog
enabled flag wasn't being cleared when exiting the part probe data block. Certain fields in that
datablock allow you to jog and if you were on one of those fields and press auxiliary, then
you could still jog in auxiliary.
560 Need to support high speed spindle speeds for programming, configuration and operation.
Updated the spindle range tables to reflect a 90,000 rpm spindle.
565 Fixed a problem that, when tapping in ISNC with Bore Dwell set to a non zero value,
destroyed the threads
567 An error message results when probing to a negative X destination (part relative) when 0 has
been entered into the X min field on the Probing Parameters screen.
569 Tool change problem during an NC program (MK-60 and new style tool changers only)
571 In a conversational program, there may an unnecessary stop during a helix or arc. Fixed a
UltiPRO problem in conversational mode where the slow line was set to decel instead of a no
decel. This occurs during an arc where the intermediate lines are do_not_decelerate and the
last line is auto_decelerate and the last line needs to be slowed down. This problem just
resulted in an unnecessary stop that was fixed by forcing the slow line contour mode to be no
decel.
572 Renishaw probe issue when running in metric mode.
Page 34
Num
581 Fixed a problem where the m-code erroneously turned the spindle on after a tool change.
Added one line of code to set the last spindle velocity parameter to zero after a tool change
because a tool change implicitly turns off the spindle.
582 Fixed a problem where the max offset field in a contour start block with profile left cutter
comp gets overridden when that tool change field is modified.
621 Fixed a problem that occurs when doing a check for errors, when spanning memory. Pointer
nc_blk_cur_ptr may have an invalid value after the check for errors is complete because the
nc block, which this pointer is pointing to, may have been deleted.
636 Added functions to calculate x, y, and z program values and fixed. (ISNC G55-G59) This is
the same problem reported in SCR 516.
637 Removed the code that slowed down the fast part of the line when there wasn't enough
distance to accelerate from the slow part to the fast part. The lookahead algorithms in the
contouring module takes care of this problem in a more efficient manner.
680 Hard drive corruption may occur if the cache sync. task is held off. By making calls to
os_delay the task is allowed to run and appears to fix this problem. The problem would occur
quite often after an upgrade when the new config sub-directory was created on the next boot
up sequence.
No Deleted some dead code that was left over from multibus video days. Came across this while
SCR making space for the newer, larger version of csimon.
No Slightly reduced the temp_stack size to make enough room for the new version of csimon.
SCR
No Added latched_key_ready flag which is only set by keyin. The user must clear this flag before
SCR using it. Needed for clearing networking text popup.

Num
591
607 Fixed by S. Wrobleski prior to IMTS (TCHGR005)
613 Previously fixed by SAW.
614
615
617
629 Fixed by SAW. TCHGR005 10/6/98
681
752 None.
589 msc_000. F96:200 "Current Rotary Jog Speed" was overwritten after change from INT CFG
screen. Value entered is no longer overwritten. RMN 11-3-98.
590 msc_000. This was an oversight in v2.11 release. The fault sensing and message was not
conditioned by coolant-through-tool option being enabled. Conditioned fault with coolant-
through-tool option being enabled (N95:241 = 1)
Page 35
610 Machine now senses A/B presence when E-Stop is released. If a rotary axis has been
removed, the system will function without support or operation of the removed axis (axes). If
a rotary axis has been added, the machine will be uncalibrated and the operator will have to
re-calibrate the machine.
612 When program is complete (mode shifts from auto to auto-prep) the door locks are now
released. Also when the operator has pressed the RUN PROGRAM softkey, the doors don't
lock until he presses the Start PB (if the doors are not closed the program won't start).
629 Fixed by SAW. TCHGR005 10/6/98
630 Fixed by SAW, cool_000 10/6/98
639 If operator attempts ATC when axes are NOT calibrated, a message is displayed "Must
Calibrate Axes Before Auto Tool Exchange". If axes ARE calibrated, but ATC is NOT
message displayed "Must Calibrate ATC Before Auto Tool Exchange". TCHGR005,
English.hrl 10/6/98.
640
642 TCHGR005, fixed by SAW
643 TCHGR005 10/6/98, fixed by Scott W. prior to 10/1/98.
644
645
648
655
675 TCHGR005 10/6/98. Fixed it.
677 If TIS = Next Tool and operator presses the auto ATC button, nothing will happen. In auto
program execution the CNC will not request a tool change if required tool = tool in spindle.
681
694 Auto T/C key is blocked when TIS is undefined. Message is already on screen "Tool In
Spindle Is Unverified". TCHGR005 10/6/98.
695 When calibrate SK is pressed (& spindle on). A spindle off is commanded. SPIN_000
10/6/98.
698 Fixed error. COOL_000 10/6/98
699 If TIS = Next Tool and operator presses the auto ATC button, nothing will happen. In auto
program execution the CNC will not request a tool change if required tool = tool in spindle.
700
701 Tool change seq. modified to allow ATC to complete when program is aborted.
703 Corrected abort logic for move Z axis to 0.0 or tool change height. TCHGR005 10/06/98.
704 If attempt to calibrate magazine with tool pocket down, message "TOOL POCKET MUST
BE UP" will be displayed. TCHGR005 10/13/98.
705 Currently we do allow operator to clamp the spindle when exchange arm is down. If he
attempts to move arm up while clamped, a message is displayed telling him the spindle must
be unclamped. He can move the arm up only when the spindle is unclamped. Need more info
- why is this a problem?
707 Logic in place to detect non-functioning magazine in position. If detected, ATC will be
forced to uncalibrated state. Please check with newest ladders. TCHGR005 10/13.
708
709
710
711
Page 36
713 I beleive ATC discrete motion (magazine, ARM, etc) is allowed with door open - according
to Ricki Stott -RMN 10/14/98. When T/C calibrates (as part of machine cal. or from ATC
diagnostics) the CE doors must be closed to initiate, and the doors lock once cal starts. If
doors open during calibration, motion aborts CATC will be uncalibrated. RMN -10/22/98
TCHGR005 10/20/98.
718 Carousel rotation is now delayed until program start [doors closed when Start PB is pressed].
TCHGR005 10/20/98. RMN 10/22/98.
721 Operation of all ATC functions modified. Cannot initiate when doors are open. Abort
current operation if doors open during execution. NOTE: Pneumatic moves cannot be
stopped once initiated. TCHGR005 10/20/98 RMN.
723 Operation of all ATC functions modified. Cannot initiate when doors are open. Abort
current operation if doors open during execution. NOTE: Pneumatic moves cannot be
stopped once initiated. TCHGR005 10/20/98 RMN.
725 I beleive ATC discrete motion (magazine, ARM, etc) is allowed with door open - according
to Ricki Stott -RMN 10/14/98 ATC diagnostic functions must be closed to initiate motion.
If doors open before start PB is pressed, pending operation is aborted. NOTE: If doors open
during motion of pneumatic operations, motion cannot be aborted by LC. TCHGR005
10/20/98, RMN 10/22/98.
733 When a "magazine jammed" condition occurs, the ATC is forced to UN-CALIBRATED -
thus Auto Program operation should be blocked. TCHGR005 10/13/98. When fault occurs,
(such as magazine jammed) the Tool in spindle becomes unverified, the magazine is un-
calibrated and ATC isn't "HOME" - All three conditions must be rectified before running
program again. TCHGR005, MSC_000 -RMN 10/22/98.
734 A change is being processed which will eliminate the rotate carousel paddle switch.
735 If axis + ATC uncal'd message displayed is "AXES NOT CALIBRATED". If AXIS IS
Calibrated but ATC is not, message displayed is "ATC not calibrated". MSC_000,
TCHGR005 10/13/98.
737 When entering interrupt the "PROGRAM IS RUNNING" message is valid. When Interrupt
mode has been achieved, the message is removed. MSC_000 10/13/98.
738
743
745
749 None.
750 None
751 None.
752 None.
753 None.
755
762 Page 2 "Orient Spindle" SK removed function already present on page 1. Corrected
placement of indicator "-->" for orient spindle. TCHGR005, English.HRL 10/13/98
763 If attempt to calibrate magazine with tool pocket down, message "TOOL POCKET MUST
BE UP" will be displayed. TCHGR005 10/13/98.
Page 37
766 ATC Auto is not allowed when servo (or control) power is off. TCHGR005 10/20/98, -RMN
10/22/98.
775
781 Relocated clearing logic. TCHGR005
784 When a fault or abort occurs during Tool Change, a popup message is displayed instructing
operator to check the map and tool in spindle. TCHGR005 10/13. When a motion fault
occurs (load arm, exchange arm, .....) the tool in spindle is unverified. TCHGR005, RMN
10/22/98.
787
789 When fault occurs, (such as magazine jammed) the Tool in spindle becomes unverified, the
magazine is un-calibrated and ATC isn't "HOME" - All three conditions must be rectified
before running program again. TCHGR005, MSC_000 -RMN 10/22/98.
801
804
813 This problem (judging by date reported – 10/19/98) may have been an interim software
problem. Changes were made dealing with permissive logic and definition of ATC HOME.
Released software will display HOME status false when IN POSITION proximity switch is
not made.
Page 38
Version 2.12 (Ladder System Version 1.07)
2.12 Ladder File Name: Version: Date Time
(new !) 2416YIN.REX 1.00 10/23/98 1:07 AM

(new !) 2416YOUT.REX 1.00 10/23/98 1:07 AM
AMPL_000.REX 1.04 10/23/98 1:07 AM
B30SIN.REX 1.04 10/23/98 1:07 AM
B30SOUT.REX 1.03 10/23/98 1:07 AM
B30YOUT.REX 1.03 10/23/98 1:07 AM
BKGND000.REX 1.03 10/23/98 1:07 AM
BMC42IN.REX 1.04 10/23/98 1:07 AM
BMC42OUT.REX 1.03 10/23/98 1:07 AM
CAL_000.REX 1.04 10/23/98 1:07 AM
CE_000.REX 1.03 10/23/98 1:07 AM
COOL_000.REX 1.03 10/23/98 1:07 AM
JOG_000.REX 1.05 10/23/98 1:07 AM
KM34IN.REX 1.02 10/23/98 1:07 AM
KM34OUT.REX 1.02 10/23/98 1:07 AM
LEDTS000.REX 1.02 10/23/98 1:07 AM
MSC_000.REX 1.05 10/23/98 1:07 AM
MSTST000.REX 1.05 10/23/98 1:07 AM
PARK_000.REX 1.02 10/23/98 1:07 AM
QUAD_000.REX 1.02 10/23/98 1:07 AM
SPIN_000.REX 1.05 10/23/98 1:07 AM
SPIN_001.REX 1.01 10/23/98 1:07 AM
SPIN_003.REX 1.02 10/23/98 1:07 AM
TCHGR000.REX 1.03 10/23/98 1:07 AM
TCHGR002.REX 1.06 10/23/98 1:07 AM
(new !) TCHGR005.REX 1.00 10/23/98 1:07 AM
WRMUP000.REX 1.04 10/23/98 1:07 AM
Page 39
The following ladders did not change for the v2.12 release.
The File Time changed only at Ladder System V1.07 (v2.12 Ultimax) Release)
Ladder System Version 1.06

Ultimax Ladder File Name: Version: Date Time
v2.11
AXTUN000.REX 1.02 5/19/98 1:06AM

B30YIN.REX 1.02 5/19/98 1:06AM
BMC45IN.REX 1.01 5/19/98 1:06AM
BMC45OUT.REX 1.01 5/19/98 1:06AM
CON_IN.REX 1.03 5/19/98 1:06AM
CON_LED.REX 1.01 5/19/98 1.06AM
CON_MSC.REX 1.00 5/19/98 1:06AM
CON_MST.REX 1.04 5/19/98 1.06AM
CON_OUT.REX 1.02 5/19/98 1.06AM
IOTST000.REX 1.02 5/19/98 1:06AM
PROBE000.REX 1.01 5/19/98 1.06AM
TCHGR003.REX 1.00 5/19/98 1:06AM
Ultimax
v2.10
AXOUT000.REX 1.01 12/16/97 1:05AM
CYCLS000.REX 1.00 12/16/97 1:05AM
INDEX000.REX 1.01 12/16/97 1:05AM
LUBE_000.REX 1.00 12/16/97 1:05AM
MCODE000.REX 1.01 12/16/97 1:05AM
PDEV_000.REX 1.00 12/16/97 1:05AM
Page 40

Num Date
920 1-22-98 Problem: Ultimax 4 allows for only 16 color choices. These colors are the same
ones used by Ultimax 3 (with CRTs). On the LCDs, these colors are faded, pale,
or appear washed out in areas of the screen, without adding more color selection,
change the default 16 colors to brighter, more vibrant colors.
Fix: Color Palette changes made to enhance the viewing quality on Max4's
passive flat-panel displays. Glyph file was changed to generate “thicker”
characters.
921 1-22-98 Problem: The horizontal and vertical cross-hairs used on the graphics screen are
very thin and is not easily located on the screen, especially if the graphics screen
has a complex drawing (the cursor does not blink and also disappears while the
graphics is drawing). The cursor can appear to be hidden because there are
numerous horizontal and vertical shapes (i.e. graphics softkeys, center point of
circles and holes, frames and part paths). Design a new cursor that is easier to
locate.
Fix: Cursor size/shape changes made to enhance the viewing quality on Max4's
passive flat-panel displays. Glyph file was changed to generate “thicker”
characters.
881 2/9/99 Problem: Error message "Unrecognized Element Extracted from Axis F1F0"
occurs; must reboot control to recover. First seen 10/23/98 during testing of
release version 2.12.
Fix: Removed debug logging that may be re-entered and exceed it’s range.
965 1/28/99 Problem: When lines (pixels) of near similar colors get drawn on top of each
other, the resulting colors seen at the intersections of the lines may become
inappropriate. More specifically, lines drawn on the graphics screen are being
XOR'd with the pixel data previously drawn.
Fix: A "byte" is not large enough to hold foreground, background and XOR flag
data now that Ultimax allows all 16 colors to be assigned for background and
foreground. A new Boolean was added to the graphics' code to hold the XOR
flag separate from the color data.
Page 41

Num
616 Most ladders required are already released. New I/O ladders, parameters etc. have been
developed.
646
649
650 (TCHGR005.rex v1.01) Corrected prompt block/status block logic so that the screen is
refreshed whenever the TIS or NEXT TOOL field changes.
656
657 MSC_000.rex v1.05, TCHGR005.rex v1.01. Added logic to MSC_000 to require pending
faults (ATC faults, Servo Faults) to be cleared before starting part program execution.
658 Increased reset signal pulse duration to 1 second.
691 (BKGND000.rex v1.04) Reset servos softkey now will clear the red status lamp.
720 Door open message is displayed, motion stops - This is apparently satisfactory behavior to the
Europeans. 1/12/99: v1.08int, CE_000.rex v1.04. New software will display an error
message informing the operator that the cycle was aborted because the door opened (Safety
system / Door Lock failure). The popup message must be cleared with the RESET SERVOS
softkey.
Europeans. 1/12/99: 1/12/99: v1.08int, CE_000.rex v1.04. New software will display an
error message informing the operator that the cycle was aborted because the door opened
(Safety system / Door Lock failure). The popup message must be cleared with the RESET
SERVOS softkey.
726 (MSC_000.rex v1.06) Changed logic in MSC_000 file for abort and forced Interrupt mode.
727 1.08int (CE_000.rex v1.04, english.hrl) Added message "DOOR LOCK FAILURE -
CHECK SAFETY SYSTEMS" when the doors are sensed open and the door locks are
supposed to be energized.
Europeans. 12-3-98: 1.08int (CE_000.rex v1.04, english.hrl) Added message "DOOR
LOCK FAILURE - CHECK SAFETY SYSTEMS" when the doors are sensed open and the
door locks are supposed to be energized.
736
767 Problem corrected. Involved sensing of "0" tool and not responding when value was changed
to non-zero number. SAW: Modified checking logic to correct problem. TCHGR005.rex
773 Increased reset signal pulse duration to 1 second.
780 Modified permission logic to allow ATC selection in Auto Prep mode. 1.08int (MSC_000.rex
v1.06)
802 When operator presses the CLEAR ATC MAP softkey, a new menu is displayed with YES
and NO (F1 and F2) with a prompt "ARE YOU SURE YOU WANT TO CONTINUE WITH
CLEAR ATC MAP?" 1.08int (TCHGR005.rex v1.01)
806 1.08int (COOL_000.rex v1.04) SEE SCR #870 for re-specification of chip auger operation.
The pause is implemented in that operation.
810 Corrected timer timebase from 1.0 sec to .01 sec. Delay time now 0.3 sec rather than 3.0 sec.
TCHGR005.rex
811 TCHGR005.rex v1.01. Modified logic for spindle unclamp pushbutton. During tool changes,
Page 42
the spindle unclamp pushbutton is only allowed for manual insertion or removal steps.
812 Operation definition detailed in SCR #873 1.08int (TCHGR005.rex v1.01)
823 Added message "DOOR LOCK FAILURE - CHECK SAFETY SYSTEMS" when the doors
are sensed open and the door locks are supposed to be energized. 1.08int (CE_000.rex
v1.04, english.hrl)
825 MSC_000.rex v1.06, QUAD_000.rex v1.03. Modified MSC_000 logic to trigger SCREEN
BLOCK redraws via QUAD_000. Current implementation of MSC_000 was redrawing
SCREEN BLOCKs only if "normal display" mode was active.
829 BKGND000 v1.04. Added flasher bit to RED lamp output logic. Also added logic to clear
the RED lamp during servo reset sequence.
855 Corrected mode restrictions for Retract Tool logic. 1.08int (TCHGR005.rex v1.01)
856 Modified ATC logic to prevent bogus orient faults from occurring and added logic to abort
tool change if fault occurs. Also modified MSC_000 logic to prevent program execution if a
pending fault hasn't been cleared.
863 TCHGR005.rex. Modified prompt/screen/status block call order.
869 modified ladders accordingly. 1.08int (BKGND000.rex v1.04, english.hrl)
870 1.08int (COOL000.rex v1.04, english.hrl) modified ladders accordingly.
871
872 1.08int (SPIN000.rex v1.06, english.hrl) modified ladders accordingly.
873 TCHGR005.rex v1.01, english.hrl. Added program File #11 to TCHGR005.rex for pocket #
detection and other logic.
890 1.08int (MSC_000.rex v1.06) Removed condition that program be running before sending
"phony" key press.
896 TCHGR005.rex v1.01. Added new integrator configuration parameter F96:208 which is the
additional dwell time for arm rotate (only effective when skip tools is in selected). The units
for the parameter are seconds.
899 TCHGR005.rex v1.01, MSC_000.rex v1.06, english.hrl. If a servo fault or ATC fault is
"active", the operator will be prompted to clear errors before initiating part program. When
errors are cleared, the part program may be started.
918 Orient spindle will take precedence over spindle on. If the spindle on button has been
pressed, and then the orient softkey is pressed, the pending spindle on request is cancelled and
the spindle will orient when the Start button is pressed. If the Orient spindle softkey has been
pressed (armed to orient spindle) the spindle ON button will be ignored. 1.08int
(SPIN_000.rex v1.06)
930 Added permission logic to program start logic. Will popup the same message as when
operator attempts to turn on the spindle when it is not clamped (or unclamped) "CANNOT
RUN WITH THE SPINDLE UNCLAMPED". 1.08i (MSC_000.rex v1.06)
931 When the washdown is turned on (2416, 6434) the COOL_000 logic will request a Auger
FWD if the auger is not running at that time. This applies to AUTO mode only, in manual
mode the two operations are independent. 1.08i (COOL_000.rex v1.04)
949
950
952
960
Page 43
Ladder File Name: Version: Date Time
2416YIN V.101 2/9/99 1:08 AM

2BASE000 V1.02 2/9/99 1:08 AM
2416YOUT V1.01 2/9/99 1:08 AM
(new !) 3017HY v1.00 02/09/99 1:08 AM
(new !) 3017Y v1.00 02/09/99 1:08 AM
(new !) 30YSMIN v1.00 02/09/99 1:08 AM
(new !) 30YSMOUT v1.00 02/09/99 1:08 AM
(new !) 4020Y v1.00 02/09/99 1:08 AM
(new !) 42YSMIN v1.00 02/09/99 1:08 AM
(new !) 42YSMOUT v1.00 02/09/99 1:08 AM
(new !) 5050Y v1.00 02/09/99 1:08 AM
(new !) 6434Y v1.00 02/09/99 1:08 AM
(new!) 6434YIN V1.00 2/9/99 1:08 AM
(new!) 6434YOUT V1.00 2/9/99 1:08 AM
AMPL_000 V1.05 2/9/99 1:08 AM
B30SIN V1.05 2/9/99 1:08 AM
B30YIN V1.03 2/9/99 1:08 AM
BKGND000 V1.04 2/9/99 1:08 AM
BMC42IN V1.05 2/9/99 1:08 AM
BMC45IN V1.02 2/9/99 1:08 AM
CAL_000 V1.05 2/9/99 1:08 AM
CE_000 V1.04 2/9/99 1:08 AM
CON_MSC V1.02 2/9/99 1:08 AM
CON_MST V1.06 2/9/99 1:08 AM
CON_IN V1.04 2/9/99 1:08 AM
COOL_000 V1.04 2/9/99 1:08 AM
KM34IN V1.03 2/9/99 1:08 AM
MSC_000 V1.06 2/9/99 1:08 AM
MSTST000 V1.06 2/9/99 1:08 AM
PARK_000 V1.03 2/9/99 1:08 AM
QUAD_000 V1.03 2/9/99 1:08 AM
SPIN_000 V1.06 2/9/99 1:08 AM
TCHGR005 V1.01 2/9/99 1:08 AM
WRMUP000 V1.05 2/9/99 1:08 AM
Page 44
ULTIMAX V2.14-ALPHA CNC BUG FIXES/ENHANCEMENTS
This document lists the changes from the V2.12 released system to the V2.14-Alpha version as of 5-28-
99. This list does not include the SCR’s included in V2.13, which was made with a subset of the SCR’s
slated for V2.14. New SCRs for V2.14 include:
SCR Category Bug Fix or Enhancement

Num
58 Path Dry run for rotary program will ignore the Z minimum height.
Planner
64 Memory Pentium Controls are capable of 128M but Memory Available only displays
64M.
114 System Virus check boot sector on power up.
219 Conv. Edit override lockout, tool change position in change parameters datablock.
Program
256 System Add a non-resetable spindle hour timer.
294 Program Interrupt cycle fails if current execution is a macro statement.
Control
303 Machine Jog-Overrides near limit switches behave badly and could slam into the limit
Setup switch unexpectedly. (Fixed in Matrix4 V2.55B firmware).
344 Serial NC Upload to hard drive is not very reliable (fails about 25% of the time).
Comm.
397 Diag- Leadscrew Map; move the Set Map to Zero Comp softkey or add Yes/No
nostics menu.
403 Path Profile left or right does not retract.
Planner
466 Conv. Modify the conversational interpreter to take advantage of the UltiPRO II
Progam improvements.
527 Toolset/ Need to add a softkey to verify that you want to delete a tool.
Partset
537 System Changes related to SCR #537 & 538 (Y2K problems). The initial setting of
538 the system real time clock was not using the correct value for year 2000 and
later.
544 Network Ultinet support for 100baseT as well as current 10baseT.
564 NC NC File ISNC Note: This program ran on 2.10 - 2nd tool change M25
generates out of Mach Limits Alarm. M25 for first tool change & at end of
pgm. No pbm. - Same on 3 pgms. Del M25 on 2nd tool change and pgm
works - It ran with M25 on all tool changes on 2.10. SAM updated
description 11/18/98: ISNC: If All tools are not calibrated to the same
value then M25 could generate an error in Z.
574 NC Not enough memory error if setup tools after loading NC program that
spans memory.
Page 45
Num
628 Graphics Modified the routine which monitors the status of the transmission of a
conversational file from an Ultimax control to a PC running conupdn, or,
from a PC running conupdn to an Ultimax control. With this change, only
the designated 'abort' key (F8) will abort this process. All other keys are
ignored.
693 Integ- Chip auger starting by itself front panel loosing focus - ie apparent lockup
ration of control - no key response.
770 NC Unexpected motion of table in auto mode. This fix may also fix numerous
other SCRs that have reported "machine out of limits" faults. The other
SCRs that may be fixed include: 783 and 953.
772 System VGA setup incorrect on first boot after software upgrade. (Same as SCR
#865)
783 NC False out of limits error in first NC prog. run after editor change. (May be
fixed as part of SCR #770)
864 DXF Editing layers in a DXF read can generate a memory fragmentation error
and lock up machine.
865 System Implement Gary Sorensen's fix for some Colorgraphics dual VGA cards
detected as single VGA. (Same as SCR #772)
877 Network Page up or page down keys will lock up the control when editing hosts file
and there are no host entries.
878 Network Selecting network drive may display invalid entires in the host selection pop
up box.
880 NC ISNC – G18 (XZ) and G19 (YZ) planar arcs generate loops. G18 planar
arcs appear to be going in the wrong direction (CW and CCW are
reversed).
891 System If a prompt block #0 is requested, the sytsem will hang up. This may be
attempted when the programmer wishes to disable the previous prompt
block.
914 System The navigation data log file needs some enhancements. The
CNC_KEY_INFO command should decode the canbus key code and log
the actual key press and not the canbus key code for improved LC debug
capability.
915 Network Abort or unusual shut down of network connection may cause networking
to stop functioning. (Fixed in fusion library).
917 Network Do not clear network popup message if key pressed when screen blanking
active.
943 System Touchscreen does not function if pressed during control reset. When
system is booting and the touchscreen is pressed it will not function after
boot up completes. It never comes back and a power down is required
(without touching the screen!) to clear the problem.
953 NC If Tool in Spindle (TIS) = 0 it could generate an inaccurate out of limits
error. (May be fixed as part of SCR #770)
961 System If file can’t be successfully read at bootup, then display message specific to
file name, prevent COR (disable), and display message: Load (specific) files
Page 46
Num
from backup floppy disk.
963 System Estimated run time is not very accurate and can display a nonsensical value
on the screen.
991 Motion Update the Ultimax application to support both the 3 axes Mx4 and the 8
axes Octavia hardware.
992 Path Rough motion in 3D conversational program with high feedrates. If the
Planner program is run at 150 ipm or slower in the program, it can be overridden to
250 ipm and it runs fine. If the program feedrate is set to 200 ipm or
higher, the program hesitates severly (the motion seems very rough).
1036 Path NC Part Program runs slower at 300 ipm than 200 ipm.
Planner
1037 System Need to utilize the canbus watchdog.
1046 System Console response out of sync. with key presses – usually one key behind.
Believed to occur more frequently with faster interrupt used for handwheel.
1049 Diag- Add ability to determine if CANbus is still functioning.
nostics
1050 Motion In auto mode, axis feedrate doesn’t match rapid feedrate setting if quickly
reduced during motion hold and then motion hold is released. Axis moves
at old higher feedrate about ½ inch, then slows down to new feedrate.
1055 System Simplify the Ultimax V2.xx software upgrade procedure.
This section shows executive SCRs that are fixed by other means than CNC software.

Num
303 Motion Jog overrides near limit switches behave badly (Fixed in Matrix4 firmware).
625
409 Param- Feed and Speed Calculator, Speed can be computed to exceed maximum.
618 eters (Fixed in parameters)
System Added logo.pcx and logo_800.pcx to SourceSafe. Changed the 1998 date
to 1999 in these files.
This section shows maintenance changes made to the software that are not tracked by a formal SCR.

Num
System Fixed an annoyance where the bootcfg.set_control_element falsely thought
that a parameter had changed due to round off error. Added a tolerance in
the check of all floating point numbers to see if the new value equaled the
old value. This shows up in the system when the user goes into the tuning
utility and exits without changing anything, yet the system prompts him to
save his changes.
Motion Moved the lookahead algorithm from navcont to a new module called
navlook. Moved some common support routines from navcont to the
navsupp module. This is in preparation of S Curve acceleration. Added the
navlook.c and navlook.h modules to SourceSafe.
Page 47
Num
System Increased the compiler task from 5K to 6K because I found a part program
that when checking for errors with the axis fifo data log flag enabled, it
exceeded the 5K stack.
System Cleaned up the math library stuff.
Added a generic macro CUBE(x) which computes x^3.

Added 1 to the field size for the print tool diameter field. The field wasn't
big enough when the fpsqrt store_bcd function was replaced with the
standard
convert floating point to ascii function.
Added MATHLIB.C
Move the generic math utilities to the new mathlib.c module.
Also added some new utilities for s curve acceleration.
Replaced the store_bcd function and its associated processing to a call to
the convert floating point to ascii routine. The store_bcd is an assembly
function left over from the PLM days.
This section shows changes that were made in the Alpha-2 version to correct problems found in the
Alpha-1 version.

Num
914 System Changed the datalog on demand hot key from alternate decimal point to
alternate zero. The alternate decimal point is an invalid key on the AT
keyboard and locks up the system if pressed. Alternate zero is a valid AT
keybaord keystroke. Also added code to generate the data log file if the
alternate zero keystroke is pressed on the AT keyboard. Also added code
to log all AT keyboard keystrokes in the error logger. This is in support of
SCR 914, data log enhancements.
914 System Added key recognition for control alternate enter. The LC uses this key as
a fake key to the system to get rid of a pop-up error message. I broke the
support for this key with SCR 914 (data log improvements) when I moved
the canbus key decoding from keyin to lcmain.
1036 Path Fixed a side effect of SCR 1036 which included a merge block optimization
Planner to the lookahead algorithm. I forgot to adjust the number of preview lines
after the marker block is identified. This in combination with the merging
of blocks caused a internal fatal error to the algorithm.
This section shows changes that were made in the Beta-1 version to correct problems found in the
Alpha-2 version.

Num
1036 Path Fixed an error associated with SCR 1036. In the case where an extra block
Planner gets merged during the decel optimization (due to roundoff error), the look
index was wrong which affected the rest of the decel routine. Now, I
Page 48
Num
restart after the decel optimization to ensure that we continue processing
the proper block. Worst case, we may unnecessarily repeat one block's
processing.
This section shows changes that were made in the Beta-2 version to correct problems found in the Beta-
1 version.

Num
1087 Path Tool not retracting then cutting through the part at an incorrect tool path.
Planner Run ROUGH979.HD3 and at block 5 it will not Z retract, start cutting
through the part but it seems to be heading to the end of the line segment
instead of the start of the line segment. It works if you single step or start
the program at block 4.
There was a problem with the previous fix. The variable pull_up should not
have been set to FALSE after processing the contour.

Num
586 During an ATC operation, if the Spindle is forced out of orient by the Tool Magazine, the
Spindle will re-orient and damage the tool magazine and/or Spindle drive key. Need to
disable orient after the Spindle Unclamp is activated during ATC.
596 Auto Run - Need to improve reaction to Abort Sequence (Motion Hold, Spindle OFF).
652 Fault during program run occurs, then machine mode goes to manual, hiding cause of fault.
Now machine goes into IDLE mode.
777 If "Remove Tool X" is displayed (for manual tool change in ATC mode) and program abort
(motion hold/spindle off) attempted, then layers of messages are given.
800 Coolant operation does not match device driver documentation.
817 V2.xx integration for Hawk 5
857 (Manual Mode) ATC Diagnostics can be blocked from entering. (VTC-40).
919 Add integration support for VTC-40.
937 Messages for Manual tool changes (tools 41-x) are confusing or not displayed properly.
(VTC-40).
938 If E-stop is pressed during a tool change while the exchange arm is down, then as soon as
Manual-Power On the exchange arm will position itself under the spindle (The Start button
has not been pressed yet) (VTC-40)
939 When ATC is in auto mode, the tool mag. will rotate if CW/CCW button is activated. Same
as SCR734 (2416) (VTC-40)
940 Pressing INTERRUPT during manual removes the message" REMOVE TOOL " and "
INSERT TOOL" leaving the operator unsure about what operation the control is expecting
him to perform. (VTC-40)
941 Pressing CYCLE STOP During a tool change does not complete tool change cycle, forcing
Page 49
the operator to go into the ATC Diagnostics to complete the change and put the tool changer
into the home position. (VTC-40)
956 If opposing machine states are both detected true at the same time then a fault condition
should be generated and COR dropped out.
977 Corrected rotary axis calibration problem, if unclamp signal is not seen, fault is recognized in
brief time (rather than 30 second delay as was previous).
993 Need Message: "Spindle Must Be Clamped" displayed in the case that spindle is detected to
not be clamped when Auto Run is selected on non-Hawk machines with 1.08.
997 If Manual tool change is called for, user should be allowed whatever time is needed to
complete task. Message "Tool Change Took Too Long" should never be given
998 The operator may now shut off the auger via the softkeys, but doing so will disable the
washdown coolant.
999 If Tool Change Auto mode is selected, and ATC Diagnostic screen entered, then selections
are available to user. Tool Change Auto mode should prevent entry into ATC Diagnostic
screen (VTC-40)
1002 Pressing the AUGER OFF softkey when coolant washdown is running will shut off coolant
and stop auger.
1003 If Tool Change Auto is selected, and Unclamp switch on head is pressed, Spindle will
unclamp. In TC Auto, manual Unclamp switch must not be responded to. (VTC-40)
1004 If Air pressure is detected LOW, then prevent Auto ATC in any and all modes, until Air is no
longer LOW.
1006 If Tool Change Auto selected, and Manual CW or Manual CCW is selected, then magazine
rotates. (VTC-40)
1011 When Stop Cycle button is pressed, the lamp will illuminate untilt he abort is complete and an
operator keystroke has been detected.
1014 If Interrupt selected while Machine Mode is TEST, then after program is resumed in TEST,
display continues to show "Interrupt Mode" at top of screen, rather than TEST MODE.
1015 If user enters TIS incorrectly such that TIS entered equals Tool in Magazine, then ATC logic
begins to attempt to put the tool in spindle into the magazine position already occupied.
When this is recognized by logic (tools both in load position and magazine when magazine at
position called), a series of incorrect events begin, culminating in the User needing to re-boot
to recover. (VTC 40 only)
1021 In ATC Diagnostics, if Move (Axis) To TC Position is selected, and then stop Cycle selected,
and then Feed Hold depressed and released, axes start motion, continuing previous move to
T/C Position.
1028 If Spindle Orient Fault occurs at start of ATC cycle, tool change continues while Orient
Status is "Not Oriented" and Message: Spindle Fault - Orient Error is displayed. (VTC-40)
1029 In Manual Machine Mode, if Auto Tool Change is in process, then various user keystrokes
cause ATC to stop in mid-position, requiring recovery via Diagnostics screen.
1030 Added logic to msc_000 to block the spindle unclamp pb while the spindle is running in
manual mode or while oriented (once orient complete, the PB is no longer blocked). Added
popup message #184 to indicate that the spindle must be stopped.
1031 If Spindle is Unclamped, then Spindle Orient and Spindle ON is not prevented
1035 If Manual Jog Handwheel is rotated, selected axis does not properly follow handwheel
command. Sluggish response and/or variable axis feedrate with constant Handwheel velocity.
1039 Support Customer being able to fully recover ATC to home by allowing limited Z Axis jog +
and - while in Customer ATC Diagnostics.
Page 50
1040 We need an 'M' or 'A' next to the Tool In Spindle field on the DRO to indicate whether the
current tool will be exchanged Manually or Automatically.
1041 During Tool Setup: If the edit tool is equal to the TIS, and is na "auto" tool the current
message "THIS TOOL IS IN POT 0" is changed to "THIS IS AN AUTO TOOL, AND IS IN
THE SPINDLE". If the tool is a "manual" tool, then no message is displayed (current
behavior).
1044 if low lube or air pressure fault occurs while the screens are already blanked, such as in the
middle of the night after the air compressor has bled off, the popup messages will not be
displayed until something else disables the blanking (key press, etc.)
1045 Delay in Flood Coolant physically getting to tool and workpiece causes tool to start
machining before coolant is present, damaging tool and workpiece.
1048 In CE mode, Park Machine, open and close Chip Enclosure Door (Door). The program
appears to have aborted. Select and release Motion Hold and the last axis moving will finish
its cycle and the Door switch will not abort the motion.
1052 Manual Jog Axis movement doesn't match handwheel rotation if handwheel rotated following
Rapid Jog movement.
1054 If CE Enabled, and in Auto Run Mode, if Chip Doors are OPENED, then the Axes continue
to move.
1057 If Hawk CE selected, and Chip Enclosure OPENED during Park, and Motion Hold selected
and released, then Park motion resumes.
1058 If Hawk CE selected, and Chip Doors OPENED in Park mode while Z moving to Park,
control appears to abort, but if Cycle Start and Motion Hold selected, then axis resume
motion to Park.
1059 RE: 1057, 1058, yet another sequence of Chip Door, Cycle Start, Motion Hold cause axes to
resume move to Park position.
1060 If Hawk CE selected, and Chip Enclosure OPENED, then Message must be posted and
keystroke required to clear Message.
1067 Stop Cycle button (Max 4 console) doesn't abort axis motion during Park cycle.
Page 51
Ladder File Name: Version: Date: Time:
2BASE000 v1.03 07/30/99 1:09 AM

3017HY v1.01 07/30/99 1:09 AM
3017Y v1.01 07/30/99 1:09 AM
4020Y v1.01 07/30/99 1:09 AM
BKGND000 v1.05 07/30/99 1:09 AM
CAL_000 v1.06 07/30/99 1:09 AM
CE_000 v1.05 07/30/99 1:09 AM
CON_MSC v1.03 07/30/99 1:09 AM
COOL_000 v1.05 07/30/99 1:09 AM
HAWK30 v1.01 07/30/99 1:09 AM
HAWK40 v1.01 07/30/99 1:09 AM
JOG_000 v1.07 07/30/99 1:09 AM
(new !) KM5 v1.01 07/30/99 1:09 AM
(new !) KM5YIN v1.00 07/30/99 1:09 AM
(new !) KM5YOUT v1.00 07/30/99 1:09 AM
MSC_000 v1.09 07/30/99 1:09 AM
PARK_000 v1.04 07/30/99 1:09 AM
QUAD_000 v1.04 07/30/99 1:09 AM
SPIN_000 v1.07 07/30/99 1:09 AM
(new !) SPIN_001 v1.01 07/30/99 1:09 AM
TCHGR002 v1.07 07/30/99 1:09 AM
(new !) TCHGR004 v1.00 07/30/99 1:09 AM
TCHGR005 v1.02 07/30/99 1:09 AM
(new !) VTC40 v1.00 07/30/99 1:09 AM
(new !) VTC40IN v1.01 07/30/99 1:09 AM
(new !) VTC40OUT v1.00 07/30/99 1:09 AM
WRMUP000 v1.06 07/30/99 1:09 AM
Page 52
HURCO MANUFACTURING
R
704-0004-033 Rev F CAD # D8556

5/12/00
retained in their directories.
Important
higher. If this is not the case, the hard disk on the control must be reformatted. Please
contact your local Hurco representative for service.
LIST OF MATERIALS
Disks Part Number Description

- 704-0004-032 Ultimax Customer Information Document (list of updates for the
current software release)
- 704-0004-026 Optikey Install Instructions
3 007-4123-016 Ultimax Upgrade Diskette
1 - System Configuration Disk
1 007-4136-005 Optikey Utility Diskette/Security Modifier
1 007-4123-010 Ultimax Patch Disk
If there are any questions or problems with this upgrade, please contact your local Hurco service
representative.
704-0004-033 Rev F Page 1

UPGRADE PROCEDURE
Be sure to save your part program to the hard drive and then erase it in the control
memory before doing the upgrade.
1. Insert the Ultimax Upgrade Diskette 1 of 3 of the set into the floppy drive.
3. After a few screen messages, the Ultimax Installation Utility will start. Follow the
instructions on the screen.
4. Insert the proper diskettes (by part number) into the floppy drive when prompted.
*** NOTE: DO NOT remove the current diskette from the floppy drive until prompted to
put in the next diskette.
5. If the existing software on the machine tool uses multiple languages (other than English), a
message will appear prompting for multiple language diskettes. If the upgrade is
completed without these language diskettes only English will be available after the
upgrade. Language diskettes are available through your local Hurco representative.
6. After files are upgraded, the parameters will be updated. This may take several minutes.
A rotating pinwheel on the screen indicates the update is in progress.
7. After the parameters are updated, you will be prompted to insert the Optikey Utility
Diskette/Security Modifier (007-4136-005) into the floppy drive. Insert the diskette, cycle
power to the machine tool and follow the furnished “OPTIKEY INSTALL
INSTRUCTIONS” document (704-0004-026, D8436).
8. After the Optikey installation is complete, remove any diskettes from the floppy drive.
10. Insert the System Configuration Disk when the prompt “INSERT THE MACHINE
CONFIGURATION DISKETTE INTO THE FLOPPY DRIVE TO BACKUP
CONFIGURATION DATA” appears.
11. “WRITING MACHINE CONFIGURATION DATA TO THE FLOPPY…” will appear on the
screen. The backup will take approximately 2-5 minutes.
12. When prompted, remove the diskette from the floppy drive.
13. Store all of the diskettes in the disk folder and place in the machine tool power cabinet.
*** NOTE: Fixes and enhancements for previous versions of Ultimax can be viewed by using
an ASCII editor such as Notepad. Browse the files named V2xxFIX.TXT on the
Ultimax Upgrade Diskette 1 of 3 where 2xx is the version of interest.
704-0004-033 Rev F Page 2

BMC 10 To BMC 15
D8329 757-3050-002 BMC10/10L Leveling Procedure

D8330 757-3050-003 BMC15 Leveling Procedure
D8331 757-3050-004 Power Supply Setup Procedure, BMC10(L)/15
D8332 757-3050-005 Yaskawa Spindle Drive Set-Up Procedure
757-3050-002 REV: A ECN #

R
11/14/85 CAD #D8329
SUBJECT: BMC-10/BMC-10L LEVELING PROCEDURE
I. INTENT
To provide a procedure and tooling requirements for properly leveling BMC-10 and
BMC-10L machining centers. To be used in conjunction with Manufacturing documents
758-3000-007 and 758-3000-008.
II. APPLICABILITY
Applicable to all BMC-10 and BMC-10L machining centers. This procedure to be used
within Hurco facilities and should be used at customer installations to help achieve factory
proven accuracies.
III. TOOLING REQUIREMENTS (Ref: Manufacturing Document 758-3000-000.)
A. Precision Level
B. 14 Inch Granite Square
C. .0001 Inch Indicator
D. Suitable holder to hold indicator in spindle nose.
E. Suitable wrench for adjusting leveling screws.
IV. PRELIMINARY PROCEDURE
A. Position leveling pads centrally under each of the (8) leveling screws to assure a stable
contact surface to level from.
B. Adjust leveling screws, reference Fig. 1, Sheet 3, 1 thru 6 to support the machine.
Screws 7 and 8 should not be contacting the pads.
The machine should be at a minimal distance from the leveling pads as all further
adjustments will be upward.
________________________________ _______ _______________________________ _______

V. MACHINE LEVELING PROCEDURE
A. Position the table in its approximate center of travel in both the X and Y axes.
B. Place a precision level at Position 1 (Reference Fig. 2) on the machine table. Level
machine front to rear to within .001 inch per foot by adjusting screws 1 thru 6.
Screws 7 an 8 should not touch.
C. Place the precision level at position 4 and check side to side level. Adjust all screws
on low side a like amount to bring level to .001 inch per foot and not disturb the front
to back alignment.
D. Place the precision level back to position 1 and adjust to .0005 inch per foot.
E. Place the precision level back to position 4 and adjust to .0005 inch per foot.
F. Continue very minor adjustments while moving the precision level from positions 1
thru 5 and maintaining .0005 inch per foot at all positions. NOTE: Screws 7 and 8
still do not touch.
VI. COLUMN SQUARING PROCEDURE
A. Check column squareness (X-Z) left to right. Ref: Manufacturing Document

A very minor adjustment of leveling screw 3 or 6 may be required to
correct X-Z squareness.
B. Check column squareness (Y-Z) front to back. Ref:: Manufacturing Document

758-3000-07. A very minor adjustment of leveling screw 3 or 6 may be required to
correct Y-Z squareness.
C. Recheck table level to assure no table movement.
VII. TOOL MAGAZINE ALIGNING PROCEDURE
A. Touch off leveling screws 7 and 8.
B. Recheck table level at positions 1 and 5 to assure table not affected.
C. Operate the tool changer manually, checking the alignment of the T-C fingers and
smooth tool pick up from the tool magazine. Only very minor adjustments of leveling
screws 7 and 8 should be required to achieve proper operation.
VIII. FINAL CHECKING PROCEDURE
A. Check to assure all leveling pads are secure and the machine is not sitting directly on
any blocks.
B. Secure all locknuts on leveling screws.
C. Recheck table level, X-Z and Y-Z squareness to assure final levelness and alignment.
2
757-3050-003 REV: A ECN #

R
11/18/85 CAD #D8330
SUBJECT: BMC-15 LEVELING PROCEDURE
I. INTENT
To provide a procedure and tooling requirements for properly leveling BMC-15 machining
centers. This procedure to be used in conjunction with Manufacturing Documents 758-3000-
007 and 758-3000-008.
II. APPLICABILITY
Applicable to all BMC-15 machining centers. This procedure to be used within Hurco
facilities and should be used at customer installations to help achieve factory proven
accuaracies.
III. TOOLING REQUIREMENTS (Ref: Manufacturing Document 758-3000-000.)
A. Precision Level
B. 14 Inch Granite Square
D. suitable holder to hold indicator in spindle nose.
E. Suitable wrench for adjusting leveling screws.
IV. PRELIMINARY PROCEDURE
A. Position leveling pads centrally under each of the (8) leveling screws to assure a stable
contact surface to level from.
B. Adjust leveling screws to support the machine. The machine should be at a minimal
distance from the leveling pads as all further adjustments will be upward. No leveling
pads should be in contact with the machine base.
________________________________ _______ _______________________________ _______

V. MACHINE LEVELING PROCEDURE
A. Position the table in its approximate center of travel in both the X and Y axes.
B. Place a precision level at position 1 (Reference Figure 2) on machine table. Level

machine front to rear to within .001 inch per foot by adjusting the leveling screws.
C. Place the precision level at position 4 (Reference Figure 2) and check side to side level.
Adjust all screws on low side a like amount to bring level to .001 inch per foot and not
disturb the front to back alignment.
D. Place the precision level back to position 1 and adjust to .0005 inch per foot.
E. Place the precision level back to position 4 and adjust to .0005 inch per foot.
F. Continue very minor adjustments while moving the precision level from positions 1
thru 5 and maintaining .0005 inch per foot at all positions.
VI. COLUMN SQUARING PROCEDURE
A. Check column squareness (X-Z) left to right. Reference Manufacturing Document 758-
3000-008. A very minor adjustment of the rear leveling screws under column may be
required to correct X-Z squareness.
B. Check column squareness (Y-Z) front to back. Reference Manufacturing Document

758-3000-07.
A very minor adjustment of rear leveling screws under column may be
required to correct Y-Z squareness.
C. Recheck table level to assure no table movement has taken place.
VII. FINAL CHECKING PROCEDURE
A. Check to assure all leveling pads are secure and the machine base is not sitting directly
on any pads.
B. Secure all locknuts on leveling screws.
C. Recheck table level, X-Z and Y-Z squareness to assure final levelness and alignment.
2
757-3050-004 REV: A ECN #

R
01/14/86 CAD #D8331
SUBJECT: POWER SUPPLY SET-UP PROCEDURE (BMC)
I. SCOPE
Adjustment and verification of power supply distribution throughout the machine.
II. TEST EQUIPMENT REQUIRED
Digital Voltmeter (DVOM)
III. PROCEDURE
A. Reference Figure 1 for potentiometer locations.
B. Carefully adjust the appropriate potentiometer to produce the voltage ranges shown
below. (Use 20 VDC range, except as noted.)
NOTE:Positive meter lead goes on the first pin number listed.
CNC-TB4 ALLOWABLE RANGE NOTE

11R to 21R + 5.10 to + 5.30 VDC -------------------------
28R to 21R + 12.00 to + 13.00 VDC -------------------------
32R to 21R - 12.00 to - 13.00 VDC -------------------------
36R to 21R + 24.00 to + 25.00 VDC (Use 200 VDC Range)
C. Other terminals to verify:
MAIN CARD CAGE
Pin 84 to 86 = + 5.10 to + 5.20 VDC

Pin 8 to 86 = +12.00 to +13.00 VDC
Pin 80 to 86 = -12.00 to -13.00 VDC
________________________________ _______ _______________________________ _______

FRONT CONSOLE CARD CAGE AREA
CRT Controller PCB 415-0174-001
Pin 2 to 1 = + 4.90 to + 5.20 VDC

Pin 4 to 6 = +12.00 to +13.00 VDC
Pin 5 to 6 = -12.00 to -13.00 VDC
Tape Controller PCB 415-0178-001
Pin 2 to 1 = + 4.90 to + 5.20 VDC

Pin 4 to 6 = +12.00 to +13.00 VDC
Pin 5 to 6 = -12.00 to -13.00 VDC
Tape Drive PCB (Part of 426-0003-005 Assembly)
Pin 3 to 2 = +12.00 to +13.00 VDC

Pin 4 to 2 = + 5.00 to + 5.20 VDC
Front Panel Cable Connect PCB 415-0193-002
TB52-1 to TB52-5 = + 5.00 to + 5.20 VDC

TB52-2 to TB52-6 = + 5.00 to + 5.20 VDC
TB52-3 to TB52-5 = +12.00 to +13.00 VDC
TB52-4 to TB52-6 = -12.00 to -13.00 VDC
TB52-7 to TB52-8 = + 5.00 to - 5.20 VDC
D. Torque seal R1, R12, R16 and R23.
2
R
757-3050-005 REV: B ECN #
03/07/86 CAD #D8332
SUBJECT: YASKAWA SPINDLE DRIVE SET-UP PROCEDURE
I. INTENT
To provide a procedure that outlines the proper adjustments and strapping of shunt
connectors involved in preparing the drive unit for operation on a BMC-10 (L) or BMC-15
machine.
II. SCOPE
The requirement for this procedure is to be included in the manufacturing steps of BMC-
10(L) and BMC-15 machines. This procedure is to be applied during initial power up of the
machine.
III. PROCEDURE
A. Visually inspect the drive unit for proper wiring and operation per inspection items and
description, page five.
B. Insure that the input voltage (X1, X2, X3 on T1) is within the parameters shown on
page six before connecting to the input of the drive unit.
C. Refer to page three for location of shunt connections. Proper strapping is shown as the
darkened squares next to shunt letters.
D. Verify installation of wire jumper from pin 2 to pin 3 of FANM terminal located on the
left hand center edge of the spindle drive control board.
E. Refer to page four insert showing potentiometer numbering system. Description of

potentiometer set-ups is on page two.
F. Set DS1 as shown on page two. Be sure to reinstall the metal locking bar and torque-
seal the plastic dust cap.
G. Document actual measured RPM at spindle in accordance with the spindle speed test
chart on page five.
________________________________ _______ _______________________________ _______

H. Pages six, seven and eight provide additional information concerning the operation of
the spindle drive unit.
I. After drive set-up has been completed, torque-seal all potentiometers except T DET.
ADJUSTMENT OF POTENTIOMETERS ON CONTROL CIRCUIT BOARD
Adjustment of N ADJ and N REV Adjustment of T DET
ADJUSTMENT OBJECTIVE: ADJUSTMENT OBJECTIVE:

Coincidence between speed command input Setting Torque detection level.
(voltage) and motor speed.
ADJUSTMENT PROCEDURE: Adjust the T DET potentiometer to graduation 7.
With the motor driven at the maximum speed,
detect the speed with a tachometer, and adjust to
±15 RPM.
Adjustment of N GAIN picture
Adjusting loop gain of speed control system.
The more the setting is brought near the 0
graduation, the lower and more stable the gain Adjustment of 13 RH Accel/Decel Time
becomes, but the slower becomes response, The
nearer the setting is adjusted, the quicker becomes The soft start time is the sum of the numerals
response, but larger becomes speed overshooting. indicated by the DIP switches in seconds.
Adjust it to the optimum gain taking into
consideration of the load conditions.
ADJUSTMENT BEFORE SHIPMENT

Graduation 5
Adjustment of N DET picture
Adjustment of speed coincidence detection level.
While the motor speed is adjusted with speed
commands, N DET lights at a certain speed which
is adjusted wit the N DET potentiometer. Adjust
the N DET potentiometer so that the N DET LED
lights at the intended goal speed. (ON at 70 RPM,
OFF at 90 RPM)
2
INSPECTION ITEMS AND DESCRIPTION
State Item Procedure Criteria Action

Run Stop
Power Check for Noise or Contact
Ο transistor noise and vibration not Yaskawa
cooling fan vibration present before representative
Power Visual Check Deposited dust Clean with
transistor of parts around vacuum
Ο* cooling fan and power cleaner
adjacent area transistor fan
Terminal Manual check Loose screws Tighten
screws in VS- of all mutual
Ο* 626MTII wiring
controller termminal
screws with
Phillips
screwdriver
Spindle Speed Test
Speed Actually measured Per- Speed Actually measured Per-

indication speed [rpm] missible indication speed [rpm] missible
[rpm] Forward Reverse range [rpm] [rpm] Forward Reverse range [rpm]
30 ± 0 30 ± 0
L 250 ± 1 L 240 ± 1
O 500 ± 3 O 450 ± 2
W 800 ± 4 W 800 ± 4
H 801 ± 4 H 801 ± 4
I 1850 ± 9 I 1540 ± 8
G 2900 ± 15 G 2400 ± 12
H 4000 ± 20 H 3300 ± 16
Power Supply Permissible Check point
voltage range
AC 180 - 220 V R, S, T terminals
+15 V 14.25 to 15.75 V Across CH27 - CH29
-15 V -14.25 to -15.75 V Across CH31 - CH29
+8 V 7.6 to 8.4 V Across CH28 - CH29
DC -8 V -7.6 to -8.4 V Across CH30 - CH29
-3 V -2.35 to -3.65 V Across CH33 - CH29
+30 V 25 to 29/VAC = 200 V Across CH25 - CH29
-30 V -25 to -29/VAC = 200 V Across CH34 - CH29
Note: Check terminals CHs are provided on the controller.
4
DESCRIPTION OF CONTROL SIGNALS

No. Pin No.
- When protective circuit for overcurrent or overload tripped, the
motor current is instantly interrupted and the motor stops after
running by inertial. Upon current interruption, [FALT] is output.
- The [FALT] relay may be selectively in the normally closed or

normally open mode. The contact is "C" type. (The normally
closed mode is the standard.)
Malfunction
[FALT] - While [FALT] is output, the motor cannot run.
- When [FALT] is used to reset [N COM], [FOR RN] or [REV RN],

displays a spindle alarm visual signal.
- [FALT] is sent to LEDs on the controller to light. For these, refer

to paragraph A-2.
- For the relationship between [FALT] and [RESET], refer to 8.

Malfunction reset [RESET] in Table A-3(c).
1CN - When the motor speed drops below a preset level, [N-DET] closes,
and the N-DET LED (green) lights.
- The speed detection level is set between 30 and 4000 rpm with
potentiometer (N-DET) in the controller.
Speed
Detection PICTURE
[N-DET]
- [N-DET] operates regardless of the run direction signals.
- [N-DET] can be used as the detection signal for the speed suitable
for clutch actuation or gear shifting.
- The standard setting is 6000 rpm.

- When the motor speed enters the preset range of [N COM],
[AGREE] closes, and AGREE LED (green) lights. However, while
a run signal is open or [Z-SPD] is closed, it is not output.
Speed
Coincidence - When this signal is used as an answer to S command in NC
[AGREE] program operation, the program is advanced to the next step.
PICTURE
5
Functions of Output Signals (Cont'd)

No. Pin No.
Excessive - Since [DEV] is output when the cutting tool takes and excessive
Speed cut or other conditions detrimental to the tool and the machine
Deviation develop. it can be used as a spindle alarm signal.
[DEV]
1CN - When torque increases above a specified level, [T-DET] closes,
and the "T-DET" LED (green) lights.
Torque
Detection - The torque detection level can be set between 0 and 120% with the
[T-DET] potentiometer (T-DET) in the controller
PICTURE
6
OEM and V1
D8160 757-4001-056 BMC20/50 Geometry Checkout Procedure

D8278 757-4001-066 Type “O” Automatic Tool Changer Setup Procedure
D8386 757-4001-059 BMC20/50 PCB Switch Configuration
D8536 757-4001-056 BMC 20 - 50 Leveling Procedure
757-4001-066 REV: C ECN #11978

R
03/10/92 CAD#D8278
SUBJECT: HURCO TYPE "0" AUTOMATIC TOOL CHANGER (ATC)

ALIGNMENT AND SETUP PROCEDURE
I. INTENT
To provide a standardized procedure for consistency in the setup and adjustment of the
Automatic Tool Changers (ATC) used on BMC-20/50 and MHP-20 type Machining Centers.
II. APPLICABILITY
Applicable to all BMC-20/50 and MHP-20 type Machining Centers with Type "0" ATC. This
is the only procedure to be used within Hurco facilities and should be used at customer
installations to help achieve factory proven performance.
III. FORMAT
Page 2 : ATC MOUNTING ALIGNMENT

Page 3 : ATC HEIGHT AND ORIENT POSITION SHIFT FOR BMC
Page 3 thru 4 : ATC HEIGHT AND ORIENT POSITION SHIFT FOR MHP
Page 4 thru 5 : FINAL ATC SETUP PROCEDURE
IV. EQUIPMENT REQUIRED
1. ATC Sweep Fixture

2. ATC Alignment Bars (for appropriate machine type)
3. Magnetic Base Assembly
4. 0.001 Graduated Plunger Indicator
________________________________ _______ _______________________________ _______

V. ATC MOUNTING ALIGNMENT
1. Using the ATC Diagnostics to manipulate the tool changer, adjust tool changer air flow
and air cylinder cushions in the following fashion:
A. Adjust air regulator to 6Kg/Cm (85 psi).
B. Preset air cylinder cushions, Full CW then 2 turns CCW (one for each direction
up/down, left/right), located in the end caps of the cylinders.
C. Move the magazine left/right, up/down and adjust the air flow controls on the
solenoid valves for smooth and consistent movement. Movement left/right, and
up/down should be equal in time duration.
D. Adjust cylinder cushions, for all four directions, to soften the stop at the end of
travel. Tighten the needle valve, by turning clockwise until the movement just
begins to bounce, then back off 1/8th turn.
2. Loosen the set screw and jam nut then adjust the tool knockout cylinder so that the tool
is pushed out by the spindle by 0.005 inches to 0.020 inches while unclamped.
Tighten the set screw, apply Loctite #271 to the jam nut and tighten.
3. Align the tool changer magazine as follows:
A. Move the magazine right and check the initial relationship to spindle. Mount the
alignment bars, one to the mill column and one to the base plate of the tool
changer.
B. Set up an indicator to sweep the largest bottom flange of the magazine with the
sweep fixture.
C. Using the alignment bars, adjust the sweep to achieve less than 0.010 inches,
keeping the magazine tool pot concentric with the spindle taper.
Note: Adjust the magazine right using the jam nut(s) on the air cylinder shaft.
Adjust the front to back using the alignment bar mounted to the mill column.
Insure that the tool position remains concentric with the spindle taper.
D. Tighten the jam nut(s) on the left/right cylinder and tighten cap screw in jam nut
if applicable. Apply #271 Loctite and tighten the ATC mounting bracket bolts.
NOTE: DRILL, REAM, AND INSTALL DOWEL PINS PER BMC BUILD
PROCEDURE 757-4001-091, OR MHP BUILD PROCEDURE 757-5000-007.
E. Lubricate Geneva Driver with Moly Lube. align Gearbox/Motor for smooth
quiet operation. NOTE: Some change to the Spindle/Tool Magazine alignment
may be made by moving the Gearbox and Motor.
2
VI. ATC HEIGHT AND ORIENT BIAS FOR BMC
1. Set ATC height as follows:
A. Orient the spindle using the "Lock Spindle" softkey and "Start" button.
B. Move the ATC Magazine Right, under the Spindle, enter ATC Diagnostics, and
depress "Enter", "488", "Enter".
C. Jog the Z axis so that the distance from the bottom of the Spindle face to the
bottom of the Magazine V Flange is 17/32 inches.
D. Note the dimension that is displayed on the CRT for "ATC Height Z Axis" and
"ATC Height SW".
E. For Software version 7.24 and earlier, set switch positions 1 thru 6 of switch
block S1 on the Machine Personality PCB to correspond with the dimension that
is displayed for the Z axis. The switch positions are a Binary input with S1-1
being the least significant bit and S1-6 being the most significant bit. Reference
757-4001-091 for additional details. For Software version 8.50 and later, press
"Store 2 Position"
F. Verify that the dimensions for both Tool Change Height (Z Axis) and (SW) now
are the same and that the "At Height" field is backlit.
F. Move the Magazine Down and place a tool in it under the Spindle. Using a
straight edge, check from the Spindle Key to the Tool Slot. Adjust the "Bias"
and "L-Bias" potentiometers on the Orient Card to insure precise mating of tool
to the Spindle.
Note: the "Bias" potentiometer will affect both L-G and H-G and should be
adjusted first. Use the "L-Bias" potentiometer to ensure that the orient position is
the same for both windings.
Both the front and rear spindle keys should line up with the magazine key. If this
is not within the range of adjustment of the potentiometer, then set the "Spindle
Off", and turn the aluminum sensor mount on the spindle, then re-tighten.
Press "Spindle Orient" "Start" to switch between L-G and H-G, recheck and fine
tune using the "Bias" and the L-Bias" potentiometers.
H. Remove the tool from the magazine and move the magazine "Left" and "Up".
VII. ATC HEIGHT AND ORIENT BIAS FOR MHP

3
1. Set ATC height for MHP machines as follows:
A. Switch the Tool Changer to manual at the control head and change to Metric
Mode in the "Set-up" screen. Orient the spindle using the "M19" CODE in the
PROGRAM mode and the "Cycle Start" button.
B. Move the ATC magazine to the right "M60".
B. Move Z axis to the position recorded in Step G of Section V, or, using the
Handwheel, jog Z axis so that the distance from the bottom of the spindle nose to
the bottom inner edge of the V-flange is 17/32 inches.
D. Record Z position to be loaded later.
_________________millimeters
D. Move the machine head up, place a tool in the magazine under the spindle. Using
a straight slot. Adjust the "Bias" and the "L-Bias" potentiometer on the Orient
Card to insure precise mating of tool to the spindle.
Note: The "Bias" potentiometer will affect both L-G and H-G and should be
is not within the range of adjustment of the potentiometer, then set the
potentiometer to mid range, turn Orient OFF by selecting "M19" CODE "Cycle
Start", and turn the aluminum sensor mount on the spindle, then re-tighten.
Using "M40 and M41" CODES' switch between L-G and H-G, recheck and fine
tune using the "Bias" and "L-Bias" potentiometers.
F. Remove the tool from the magazine and move the magazine left "M63".
VII. FINAL ATC SETUP
1. Verify tool retention force is set properly. Reference 757-4001-091 or 757-5000-007

for details.
A. Adjust Right, Left, Up, Down, and reference ATC micro switches as shown
below:
4
Roller Type Switch
1/2 of Hole Dia. Shown
Actuator
B. Unclamp switch - Set for 0.050" to 0.075" push on the roller to allow proper
unclamp action.
B. Magazine Out of Position Proximity switch - Set for 0.015" to 0.025" gap
between end of switch and actuator.
2. Load magazine full of tool holders and cycle the ATC, using the ATC/Magazine
Diagnostics, through several tool changes. Minor adjustments to the flow control
valves, air cushions, and limit switches may be necessary.
3. When all above steps have been completed put the machine into an Automatic cycle and
make two complete cycles of all tools in the magazine. Verify the pneumatic oiler is
set for 1 drop per every two tool changes.
4. Insure the ATC tool to tool time (from orient complete to magazine left, thru one
change of adjacent tools) is equal to the advertised specifications.
MACHINE SECONDS
BMC-20 6
BMC-30 8
BMC-40 8
BMC-50 8
MHP-20 6
5
R
757-4001-056
01/27/88 CAD #D8536
SUBJECT: MACHINE LEVELING PROCEDURE
ORIGINATORS: REVIEWED & APPROVED:

_________________ ________
_________________ ________
____________________________ ________
Name Signature Date Mgr./V.P. Engineering Date
I. INTENT
To provide a procedure and tooling requirement for properly leveling Machining Centers. To be
used in conjunction with Engineering Document Machine Acceptance to Ship Document.
II. APPLICABILITY
Applicable to all Hurco Machining Centers. This procedure to be used within HURCO facilities
and should be used at customer installations to help achieve factory proven accuracies.
A. Precision Level
B. 14 inch Granite Square
D. Suitable holder to hold indicator in spindle nose
E. Suitable wrench for adjusting leveling bolts
IV. FORMAT
Page 1 - Preliminary Notes and Checks

Page 1 thru 2 - “A” Frame
Page 3 thru 4 - BMC 40/50
PRELIMINARY CHECKS:
1. Always check your Level. They can vary by several thousandths day to day. Temperature, nicks
on the bottom, and touching the vial with your fingers will throw the Level off.
2. Always check the calibration of your Level by turning it 180 degrees and verifying the bubble reads
the same.
3. Always thoroughly clean the Mill Table and the Level using a suitable non-flammable cleaning
solvent.
PRELIMINARY NOTES:
1. Leveling is the first step of Geometries. Careful leveling will make other adjustments easier.
2. Locations of Machine Leveling Bolts can be found in the Machine Owner’s Manual, Section 2.
“A” FRAME
NOTES:
A. With six bolts for leveling, there is more adjustment in the base of the machine, so level and
geometries can be finely adjusted. Slight adjustments make large changes. 1/8 turn could be more
than enough if the machine leveling is done properly.
B. When fine adjusting the geometries, keep in mind that there are more bolts, so changing one has
more effect on the others.
C. To adjust column squareness X to Z, adjust the left side center and rear bolts as a set or the right
side center and rear bolts as a set. Turn the bolts the same amount, remember to turn the left hand
and right hand bolts in opposite directions to split the amount of adjustment.
D. To adjust column squareness Y to Z, use the rear bolts and the center bolts as sets. For example, if
the column is leaning forward at the top, tighten the center bolts and loosen the rear bolts. Be
aware that slight adjustments make large changes.
E. Slight spindle sweep adjustments can be made by using the left side center and rear bolts and the
right side center and rear bolts as sets. In general, if sweep is high in front (+ indicator reading),
tighten left and right center bolts. If high in back, tighten left and right hand rear bolts. If high on
left side, raise left hand center and rear bolts and lower right hand center and rear bolts. If high on
right side, raise right hand center and rear bolts and lower left hand center and rear bolts.
1
F. These adjustments will change column squareness and machine level so work slowly, do not expect
over .0004” change so try to split errors between the various measurements and strive for machine
level within .0005”/ft.
G. X to Y squareness can be altered using left front and right center or right front and left center bolts.
You will have to be very careful with this adjustment. Make very slight adjustments. If
measurements worsen, return to original settings and use opposite pair of bolts. A very slight
adjustment is all that is necessary to correct X to Y squareness.
PROCEDURE:
1. Slowly lower machine onto six (6) mill foot pads.
2. Use a precision level (resolution 0.0005 inch per foot) on the worktable surface to check its level,
both lengthwise and crosswise.
3. Leveling is accomplished by adjusting the leveling bolts at the base of the machine (6 bolts) as
required to obtain .0005”/ft. of “level” for the worktable. The weight of the machine should be
distributed evenly on these six (6) leveling bolts before tightening locknuts.
4. Touch off the six (6) bolts to even pressure and raise evenly at least one (1) turn.
5. Level front to back, raise low end using the left and right front bolts or the left and right rear bolts,
depending on whether the front or back of the machine is low. Make sure to turn the left and right
bolts as a set, the same amount, to center the bubble on the level.
6. Touch off the center bolts (left and right side), making sure not to affect the level of the machine.
7. With even pressure on all six bolts, level side to side (X axis). Use three bolts on either side as a
set and turn them the same amount.
8. Level Y axis ways using the front or back bolts, remembering that the machine will pivot on the
center bolts. Split the amount needed to 1/2 and use the bolts in pairs.
9. Recheck the table, split any error between the Y ways and Y table.
10. Repeat the above steps until machine remains level both front to back and side to side. All six bolts
should have even pressure on them.
11. When all of the above steps are complete, tighten the leveling bolt locknuts.
2
BMC 40/50
NOTES:
A. With eight (8) leveling bolts, more complex patterns and frame adjustments (twist) are possible.
B. Strive for level table and level Y ways.
C. The BMC40 and 50 are heavy so you may not be able to turn just one bolt, so use adjacent bolts to
lift with and always taper off any adjustment by checking the pressure of the adjacent bolts.
D. The machine will sit low in the center, so level with the two front and two back bolts, but bring up
the center as you work, then do side to side.
E. Use all four (4) bolts on either side as a set and check Y ways to avoid problems adjusting the Y
ways.
F. With machine level, recheck pressure of all bolts. Make it as even as possible to start. This will
allow the most adjustment for geometries without putting the frame in a twist or throwing the level
off more than necessary.
G. With eight (8) bolts, use left side rear two (2) and right side rear two (2) bolts for column
squareness and spindle sweep adjustments.
H. Use left side front two (2) and right side front two (2) bolts for Table Flatness and X to Y
squareness adjustments.
I. BMC40 and 50 leveling and geometric adjustments are the same as the BMC30, only consider four
(4) center bolts instead of two (2).
PROCEDURE:
1. Slowly lower machine onto eight (8) mill foot pads.
2. Use a precision level (resolution 0.0005” per foot) on the worktable surface to check its level, both
lengthwise and crosswise.
distributed evenly on these eight (8) leveling bolts before tightening locknuts.
4. Touch off the eight (8) bolts to even pressure and raise evenly at least one (1) turn.
3
7. With even pressure on all eight bolts, level side to side (X axis). Use four bolts on either side as a
10. Repeat the above steps until machine remains level both front to back and side to side. All eight
bolts should have even pressure on them.
4
Engineering Docment 757-4001-056 CAD # D8536
Rev. B ECN #14073
Rev. ECN # Revision Description Pg. # Date By Appv.

B 14073 Changed description to Machining Center 7/2/97
Omitted BMC20
OEM 2 and V2 IP
D8122 757-4001-089 Leadscrew Mounted Encoder Assembly Procedure

D8278 757-4001-066 Type “O” Automatic Tool Changer Setup Procedure
D8279 757-4001-120 Type “1” Automatic Tool Changer Setup Procedure
D8374 757-4001-081 BMC20/50 Laser Measurement of Linear
Positioning
1066 FSB BMC20/50 PCB Switch Configuration
D8411 757-4001-090 BMC20/50 Control Relay Panel 2 Switch
Configuration
D8536 757-4001-056 BMC 20 - 50 Leveling Procedure
757-4001-089 REV: B ECN #11668

01/23/92 CAD#D8122
SUBJECT: LEADSCREW MOUNTED ENCODER ASSEMBLY
I. INTENT
To provide a procedure and tooling requirements for properly installing the leadscrew
mounted encoders on the BMC/MHP 30-50 machining centers.
II. TOOLING REQUIREMENTS
A. Magnetic Base
B. .001 inch Indicator
C. Straight Blade Screwdriver
D. M6 Allen Wrench
E. M8 Allen Wrench
F. 7/64 Allen Wrench
III. PROCEDURE
A. Remove clamp plate from the leadscrew pulley.
B. Install driver 802-2511-001 with 4 M6 X 16 SHCS over the leadscrew shaft to the pulley
using Loctite 242.
C. Ensure that the belt tension on each axis is snug to reduce the physical backlash in the
belt tension.
________________________________ _______ _______________________________ _______

D. Indicate the driver shaft by turning the ballscrew by hand to be within .001 inch T.I.R.
E. Install the housing cover 802-2503-002 with 4 M10 x 20 SHCS using Loctite 242. DO
NOT tighten fasteners.
F. Install set-up plate 802-2500-009 over drive shaft and fasten to the housing cover with
M6 x 16 SHCS. This aligns the housing cover to the drive shaft. Tighten housing cover
fasteners.
G. Remove set-up plate.
H. Install hub clamp 205-0004-006 over the drive shaft.
I. Install flex coupling 205-0004-007 over the drive shaft between hub clamp and shaft.
Tighten the hub clamp down to the shaft.
J. Install hub clamp over flex coupling at encoder end. DO NOT TIGHTEN.
K. Install encoder adapter 802-2514-002 over flex coupling and mount to the housing cover
with 4 M6 x 60 SHCS using Loctite 242.
L. Line up tightening bolt on hub clamp with access hole in encoder adapter.
NOTE: Remove the play from the flex coupling. Loosen retainer cap on front end of
coupling. Pull coupling towards ballscrew to reduce end play and re-tighten retainer cap.
M. Install encoder 416-0248-044 into flex coupling.
N. Tighten hub clamp to encoder and flex coupling.
O. Install mounting cleats 604-0002-001 to the encoder adapter using Loctite 242, and
tighten down to hold the encoder in position.
P. Install connector to the encoder.
Q. Install encoder cover over the encoder assembly into the housing cover using 2 M6 x
16 SHCS and 2 M6 flat washers. Use Loctite 242.
2
NOTE: Upon completion of the laser test, the housing cover must be pinned using two
1/4" x 1 1/4" spring pins 112-5008-004.
PRECAUTION: DO NOT pry against the housing cover for increasing the belt tension
during the laser test. This will misalign the encoder assembly.
This procedure is written for BMC 40/50 machines. The same procedure applies for the
BMC/MHP-30 except for some part differences. The following is a materials list for all
BMC/MHP 30-50 assemblies.
PART NUMBER DESCRIPTION WHERE USED
205-0004-006 Hub Clamp 30/40/50

205-0004-007 Flex Coupling 30/40/50
416-0248-044 Encoder 30/40/50
604-0002-001 Mounting Cleat 30/40/50
802-2503-002 Housing Cover 40/50
802-2511-001 Driver 30/40/50
802-2514-002 Adapter 40/50
802-2503-005 Cover 40/50
802-2503-001 Housing Cover 30
802-2514-001 Adapter 30
802-2503-004 Cover 30
BMC/MHP-30 Assembly 002-3839-001
BMC 40/50 Assembly 002-3839-002
Set-up Plate BMC/MHP-30 802-2500-010
Set-up Plate BMC 40/50 802-2500-009
3
757-4001-066 REV: C ECN #11978

R
03/10/92 CAD#D8278

I. INTENT
Automatic Tool Changers (ATC) used on BMC-20/50 and MHP-20 type Machining
Centers.
II. APPLICABILITY
III. FORMAT


________________________________ _______ _______________________________ _______

is pushed out by the spindle by 0.005 inches to 0.020 inches while unclamped. Tighten
the set screw, apply Loctite #271 to the jam nut and tighten.
alignment bars, one to the mill column and one to the base plate of the tool changer.
sweep fixture.
quiet operation. NOTE: Some change to the Spindle/Tool Magazine alignment may
be made by moving the Gearbox and Motor.
2
C. Jog the Z axis so that the distance from the bottom of the Spindle face to the
"ATC Height SW".
D. For Software version 7.24 and earlier, set switch positions 1 thru 6 of switch
is displayed for the Z axis. The switch positions are a Binary input with
S1-1 being the least significant bit and S1-6 being the most significant bit. Reference
"Store 2 Position"
F. Move the Magazine Down and place a tool in it under the Spindle. Using a
straight edge, check from the Spindle Key to the Tool Slot.
Adjust the "Bias" and "L-Bias"potentiometers on the Orient Card to insure precise
mating of tool to the Spindle.
Off", and turn the aluminum sensor mount on the spindle, then re-tighten. Press
"Spindle Orient" "Start" to switch between L-G and H-G, recheck and fine tune
using the "Bias" and the L-Bias" potentiometers.

3
B. Move Z axis to the position recorded in Step G of Section V, or, using the
_________________millimeters
E. Move the machine head up, place a tool in the magazine under the spindle. Using
a straight slot. Adjust the "Bias" and the "L-Bias" potentiometer on the Orient Card
to insure precise mating of tool to the spindle.
Both the front and rear spindle keys should line up with the magazine key. If this is
not within the range of adjustment of the potentiometer, then set the potentiometer
to mid range, turn Orient OFF by selecting "M19" CODE "Cycle Start", and turn
the aluminum sensor mount on the spindle, then re-tighten. Using "M40
and M41" CODES' switch between L-G and H-G, recheck and fine tune using the
"Bias" and "L-Bias" potentiometers.
4
for details.
A. Adjust Right, Left, Up, Down, and reference ATC micro switches as shown below:
Roller Type Switch
Actuator
unclamp action.
C. Magazine Out of Position Proximity switch - Set for 0.015" to 0.025" gap between
end of switch and actuator.
Diagnostics, through several tool changes. Minor adjustments to the flow control valves,
air cushions, and limit switches may be necessary.
make two complete cycles of all tools in the magazine. Verify the pneumatic oiler is set
for 1 drop per every two tool changes.
5. Insure the ATC tool to tool time (from orient complete to magazine left, thru one change
of adjacent tools) is equal to the advertised specifications.
MACHINE SECONDS
BMC-20 6
BMC-30 8
BMC-40 8
BMC-50 8
MHP-20 6
5
757-4001-120 REV: A ECN #11978

R
03/11/92 CAD#D8279

ALIGNMENT AND SET-UP PROCEDURE
I. INTENT
To provide a standardized procedure for consistency in the setup and adjustment of the ATCs
used on BMC-25, 30, 30K 40SLV and MHP-30 machining centers.
II. APPLICABILITY
Applicable to all BMC-25, 30 40SLV, and MHP-30 machining centers. This procedure is the
only procedure to be used within Hurco facilities and should be used at customer installations
to help achieve factory proven performance.
III. FORMAT
Page 2 thru 3 : ATC MOUNTING ALIGNMENT

IV. EQUIPMENT
ATC Sweep Fixture

ATC Alignment Bars (for appropriate machine type)
Magnetic Base Assembly
0.001 Inch Graduated Plunger Indicator
________________________________ _______ _______________________________ _______

1. ATC speed and cushion adjustment.
A. Adjust the air regulator to 6 kg/cm (85 psi).
B. Preset cylinder cushions full CW then 2 turns CCW, located on both ends of the
cylinder.
C. Move the magazine left/right and adjust the air flow controls on the solenoid
valves for smooth and consistent movement. Movements left and right should be
equal in time duration.
D. Adjust cylinder cushions, for both directions to soften the stop at the end of
travel. Adjust the needle valves to eliminate any bounce or noise at the end of travel.
2. Loosen the jam nut then adjust the tool unclamp cylinder knockout adjustment bolt so
that the tool is pushed out of the spindle 0.005 to 0.020 inches while the spindle is
unclamped. Apply #271 Loctite to the jam nut and tighten securely. This nut must not
come loose during machine operation.
A. Mount the ATC alignment bars. Remove the ATC mounting bracket bolts, apply
#271 Loctite then install the bolt again (do one bolt at a time).
B. Move the ATC right under the spindle and check the relation of the ATC tool pot
to the spindle nose.
C. Setup an indicator to sweep the largest bottom flange of the magazine with the
sweep fixture.
C. Using the alignment bars, adjust the sweep (front to back) to be less than 0.010
inches while keeping the ATC tool pot centerline aligned with the spindle nose
centerline. The tool pot and the spindle nose must be concentric to make a
smooth tool change.
E. Tighten the ATC mounting bracket bolts. Recheck alignment under spindle nose.
F. Jog Z so that the distance from the bottom of the spindle nose to the bottom inner
edge of the V-flange is 17/32 inch.
G. Record Z position for later use __________________.
H. Move ATC left then insert tool holder into the spindle.
2
I. Loosen the (4) set screws on the top of the right/left cylinder mounting brackets.
Use the machine control to move the ATC to the right. Align the tool holder to
the tool changer pot and move the cylinder to mate the tool changer to the
tool holder securely. Tighten the set screws and move the ATC to the left.
Remove the tool holder.
J. Lubricate the Geneva wheel with Moly lube.
Note: Adjustments may need to be altered after magazine is fully loaded with tool
holders.
VI. ATC HEIGHT AND ORIENT BIAS FOR BMC AND SLV
1. Set ATC height for BMC and SLV machines as follows:
A. Orient the spindle using the "Lock Spindle" softkey in the Manual mode and the
"Start" button.
B. Move the ATC magazine to the right, enter ATC Diagnostics, then press "Enter",
"101", "Enter".
C. Move Z axis to the position recorded in Step G of Section V, or, using the
Jogwheel, jog Z axis so that the distance from the bottom of the spindle nose to .
D. Press "Store Z Position".

Note: The dimensions that are displayed on the CRT for "ATC Height Z Axis"
and "ATC Height SW", both numbers should be equal and "At Height" must be
backlit or Z limit switches need to be reset to allow the ATC height to be set.
E. Move the machine head up, place a tool in the magazine under the spindle. Using a
straight edge, check from the spindle key to the tool slot. Adjust the "Bias and
"L-Bias" potentiometer on the Orient card to insure precise mating of tool to the
spindle.
potentiometer to mid range, turn Orient OFF by pressing "Spindle Off", and turn
the aluminum sensor mount on the spindle, then switch between L-G and H-G,
recheck and fine tune using the "Bias" and "L-Bias" potentiometers.
E. Remove the tool from the magazine and move the magazine "Left".
VI. ATC HEIGHT AND ORIENT BIAS FOR MHP

3
C. Move Z axis to the position recorded in Step G of Section V, or using the

__________________ millimeters
F. Move the machine head up, place a tool in the magazine under the spindle. Using
a straight edge, check from the spindle key to the tool slot. Adjust the "Bias" and
spindle.
Both the front and rear spindle keys should line up with the magazine key. If this is
not within the range of adjustment of the potentiometer, then set the potentiometer
to the mid range, turn Orient OFF by selecting "M19" CODE "Cycle Start", and turn
the aluminum sensor mount on the spindle, then re-tighten. Using "M40 and M41"
CODES, switch between L-G and H-G, recheck and fine tune using the "Bias" and
"L-Bias" potentiometers.
1. Verify tool retention force is set properly. Reference 757-4001-091 or 757-5000-007 for
details.
2. Adjust the Right, Left and Clamp switches so that when actuated the plunger is
depressed so half of the roller is concealed.
4
Roller Type Switch
Actuator
Adjust the Unclamp switch so that when actuated the plunger is depressed to the edge of the
rivet hole in the roller to allow the spindle to be fully unclamped before the next tool
change movement.
3. Set the Magazine out-of Position and Magazine Reference Proximity switches for 0.015
to 0.025 inch gap between the end of the switch and the actuator.
4. Load the magazine full of tool holders and cycle the ATC and made any adjustments
needed to facilitate a smooth tool change.
5. Run the tool changer through two complete revolutions of the carousel.. Verify the
pneumatic oiler is set for 1 drop per every two tool changes.
6. Insure the ATC tool to tool time (from orient complete to magazine left, through one
change of adjacent tools) is less than or equal to the advertised specifications.
MACHINE SECONDS
BMC-25 12
BMC-30 12
BMC-30K 12
BMC-40SLV 12
MHP-30 12
5
R
757-4001-081
10/13/93 CAD #D8374
SUBJECT: LASER MEASUREMENT OF LINEAR POSITIONING
________________________________ _______ _______________________________ _______

REV. D
ECN #12849

A 12455 Original Issue
B
C 12249 Revised sections V and VI 10/14/92
D 12849 Replaced section VI, F, 2, d; added new section VI, C, 6 10/13/93
E 14073 Changed description from BMC20-50 to Machining Center
2
CONTENTS PAGE
I. INTENT................................................................................................................ 2
II. APPLICABILITY ................................................................................................. 2
III. EQUIPMENT ....................................................................................................... 2
IV. SPECIFICATIONS/ACCEPTANCE CRITERIA .................................................. 2

A. ACCURACY............................................................................................. 2
B. REPEATABILITY .................................................................................... 3
V. FACTORS IN THE ASSESSMENT OF POSITIONAL ACCURACY.................. 3

A. POSITIONAL UNCERTAINTY (P) ......................................................... 3
B. POSITIONAL SCATTER (Ps) .................................................................. 3
C. POSITIONAL DEVIATION (Pa).............................................................. 3
D. REVERSAL ERROR (U) .......................................................................... 3
VI. MEASUREMENT PROCEDURE ........................................................................ 3

A. MACHINE SETUP ................................................................................... 3
B. EQUIPMENT SETUP............................................................................... 4
C. PART PROGRAM SETUP........................................................................ 5
D. AXIS WARM-UP...................................................................................... 7
E. TWO-PASS LASER MEASUREMENT.................................................... 8
F. TWO-PASS LASER MEASUREMENT ANALYSIS................................ 8
G. LEAD SCREW COMPENSATION DATA ENTRY ................................. 10
H. FOUR-PASS LASER MEASUREMENT .................................................. 11
I. FOUR-PASS LASER MEASUREMENT ANALYSIS .............................. 12
J. SAVING LEAD SCREW COMPENSATION DATA................................ 16
K. RE-LASERING CRITERIA ...................................................................... 17
3
I. INTENT
To establish an accepted standard for:

A. measuring the positional accuracy of an unloaded machine tool by direct
measurement on the machine and
B. providing for the software compensation of geometrical deviations.
This standard is to be used to verify:

A geometrically correct construction
B. no excessive lead screw backlash
C. machine positional accuracy is achievable.
II. APPLICABILITY
Applicable to all Machining Centers. This is the only procedure to be used by

Quality Control for the confirmation and acceptance of machine positioning accuracy and
repeat accuracy.
III. EQUIPMENT
A. LASER Measurement System (Hewlett-Packard or equivalent)

1. Computer with I/O ROM
2. Printer/Plotter ROM
3. Printer/Plotter
4. Metrology software (Pullman & Associates, Model 11085A or
HP 55286A or equivalent)
5. Associated cabling
B. Adapter Plate AD-1
C. Hurco LASER Program Diskette (704-2000-003)

Note: these specifications are based on full travel of the axis.
A. ACCURACY
The positional Uncertainty (P) value calculated after completion of the qualifying 4
pass (per VDI/DGQ 3441) is not to exceed 0.0008 inches.
P < 0.0008 in.
(P < 0.020mm)
B. REPEATABILITY
4
The Positional Scatter (Ps) added to the Reversal Error (U) calculated after
completion of the qualifying 4 pass (per VDI/DGQ 3441) is not to exceed 0.0004
inches.
Ps + U < 0.0004
(Ps + U < 0.010mm)

Reference "Verein Deutscher Ingenieure/Deutsche Gesellschaft fur Qualitat 3441",
Statistical Testing of the Operational and Positional Accuracy of Machine Tools,
VDI/DGQ 3441.
A. POSITIONAL UNCERTAINTY (P)

The total deviation on the selected test axis taking into account the characteristic
values determined in the individual positions: Positional Deviation, Reversal Error,
and Positional Scatter. It includes both system and random deviations.
B. POSITIONAL SCATTER (Ps)

Represents the effect of random deviations in each position on the selected test axis.
It is expressed to a specified degree of probability.
C. POSITIONAL DEVIATION (Pa)

As a system deviation, it is the maximum difference of the mean values of all
measuring positions on the selected test axis.
D. REVERSAL ERROR (U)

As a system deviation, it represents the difference obtained from the mean values in
both directions of travel for each position on the selected test axis.
VI. MEASUREMENT PROCEDURE
A. MACHINE SETUP
1. Verify that the Way Lube is at an adequate level to complete the measurement
of the axis.
2. For Ultimax II Controls, with Control power off, remove the two Dual Axis
PCBs and reset the Lead Screw and Backlash Compensation switches to OFF or
0 for X, Y, and Z axes (reference the following switch block assignments).
SWITCH ASSIGNMENTS DUAL AXIS I DUAL AXIS II

X axis Lead Screw Compensation S4 S3
X axis Backlash Compensation S5 S4
Y axis Lead Screw Compensation S2 S1
Y axis Backlash Compensation S3 S2
Z axis Lead Screw Compensation S4 S3
Z axis Backlash Compensation S5 S4
3. With Control power on, calibrate the machine axes.
5
4. Select Manual followed by the CHANGE TOOL OR DIAGNOSTICS and the
ATC AND MACHINE DIAGNOSTICS softkeys.
5. Enter the following: "Enter 102 Enter".
6. Select the LOAD DUAL AXIS DEFAULTS softkey to set all Lead Screw
Compensation data points for ALL axes to zero (for Dual Axis PCB's, set the
Axis Lead Screw Compensation switches to OFF or 0).
7. Select the MANUAL DATA ENTRY softkey to display the X AXIS

FORWARD LEAD SCREW COMPENSATION table and verify that all of the
data values zero. Use the Advance key to verify the Y and Z axes,
respectively.
8. Select the REVERSE COMPENSATION softkey and verify that all of the data
values are zero.
9. Select the EXIT softkey to return to the Lead Screw Setup screen.
10. Select the EXIT softkey to return to Diagnostics.
B. EQUIPMENT SETUP
1. Obtain all necessary equipment to perform the measurement on the selected

axis.
2. Mount Adapter Plate to the mill table. Using a Square, ensure that the Plate is
mounted square with the table, making certain that the Plate position permits
mounting of the Interferometer with adequate clearance to the Retro reflector
with the table at the end of travel.
3. Mount the Interferometer to the mounting plate. Place the Reflector assembly
over the unused port of the Interferometer.
a. For X and Y axes: mount to a rod in the Tool holder and insert the
Tool holder into the Spindle.
b. For Z axis: mount on a magnetic base and attach to a machined surface
on the front of the machine ram.
4. Attach the assembly to the Adapter Plate and use a Square to align it to the
Plate. Ensure that the orientation of the Interferometer is correct by aligning
the direction of the arrows on the Interferometer with the selected test axis.
5. Jog the selected axis to its "home" limit switch then jog the axis away by
approximately 0.2500 inches.
6. Position the Retro reflector to be horizontally in line with the Interferometer on

the sides parallel to the selected axis by using a Square and by positioning the
table in the planes perpendicular to the selected axis.
6
7. At their closest point, the Interferometer and Retro reflector should be about
one inch apart.
8. Position and level the tripod with the LASER Head attached. Connect the
cabling between the Head, the Display, the Compensator, and the Computer.
Mount the Temperature Sensor as close as possible to the Ball Screw of the
selected axis. Mount the Air Sensor at the same height as the optics mounted
on the table.
9. Perform the LASER alignment by following the LASER System Users Guide.
Alignment must be carefully done to minimize cosine errors. Ensure that the
Beam strength is at maximum for the entire travel of the selected axis.
CAUTION: DO NOT LOOK INTO THE LASER BEAM; EYE DAMAGE

MAY RESULT.
10. Load the Metrology software into the Computer and select the program
Linear Measurement. Enter the proper values for Material Compensation as
required (6.5 for Inch or 11.7 for Metric)
C. PART PROGRAM SETUP
Insert the LASER Program Disk (704-2000-003) into the Floppy Drive of the
Control. At the Control, select Auxiliary followed by the STORAGE FUNCTIONS
softkey. Select the SELECT CURRENT STORAGE UNIT softkey and then the
appropriate softkey of the Drive. Select the LIST DIRECTORY softkey followed by
READ PROGRAM and select the appropriate program for the axis to be measured.
LASER PROGRAM DISK 704-2000-003

X_LASER.HDB - X axis LASER program
Y_LASER.HDB - Y axis LASER program
Z_LASER.HDB - Z axis LASER program
These programs position the selected axis in one inch increments at a feedrate of 100
IPM and include an additional 0.2500 inch of travel for the backlash move at the end
of each direction. The programs are to be edited as follows for the selected axis:
1. Determine the maximum travel of the selected axis (example: 24.2500 inches).
2. Round the maximum travel down to the nearest whole number (example:
24.0000 inches).
3. Subtract one inch (example: 23.000 inches).
4. Select the Input key followed by PART PROGRAMMING.
7
5. For X_LASER.HDB and Y_LASER.HDB programs (see appropriate chart for
common machine type values):
a. Use the Advance key to display Block 5; use the Enter key to move the
cursor to "NUMBER" and enter the value from step 3 (ex: NUMBER 23).
b. Use the Advance key to display Block 8; use the Enter key to move the
cursor to the selected axis and enter the value from step 3 PLUS 0.2500
inches (ex: 23.2500).
c. Use the Advance key to display Block 9; use the Enter key to move the
cursor to the selected axis and enter the value from step 3 (ex: 23.0000).
d. Use the Advance key to display Block 10; use the Enter key to move the
cursor to "NUMBER" and enter the value from step 3 (ex: NUMBER 23).
e. Use the Advance key to display Block 11; use the Enter key to move the
cursor to the selected axis and enter the value from step 3 MINUS one
inch (ex: 22.0000).
6. For Z_LASER.HDB program (see chart for common machine type values):
a. Use the Advance key to display Block 2; use the Enter key to move the
cursor to "SEGMENT" and enter the value from step 2 (ex: SEGMENT
24).
b. Use the Enter key to move the cursor to "Z" and enter the value from step
3 PLUS 0.2500 inches (ex: 23.2500).
c. Select the EXIT softkey followed by using the Back key to display the
SEGMENT with a "Z" which equals the value from step 2.
d. Select the DELETE SEGMENT softkey; repeat use of the DELETE
SEGMENT softkey until the SEGMENT with the value enter in step 6b
is displayed.
e. Use the Advance key to display the Segment past the one entered in step b
and use the DELETE SEGMENT softkey to delete the Segments in step d.
X_LASER.HDB
BMC BMC BMC BMC 40SLV BMC
20LR 25 30 40 50
Block 5, Number 23 23 29 39 39 51
Block 8, X 23.2500 23.2500 29.2500 39.2500 39.2500 51.2500
Block 9, X 23.0000 23.0000 29.0000 39.0000 39.0000 51.0000
Block 10, Number 23 23 29 39 39 51
Block 11, X 22.0000 22.0000 28.0000 38.0000 38.0000 50.0000
Y_LASER.HDB
BMC BMC 25 BMC 30 BMC 40 40SLV BMC 50
20LR
Block 5, Number 13 15 19 29 19 29
8
Block 8, Y 13.2500 15.2500 19.2500 29.2500 19.2500 29.2500
Block 9, Y 13.0000 15.0000 19.0000 29.0000 19.0000 29.0000
Block 10, Number 13 15 19 29 19 29
Block 11, Y 12.0000 14.0000 18.0000 28.0000 18.0000 28.0000
Z_LASER.HDB
BMC BMC 25 BMC 30 BMC 40 40SLV BMC 50
20LR
Segment 25, Z 13.2500 21.2500 19.2500 21.2500 no change 23.2500
Delete all 14.0000 22.0000 20.0000 22.0000 no change 24.0000
Segments with through through through through
Z equal to... 24.0000 24.0000 24.0000 24.0000
7. When editing is complete, select Auxiliary followed by the STORAGE

FUNCTIONS softkey; then select the SELECT CURRENT STORAGE
DEVICE softkey followed by the MEMORY or HARD DRIVE C softkey and
then WRITE PROGRAM (to write the edited program into Memory).
8. At the Control, select Manual followed by the TOOL IN SPINDLE softkey.

Enter "1" for the Tool In Spindle.
9. At the Control, select Input followed by the PART SETUP softkey. With the
LASER aligned at 0 position select the STORE MACHINE POSITION softkey
for Part Zero X and Y. Use the Enter key to advance the cursor to the Z Top
(+) display and again select the STORE MACHINE POSITION softkey.
D. AXIS WARM-UP
Do not begin the Axis Warm-up unless the selected axis has been idle for at least
one hour; "idle" is defined as not executing a RUN PROGRAM involving the
selected axis. Axis Warm-up should be executed before every Two-Pass LASER
measurement.
1. At the Control, select Single followed by RUN PROGRAM.
2. Press the Start push button to begin execution of the program.

3. At the completion of each cycle, wait two to five seconds before pressing the
Start push-button to execute the next cycle.
4. Run the program for two complete back-and-forth cycles (four unidirectional
passes).
E. TWO-PASS LASER MEASUREMENT
1. Execute Axis Warm-up (see section D).
9
2. With the table returned to the Part display 0.0000 for the selected axis (after
the initial backlash move), select the Reset button at the LASER Display and
then press the Print Switch on the LASER Display (or the remote) to transfer
the measurement to the Computer (verify the print-out).
3. Press the Start push-button to execute the next machine cycle.
4. After allowing the LASER display to completely settle (allow two to five
seconds) press the Print Switch on the LASER Display (or the remote) to
transfer the measurement to the computer (verify the print-out). "Settle" is
defined as no greater than 0.00001 inch fluctuation of the LASER Display.
NOTE: Axis measurement is to be aborted if the LASER display indicates that
an axis is overshooting (moving beyond the target and then back to the target);
report all overshoot cases to Product Engineering.
5. Repeat steps 2 and 3 for one complete back-and-forth cycle (two

unidirectional passes).
NOTE: Do not record data of the axis backlash moves. (the short moves at
the beginning and end of travel moves)
F. TWO-PASS LASER MEASUREMENT ANALYSIS
1. LEAD SCREW EVALUATION

a. In Run 1 (Forward), subtract the Error value of every Inch increment from
the one preceding it.
b. In Run 2 (Reverse), subtract the Error value of every Inch increment from
the one following it.
c. If the difference between any two increments is greater than the
Repeatability specification (see Section IV, Paragraph B) then advance to
the next comparison and determine if the difference is also greater than the
Repeatability BUT in the opposite direction.
d. If two consecutive comparisons both exceed the Repeatability specification
in opposite directions then the axis has failed and must be returned to
Manufacturing for rework; else, continue to step 2.
Example 1:
For a Repeatability specification of 0.0004 in.:
10
RUN TARGET ERROR
1 +0.000000 +0.000000 +0.000040
1 +1.000000 +0.000040 -0.000050 Run passes because
1 +2.000000 -0.000010 -0.000140 no difference
1 +3.000000 -0.000150 -0.000130 between any two
1 +4.000000 -0.000280 -0.000010 increments exceeds
1 +5.000000 -0.000290 [Ps + U]
1 +6.000000 -0.000070 +0.000220
1 +7.000000 -0.000250 -0.000180
1 +8.000000 +0.000000 +0.000250
1 +9.000000 -0.000210 -0.000210
Example 2:
RUN TARGET ERROR
2 +23.000000 -0.001670 +0.000820
2 +22.000000 -0.000850 +0.000270 Run passes because
2 +21.000000 -0.000520 +0.000100 even though the
2 +20.000000 -0.000420 +0.000050 first comparison
2 +19.000000 -0.000370 +0.000010 (22 Inch - 23 Inch)
2 +18.000000 -0.000360 exceeds [Ps + U]
2 +17.000000 -0.000360 +0.000000 the next comparison
2 +16.000000 -0.000390 -0.000030 (21 Inch - 22 Inch)
2 +15.000000 -0.000440 -0.000050 does not
2 +14.000000 -0.000520 -0.000080
Example 3:
RUN TARGET ERROR
1 +0.000000 +0.000000 -0.000040
1 +1.000000 -0.000040 -0.000130 Run fails because
1 +2.000000 -0.000170 -0.000050 the first comparison
1 +3.000000 -0.000220 -0.000100 (6 Inch - 5 Inch)
1 +4.000000 -0.000330 -0.000160 exceeds [Ps + U]
1 +5.000000 -0.000490 and the next comp-
1 +6.000000 -0.000070 +0.000420 parison (7 Inch -
1 +7.000000 -0.000480
-0.000550 -0.000200 6 Inch) also exceeds
[Ps + U] but in the
1 +8.000000 -0.000750 opposite direction
1 +9.000000 -0.001000 -0.000250
2. BACKLASH EVALUATION
a. Subtract the Error value of the first Inch increment of Run 2 (Reverse)
from the last Inch increment of Run 1 (Forward). The absolute value of
this result is the Backlash move for the axis.
b. If the Backlash move is greater than 0.0030 in. then the axis has failed and
must be returned to Manufacturing for rework (see e); else, continue to
step c.
c. Subtract the Error value at each Inch increment of Run 2 (Reverse) from
Run 1 (Forward).
11
d. If the difference at any increment is greater than 0.0030in plus the
Accuracy
specification (see Section IV, Paragraph A) then the axis has failed and
must be returned to Manufacturing for rework (or see step e); else
continue to Paragraph G.
Example 4:
For an Accuracy specification of 0.0008 in.:
RUN TARGET ERROR RUN TARGET ERROR DELTA(1-2)
1 +0.000000 +0.000000 2 +0.000000 +0.000170 -0.000170
1 +1.000000 -0.000650 2 +1.000000 +0.000020 -0.000670
1 +2.000000 -0.000760 2 +2.000000 -0.000010 -0.000750
1 +3.000000 -0.000740 2 +3.000000 -0.000020 -0.000720
1 +4.000000 -0.000860 2 +4.000000 -0.000020 -0.000840
1 +5.000000 -0.000810 2 +5.000000 -0.000050 -0.000760
1 +6.000000 -0.000990 2 +6.000000 +0.000010 -0.001000
1 +7.000000 -0.000960 2 +7.000000 +0.000070 -0.001030
1 +8.000000 -0.001030 2 +8.000000 +0.000080 -0.001110
1 +9.000000 -0.001070 2 +9.000000 +0.000100 -0.001170
The axis passes because the result is less than 0.0038 in.
e. The Manager of Product Engineering reserves the right to review all failed
Backlash Evaluations and, after through analysis of the data and
investigation of the machine, approve in writing the axis for Lead
Screw Compensation.
G. LEAD SCREW COMPENSATION DATA ENTRY
1. Select Manual followed by the CHANGE TOOL OR DIAGNOSTICS and the

ATC AND MACHINE DIAGNOSTICS softkeys.
2. Enter the following: "Enter 102 Enter".
3. Select the MANUAL DATA ENTRY softkey.

4. Use the Advance key to display the Lead Screw Map data for the selected axis.
5. Enter the Run 1 data into the Forward Lead Screw Compensation table; select
the REVERSE COMPENSATION softkey to enter the Run 2 data into the
Reverse Lead Screw Compensation table; enter only the numerical portion of
12
the data without the decimal point or the leading zeroes (example: measurement
data of -0.000040 is to be entered as -40).
6. If the Lead Screw Compensation table displays more INCH values than there
are measured data points, fill in the remaining INCH values with the last Inch
value from the measurement data (example: if Compensation table displays up to
24 INCH but measurement data is available only up to the 23rd Inch, enter the
23rd Inch measurement data for the 23 INCH and the 24 INCH values in the
Compensation table).
7. Select the EXIT softkey to return to the Lead Screw Setup screen.
8. Select the EXIT softkey to return to Diagnostics.
H. FOUR-PASS LASER MEASUREMENT
1. Execute Axis Warm-up (see section D).
2. With the table returned to the Part display 0.0000 for the selected axis (after the
initial backlash move), select the Reset button at the LASER Display and
then press the Print Switch on the LASER Display (or the remote) to transfer
the measurement to the computer (verify print-out).
3. Press the Start push-button to execute the next machine cycle.
4. After allowing the LASER display to completely settle, press the Print Switch
on the LASER Display (or the remote) to transfer the measurement to the
Computer (verify the print-out). "Settle" is defined as no greater than 0.00001
inch fluctuation of the LASER display.
NOTE: Axis measurement is to be aborted if the LASER display indicates that
an axis is overshooting (moving beyond the target and then back to the target);
report all overshoot cases to Product Engineering.
5. Repeat steps 2 and 3 for two complete back-and-forth cycles (four unidirectional
passes).
NOTE: Do not record data of the axis backlash moves. (The short moves at the
beginning and end of travel moves.)
I. FOUR-PASS LASER MEASUREMENT ANALYSIS
1. INCREMENTAL DATA INSPECTION
13
During any of the four runs, if the Error for any Inch value exceeds one-half of
the Repeatability specification (see Section IV, Paragraph B) then the run may
be aborted after completion of the second pass or at the completion of the fourth
pass, whichever is relevant. Note that this is a "rule-of-thumb" specification
and that a four-pass LASER run may pass the Accuracy and Repeatability
specifications with error values in excess of one-half the Repeatability
specification. If the Incremental Data Inspection fails then go to section 3,
Lead Screw Map Adjustment.
2. ACCURACY AND REPEATABILITY CERTIFICATION

a. If the four pass run passes the Incremental Data Inspection then calculate
the Positional Accuracy at the Computer.
b. The axis is certified if both the Accuracy and Repeatability specifications
in Section IV are met.
c. If the Repeatability specification fails then go to section 4, Repeatability
Analysis and adjustment.
d. If the Accuracy specification fails then go to section 5, Accuracy Analysis
and Adjustment.
3. LEAD SCREW MAP ADJUSTMENT

a. Access the Lead Screw Map (see Lead Screw Compensation Data Entry)
for the appropriate direction and advance to the Inch increment.
b. Always add the Error (maintaining the signs) to the Lead Screw
Compensation from the two-pass.
c. If a four-pass has been completed then average the Error of the two runs
in the same direction before adding to the two-pass Lead Screw
Compensation.
d. When adjusting a Lead Screw Map, always adjust the Target increment
and the Target + 1 Inch increment together. For example, if the 21 Inch
increment is to be adjusted then also adjust the 22 Inch increment,
regardless of Forward or Reverse Map.
Example 5:
For Repeatability specification of 0.0004 in.:
RUN TARGET ERROR 2-PASS COMP NEW COMP
2 +23.000000 -0.000080 -1670 -1670
2 +22.000000 -0.000070 -850 -920
2 +21.000000 -0.000120 -520 -640
2 +20.000000 -0.000090 -420 -420
2 +19.000000 -0.000060 -370 -370
4. REPEATABILITY ANALYSIS AND ADJUSTMENT

a. If the Repeatability specification of the four-pass fails then subtract the
Error value at each Inch increment of Run 3 from Run 1 followed by
subtracting the Error value at each Inch increment of Run 4 from Run 2.
14
b. If any of the differences in the Run 1 minus Run 3 calculation exceed one-
fourth of the Repeatability specification then that Inch increment and he
Inch increment + 1 require adjusting in the Forward Lead Screw Map
only.
c. If any of the differences in the Run 2 minus Run 4 calculation exceed one-
fourth of the Repeatability specification then that Inch increment and the
Inch increment + 1 require adjusting in the Reverse Lead Screw Map
only.
d. For each Inch increment which fails the b and/or c tests above, average
the two Error values and add to the compensation in the Lead Screw Map
for that direction.
e. For each Inch increment adjusted in step d, also adjust the Inch increment
+1 value by averaging the two Error values and adding to the
compensation in the Lead Screw Map for that direction.
Example 6:
For a Repeatability specification of 0.0004 in., if the Run 1 and Run 3
data are:
RUN TARGET ERROR
1 +0.000000 +0.000000
1 +1.000000 +0.000020
1 +2.000000 +0.000040
1 +3.000000 +0.000000
1 +4.000000 +0.000020
RUN TARGET ERROR

3 +0.000000 +0.000070
3 +1.000000 +0.000100
3 +2.000000 +0.000160
3 +3.000000 +0.000050
3 +4.000000 +0.000100
Subtract the Error values of Run 3 from Run 1 and for the Inch increment
which exceeds 0.0001 in., compute the average Error (also compute the
average Error for the Inch increment + 1).
DELTA (1-3) AVERAGE (1, 3)

0.000070
0.000080
0.000120 +0.000100
0.000050 +0.000025
0.000080
In the Forward Lead Screw Map, add the average Error to the respective
Inch increments:
INCH COMP NEW COMP

0 0 0
15
1 40 40
2 -10 90
3 80 105
4 120 120
f. After Lead Screw Map adjustment, return to step H, Four-Pass Laser

Measurement. If Repeatability fails a second time, either return to step A,
Machine setup, or notify Engineering.
5. ACCURACY ANALYSIS AND ADJUSTMENT

a. If the Accuracy specification of the four-pass fails then subtract the Error
value at each Inch increment of Run 2 from Run 1 followed by subtracting
the error value at each Inch increment of Run 4 from Run 3.
b. If any of the differences in the Run 1 minus Run 2 or the Run 3 minus
Run 4 calculation exceeds one-fourth of the Accuracy specification then
that Inch increment and the Inch increment +1 require adjustment in both
the Forward and Reverse Lead Screw Maps.
c. For each Inch increment which fails the b test, average the Error values
from Runs 1 and 3 and add to the Forward Lead Screw Map and then also
average the Error values from Runs 2 and 4 and add to the Reverse Lead
Screw Map.
d. For each Inch increment adjusted in step c, also adjust the Inch increment
+1 value by averaging the two Error values and adding to the
compensation in the Lead Screw Map for that direction.
16
Example 7:
For an Accuracy specification of 0.0008 in., if the data for four Runs are:
RUN TARGET ERROR RUN TARGET ERROR
1 +0.000000 +0.000000 2 +0.000000 +0.000170
1 +1.000000 +0.000020 2 +1.000000 +0.000160
1 +2.000000 +0.000040 2 +2.000000 +0.000180
1 +3.000000 +0.000000 2 +3.000000 +0.000150
1 +4.000000 +0.000020 2 +4.000000 +0.000120
RUN TARGET ERROR RUN TARGET ERROR

3 +0.000000 +0.000070 4 +0.000000 +0.000220
3 +1.000000 +0.000060 4 +1.000000 +0.000270
3 +2.000000 +0.000040 4 +2.000000 +0.000280
3 +3.000000 +0.000030 4 +3.000000 +0.000160
3 +4.000000 +0.000060 4 +4.000000 +0.000170
Subtract the error values of Run 2 from Run 1 and Run 4 from Run 3.
INCH DELTA (1-2) INCH DELTA (3-4)
0 0.000170 0 0.000150
1 0.000140 1 0.000210
2 0.000140 2 0.000240
3 0.000150 3 0.000130
4 0.000100 4 0.000110
With the 1 and 2 Inch values in the Run 3 and 4 comparison exceeding
0.0002 in., compute the average Error for the Inch increments for Runs 1
and 3 (also compute the average Error for the Inch increment +1) and add
to the Forward Lead Screw Map; repeat for Runs 2 and 4 in adjusting the
Reverse Lead Screw Map.
INCH AVERAGE (1,3) INCH AVERAGE (2,4)
0 +0.000034 0 +0.000195
1 +0.000040 1 +0.000215
2 +0.000040 2 +0.000230
3 +0.000015 3 +0.000155
4 +0.000040 4 +0.000145
FORWARD REVERSE
INCH COMP NEW COMP INCH COMP NEW COMP
0 0 0 0 1150 1150
1 40 80 1 920 1135
2 50 90 2 890 1120
3 90 105 3 915 1070
4 120 120 4 940 940
17
e. After Lead Screw Map adjustment, return to step H, Four-Pass LASER
Measurement. If Accuracy fails a second time, either return to step A,
Machine Setup, or notify Engineering.
J. SAVING LEAD SCREW COMPENSATION DATA
1. ULTIMAX II
a. Select Auxiliary followed by STORAGE FUNCTIONS, then SELECT
CURRENT STORAGE DEVICE and the appropriate Drive.
b. Insert the Lead Screw Mapping diskette into the Floppy Drive.
c. If necessary, select FORMAT DISK.
d. Select Manual followed by the CHANGE TOOL OR DIAGNOSTICS and
the ATC AND MACHINE DIAGNOSTICS softkeys.
e. Enter the following: "Enter 102 Enter".
f. Select the STORE DATA ON DISKETTE softkey.
g. Select the EXIT softkey to return to Diagnostics.
2. ULTIMAX 3
a. Select Auxiliary followed by STORAGE FUNCTIONS, then CHANGE
CURRENT DRIVE and then FLOPPY DRIVE A.
b. Insert the Formatted Lead Screw Mapping diskette into Floppy Drive.
(Machine Configuration Diskette)
c. Select Manual followed by the CHANGE TOOL OR DIAGNOSTICS and
the ATC AND MACHINE DIAGNOSTICS softkey.
d. Enter the following: "Enter 102 Enter".
e. Select the STORE DATA ON DISK softkey.
f. Select the FLOPPY DRIVE then select the HARD DRIVE softkey.
g. Select the EXIT softkey to return to Diagnostics.
3. Fill out hard copy of Lead Screw Compensation data and store copy inside
Diskette Storage folder.
4. Indicate the Control version number (see Input screen) and the date on the Lead
Screw Mapping diskette and place inside the Diskette Storage folder.
5. Place the Diskette Storage folder inside the Control cabinet.
6. Fill out the LASER COMPENSATION label inside the Control cabinet.
K. RE-LASERING CRITERIA
18
1. MOVE LIMIT SWITCHES
If a limit switch is moved by more than 0.500" then the axis should be re-
certified with the LASER.
2. CHANGING EXECUTIVE/FIRMWARE
Re-certification is not necessary for an Executive or firmware change unless
specifically directed via the ECN documentation or by Engineering.
3. CHANGING AXIS CONTROLLER PCB

Exchanging an axis PCB for another requires that those axes be re-certified.
4. CHANGING SERVO SETUP

Any change to the Servo setup (including Drive amplifier) requires that the axis
be re-certified.
5. CHANGING MECHANICS
Any mechanical adjustment to an axis requires that the axis be re-certified.
19
DATE: MARCH 23, 1989 ISSUE NUMBER: 1066
SUBJECT: DIP SWITCH SETTINGS ON ULTIMAX MILLS SUPERSEDES NUMBER: 267
PRODUCT LINE: ALL ULTIMAX MILLS CONTROLS PAGE 1 OF 9
INTENT: TO PROVIDE UNIFORMITY IN SETTING SWITCH POSITIONS ON ALL ULTIMAX

CONTROL MACHINES.
INDEX
A. 128K MEMORY BOARD (415-0168-001)
B. 256K MEMORY BOARD (415-0168-002)
C. X/Y DUAL AXIS BOARD (415-0176-00X)
D. Z/SPINDLE DUAL AXIS BOARD (415-0176-00X)
E. MACHINE PERSONALITY BOARD (415-0176-001/002)
F. CRT CONTROLLER BOARD (415-0174-001/002)
G. MICRO MEMORY BOARD MAX II
H. CONTROL RELAY PANEL
NOTE: CONTROL MUST BE RESET (POWER DISCONNECTED) TO DETECT A CHANGE IN

SWITCH CONFIGURATION.
ORIGINATOR:
REVISED BY: R. BRYANT
A. 128K MEMORY BOARD: 415-0168-001 SWITCH AND JUMPER CONFIGURATION.
FOR ANY BOARD WITH IT'S ADDRESS STARTING ABOVE 256K, A JUMPER MUST BE
PRESENT BETWEEN E1 AND E2.
Battery Select
Brd 1 0 = OPEN
thru 4
Configurations
S1
6 5 4 3 2 1
1 = CLOSED
Battery Select
A. #1 CLOSED, #2 OPEN = MEMORY SUPPORTED BY +5V SUPPLY AND NOT BATTERY
VOLTAGE BOARD
B. #1 OPEN, #2 CLOSED = MEMORY SUPPORTED BY BATTERIES FOR DATE

RETENTION. (NORMAL SETTING)
Board # Switch Position

6 5 4 3
#1 1 1 1 1
#2 0 1 1 1
#3 1 1 1 1 Jumper E1 to E2
#4 0 1 1 1 Jumper E1 to E2
B. 256K MEMORY BOARD 415-0168-002
NOTE: 1= CLOSED = ON
O= OPEN = OFF
SWITCH # FUNCTION
SW1 BANK SELECT

SW2 READ TIME CLOCK (RTC) SELECT
SW3 UPPER LIMIT BLOCK A
SW4 LOWER LIMIT BLOCK A
SW5 UPPER LIMIT BLOCK B
SW6 LOWER LIMIT BLOCK B
SW7 (1 THRU 3) BATTERY ENABLES
SW7 (4) RTC WRITE PROTECT
SW7 (5) +4 VDC RACK TO RAM ARRAY
SW7 (6) VBB (BATTERIES) TO RAM ARRAY
SW9 RTC SELECT
COMMON SWITCH SETTINGS (ALL 256K BOARDS)
SWITCH # SETTINGS
SW1 1 THRU 4 = CLOSED

SW2 1 THRU 5, 7, 8 = CLOSED; 6= OPEN
SW9 1 THRU 4 = CLOSED
SW7 #1 CLOSED BATTERY 1 IN CIRCUIT
SW7 #4 CLOSED HARDWARE WRITE PROTECTED
SW7 #5 OPEN +5V FROM BUS DISABLED
SW7 #6 CLOSED BATTERY VOLTAGE TO RAM
COMMON WIRE JUMPERS (256K BOARDS)
WIRE JUMPER FUNCTION
REMOVE E28 TO E 27 DISABLES INTIALIZATION GEN. BY +5 MONT

REMOVE E24 TO E35 NEEDED FOR 16 BIT OPERATION
INSTALL E31 TO E32 NEEDED FOR 16 BIT OPERATION
INSTALL E29 TO E30 NEEDED FOR 16 BIT OPERATION
INSTALL E21 TO E22 XACK DELAY AT 310 NSEC
SWITCH SETTINGS TO MAKE PER BOARD
FIRST 256K (MEMORY PCB #1) 0-3FFFF TOTAL
SW3 SW4 SW5 SW6

1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
0 0 0 1 1 1 1 1 1 1 1 1 0 0 0 0 1 1 1 1 1 0 1 1
SECOND 256K (MEMORY PCB #2) 4000-7FFFF
SW3 SW4 SW5 SW6

1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
0 0 0 1 0 1 1 1 1 1 0 1 0 0 0 0 0 1 1 1 1 0 0 1
WARNING: SW7 POSITIONS 1,2,3 MUST BE OPEN BEFORE PCB BATTERY OR

BATTERY FUSES ARE DESOLDERED!
C. DUAL AXIS BOARD (X/Y) 415-0176-00X FOR ALL ULTIMAX MILLS
S1 NOTE: 1 = ON = CLOSED, O = OFF = OPEN 1 2 3 4

BOARD ADDRESS
STANDARD CONFIGURATION On
1,2 AND 3 OPEN
4 CLOSED Off
S2 S3
MSB LSB MSB LSB
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
Sign Bit Scale/Encoder

On = Shorten Travel On = Rotary Encoder
Off = Lengthen Travel Off = Scale
Y axis Leadscrew Comp. Y axis Backlash Comp.
S4 S5
MSB LSB MSB LSB
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

X axis Leadscrew Comp. X axis Backlash Comp.
LEADSCREW ERROR IS COMPENSATED OVER 20".

SIGN BIT IN BACKLASH USED IN BMC 20-50 MACHINES ONLY.
SCALES = .000039" PER BIT (MD3, BMC 10 THRU 15)
ROTARY ENCODERS = .00005" PER BIT (MD-1, KM3 & KM3P)
ROTARY ENCODERS = .0000197 PER BIT (BMC 20-50)
NOTE: BMC 10 THRU 15 USE A ROTARY ENCODER BUT ARE SET AT SCALE VALUES.
SET SWITCHES IN BINARY CONFIGURATION FOR TOTAL ERROR COMPENSATION.
FOR SCALES : ENCODERS : BMC 20-50 Max 1 & 2 until 7.24

POSITION 8 = .000039" 8 = .00005" 8 = .0000197"
7 = .000078" 7 = .00010" 7 = .0000394"
6 = .000156" 6 = .00020" 6 = .0000788"
5 = .000312" 5 = .00040" 5 = .0001576"
4 = .000624" 4 = .00080" 4 = .0003152"
3 = .001248" 3 = .00160" 3 = .0006304"
2 = .002496" 2 = .00320" 2 = .0012608"
EXAMPLE: MD1 HAS .0005" OF BACKLASH. TO STRAP. FOR THIS YOU WOULD TURN ON
POSITIONS 7 AND 5. FOR A DIFFERENT VALUE TURN ON OTHER SWITCHES. THE BIT
VALUE ADDS AS THE SWITCHES ARE TURNED ON.
NOTE: ON BMC 20-50, YOU MAY HAVE A TWO TO ONE PULLEY RATIO
AND THE VALUES HAVE TO BE CUT IN HALF.
D. DUAL AXIS BOARD (Z/SPINDLE) 415-0176-001 USED IN MD1, MD3, BMC10 & 15
S1 NOTE: 1 = ON = CLOSED, O = OFF = OPEN 1 2 3 4
BOARD ADDRESS
STANDARD CONFIGURATION On
1,2 AND 3 OPEN
4 CLOSED Off
S2 On HSS On=Shot pin enabled S3 With 1 turned On 8-4 speeds up dwell.

Off LSS Off = Shot pin disabled 1 turned Off 8-4 Slows down dwell.
LSB
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
Orient Speed Mill type
Adjust On=MD3 8=LSB 4=MSB with a
Off=MD1 Max 70% Change with 4-8 on
Spindle Type/Shotpin Select Tap / Dwell
S4 S5
MSB LSB MSB LSB
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
Z axis Leadscrew Comp. Z axis Backlash Comp.
LEADSCREW ERROR IS COMPENSATED OVER 20".

SIGN BIT IN BACKLASH USED IN BMC 20-50 MACHINES ONLY.
SCALES = .000039" PER BIT (MD3, BMC 10/15)

ROTARY ENCODERS = .00005" PER BIT (MD-1, KM3 & KM3P)
ROTARY ENCODERS = .0000197 PER BIT (BMC 20-50)
NOTE: BMC 10 /15 USE A ROTARY ENCODER BUT ARE SET AT SCALE VALUES.
SET SWITCHES IN BINARY CONFIGURATION FOR TOTAL ERROR COMPENSATION.
FOR SCALES : ENCODERS : BMC 20-50 Max 1 & 2 until 7.24

POSITION 8 = .000039" 8 = .00005" 8 = .0000197"
7 = .000078" 7 = .00010" 7 = .0000394"
6 = .000156" 6 = .00020" 6 = .0000788"
5 = .000312" 5 = .00040" 5 = .0001576"
4 = .000624" 4 = .00080" 4 = .0003152"
3 = .001248" 3 = .00160" 3 = .0006304"
2 = .002496" 2 = .00320" 2 = .0012608"
NOTE: ON BMC 20-50, YOU MAY HAVE A TWO TO ONE PULLEY RATIO
AND THE VALUES WILL HAVE TO BE CUT IN HALF.
S1
E. MACHINE PERSONALITY BOARD 415-
0177-00X
NOTE: 1 = ON = CLOSED
O = OFF = OPEN 1 2 3 4 5 6 7 8
Not used
Spindle Type
On = Hss
Off= Standard
TO CHANGE A ULTIMAX ONE PERSONALITY Tool Changer
On = Enabled
BOARD TO A ULTIMAX TWO BOARD, Off = Disabled
REMOVE THE JUMPER ON TB 6 AND INSTALL
IT TO PINS 4 AND 9. REMOVE THE JUMPER ON
TB7 AND INSTALL IT TO PIN 12 ONLY.
CHANGE THE Machine Pos:1 Pos:2 Pos:3 Pos:4
PART NUMBER
Auto Spindle MD1 0 0 0 0
FROM 415-0177-001
MD3 1 0 0 0
TO 415-0177-002.
MD1 Manual Spindle 0 0 0 1
Training Console 1 1 1 1
BMC 10 0 1 0 0
BMC 10 L 1 1 0 0
BMC 15 0 0 1 0
BMC 10N 1 0 1 0
BMc 10NL 0 1 1 0
KM3 Auto Spindle Speed 1 0 0 1
KM3P Auto Spindle Speed 0 1 0 1
KMC3P 0 0 1 1
KM3 1 0 1 1
KM3P Manual Spindle 0 1 1 1
S2
Not used
Note: To turn off the Auto Spindle for a 1 2 3 4 5 6 7 8

KM3P reverse pos# 3 Not used
B Axis Select
Language Pos Pos Pos On = Present
English 0 0 0 A Axis Select
On = Present Off=Disable
German 1 0 0 Off=Disable
French 0 1 0
Spanish 1 1 1 on S1
S1
Not used
Normal / Local Mode

1 2 3 4 5 6 7 8 On =Normal
Off = Local or Test mode
50/60 Hz On = 60 Hz
Off = 50 Hz
1,2&3 OFF Not used
Baud rate 9600
S3
STANDARD CONFIGURATION: POSITIONS 1 THRU 7 =OFF, POSITION 8 = ON
F. CRT CONTROLLER ONE BOARD (415-0174-001) SWITCH CONFIGURATIONS
NOTE: POSITIONS 4,6,7 ARE NOT CURRENTLY USED.
CRT CONTROLLER TWO BOARD (415-0174-002) SWITCH CONFIGURATIONS
Jumper X1B is jumpered1-2 = Normal mode, Jumper removed = local or test mode.
Jumper X1A 1-2 = 60 Hz, Jumper removed = 50 Hz
G. MICRO MEMORY BOARD FOR MAX2

NOTE: 1 = CLOSED = ON
O = OPEN = OFF
Switch 1 2 3 4 5 6 7 8 Memory
SW1 1 1 1 1 1 1 1 1 BLOCK A LO = $00000
SW2 1 1 0 1 1 1 1 1 BLOCK B LO = $40000
SW3 0 0 1 1 1 1 1 1 BLOCK A HI = $3FFFF
SW4 0 0 0 0 1 1 1 1 BLOCK B HI = $FFFFF
H: CONTROL RELAY PANEL

SW1
Frame type S1 S2 ATC type S3 S4
BMC 30 0 0 20 Station 0 0
SW2 SW3
Spindle Speed S1 S2 ATC Solenold type S1 Spindle Clutch S2
4000 RPM 0 0 Single ended 0 Enable 0
6000 RPM 0 1 Double ended 1 Disable 1
10000 RPM 1 0
3000 RPM 1 1
SW4 ATC Enable/Disable
Rotary Axis Resolution Up Enabled
4000 Ticks/Degree 0 Center Disabled
2000 Ticks/Degree 1 Down Enable
R
757-4001-056
01/27/88 CAD #D8536
SUBJECT: MACHINE LEVELING PROCEDURE

_________________ ________
_________________ ________
____________________________ ________
I. INTENT
To provide a procedure and tooling requirement for properly leveling Machining Centers. To be
used in conjunction with Engineering Document Machine Acceptance to Ship Document.
II. APPLICABILITY
Applicable to all Hurco Machining Centers. This procedure to be used within HURCO facilities
and should be used at customer installations to help achieve factory proven accuracies.
A. Precision Level
B. 14 inch Granite Square
D. Suitable holder to hold indicator in spindle nose
E. Suitable wrench for adjusting leveling bolts
IV. FORMAT
Page 1 - Preliminary Notes and Checks

Page 1 thru 2 - “A” Frame
Page 3 thru 4 - BMC 40/50
PRELIMINARY CHECKS:
1. Always check your Level. They can vary by several thousandths day to day. Temperature, nicks
on the bottom, and touching the vial with your fingers will throw the Level off.
2. Always check the calibration of your Level by turning it 180 degrees and verifying the bubble reads
the same.
3. Always thoroughly clean the Mill Table and the Level using a suitable non-flammable cleaning
solvent.
PRELIMINARY NOTES:
1. Leveling is the first step of Geometries. Careful leveling will make other adjustments easier.
2. Locations of Machine Leveling Bolts can be found in the Machine Owner’s Manual, Section 2.
“A” FRAME
NOTES:
A. With six bolts for leveling, there is more adjustment in the base of the machine, so level and
geometries can be finely adjusted. Slight adjustments make large changes. 1/8 turn could be more
than enough if the machine leveling is done properly.
B. When fine adjusting the geometries, keep in mind that there are more bolts, so changing one has
more effect on the others.
C. To adjust column squareness X to Z, adjust the left side center and rear bolts as a set or the right
side center and rear bolts as a set. Turn the bolts the same amount, remember to turn the left hand
and right hand bolts in opposite directions to split the amount of adjustment.
D. To adjust column squareness Y to Z, use the rear bolts and the center bolts as sets. For example, if
the column is leaning forward at the top, tighten the center bolts and loosen the rear bolts. Be
aware that slight adjustments make large changes.
E. Slight spindle sweep adjustments can be made by using the left side center and rear bolts and the
right side center and rear bolts as sets. In general, if sweep is high in front (+ indicator reading),
tighten left and right center bolts. If high in back, tighten left and right hand rear bolts. If high on
left side, raise left hand center and rear bolts and lower right hand center and rear bolts. If high on
right side, raise right hand center and rear bolts and lower left hand center and rear bolts.
1
F. These adjustments will change column squareness and machine level so work slowly, do not expect
over .0004” change so try to split errors between the various measurements and strive for machine
level within .0005”/ft.
G. X to Y squareness can be altered using left front and right center or right front and left center bolts.
You will have to be very careful with this adjustment. Make very slight adjustments. If
measurements worsen, return to original settings and use opposite pair of bolts. A very slight
adjustment is all that is necessary to correct X to Y squareness.
PROCEDURE:
1. Slowly lower machine onto six (6) mill foot pads.
2. Use a precision level (resolution 0.0005 inch per foot) on the worktable surface to check its level,
both lengthwise and crosswise.
distributed evenly on these six (6) leveling bolts before tightening locknuts.
4. Touch off the six (6) bolts to even pressure and raise evenly at least one (1) turn.
7. With even pressure on all six bolts, level side to side (X axis). Use three bolts on either side as a
10. Repeat the above steps until machine remains level both front to back and side to side. All six bolts
should have even pressure on them.
2
BMC 40/50
NOTES:
A. With eight (8) leveling bolts, more complex patterns and frame adjustments (twist) are possible.
B. Strive for level table and level Y ways.
C. The BMC40 and 50 are heavy so you may not be able to turn just one bolt, so use adjacent bolts to
lift with and always taper off any adjustment by checking the pressure of the adjacent bolts.
D. The machine will sit low in the center, so level with the two front and two back bolts, but bring up
the center as you work, then do side to side.
E. Use all four (4) bolts on either side as a set and check Y ways to avoid problems adjusting the Y
ways.
F. With machine level, recheck pressure of all bolts. Make it as even as possible to start. This will
allow the most adjustment for geometries without putting the frame in a twist or throwing the level
off more than necessary.
G. With eight (8) bolts, use left side rear two (2) and right side rear two (2) bolts for column
squareness and spindle sweep adjustments.
H. Use left side front two (2) and right side front two (2) bolts for Table Flatness and X to Y
squareness adjustments.
I. BMC40 and 50 leveling and geometric adjustments are the same as the BMC30, only consider four
(4) center bolts instead of two (2).
PROCEDURE:
1. Slowly lower machine onto eight (8) mill foot pads.
2. Use a precision level (resolution 0.0005” per foot) on the worktable surface to check its level, both
lengthwise and crosswise.
distributed evenly on these eight (8) leveling bolts before tightening locknuts.
4. Touch off the eight (8) bolts to even pressure and raise evenly at least one (1) turn.
3
7. With even pressure on all eight bolts, level side to side (X axis). Use four bolts on either side as a
10. Repeat the above steps until machine remains level both front to back and side to side. All eight
bolts should have even pressure on them.
4
Engineering Docment 757-4001-056 CAD # D8536
Rev. B ECN #14073

B 14073 Changed description to Machining Center 7/2/97
Omitted BMC20
BMC 2416
D8612 757-4002-201 BMC2416 Machining Center Technical Specifications

D8630 757-4002-218 Procedure for Replacement of 2416 ATC Transmission
D8699 757-4002-282 Installation Procedures for Heidenhein LS176 Linear Scales
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R
757-4002-201 CAD # D8612
SUBJECT: BMC2416 MACHINING CENTER

TECHNICAL SPECIFICATIONS
Originators Date Manager Date

RECORD OF CHANGES
757-4002-201
REV A CAD # D8612

A 14493 Original Release J. DILK 8DEC98
1.0
Machine Capacity
Table Working Surface 30” x 16” 750mm x 400mm
T-Slots 3 x 0.63” 3 x 16mm
On 4.92” centers On 125mm centers
Maximum Load
With Uniform Distribution 760 lb. 350 kg
Enclosure Door Opening 34.5” 876mm
Spindle Center To Column 17.3” 440mm
Spindle Nose To Table
Minimum/Maximum 6” / 26” 152mm / 660mm
(For table and machine clearances, please see attachment “B”)
2.0
Spindle
Type Cartridge, #40 Taper
Speeds 0-8000 rpm
Bearings ABEC Class 7 angular contact
Bearing Lubrication Grease packed

Spindle Motor AC Induction Motor, Dual winding, Fan cooled
Spindle Drive 200VAC, 3 Phase, 50/60 Hz, Regenerative Braking
Spindle Taper #40
Spindle HP 10 HP (7.5 kW) 30 minute rating *
7.5 HP (5.5 kW) continuous rating
Spindle Torque 105 lb-ft (142 Nm) at 500 RPM 30 minute rating *
77 lb-ft (104 Nm) at 500 RPM continuous
Drive Belt Ratio 1-1 Standard

Belt Type 8mm pitch , Poly Chain
Maximum Speed 8000 rpm Standard
Spindle Acceleration Time 0-8000 rpm in 5 seconds

Spindle Decelerate Time 8000-0 rpm in 4 seconds
Spindle Orientation Electronic - Spindle motor encoder
Spindle Air Blast Standard
Spindle Configuration Cartridge-type, flange mounted
(For spindle cross section, see attachment “C”. For motor and spindle HP, speed and torque curves, see attachment “E”)
Note:
* 30 minute rating: Motor can run at this power rating for 15 minutes and must be at no load for the remaining 15
minutes.
3.0
Movement and Ranges
Longitudinal (X) axis 24” 610mm
Cross (Y) axis 16” 406mm
Vertical (Z) axis 20” 508mm
Floor to Table Surface 35” 889mm
4.0
Position/Feed Rates
Rapid Feed Rate:
X axis 940 inches per minute 24m/minute
Y axis 940 inches per minute 24m/minute
Z axis 590 inches per minute 15m/minute
Cutting Feed Rate:

X axis 300 inches per minute 7.6m/minute
Y axis 300 inches per minute 7.6m/mimute
Z axis 300 inches per minute 7.6m/minute
Programming Resolution 0.0001” 0.002mm
5.0
Automatic Tool Changer
Number of Stations 24
Maximum Tool Diameter 3.2” 80mm
Maximum Tool Diameter (Adjacent Sides Empty) 5.0” 127mm
Tool Pocket Pitch 3.2” 81mm
Maximum Tool Length 11.8” 300mm
Maximum Tool Weight 15 lb. 6.8 kg
Adapter ANSI Standard V-Flange
ATC Time:
Tool to tool next station 3 seconds
Chip-to-Chip 2000 rpm 12” Z travel 7 seconds
Tool Selection System Random pot, bi-directional, swing arm
Retention Knob See attachment “D”
Note:
Tools to be loaded in the Automatic Tool Changer by using the spindle. Do not manually load tools directly into the Automatic Tool Changer.
6.0
Axis Movement
Axis Motors:
X AC 48 lb-in
Y AC 48 lb-in
Z AC 74 lb-in, with brake
Axis Thrust: Peak

X 1655 lb. 7.4 kN
Y 1655 lb. 7.4 kN
Z 2800 lb. 12.4 kN
Axis Trust: Continuous

X 650 lb. 2.8 kN
Y 650 lb. 2.8 kN
Z 1000 lb. 4.4 kN
(For motor and spindle HP, speed and torque curves, see attachment “E”.)
Ball Screw Diameter

X 1.26” 32mm
Y 1.26” 32mm
Z 1.57” 40mm
Ball Screw Pitch

X .394” 10mm
Y .394” 10mm
Z .394” 10mm
Ball Screw Mounting
X, Y, and Z Single nut anchored on both ends
Ball Screw Drive System Direct drive

Encoder Mounting Drive motor mounted
Guideway Systems:
X Precision linear ball rails
Y Precision linear ball rails
Z Precision linear ball rails
Bearing Trucks in X axis 4 total, 2 per rail Bearing Trucks in Y
axis 4 total, 2 per rail
Distance between X axis ways (centers) 10” 254mm
Distance between Y axis ways (centers) 17.7” 450mm
Distance between Z axis ways (centers) 12” 305mm
(Telescoping way covers used over all exposed ways)
7.0
Accuracy (at 68o F)
Positioning Accuracy (4 Pass VDI - 3441 method) -/+0.0002” -/+0.005mm
Repeatability (4 Pass VDI - 3441 method) -/+0.0001” -/+0.0025mm
( At final assembly, all machines are laser mapped, contour balanced with ball bar check, and run a capacity cutting test.. Therefore, the machine
is capable of producing these accuracies. If at installation, the machine cannot achieve these accuracies, Hurco will determine the reason for non-
attainment. If the reason is mechanical components, these will be replaced under the warranty. If the reason is improper transportation or rigging,
the customer will be charged at normal service rates. )
8.0
Draw Bar Actuation
Type Air/Oil Cylinder
Stroke 6.5mm
Maximum Force to Unclamp 3300 lb. (14.7 kN)
Air Supply 85-90 PSI (6 bar)
Maximum Clamping Force 2200 lb. (9.8 kN)
Draw Bar Type Gripper finger, Disc springs
9.0
Machine Dimensions
Table Size 30” x 16” 762mm x 400mm
T-Slots
Number 3
Width x Spacing 0.63” @ 4.92” 16mm @ 125mm
(See attachment for slot and table dimensions)
Shipping Dimensions
Width 88.6” 2250mm
Depth 116” 2950mm
Height 101” 2565mm
Operating Dimensions
Width 139.1” 3534mm
Depth [SSM] 137.3” 3488mm
Depth [DSM] 144.4” 3668mm
Height 104.5” 2653mm
Machine Weight (approximate) 8380 lb. 3800 kg
Shipping Weight (approximate) 9040 lb. 4100 kg
(See attachment “A” for machine envelope dimensions)
10.0
Lubrication
Type Positive displacement by electric pump
Lubrication Type See Attachment `F’
Lubrication Volume 2 liter reservoir with float switch to maintain liquid level. Tank should last 80 hours
before refilling.
Lubrication pump 115 VAC, single phase, electric pump with maximum
discharge of 3-6 cc/cycle - 4 cycles per hour
Maximum pump pressure 42 PSI ( 2.9 bar)
11.0
Coolant Facilities
Coolant Tank Capacity 40 gallons 151 liters
Flood Pump Rating 20 gallons/minute 76 liters/minute

Flood Pump Size .25 HP .186 kW
Washdown Pump Size
Full Chip and Coolant Enclosure Standard

Worklights Dual Standard
12.0
Machine Enclosure
Enclosure Door Opening 34.5” 876mm
Left Side (ATC door)

Hinged Door (L x H) 28” x 37.3” 713mm x 948mm
Right Side
Hinged Door (L x H) 28” x 37.3” 713mm x 948mm
Dual Worklights Left side Right side
Chip Pan Side pull-out

Washdown System Standard
13.0
Service Requirements
KVA Rating 19
Voltage Required 200-250 VAC / 60 Hz / 50 amp
Air Requirements 5 CFM @ 80-100 psi 0.14 M3/min. @ 6-8 bar
IMPORTANT:
As with all computer equipment, it is vital that the incoming power be free from high or low voltages, spikes, surges, and noise. The following
are the extremes from normal constant RMS sinusoidal supply voltages the system can tolerate:
Frequency.................................................................................. 47-63 Hz
Impulse Voltage ........................................................................ 200 percent peak voltage up to one msec duration.
One (1) pulse per half cycle maximum.
Voltage Drop............................................................................. Reduction of 20 percent for one cycle or reduction of 50 percent per half cycle. One
(1) drop per second maximum. Deviation from constant voltage will not ±10% of
input voltage. Failure to provide required power parameters may affect warranty.
List of Attachments
Machine Floor Layout ______________________________Attachment A
Table and Clearance _______________________________Attachment B
Spindle Assembly _________________________________Attachment C
Tool Holder and Retention Knob______________________Attachment D
Spindle Torque Charts______________________________Attachment E
Machine Oil Specifications_____________________ Attachment F
R ENGINEERING DOCUMENT
757-4002-218 CAD #D8630
SUBJECT: Procedure for Replacement of 2416 ATC Transmission
Russell Williams 02/15/99 Dave Skrzypczak 02/15/99

757-4002-218 Page 1 of 9 CAD#D8630

RECORD OF CHANGES
757-4002-218 CAD #D8630

A 14547 Original Release RJW 2/15/99 DJS 2/15/99
757-4002-218 Page 2 of 9 CAD#D8630

Objective:
Removal and replacement of swing arm tool changer transmission mechanism only. This procedure does
not include removal or replacement of magazine components.
Tools Required:
1”X6’ closed strap, 3pc 40 taper alignment tool, Swing arm jig, flashlight, Loctite 271 and 242, adjusting
brackets for ATC mounting, hand tools, torque wrench.
Removal Procedure:
1. Unpack and inspect the new tool changer transmission for damage.
2. Remove machine head covers.(Head covers will not have to be removed if unit has pull pins described
below, item 4)
3. Remove front ATC cover.
4. Jog the Z-axis to the point, which allows the best access for locating and removing the M6 alignment
pins. There will be 2-M4 threaded pins at the lowest mounting point for the ATC assembly on both
sides. Remove the alignment pins. Break free the 4-M12 SHCS mounting bolts but do not remove at
this time.
5. Now move the Z-axis to a point that will allow you to remove the transmission with the least
interference. The transmission will need to move toward the head ½” to ¾” and then upward for
removal.
6. Turn power off and remove the air supply to the machine. Also, bleed the air from the storage tank by
opening the valve on the side of the tank.
7. Unwire and tag the wiring at the small electrical box on top/rear of the ATC. Tagging all wiring will
ease re-assembly.
8. With air removed, tag each air line as it is removed from air cylinders or the solenoid manifold.
9. Remove the swing arm by loosening the 4-M6 SHCS from the bottom of the swing arm. Back out the
screws approximately ¼” but do not remove completely. With a rubber or rawhide mallet tap the
swing arm upward. This will free up the compression sleeves. Remove the arm.
10. Attach the 1”X6’ closed strap in slip knot around the top of the air cylinder exiting the topside of the
transmission and attach the other end of the strap to a crane or forklift. Reference figure “a”. Remove
slack in the strap and remove the 4-M12 SHCS holding the transmission to the ATC unit. Remember
the transmission will have to move toward the head a bit before lifting straight up. Do not remove the
2-M6 SHCS with oversized washers as these help locate the transmission up and level.
757-4002-218 Page 3 of 9 CAD#D8630

Figure a
Installation Procedure:
1. Reverse removal procedure back to item 6 skipping item 9 to install new transmission. Do not put the
swing arm back on the shaft.
2. After verifying wiring and air plumbing is connected back properly, power up and calibrate machine.
3. If transmission assembly is shipped without oil. You will need to vent the casting to ease refilling the
transmission with oil. Remove one front upper air cylinder bolt for venting. Reference figure ”b”.
Important: The oil level should not exceed 1/3 full in the sight glass. Oil specification is Mobil
AW32.
757-4002-218 Page 4 of 9 CAD#D8630

Figure b
4. Caution, do not run the ATC without oil. After filling with oil go to ATC diagnostics in the “enter
100 enter” screen. Cycle the ATC manually through the screen sequence (F1-F6 then F5-F2). Each
motion should be smooth and quiet without the swing arm mounted. Verify each movement
corresponds with the selected F function. Cycle through this sequence a couple of times and recheck
the oil level.
5. Now while still in the diagnostics screen, set the ATC height to 0.000 (Z-axis at 0.000).
6. Orient the spindle (if the orient has not been changed it will be close to the correct position).
7. From diagnostics select Tool Pot Down. Install the 3pc 40 taper alignment tool into the pot. The
deepest opening in the tool should align with the stationary key in the tool pot.
8. Select Load arm 60° (shaft will move CCW).
9. Before installing swing arm, remove the tool locking pins. Remove 6-M6 FHSCS from each plate on
the swing arm that holds the locking pins. Carefully remove the pins so you don’t lose the washers if
757-4002-218 Page 5 of 9 CAD#D8630

washers have been used. Pay attention to detail and mark the pieces removed so you can put them
back in the same location.
Note: You should have the 4-M12 SHCS snug but loose enough to move the transmission with a
rawhide or dead blow hammer.
10. Slide the swing arm onto the shaft and then install the arm alignment jig. Reference figure “c”. The
SHCS holding the alignment jig onto the bottom of the shaft will aid in moving the arm up and down
and will hold the arm in position during alignment. Turn the swing arm by hand into the alignment
tool in the tool pot.
Note: You may have to tap the transmission mounting bracket back or forward to allow the swing arm
to engage properly on the tool. Keep in mind the alignment jig will allow the arm to adjust up or
down.
Figure c
11. The swing arm should be able to slide onto and off of the tool freely. Check your height on the left
side of the tool, making sure the extruded key in the swing arm is centered in the groove of the tool.
757-4002-218 Page 6 of 9 CAD#D8630

12. When the alignment is done, remove one M12 SHCS at a time and apply a small amount of 271
Loctite and torque to 100 Ft. Lbs. After all four bolts are tightened recheck the alignment of the
swing arm to the tool in the pot.
13. Now tighten the 4-M6 SHCS in opposing sequence with the arm engaged into the tool. Torque to 12
Ft. Lbs..(Tighten each bolt gradually so you do not cock arm on shaft)
14. In the diagnostic screen select Load arm 0° (the arm will move to home position).
15. With the tool pot still down and the tool in the pot, select Load arm 60°. The arm should engage the
tool without banging into the tool (no tool deflection). If tool deflection is noticed, you will need to
loosen the 4-M6 SHCS and push the swing arm away from the tool .010 to .020 and re-torque to 12
Ft. Lbs. Repeat this step until no deflection is noticed.
16. Remove the arm alignment jig.
17. Select Load arm 0° and remove the 3pc tool from the tool pot. Disassemble the 3pc tool and install
the tapered piece into the spindle.
18. Orient the spindle. The tool pot should be down and empty. Select Load arm 60°.
19. Now slide the center section of the 3pc tool into the swing arm opening under spindle. The shallow or
dimpled side of this piece should be facing the swing arm key. Make sure the center section is seated
well into the arm.
20. Move the Z-axis down slowly so the tapered piece in the spindle is about .010 above the center
section. Verify correct orient by watching the drive key alignment to the center section of the 3pc tool
as you move Z down.
21. Install the threaded piece of the 3pc-alignment tool into the tapered section. This should not cause
movement of the center section. If the tool will not thread into the tapered section, you will need to
adjust the complete ATC unit itself. The alignment of the swing arm to the spindle must be corrected
using the ATC support arm mounting. Do Not adjust the transmission mounting or the swing arm
mounting for this alignment.
Note 1: ATC support arm mounting to the column is used to move the ATC unit in the Y directions.
This mounting uses M16 SHCS torque to 210 Ft. Lbs.
Note 2: ATC mounting to support arm is used to move the ATC unit in the X directions.
This mounting uses M12 SHCS torque to 90 Ft. Lbs.
Note 3: Only loosen the fasteners just enough so that adjusting brackets can push or pull the assembly
into position. Remember to re-torque the fasteners for alignment checks.
22. With the ATC aligned and all fasteners torqued to specification, remove the 3pc alignment tool and
return the ATC to home position.
757-4002-218 Page 7 of 9 CAD#D8630

23. Install the tool locking pins, washers and springs. Re-install the 6-M6 FHSCS on each plate on the
swing arm. Check to make sure the locking pins operate correctly (do not stick).
24. Set the ATC height with no tooling in the spindle. Orient the spindle. Select Tool pot down. Select
Load arm to 60°. Move the Z-axis so that the spindle nose is 6mm (.236”) above the top of the swing
arm. Store the ATC height in the diagnostic screen. Select Load arm 0° and install a small standard
tool into the spindle. Select Load arm 60°. If the height is correct, and the tool knockout distance is
correct, you will be able to clamp and unclamp the tool without deflecting the swing arm up or down.
If the swing arm is deflecting up or down, adjust the ATC height up or down according to the swing
arm deflection. Remember to store the ATC height.
25. In the diagnostics screen manually cycle the ATC through the tool change sequence. If the motion
from 0° to 60° is too fast or too slow you can adjust the top cylinder that mounts horizontally on the
backside of the transmission to correct. If 180° motion is too fast or too slow adjust the cylinder just
below the 0° to 60° cylinder. Reference figure “d”
Note: The 0° to 60° cylinder has two air flow adjusting screws. The one furthest away from the
transmission is for 0° motion, the closest adjustment is for 60°. The 180° cylinder has only one
adjustment screw for the 180° motion. Turning any adjusting screws CW will decrease flow and
turning CCW will increase flow. Turn the adjusting screws on these two cylinders full CCW, then one
full turn CW for a preliminary adjustment. Check the speed of motion and adjust for fast, but smooth
motion. Reference figure ”d”.
Figure d
757-4002-218 Page 8 of 9 CAD#D8630

26. Load the ATC with tooling and cycle to verify correct operation. While the ATC is cycling and after
operation has been verified, check the FLR unit lubricator for one drop per 8 to 10 changes.
27. After ATC operation has been completed, you should re-pin the transmission to the magazine unit at
two points. You should attempt to pin at the lower transmission mounting points. If you cannot pin
at the lower location, you should lower the Z-axis and pin at the two upper transmission mounting
points. You should use M6 X 500mm or ¼” X 2” pull pins.
28. Recheck the oil level in the plastic sight-glass on the transmission assembly. The oil level should be
1/3 full with the ATC in home position.
29. Reinstall covers on the ATC and the head assembly.
Caution: When reinstalling the ATC cover, use the shortest fasteners where the cover bolts into
the magazine assembly. Damage can result to the plastic tool pots if the wrong length fasteners are
installed.
757-4002-218 Page 9 of 9 CAD#D8630

757-4002-282 CAD #D8699
SUBJECT: INSTALLATION PROCEDURES

FOR HEIDENHAIN LS-176 LINEAR SCALES.
VMX24

Mihai Leahu _________________ ________
Dan Ornelas _________________ ________ ____________________________ ________

757-4002-282 VMX24 Linear Scales Rev. A page1

Rev ECN # Revision Description Pg. # Date By Appv.
.
A 15125 Original Issue 11-8-00 ML/
DO

INSTALLATION PROCEDURES
1.0 INTRODUCTION
This document is intended as a guideline to install Heidenhain Linear Scales on

VMX24 series machines. This option can be ordered as one complete package
Linear Scales. This procedure can be used for installing a complete option package
of Linear Scales.
1.1 REFERENCE DOCUMENTS/DRAWINGS
a) HEIDENHAIN Mounting Instruction Manual

b) 003-1018-011, ASS’Y, OPTION LINEAR SCALES, VMX24
c) 003-1018-009, KIT, LINEAR SCALES, VMX24
d) 003-1018-008, ASS’Y, LINEAR SCALES, VMX/VSX24 (OPTION)
2.0 ASSEMBLY/BILL OF MATERIAL.

BILL OF MATERIAL FOR ASS’Y, 003-1018-008, ASS’Y, LINEAR SCALES FOR VMX24.
1 757-4005-038 PARAMETERS, VMX24 LINEAR SCALES 39

10 406-0802-080 CONTACT, MALE SILVER 38
1 757-4002-282 INSTALLATION PROCEDURE 37
2 108-5004-004 BHSCS, M6 X 1.0 P X 16 LG. 36
1 803-1000-109 PLATE, Z LINEAR SCALE 35
1 803-1000-108 PLATE, X LINEAR SCALE, RIGHT 34
1 803-1000-107 PLATE, X LINEAR SCALE, LEFT 33
19 406-5001-006 TIE WRAP, MEDIUM 32
4 110-5001-002 WASHER, M4 FLAT 31
4 101-5021-010 SHCS, M4 X 0.7 P X 25 LG. 30
3 FT 508-2001-011 TUBING, 12 mm O.D. NYLON 29
1 506-3009-049 UNION, ELBOW 28
1 REF 416-0250-082 UNIT, COMPRESSED AIR 27
1 506-3001-050 COUPLING MALE 26
1 506-6053-009 STREET TEE, 3/8” F X 3/8” F X 3/8” M PT 25
2 101-5008-006 SHCS, M6 X 1.0 P X 20 LG. 24
1 803-1002-210 BRACKET, ADJUSTING, Z READER HEAD 23
22
4 101-5007-003 SHCS, M5 X 0.8 P X 12 LG. 21
1 803-1002-164 BRACKET, Z READER HEAD 20
1 REF 423-4401-444 HARNESS, Z-AXIS SERVO DRIVE, SCALE 19
1 803-1000-093 PLATE, Z LINEAR SCALE 18
1 803-1003-092 COVER, Y LINEAR SCALE 17
1 REF 423-4401-410 HARNESS, Y-AXIS SERVO DRIVE, SCALE 16
32 101-5008-008 SHCS, M6 X 1.0 P X 25 LG. 15
1 803-1002-165 BRACKET, ADJUSTING, Y READER HEAD 14
1 803-6001-052 BRACKET, Y READER HEAD 13
1 REF 416-0250-054 SEALED, LINEAR ENCODER, Y AXIS 12

1 REF 423-4401-409 HARNESS, X-AXIS SERVO DRIVE, SCALE 11
8 101-5008-004 SHCS, M6 X 1.0 P X 16 LG. 10
1 803-1000-094 BRACKET, ADJUSTING, X READER HEAD 9
26 110-5001-004 WASHER, M6 FLAT 8
26 110-0046-007 LOCKWASHER, M6 HELICAL SPRING 7
2 117-5013-001 NUT, M6 X 1.0 P HEX 6
2 101-5008-012 SHCS, M6 X 1.0 P X 45 LG. 5
1 803-1002-209 BRACKET, X READER HEAD 4
29 101-5007-008 SHCS, M5 X 0.8 P X 25 LG. 2
2 REF 416-0250-055 SEALED, LINEAR ENCODER, X/Z AXIS 1
QTY PART NUMBER ITEM DESCRIPTION ITEM REV.
PARTS LIST
3.0 INSTALLATION PROCEDURE.
3.1 MECHANICAL INSTALL PROCEDURE FOR ASS’Y, LINEAR SCALES, DRAWING

#003-1018-008.
4. “X” AXIS SCALE INSTALLATION
VMX24 series machines, are designed to accept this option.
4.1.1. Remove the front table guard.

4.1.2. Remove the left and right “X” axis telescoping way covers.
4.1.3. If necessary, remove the “X” axis limit switch and bracket. Limit
switch does not need to be disconnected.
4.1.4 Locate mounting holes for the reader head and scale brackets. If the
mounting holes have not been drilled and tapped, use Bracket,
Adjusting X Reader Head, item #9, Bracket X Reader Head, item #4,
Plate, X Linear Scale, Left, item #33 and Plate, X Linear Scale, Right
item #34 to locate the holes. Use also Table and Saddle details to
locate those holes.
4.1.5 Install Bracket, Adjusting X Reader Head, item #9 on Table.
4.1.6 Install Reader Head and Bracket, X Reader Head, items #1, #4.
4.1.7 Install limit switch mounting bracket.
4.1.8 Clean the Scale mounting surface.
4.1.9 Install Linear scale for X axis on Saddle.
4.1.10 Install items #33, #34, Plate, X Linear Scales Left/Right on Saddle.
4.1.11 With the scale assembly installed, verify that the mounting holes for the
reader head and mounting brackets are aligned. Verify and measure the
parallelism with X axis travel.

4.1.12 Reference the HEIDENHAIN Mounting Instruction Manual for alignment of
the scale and reader head.
4.1.13 The linear scales are equipped with white plastic strips that mount in a slot
along the length of the housing. A brown magnetic strip is placed in the slot
to invoke the reporting of the next marker pulse. The slot, which holds the
strips, must be completely filled, so as to prevent significant movement of
the strips. The magnetic strips are to be placed as follows:
X Axis – Third strip from (-) travel end (white, white, brown)
4.1.14 “X” axis travel verification (VMX24). Distance between hard stops 640
mm.
4.1.15 Routing of harness 423-4401-409 may be done from scale or cabinet end
first. If from scale end, disconnect HEIDENHAIN cable (416-0250-041)
from MX4 connector and route from scale back to cabinet. Be sure to re-
insert pins back in same MX4 connector locations.
4.1.16 Connect the air from Unit Compressed Air to scale assembly. Reference the
HEIDENHAIN Mounting Instruction Manual.
4.1.17 Re-install all the covers in reverse order.
5. “Y” AXIS SCALE INSTALLATION

5.1.1 Remove front and rear telescoping cover.
5.1.2 If necessary, remove the “Y” axis limit switch and bracket. Limit switch does
not need to be disconnected
5.1.3 Locate mounting holes for the reader head and scale brackets. If the mounting
holes have not been drilled and tapped, use Bracket, adjusting Y Reader Head,
item #14, Bracket Y Reader Head, item #13, to locate the holes. Use also
Saddle and Base to locate those holes.
5.1.4 Install Bracket, Adjusting Y Reader Head, item #14 on Saddle.
5.1.5 Install Reader Head and Bracket, Y Reader Head, items #12, #13.
5.1.8 Install Linear Scale for Y axis on Base.
5.1.9 Install item #17, Cover Y Linear Scale on Base.
5.1.10 With the scale assembly installed, verify that the mounting holes for the reader
head and mounting brackets are aligned. Verify and measure the parallelism
with Y axis travel.
5.1.11 Reference the HEIDENHAIN Mounting Instruction Manual for alignment of the
scale and reader head.
Y Axis – Third strip from (-) travel end (white, white, brown)
5.1.13 “Y” axis travel verification (VMX24). Distance between hard stops 540 mm
5.1.14 Routing of harness 423-4401-410 may be done from scale or cabinet end first.
If from scale end, disconnect HEIDENHAIN cable (416-0250-041) from
MX4 connector and route from scale back to cabinet. Be sure to re-insert pins
back in same MX4 connector locations.
6. “Z” AXIS SCALE INSTALLATION
6.1.1. Move the Head up and down, so you can reach all the mounting holes
for the Linear Scale. Locate mounting holes for the reader head and
scale brackets, item #20, Bracket Z Reader Head, item #23, Bracket,
Adjusting, Z Reader Head, and item #35, Plate Z Linear Scales, if the
mounting holes have not been drilled and tapped. Use also Column and
Head details to locate those holes.
6.1.2. Install the reader head bracket, item #23 on Head.
6.1.3. Install the scale mounting bracket, item #20 to the Reader Head.
6.1.4. Install item #35, Plate Z Linear Scales.
6.1.5. Clean the Scale mounting surface.
6.1.6. Install Linear Scale for Z axis on Column.
6.1.7. With the scale assembly installed, verify that the mounting holes for
the reader head and mounting brackets are aligned. Verify and measure
the parallelism with Z axis travel.
6.1.8. Reference the HEIDENHAIN Mounting Instruction Manual for alignment of
6.1.9. The linear scales are equipped with white plastic strips that mount in a slot
Z Axis – Third strip from (-) travel end (white, white, brown)
6.1.10. “Z” axis travel verification (VMX24). Distance between hard stops 640
mm.
6.1.11. Routing of harness 423-4401-444 may be done from scale or cabinet end
6.1.12. Connect the air from Unit Compressed air to scale assembly. Reference the
HEIDENHAIN Mounting Instruction Manual
7. CONTROL PARAMETERS
Enter Parameters, VMX24 Linear Scales from document 757-4005-038. Changes
are primarily found in sections F1- CNC Configuration and F6 – Servo Tuning. Section
“8” will discuss special procedure for Vertical Parmeters Travel Limit and Home
Position.
8. ELECTRICAL CALIBRATION
Special calibration procedures must be used when setting up the machine Travel Limit
and Home Position. Because the marker pulse location is not as near the travel limit as is
the case with leadscrew encoders, the following technique should be used.
Example: With leadscrew encoders the X, Y and Z axis CALIBRATE HOME

POSITION = 0. (Assumes 16.0 mm Limit Switch to Marker distance for all three
Axes).
8.1. Change F96:0, X-axis Limit Switch to Marker Distance (mm) = 50.0000
8.2. Change F96:1, Y-axis Limit Switch to Marker Distance (mm) = 50.0000
8.3. Change F96:2, Z-axis Limit Switch to Marker Distance (mm) = 50.0000
8.4. Perform and allow to complete machine calibration. All three linear axes
should read 0.000 on DRO. Each axis will be positioned at the linear scale
marker position, aligned with brown magnetic strip. This will be approximately
30 to 60 mm from the limit switch.
8.5. For Z-Axis
8.5.1. Initiate another Calibrate cycle.
8.5.2. While Z-axis is still on Z+ limit switch (as indicated on DRO) abort the cycle
with CYCLE STOP button.
8.5.3. Slowly begin handwheel jogging Z-axis in negative direction (x1 mode) and stop
when Z+ limit switch indication is no longer displayed. Note Z-axis
MACHINE POSITION on DRO [i.e. +46.0].
8.5.4. Subtract 16 mm from current position [46.0-16.0 = +30.0].
8.5.5. Multiply result by –1. This results in Z CALIBRATE HOME POSITION
value [-30.0 mm].
8.6. For X-Axis
8.6.2. While Z axis calibrates watch X- and Y- limit switches to be “true” (as
indicated on DRO), abort the cycle with CYCLE STOP button.
8.6.3. Slowly begin handwheel jogging X-axis in positive direction (x1 mode) and stop
when X- limit switch indication is no longer displayed. Note X-axis
MACHINE POSITION on DRO [i.e. -36.5].
8.6.4. Add 16 mm from current position [-36.5+16.0 = -20.5].
8.6.5. Multiply result by –1. This results in X CALIBRATE HOME POSITION
value [20.5 mm].
8.7. For Y-Axis
8.7.1. With the Y-axis still on the Y- limit switch, slowly begin handwheel jogging Y-
axis in positive direction (x1 mode) and stop when Y- limit switch indication is
no longer displayed. Note Y-axis MACHINE POSITION on DRO [i.e. –
42.3]
8.7.2. Add 16 mm from current position [-42.3+16 = -26.3]
8.7.3. Multiply result by –1. This results in Y CALIBRATE HOME POSITION
value [26.3].
8.8. Note: Any machine specific dimensions (Tool Change Height, TPS Fixture Position, TPS
Access Position, etc.) will need to be redefined.
9. AIR PURGE ASSEMBLY
9.1 Locate and mount per the drawing “ASSEMBLY, LINEAR SCALE”.
9.2 Unlubricated Air Supply to scale filter/regulator.
9.3 Reference HEIDENHAIN Mounting Instruction Manual for operation.

BMC30 / VMX30
D8298 757-4001-128 Specifications for 30” Bed Machining Centers / Frame “A”
D8700 757-4002-283 Installation Procedures for LS176 Heidenhain Linear Scales
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757-4001-128 REV: A ECN #13198
DATE: August 5, 1994 CAD #D8298
Rev. ECN No. Rev. Description Page # Date

SUBJECT: SPECIFICATIONS FOR 30" BED MACHINING CENTERS - FRAME

A FAMILY OF MACHINING CENTERS
SCOPE: This document provides a guideline for development and manufacture of 30" Bed
Machining Centers. Through mutual efforts of Hurco and the contract
manufacturer, the contents of this document shall assist the contract manufacturer
to supply quality Machining Centers. This document shall be regarded as a bench
mark for a variety of machines that are defined in the sections below, using a
common frame.
1.0 INTRODUCTION
This specification describes a 30" CNC bed machining center together with associated
design, manufacture, geometry and test criteria and specifications. This document shall also
help apply electrical/electronic apparatus, equipment or systems to the machine in a uniform
method.
The 30" bed machining centers will be used to machine ferrous as well as non-ferrous
materials and will not be limited to certain materials only.
The basic components of a 30" bed machining center shall consist of a base, column, saddle,
ballscrew assembly for saddle travel, table, ballscrew assembly for table travel, head, the
ballscrew assembly for head travel, ATC (Automatic Tool Changer) the auto lube,
pneumatic and the coolant systems, full enclosure, electrical power head cabinet and the
CNC control, and all motors and drives. The X and Y axis shall have linear rails and
bearings for the linear motion while the Z axes will have hardened and ground cast ways.

Himat Patel ___________________ ________
Joe Winkler ___________________ ________ ______________________ ________
The cast iron frame described in this specification to build a 30" bed machining center shall
be used to produce a family of bed machining centers to cover a wide range of Global
applications and controls. These machines will be defined into the following categories.
1.1 Value Advantage Machining Centers
These machining centers will be called BMC 30/D and will consist of the following
configuration.
1.1.1 Spindle Motors and Drives shall be AC.

1.1.2 The Axes Motors and Drives shall be DC.
1.1.3 The control shall be Delta 2000.
1.1.4 Other specifications of the machining center shall be as described in Section
3.0 and separate drawing sets.
1.2 Performance Advantage Machining Centers
These machining centers will be called BMC 30/M for the standard machine and
BMC 30HT/M for an optional high torque machine. These machines will consist of
the following basic configuration.

1.2.2 The Axis Motors and Drives shall be AC.
1.2.3 The control shall be Ultimax 3 with ISA.
1.2.4 Other specifications of the machining center shall be described in Section 3.0
and separate drawing sets.
1.3 Production Advantage Machining Centers
These machining centers will be called BAR 30/D for the standard machine. The
spindle shall be a quill type and shall have a taper conforming to DIN 63 standards
and specifications. The BAR 30/D machines will consist of the following basic
configuration:

1.3.2 The Axis Motors and Drives shall be AC.
1.3.3 The control shall be a Delta 3000
1.3.4 Other specification of the machining center shall be as described in Section
3.0 and separate drawing sets.
1.3.5 An optional BAR 30/F shall have a Fanuc control.
Page 2
2.0 CODE COMPLIANCES
The 30” Bed machining centers shall be in general compliance to the following codes:
2.1 ISO 9000. The contract manufacture shall follow the guidelines of these
specifications whether the contract manufacturer has an ISO 9000 Certification or
not.
2.2 The American National Standards Institute (ANSI) B5.18 - 1972 Spindles, Noses
and Arbors for Milling Machines B46.1, Surface Texture.
2.3 The American National Standards Institute (ANSI) B15.1 - 1972, Safety Standards
for Mechanical Power Transmission.
2.4 Occupational Safety and Health Act of 1970, as it pertains to the general safety
requirements for belts, drives etc. for guarding..
2.5 “NMTBA” Noise Measuring Techniques.
2.5.1 Sound Level Measurement of the Machinery/Spindle is to be taken in

unloaded mode after the machine has been checked, test run and certified.
Sound pressure levels are not to exceed 80 dbA time weighted average with a
variation of ±5 dbA.
2.6 JIC Standards for General Purpose Machine Tools, EGP1-67
2.7 JIC Pneumatic Standards for Industrial Equipment
2.8 EN 60204-1 Electrical Equipment of Industrial Machines, European Standard for

European market.
2.9 “CE” compliance for machines for European market.
2.10 UL 1063-1981 Standard for Safety, Machine Tool Wires and Cables, Underwriters
Laboratories Inc.
2.11 IEC, International Electrotechnical Commission
2.12 NEMA, National Electrical Manufacturers Association
2.13 NFPA 79 Electrical Standard for Industrial Machinery, National Fire Protection
Association
NOTE: Where specific electrical provisions are not made in these specifications,
the provisions of the National Electric Code shall be observed.
Page 3
3.0 GENERAL SPECIFICATIONS AND OPTIONS LIST
The 30” Bed machining centers which are known as Frame A machines, are designated Metric machines. Even though these
machines are Metric machines, there shall be hardware and components in inches that are either not readily available or totally
unavailable in Metric.
3.1 The following are the general specifications of the machines defined in Section 1.1, 1.2 and 1.3. All dimensions are in Inch
system with Metric in parenthesis.
Description BMC 30/D BMC 30/M BMC 30HT BAR 30/D

1. X-Axis 30 (762) 30 (762) 30 (762) 30 (762)
2. Y-Axis 18 (457) 18 (457) 18 (457) 18 (457)
3. Z-Axis 24 (610) 24 (610) 24 (610) 8 + 24 (203 + 610))
4. Table Surface 40 x 13.7 (1016 x 348) 40 x 13.7 (1016 x 348) 40 x 13.7 (1016 x 348) 40 x 13.7 (1016 x 348)
5. Overall Table Size 43.8 x 15.7 (1112 x 43.8 x 15.7 (1112 x 43.8 x 15.7 (1112 x 43.8 x 15.7 (1112 x
399) 399) 399) 399)
6. T-Slots 4.92 Ctr (125) 4.92 Ctr (125) 4.92 Ctr (125) 4.92 Ctr (125)
7. Table Load 1100# (500kg) 1100# (500kg) 1100# (500kg) 1100# (500kg)
8. Spindle Motor 10HP Dual Winding 10HP Dual Winding 15HP Dual Winding 15HP Dual Winding
Spindle Motor RPM/Base Speed 8,000/500 8,000/500 8,000/600 8,000/600
9. Spindle 8,000 8,000 8,000 8,000
10. Bearings ABEC-7 ABEC-7 ABEC-7 ABEC-7
11. Spindle Nose to Table “Min” 6 (152) 6 (152) 6 (152) 3 (76)
12. Spindle Nose to Table “Max” 30 (762) 30 (762) 30 (762) 33 (838)
13. Spindle Taper/Tool holder #40/CAT-V #40/CAT-V #40/CAT-V DIN 63
14. Spindle System, Electronic Orient/ Yes Yes Yes Yes
Rigid Tap
15. Spindle Torque at Motor Base 105ft-lb (142 N-M) 105ft-lb (142 N-M) 131ft-lb (177.5 N-M) 87ft-lb (118 N-M)
Speed 500 RPM 500 RPM 600 RPM 600 RPM
16. ATC Stations 24 24 24 22
Page 4
17. ATC - Tool Diameter 3.9 (99) 3.9 (99) 3.9 (99) 3.7 (94)
ATC - Tool Length 12 (305) 12 (305) 12 (305) 12 (305)
18. ATC - Tool Weight 15# (6.8kg) 15# (6.8kg) 15# (6.8kg) 15# (6.8kg)
19. Max Weight in Carousel 200# (91kg) 200# (91kg) 200# (91kg) 200# (91kg)
20. ATC (Spec) Chip to Chip Tool 12 sec 10 sec 10 sec 4.5 sec
Change Time
21. ATC to be Chip Free Yes Yes Yes Yes
22. Coolant Flood Flood Flood Flood
23. Rapid Traverse X&Y 591”/min (15m/min) 945”/min (24m/min) 945”/min (24m/min) 945”/min (24m/min)
Z 394”/min (10m/min) 591”/min (15m/min) 591”/min (15m/min) 980”/min (25m/min)
24. Axis Motors 40lb-in (0.45kg-m) DC 52lb-in (0.6kg-m) AC 78lb-in (0.9kg-m) AC 52lb-in (0.6kg-m) AC
25. Feedback Encoder Encoder Encoder Encoder
26. Auto Lube Yes Yes Yes Yes
27. Auto Lube Pump Capacity .5 Gal (2 Liter) .5 Gal (2 Liter) .5 Gal (2 Liter) .5 Gal (2 Liter)
15 Min cycle 15 Min cycle 15 Min cycle 15 Min cycle
28. Cast Iron & Way System
- X Linear Yes Yes Yes Yes
- Y Linear Yes Yes Yes Yes
- Z Solid Ground (Rectangular) Yes Yes Yes Yes
29. Casting to Have Least Number of Yes Yes Yes Yes
Cores
30. Frame Machined for Scales Yes Yes Yes Yes
31. Counter Weight Yes Yes Yes No
32. Elect. Cabinet 230 Single Volt Yes Yes Yes Yes
33. Convection Cooling Yes Yes Yes Yes
34. Single Cabinet Design with Yes Yes Yes Yes
Commonality
Page 5
35. Coolant Pump Attached to Coolant 3 Pumps 3 Pumps 3 Pumps 3 Pumps
Tank
1) Flood Coolant
2) Flood, Chip Wash
36. Full Enclosure Std Std Std Std
- Sheet Metal Enclosure Yes Yes Yes Yes
- Fiberglass Hood Yes Yes Yes Yes
- Decals and Stripes Yes Yes Yes Yes
- Gaskets/Seals Yes Yes Yes Yes
- Rear Side Panels No Yes Yes Yes
37. Head Cover Yes Yes Yes Yes (2)
38. Frame and Full Enclosure Design to
accommodate: Yes Yes Yes Yes
- Front Load Pallet System Yes Yes Yes Yes
- Side Load Pallet System Yes Yes Yes Yes
- O/H Loading of Part/Fixture Yes Yes Yes Yes
39. Ship Complete with Control Yes Yes Yes Yes
40. Metric Throughout where possible Yes Yes Yes Yes
41. Double Nut 12mm Pitch Ball Yes Yes Yes Yes (lead)
Screws
42. 60° Angular Contact Precision Yes Yes Yes Yes
Bearings
43. Coolant Tank w/Easy Access to Yes Yes Yes Yes
Remove Chips
44. X, Y, Z Switches to be Honeywell Yes Yes Yes Yes
or Equivalent
45. X, Y, Z Way Cover with New Yes Yes Yes Yes
Concept for “Y”
46. Control Pendant - Ship w/ Machine Yes Yes Yes Yes
(Wired)
Page 6
47. Control Swing Arm Mounted to Yes Yes Yes Yes
Base
48. Complete Pneumatic System, with Yes Yes Yes Yes
FRL unit
49. Three Coats of Paint, 1 Primer, 2 Yes Yes Yes Yes
Finish Coats
50. All Electr Including PC Wiring & Yes Yes Yes Yes
Conduits
51. Work Lights (2) Std Std Std Std
52. Indexer Interface Std Std Std Std
53. Axis motors and Drives DC AC AC AC
Page 7
3.2 The design of the machine and full enclosure shall accommodate the following
options for all models unless specified.
3.2.1 Head Design to accommodate Gear Box (ZF), or equivalent

3.2.2 Rigid Tapping
3.2.3 Air Conditioner for Power Cabinet (BMC 20 size)
3.2.4 Probing for Part Set-up
3.2.5 Probing for Tool Set-up
3.2.6 Digitize Part Inspection (for BMC 30/D and BAR 30/D Only)
3.2.7 High Torque Options and Spindles
3.2.7.1 15 HP Dual Winding Motor for BMC 30/M

3.2.7.2 12,000 RPM Spindle
3.2.8 Special Voltage Transformer (GE)

3.2.9 Indexer (SMW)
3.2.10 Rotary Table (4th Axis) Interface Only
3.2.11 Rotary Tables
3.2.12 Pallet Changers
3.2.13.1 Front Load, Manual (SMW)

3.2.13.2 Side Load, Automatic (Eimeldingen)
3.2.13 Linear Scales for all 3 Axes (Heidenhain)

3.2.14 Chip Conveyor with Manual Switch (External)
3.2.15 Special Tests for Machine Certification
3.2.16 Coolant through the Spindle
3.2.17 Control Options (Not Included as Part of this Specification)
Page 8
4.0 DESIGN
4.1 The design and manufacture of the Frame A machines shall comply with the high
standards of material and workmanship associated with high precision industrial
machinery. All components shall be constructed for long life under continuous
service.
4.2 The overall design of the Frame A machines shall place emphasis on the accessibility,
maintainability and/or adjustment of components without major disassembly.
4.3 The overall design of the Frame A machines shall also place emphasis on esthetics
and the surface finish. All the cast iron frame components and other accessories
mounted to the cast iron frames must have a “glass smooth” finish.
4.4 The design of Frame A machines shall place emphasis on commonality so that
common components could be used not only within the family (various models) but
also within the machine itself (e.g., a common ballscrew must be used for all the
axes). Emphasis must be placed on inventory, storage, replacement and
serviceability when designing for commonality.
4.5 The design of the Frame A machines was originated by Hurco Manufacturing and is
for Hurco’s use only. Once the final drawings are released by Hurco, the contract
manufacturer shall not make any changes to the drawings, procedures and the frame
without PRIOR WRITTEN APPROVAL FROM HURCO. Under no
circumstances shall the contract manufacturer substitute components or make
changes in component layout without submitting the proposed changes to Hurco for
review and approval.
4.6 An appendix shall be added to this specification describing the CE Requirements for
the European countries. These requirements will also be supported by a separate
drawing set defining the CE Requirements.
Page 9
5.0 OPERATING CONDITIONS
5.1 Environment
5.1.1 The 30” Bed Mill Centers may be subjected to machining of abrasive
materials such as fiberglass, graphite and other composite materials,
therefore, shall be designed and constructed to operate continuously in such
environment.
5.1.2 The 30" Bed Mill Centers may operate in an environment having an ambient
temperature of 50°F to 120°F and relative humidity of 1 to 95%.
5.2 Services and Utilities
5.2.1 The air supply to the machine shall be at 90 PSI ±10%.
5.2.2 The voltage variations shall be ±10%.
5.2.3 The oil lubrication and pneumatic systems shall be supplied as discussed in
section 6.23.
5.3 Component Ratings
5.3.1 The lube pump shall be rated at 115 VAC, single phase, 50/60 Hz.
5.3.2 The coolant pump shall be rated at 230/380 VAC, 3-phase, 50/60 Hz.
5.3.3 Relays to be 24 VDC.
5.3.4 Solenoids and contactors shall be 24 VDC (low consumption coils preferred).
Some components (defined by Hurco) shall be 115 VAC.
Page 10
6.0 GENERAL REQUIREMENTS
The requirements described in this section shall be considered minimal and are not intended
to restrict or limit the use of innovations the contract manufacturer has currently available or
under development. The contract manufacturer is encouraged to propose separately, any
options or specification changes that may result in an overall improvement in machine
capability, efficiency or cost. However no changes shall be made without a written approval
from Hurco.
6.1 The machine and all its components shall be new and manufactured using the latest
industry standards and practices.
6.2 The materials and workmanship shall be of the highest quality. All components shall
be constructed for long life and continuous service. All necessary devices to protect
the personnel and equipment from hazards which might reasonably be anticipated
shall be incorporated.
6.3 The cast iron must be of the meehanite process or equivalent (approved) and must
comply to the gray iron class 40 or 45. There shall be no “process” stamp on the
main cast iron frame components, especially the column.
6.4 The cast iron components must be shot blast, and rough and sharp edges ground off
either at the foundry or at the contract manufacturer’s facility. All residual mold
sand shall be thoroughly removed from all cast iron components.
6.5 The contract manufacturer shall inspect all cast iron frames visually for flaws, cracks,
hot tears and presence of sand in pockets.
6.6 The contract manufacturer shall submit, with each frame, a complete inspection
certificate with spectrograph. The contract manufacturer shall request this report
from the foundry, if necessary.
6.7 All thermal stresses must be relieved from the cast iron frames before and after
rough machining, and also prior to the flame hardening process.
6.8 No repairing by plugging or welding of any kind will be permitted on any of the way
surfaces and the table top or within 75mm of the way surfaces.
6.9 Pin holes or repairs of any sort shall not be permitted on the table top and the way
surfaces.
6.10 Defects on surfaces requiring no machining, and surfaces which require machining
but are not sliding or contacting surfaces, may be repaired by plugs, welding or with
some non-ferrous materials. All repairs including the repair method must be
reported on the inspection certificate.
Page 11
6.11 The hardness of the cast iron shall be as follows:
6.11.1 The cast iron frames and other components shall be 200-220 Brinell
(18-23 Rc), except base which will be 180-190-Brinell. The contract
manufacturer will check at least 15 locations over the entire base. Any one
location below 180 shall not be accepted.
6.11.2 The table top shall be 20-23 Rc.
6.11.3 All way surfaces to be 50-53 Rc.
6.11.4 Ground spindle taper shall be 58-62 Rc.
6.12 Parts must be interchangeable from frame to frame and for field service
replacements. To ensure this interchangeability, all machining, drilling and tapping
must be done on CNC machines while the components are being finished machined.
No hand drilling and tapping shall be performed during the assembly stages. The
only hand drilling and tapping that shall be permitted will be for accessories such as
hose clamps, wire retainers, retaining clips for lube lines, etc., that have no functional
relationships.
6.13 Chips from machining must be removed from cast pockets and corners inside the
large cast iron frames. These frames must be thoroughly cleaned prior to any
surface treatment. The inside of all castings shall be primed with a protective paint
which is a rust inhibitor.
6.14 All machining shall commence from a qualified pad or a machined surface(s) which
shall be used as a starting datum. If a pad is not available to be used as a machining
reference, then a surface must be qualified as a reference for machining.
6.15 No machined bores, drilled holes or tapped holes shall be located from an
unmachined cast surface. All machined features shall be located from machined
surfaces or datums established from machined surfaces.
All milling, drilling, tapping, boring shall be performed on CNC machines, so that
parts could be interchanged from frame to frame and for field service replacements.
No hand drilling or custom fitting of parts shall be permitted.
6.16 All holes for taps must first be center drilled before tap drilling (Process #1) or all
tap drills must be chamfered prior to tapping (Process #2). See Sketch #1 for the
two processes.
Page 12
PROCESS #1
STEP 1: STEP 2: STEP 3:

CENTER DRILL TAP DRILL TAP
PROCESS #2
STEP 1: STEP 2: STEP 3:

TAP DRILL CHAMFER TAP
TAP DRILL
SKETCH NO. 1
6.17 All sharp corners and edges created by drilling and machining must be broken or
rounded.
6.18 Chips from machining must be removed from cast pockets and corners inside the
large cast iron frames. These frames must be thoroughly cleaned prior to any
surface treatment.
6.19 Chips from any hand drilling and tapping that may be necessary during assembly and
checkout, must be carefully removed and components/assemblies thoroughly cleaned
to prevent contamination and damage of moving/sliding parts.
6.20 The column shall have solid, hardened and ground rectangular ways. The mating
slide (head) for the hardened ways shall be lined with turcite. Taper Gibs and liners
shall be used for adjustments of any looseness. Provisions for Gib adjustment and
securing the Gib once it has been adjusted must be easily accessible.
6.21 The turcite shall have oil grooves for lubrication of ways. The oil grooves shall be
min 0.4mm deep and must not break through the turcite. These oil grooves shall be
machined uniformly and not cut by hand. The turcite shall have a contract area of at
least 20 points per inch. The width of the groove shall be 4-5mm wide.
6.22 Linear rails and bearings with ball rollers shall be used for the linear motion for X
and Y axis.
6.23 A complete automatic lubrication system must be supplied for lubrication of

slideways, ballscrews and linear rails. The lube pump rating shall be 110VAC,
single-phase, 50/60 Hz and shall have a low level lube switch. All non-flexible lube
lines/tubings shall be made of copper.
Page 13
6.24 All metering units for auto lube shall be HJB-1. The metering units must be located
such that they are easily accessible for maintenance and leak checks.
6.25 X, Y and Z axis shall use a 12mm pitch hardened and ground ballscrews with a
double preloaded nut. Same ballscrew shall be used for all (3) axes.
6.26 All ballscrew support bearing and spindle bearings shall be ABEC-7 class and
lubricated using KLUBER NBU-15 grease.
6.27 The BMC models of Frame A shall use a cartridge type, #40 taper spindle and shall
be balanced to the specifications described in section 6.35, 6.36, 6.37 and 8.2.6.
6.28 The tools shall be retained in the spindle by a drawbar using spring washers. The
retention force for the tools shall be 10.8 to 12.0 KN.
6.29 A thick hardened washer must be used at both ends of the spring-pack to prevent
scoring or “digging” of the spring washer into the face of the spindle bore. Each
spring washer of the spring pack must be coated with grease (ANDOK-C grease by
Exxon is preferred). The drawbar as well as the outside diameter of the spring pack
must also be coated with grease. The drawbar shall be hardened to about 42-48 Rc.
6.30 The spring washer stack shall not exceed 80% compression at full stroke.
6.31 The tool release force shall not exceed the static load capacity of the spindle
bearings.
6.32 The spindle nose and the rear of the spindle must be designed with a labyrinth seal to
prevent contamination entering the bearings.
6.33 In addition to the labyrinth seals, contamination shall be prevented from entering
lower and upper bearings by maintaining a positive, low air pressure (Air-purge)
through the spindle.
6.34 Every spindle must be tested for bearing temperatures, vibration and balance as
defined in section 10.2.1 through 10.2.5. All readings must be recorded in the
“Machine Acceptance to Ship” document for each machine. The spindle bearing
temperature shall not exceed 130°F.
6.35 All critical components of the spindle must be individually balanced. The spindle
pulley shall be balanced individually before installing on the spindle and balancing the
completely assembled spindle. Half “dummy” keys shall be used to compensate the
keyways in the spindle and the spindle pulley.
6.36 The spindle motor pulley shall be balanced individually with a half “dummy” key to
compensate for the keyways, during balancing.
Page 14
6.37 The noise level with the front enclosure doors open shall not exceed 85 dbA.
Insulating pads shall be used inside the head covers to dampen the noise level, if
necessary.
6.38 The X-axis motor shall be protected from coolant and chips by installing a deflector
cover around the motor. This deflector shield shall be so designed as to act as a chip
brush/scraper and direct the chips into the chip trough during Y-axis movement.
6.39 The full enclosure design shall allow full access for overhead crane loading of parts
on to the table. The top of the enclosure shall be sloped with the upper edge for the
head clearance no more than 12mm. The front doors shall follow the inside
container of the full enclosure and shall have minimum clearance between door and
enclosure.
6.40 Every Frame A machine enclosure shall be tested for coolant leakage. This test shall
include spraying the inside of the machine/enclosure with coolant using a hose. Just
running the coolant nozzles at the spindle shall not be an acceptable leak test.
6.42 All edges and other surfaces of the sheet metal enclosure and its accessories shall be
smooth and well rounded. Sharp corners must be rounded or formed.
6.43 When two edges of panels are welded together, the joint must be a continuous weld
(wire welding preferred). Hairline cracks in paint and where two edges have been
welded shall not be permitted.
6.44 The two sides of the enclosure shall have access panels. The left panel shall be a
hinged door to provide easy access for maintenance and manual loading/unloading of
tools in the ATC. The right side panel shall be fastened to the full enclosure using
1/4 turn quick turn screws and shall be large enough to accommodate the side Load
Pallet Changer option. These panels shall fit in a recessed pocket and shall be flush
to the full enclosure when installed on the full enclosure. A gasket shall be used all
around the panel or panel opening to prevent coolant leakage.
6.45 All sheet metal components must be properly treated and cleaned to remove oil film
prior to apply a rust preventive primer and the finish paint coats. Chipped and
cracked paint shall not be acceptable along the edges. The access doors and panels
must fit properly to prevent panels from rubbing and scratching the paint.
6.46 The linear rails, hardened and ground ways and the ballscrews for X, Y and Z axis
must be protected from coolant and chips by using telescopic waycovers. The
telescopic waycovers must fit tight using a heavy duty rubber wiper to prevent
contamination from entering the ballscrews, etc. Coolant shall not leak through the
telescoping box sections.
Page 15
6.47 The front Y-axis telescopic waycovers shall have a minimum collapsed length to
allow the operator to be as close to the table as possible to load fixtures and parts
pieces.
6.48 The telescopic waycovers shall be designed to have the smallest collapsed length and
height. The extended length of waycovers shall be designed for axis travel between
mechanical stops (full workable travel plus 12mm overtravel at each end) and an
additional travel of 12mm or more. When extended during normal operations, the
waycovers shall not stretch out of travel. When waycovers are collapsed, there shall
be additional 12 to 25mm of “collapsed” travel available.
6.49 The machine and full enclosure shall be designed for easy access for maintenance and
chip removal.
6.50 The machine and the full enclosure shall also be designed for coolant nozzles that
shall be used for washing the chips into a chip trough.
6.50.1 A wash down hose and a nozzle shall be provided with each machine.
6.51 The full enclosure shall be designed to accommodate a coolant tank and a chip tray
around the front and sides of the base. The chip tray shall be built into the coolant
tank and shall have rollers for removal of chip tray for removing chips.
6.52 The bottom of the chip tray shall have a screen to prevent the chips from flowing
into the coolant tank.
6.53 The coolant tank shall also be designed to accommodate rollers for removing the
tank for maintenance.
6.54 The coolant capacity of the coolant tank shall be 300 liters (80 gals).
6.55 The coolant tank shall also have screens to filter chips that have drained past the
screens in the chip tray.
6.56 The rear of the coolant tank shall have provisions for (3) coolant pumps: 2
washdown, 1 coolant. The rear of the tank shall have heavy duty covers for the
coolant pump mounting. These covers shall be used as a step for servicing the
pneumatic and lube systems, and shall be removable for cleaning and maintenance of
coolant tank.
6.57 The front left side corner of the coolant tank shall have a removable cover. This
cover shall be removed to provide access for the chip conveyor option.
6.58 The front door opening shall be 900mm minimum when the doors are fully open.
This opening shall provide access for the Front Load Pallet Changer option.
Page 16
6.59 A machine configured with a Front Load Pallet Changer may require a modified
coolant tank. The changes necessary to accommodate the Front Load Pallet Changer
(including pendant arm) shall be defined in a separate drawing.
6.60 The machine frame shall be designed to accommodate Heidenhain Linear Scales for
all (3) axis, X, Y and Z.
6.61 The mounting pads for the linear rails for X and Y axis shall be designed with a
groove on either side of the linear rail to drain the lubricating oil to a collection area.
A shield shall be mounted on the outer sides of the linear rail mounting surface to
prevent coolant and chips splashing onto the linear rail and draining out onto the
floor from the rear of the base.
6.62 The lubricating oil from the Z-axis column ways shall be collected in a pan which
shall drain the lubrication oil to a collection box in the back of the column.
6.63 Lubricating oil after circulation shall be collected in an oil separator which shall
separate coolant from the lubrication oil contaminated with coolant. Coolant shall
be drained back into the coolant tank.
6.64 The pressure gage for the FRL (Filter, Regulator and Lubricator) unit must be
calibrated in both, inch and metric units. The FRL must be rated from zero to 120
PSI.
6.65 The contract manufacturer must verify the lube system for flow and leaks for each
sub-assembly and components. Whenever the flow and leak cannot be verified at the
final inspection and certification of the machine, the verification must be done at the
time of completing the sub-assembly.
6.66 The machine base shall be designed to accommodate a 3-point leveling principle.
This 3-point leveling method shall be used for rough leveling the machine.
6.67 The final level of the machine shall use the leveling screws on the sides of the base.
6.68 The machine base shall be designed to accommodate (4) .75” diameter holes besides
the leveling screws that are at the front and rear sides of the base. These holes shall
be used to secure the machine to the skid for shipping. NOTE: holes for leveling
screws shall not be used for securing machine to skid.
6.69 Leveling screws shall have a hole in the middle for a hold-down screw. The wall
thickness of the level screw should be 4mm minimum. The bottom of the leveling
screws shall have a chamfer to prevent the leveling screw from digging into the
foundation block.
6.70 Leveling screws shall be easily accessible for adjustment and leveling of the machine.
Page 17
6.71 The major cast iron frame components shall have provision for lifting. The contract
manufacturer shall provide lift rings or lift lugs where necessary.
6.72 The machine shall be designed for lifting using an overhead crane as well as a fork
lift truck.
6.73 Markings of Machinery and/or parts.
ALL machines and/or parts are to be clearly marked with the country of origin. This
marking must be English and must be permanently affixed in such a manner that
normal handling will not cause the marking to become separated from the item being
marked. The marking shall be accomplished in the following manner.
6.73.1 The completely assembled frame shall be identified with an engraved metal
name plate approximately 105mm wide and 150mm long. This name plate
(in English) will consist of the model number, serial number, date of
completion, power requirements, Country of origin, etc. and shall be secured
on the frames by screws or rivets. The nameplate shall be located on the
right side of the column, below the lube assembly.
Hurco shall provide a sample plate for reference.
6.73.2 Foundry will permanently mark each casting (cast-in-the-mold lettering) with
a part number and latest revision letter. Markings on large frame castings
shall be located in a hidden location so that the marking is not clearly visible
and does not affect the esthetic appearance of the frame.
6.73.3 Other (loose) parts shall be marked with tags that are attached in a manner
which assure that unless deliberately removed, they will remain on the article
while in transit to Hurco as well as in storage at Hurco's facilities.
6.73.4 Any article which by its size is incapable of being marked will be so packaged
that the country of origin, part number, description and quantity in the
packaging is clearly marked on the package.
6.74 Spare parts from the recommended spare parts list as well as non-recommended
spares must be available with a short notice to the suppliers, in case of a breakdown
of a machine in the field.
6.75 Hurco shall provide machining specifications for all the axis motor mounting. This
information shall include the diameter of the motor shaft and the length of the motor.
6.76 The contract manufacturer shall have clean, well-ventilated area for storage of
machined and fabricated components. Unless these components are black oxided for
protection, all components must be ‘oiled’ and protected from moisture to prevent
rust.
Page 18
6.77. All non-painted sheet metal components must be stored inside and all surface rust
must first be sanded off and sanded surfaces washed with acid or solvent. The
cleaned surface must immediately be coated with primer.
Rust that has penetrated below the surface must be removed by machining where
possible.
6.78 ATC (Automatic Tool Changer).

The ATC for the VALUE AND PERFORMANCE ADVANTAGE Machining
Centers shall consist of the following.
6.78.1 A 24 tool disc with plastic gripper fingers to hold the tools. This disc also
has locating bushings for positive positioning of the tool disc.
6.78.2 A swing arm which pivots about a pin in bearing blocks mounted on the left
hand side of the column. The swing arm is swung into tool change position
by a pneumatic cylinder.
6.78.3 The tool disc is indexed into a desired position using an Air motor. An
encoder is used to provide feedback for tool disc position. A shot pin
activated by a pneumatic cylinder shall engage into locating bushings in the
tool disc to provide positive index position desired.
6.78.4 Pneumatic valves are timely activated to provide disc rotation start, slow
down, stop and reverse.
6.78.5 Flow control valves must be properly adjusted to provide smooth and reliable
operation of the pneumatic components.
6.78.6 The ATC cover has an opening on the left hand side for manual loading and
unloading of tools. An automatic door on right side of ATC cover shall open
prior to swinging the swing arm into tool change position. This automatic
door shall prevent tool disc and tool fingers from being contaminated from
chips.
6.78.7 The tool changer must be accurately aligned with the spindle. An alignment
fixture shall be used to align the ATC for tool change position and alignment
of tool disc parallel (sweep) to the table top.
6.78.8
Page 19
THE PLANE OF ROTATION OF THE TOOL DISC
MUST BE PERPENDICULAR TO THE SPINDLE
CENTERLINE WITHIN 0.5 MM.
WHEN THE DISC IS IN THE ENGAGEMENT POSITION

UNDER THE SPINDLE, THE CENTERLINE OF THE
STORED TOOL HOLDER AT THE FLANGE AND THE
SPINDLE SHOULD BE CONCENTRIC WITHIN 0.5 MM.
6.79 The tool change for the PRODUCTION ADVANTAGE machining center consists
of the following:
6.79.1 A tool disc with 22 tool pockets to hold Din 63 tool holders with special
adapters. The upper tool disc is mounted to bottom of the head.
6.79.2 The center shaft of the disc is rotated within bearings that are fixed to the
head. The disc rotates the tool holder under the spindle.
6.79.3 The spindle is extended to engage and lock the tool holder to the spindle. A
small spindle rotation disengages the tool holder from the tool disc and the
spindle with engaged tool holder extends through the disc to start the
machining operation.
When the machining has been completed, the spindle is radially oriented and
retracts through the tool disc. A small spindle rotation engages the tool
holder into the pocket of the tool disc. The tool holder is then unlocked from
the spindle and the spindle retracts to “clear” position so the disc can rotate
to another position.
6.79.4 The drive for tool disc rotation is the same as described in Section 6.78.3.
Page 20
7.0 GENERAL ELECTRICAL REQUIREMENTS
Purpose
The purpose of this standard is to provide specifications for the design, construction and
application of electrical systems and controls for industrial equipment. This standard is not
intended to limit or inhibit new technology.
This standard is intended to promote:
1) Safety.
2) Uninterrupted production of quality products.
3) Equipment reliability and maintainability.
4) Minimum purchase and operational costs.
5) Conservation of energy.
6) Implementation of new technology.
Scope
The provisions of this standard shall apply to all electrical systems, furnished as part of industrial
equipment, which operate from a supply voltage of 600 volts ac or less, commencing at the power
supply terminals on the main disconnecting means.
In this standard, the word “shall” is understood as a requirement, the word “should” as a
recommendation.
General
Craftsmanship shall be of the best quality and appearance. Electrical equipment shall be new and
unused.
Electrical equipment shall be applied, installed and used per the specifications of the manufacturer.
Electrical equipment and installations shall comply with FCC regulations.
Approval Requirements
The industrial equipment supplier shall submit all necessary documentation to Hurco and receive
approval before devices are purchased or installed on the industrial equipment. After preliminary
approval, any modifications made by the equipment builder shall have the advance approval of
Hurco.
Approvals and Final Documentation
Page 21
Compliance. The equipment supplier shall be held responsible for compliance to this standard
and shall also be held responsible for correcting any discrepancies found upon receipt of the
machinery or equipment.
Disconnect
A single electrical supply source and single disconnecting device shall be provided for each
individual machine or piece of equipment. The disconnecting means shall disconnect all
ungrounded conductors of the supply circuit simultaneously. Multiple power sources shall not be
used.
The electrical supply conductors shall be contained in their own separate conduit or raceways.
The electrical supply conductors shall enter through the side or top of the electrical enclosure
above the disconnecting means. Where the supply conductors cannot enter adjacent to the
disconnecting means, they shall be enclosed in rigid or flexible conduit between the enclosure
entrance and the disconnecting means. The electrical supply conductors shall terminate at the
disconnecting means with no connection to terminal blocks or other devices before the
disconnecting means.
There shall be no exposed live parts when the disconnecting means is in the open position.
Rating
The ampacity of the disconnecting means shall be not less than 115 percent of the sum of the full-
load currents required for all equipment which may be in operation at the same time under normal
conditions.
The interrupting capacity of the disconnecting means shall be not less than the sum of the locked
rotor current of the largest motor plus the full-load current of the other connected operating
equipment.
Protection
Protective devices shall be selected and applied with proper consideration of the inrush and
normal operating current of the load as well as the thermal capacity and the short circuit
withstandability of the series connected devices and any equipment being protected by the device.
Two or more protective devices applied in series shall be selected with proper time-current and
let-through energy characteristics to provide as much selective circuit protection for the fault and
overload conditions as possible, based on the manufacturers’ data.
When the main disconnect overcurrent protection provides adequate protection for a large single
motor, additional branch circuit protection is not required.
Page 22
Two motors from one to five horsepower may be on the same branch circuit. Multiple fractional
horsepower motors may be used on a single branch circuit. The rating or setting of the
overcurrent protective device shall be as low as practicable.
Motor Overload Protection
Each motor and its related conductors shall be protected against running overload by the use of a
separate current sensitive overload device in each phase.
The rating of the overload sensing device shall be based on the motor nameplate full load current.
If the motor rating does not match a standard overload size, then the next standard larger size
shall be used. The sizing of the required overload device involves consideration of the service
factor, ambient temperature of both the motor and its controller and the type of motor enclosure.
All necessary transformation and conditioning of incoming power shall be the

responsibility of the equipment supplier. The recommendations from the manufacturer(s)
of electronic device(s) are minimum requirements.
Flexible Wiring
Connections to continuously or frequently moving parts shall be made with extra flexible
conductors Class K encased in liquid-tight, flexible, non-metallic conduit or with extra flexible
multiconductor cable.
Flexible cable and conduit shall have vertical connections and shall have sufficient slack to avoid
sharp flexing and straining and shall be adequately supported.
Where there is relative motion between flexible conduit or cable and parts in process or equipment
components, the construction and supporting means shall be such that there will be a clearance of
at least one inch under all operating conditions. Barriers or guides shall be provided where the
clearance cannot be maintained.
Plugs and Receptacles
Plugs used for circuits 150 volts and above shall not be removable or insertable when voltage is
applied to the receptacle.
A properly sized grommet around the cord shall prevent entrance of contaminants.
A means shall be provided to effectively seal the receptacle whenever the plug is removed.
Exception: Does not apply to subassemblies mounted within the control panel enclosure.
The grounding pole of plugs and receptacles shall only be used for grounding purposes.
Page 23
Grounding poles of plugs shall be designed to prevent contact with current-carrying parts of
receptacles or cord connectors.
Plugs and receptacles shall be identified and mechanically keyed to prevent incorrect insertion.
Plugs and receptacles shall be designed to prevent any part from accidentally shorting.
Disconnected plugs or receptacles shall not have any voltage to exposed pins.
7.1 Safety Grounding (Protective Bonding Circuit)
7.1.1 Equipment Grounding, Terminal Mounting
The electronic equipment shall provide safeguarding of persons against

electrical shock both in normal service and in case of fault. The entire
grounding circuit shall be interconnected such that a single point for an
external connection will be conductivley connected to all grounded parts. A
terminal suitable for connecting an external ground shall be provided at the
main power disconnect. The equipment grounding terminal shall be identified
with the word “GROUND”, or the letters “GND”, and the letters “PE”. The
IEC symbol for Equipment Grounding (417-IEC-5019) may also be used.
7.1.2 Equipment Grounding

The machine and all exposed, noncurrent-carrying conductive parts, material
and equipment, including metal mounting panels that are likely to become
energized, shall be effectively grounded.
7.1.3 Grounding Conductors

Grounding conductors shall be insulated or covered and shall be protected
against physical damage. Insulated or covered grounding conductors shall be
identified by a green color with or without one or more yellow stripes.
It is permissible to use machine members or structural parts of the electrical

equipment in the grounding circuit provided that the cross sectional area of
the parts are at least electrically equivalent to the minimum cross sectional
area of required copper conductor required. Where the electrical equipment
is mounted on lids, doors or coverplates, continuity of the protective bonding
circuit shall be ensured. This shall not depend upon fastenings, hinges, or
support rails, a conductor must be used.
7.2 Control Enclosures and Compartments
7.2.1 Type
Page 24
Enclosures and compartments shall be non-ventilated with construction and
sealing suitable for the intended environment. All cables and harnesses shall
be sealed at the entry/exit of the enclosure. All sub-panels and covers shall be
sealed by a gasket or using silicone sealant.
7.2.2 Wall Thickness

The wall thickness of compartments and control enclosure shall be not less
than 1.5mm.
7.2.3 Doors
Enclosures or compartments shall have one or more hinged doors that shall
swing about a vertical axis and shall be held closed by vault type hardware.
The width of the door shall not exceed 1016mm.
7.2.4 Gaskets
Where gaskets are used, they shall be of an oil resistant material and shall be
securely attached to the door or enclosure.
7.2.5 Interlocks
Any door(s) that permit access to live components operating at 50 volts or
above shall be interlock such that the door(s) cannot be opened unless all
power is disconnected. Exception: It shall be permitted to provide means for
qualified persons to gain access without removing power. The interlocking
must reactivate automatically when the door(s) is(are) closed.
7.2.6 Interior Finish

The interior of control enclosures and exposed surfaces of panels mounted
therein shall be finished in a light color. Orange is preferred.
7.2.7 Warning Mark

All control enclosures and compartments that do not clearly show that they
contain electrical devices and that are not electrically interlocked shall be
marked with a black or red lightning flash on yellow background within a
black or red triangle.
7.2.8 Print Pocket

A print pocket sized to accommodate electrical diagrams shall be attached to
the inside of the control enclosure door.
Inside Electrical Enclosures and Compartments
Components shall be mounted to provide mechanical clearances sufficient for mounting, wiring,
adjustment, testing and replacement. Each component shall be mounted to provide heat
Page 25
dissipation consistent with the temperature rating of the component, adjacent components and
conductors. Each component shall be arranged and oriented so that the identification may be
determined without moving the component or its wiring.
Equipment shall be mounted so that any component or component part can be replaced without
removing the subplate. No components shall be mounted behind door pillars unless adequate
space is provided for replacement and servicing. In no case shall any component be mounted
directly above or behind the disconnecting means.
Control components shall be front mounted on a rigid metal subplate so that the complete
subplate can be removed through the enclosure opening. Subplate metal shall be a minimum of
0.106 inch (MSG No. 12) nominal for mounting components with one-quarter inch screws or
smaller. Where larger screws are required, additional reinforcement or heavier gage subplates
shall be provided.
Separately grouped terminals shall be used for all power circuits, control circuits, remote interlock
wiring and signal circuits.
Any component(s) mounted on the subplate carrying line voltage or a combination of line voltage
and control voltage shall be grouped above or to the side and segregated from devices which
carry only the control voltage. This does not apply where the line voltage is 120 volts.
To minimize electromagnetic interference, electronic devices and the associated wiring shall be
segregated from the electromagnetic control and power wiring.
Outside Electrical Enclosures
Components shall not be mounted on the exterior of the control panel enclosure.
Exceptions:
1. Power factor correction capacitors.

2. Control transformers larger than 2 kVA.
3. Line conditioning and regulating transformers of 500 VA or larger.
4. Other major heat generating devices suitable for such mounting.
Such devices shall be mounted so that no portion of the equipment immediately above the door
opening and less than 84 inches from the floor projects more than six (6) inches beyond the door
frame.
Attachments and fittings between these devices and the enclosure shall be liquid tight.
Control components shall not be mounted on the door or side of the enclosure. Devices such as
pushbuttons, selector switches, meters, operator adjustable controls and pilot lights may be door-
mounted; however, they shall be wired from terminal strips on the subplate and shall not exceed
120 volts. Wiring between devices on the door is acceptable.
Page 26
Mounting Methods for Components
When components are mounted with studs or machine screws, the mounting plate shall have a
minimum thickness of 1.25mm.
Sheet metal drive screws shall not be used to mount components.
Rivets, welds, solders or bonding materials shall not be used to mount components.
Electronic Subassemblies and Components
Plug-in subassemblies shall be mechanically secured in place with captive fasteners and keyed for
proper insertion.
Printed circuit boards shall be mounted in the vertical plane.
Components shall be mounted for ease of replacement and maintenance after assembly. Controls
and adjustments for maintenance personnel shall be separately located from those required by
operation personnel.
Transducers and associated parts shall be constructed and installed in such a manner as to provide
accessibility and adequate protection against mechanical damage, degradation of performance and
contamination from the environment.
Electrical Enclosures
The equipment supplier shall verify by performing heat load calculations that the enclosure
ambient temperature will not exceed 60°C under maximum load conditions and with an in-plant
ambient temperature of 40°C. These calculations shall be submitted for approval as part of
requirements. Where these requirements cannot be met due to electrical enclosure size
restrictions or where in-plant operating ambients may exceed 40°C, the temperature inside the
enclosure shall be reduced to comply with these requirements by the following means:
1. Relocate heat generating equipment to another enclosure or utilize enclosed devices mounted
external to the enclosure.
2. Air-to-air convection type heat exchanger.
3. Forced circulation air inside the enclosure.
4. Air-to-air heat exchanger - forced air.
5. Air conditioning (industrial grade).
The above items are listed in order of preference.
Electrical Compartments
Page 27
Compartments for built-in controls shall be completely enclosed, rated a minimum NEMA 12 and
isolated from coolant and oil reservoirs.
Compartments shall be readily accessible and contain only electrical components.
7.3 Location and Mounting of Control Equipment
7.3.1 General
Control equipment shall be mounted and located according to the most
recently approved cabinet layout drawing and so that the components will not
interfere with machine adjustments or maintenance.
7.3.2 Control Enclosure

The enclosure shall be mounted in a manner and position to guard it against
oil, dirt, coolant, and dust, and to minimize the possibility of damage from
floor trucks or other moving equipment.
7.3.4 Machine Mounted Control Equipment

Control equipment, such as limit switches, brakes, solenoids, position
sensors, etc., shall be mounted rigidly in a reasonably dry and clean location,
shall be protected from physical damage, and shall be free from the possibility
of accidental operation by normal machine movements or by the operator.
Such equipment shall be mounted with sufficient clearance from surrounding
surfaces to make its removal and replacement as easy as possible.
All limit switches or position sensors shall be installed so that accidental

overtravel by the machine will not damage the limit switch or sensor.
7.4 Lighting
7.4.1 Machine Work Light

The lighting circuit voltage shall not exceed 50 volts between conductors.
An isolation transformer connected to the load side of the machine power
distribution with overcurrent protection in the secondary circuit shall be
provided. The conductors to stationary machine work lights can be flexible
type cords of type SO, STO, SJO or equivalent.
7.5 Wiring Methods and Practices
7.5.1 Conductor Sizing
Conductors shall not be smaller than:

Power Circuits No. 14 or 2.0 mm x 2
Page 28
Lighting and control circuits on the machine No. 16 or 1.3 mm x 2
and in raceways
Control circuits within control enclosures or No. 18 or 1.0 mm x 2
operator stations
I/O and static control No. 24 or .5 mm x 2
7.5.2 Conductor Ampacity

• The continuous current carried by conductors shall not exceed the values
given in Table 6.2.1.
• Motor circuit conductors shall have an ampacity not less than 125
percent of the full load current rating of the highest rated motor in the
group plus the sum of the full load current ratings of all other connected
motors and apparatus that may be in operation at the same time.
7.5.2.1
Conductor Ampacity in Cable Ampacity in Ampacity in
Size AWG or Raceway Cable or Control Enclosure
60 Degrees C Raceway 60 Degrees C
75 Degrees C
24 2 2 2
22 3 3 3
20 5 5 5
18 7 7 7
16 10 10 10
14 15 15 20
12 20 20 25
10 30 30 40
8 40 50 60
Page 29
7.5.3 Conductor Color Coding
Conductors shall be color coded as follows:
BLACK Line, load, and control circuits at line voltage.

RED AC control circuits, at less than line voltage.
BLUE DC control circuits.
YELLOW Interlock control circuits supplied from an
external power source.
GREEN (w or w/o yellow stripe) Equipment grounding conductor where
insulated or covered.
WHITE or NATURAL GRAY Grounded circuit conductor.
Conductors and cables shall be run without splices from terminal to terminal.
Exceptions:
1. Internal wiring on individual devices purchased completely wired.
2. Multicolored Cable
3. Conductors used to connect electronic, precision, static, or similar
devices or panels.
4. Splices shall be permitted to leads attached to electrical equipment,
such as motors, and shall be insulated with oil-resistant electrical
tape or insulation equivalent to that of the conductors. Where
applicable, plugs and receptacles may be used.
7.5.4 Machine Wiring

• Fittings used with raceways or multiconductor cable shall be liquidtight.
• Conductors connected in ac circuits and conductors connected in dc
circuits shall be permitted in the same raceway regardless of voltage,
provided they properly insulated and noise generation precautions are
taken.
• Liquidtight, flexible non-metallic conduit is preferable over metallic
conduit, and will be installed where ever possible in a manner that liquids
will tend to drain away from fittings.
• Where wires are terminated into wago type connectors or other suitable
receptacles, appropriate size ferrules shall be used.
• Where a conduit enters a box or other fitting, a bushing or adapter shall
be provided to protect the wire from abrasion unless the design of the
box or fitting is such as to provide equivalent protection.
• Conduit bends shall be so made that the conduit will not be injured and
the internal diameter of the conduit will not be effectively reduced. The
radius of the curve of any field bend shall not be less than 5-6 times the
size of the conduit.
• A run of conduit shall contain not more than the equivalent of four
quarter bends (360 degrees total).
Page 30
• Several motors each not exceeding 600 volts, nominal, or less, protected
at not over 15 amperes, where all of the following conditions are met:
1. The full load rating of each motor does not exceed 6 amperes.
2. The rating of the branch-circuit short-circuit and ground-fault
protective device marked on any of the controllers is not exceeded.
3. Individual overload protection conforms to the following:
a. Overload devices shall be provided to protect each motor and

branch-circuit conductor against excessive heating due to
motor overloads or failure to start.
b. Resetting of the overload device shall not restart the motor.
c. An approved means of protection against overcurrent exists
and is in place.
7.6 Electrical Documentation
7.6.1 All documentation must be submitted by the electrical controls engineer.

Documentation submitted for approval shall be reproducible and identical in
size and format as final documentation. Approval drawings shall include all
information necessary to allow an engineer to understand the complete
control system. Documentation shall be delivered to the appropriate project
engineer. Only after the Hurco Engineers have indicated the approval status
shall the supplier enter the information from the approval title block into the
drawing CAD file.
7.6.2 Hardware documentation shall be submitted for approval early enough to

allow adequate time for a proper review without affecting product delivery.
The following approval states apply:
7.6.2.1 Approved - Design is approved but some documentation concerns

may exist that require correction.
7.6.2.2 Approved as noted - Design is approved but some corrections are

required to achieve compliance. Documentation concerns may also
exist that require correction. Documentation does not have to be
resubmitted but all corrections shall be reviewed with Hurco prior
to acceptance.
7.6.2.3 Resubmit - Design is not approved due to significant specification

violations, or documentation is incomplete and a proper review is
not possible. Contact the Electrical Engineers as soon as possible
to resolve all concerns. Approval shall be obtained before
components are purchased.
7.7 Preferred List of Electrical Components
Page 31
The following is a list of preferred electric and pneumatic components. Hurco shall
add or delete components from the below list after design reviews and availability of
these components have been discussed with the contract manufacturer.
7.7.1 CIRCUIT BREAKERS

Square D
Telemechanique
G.E.
Klockner-Moeller
7.7.2 CONDUIT
Corrlock
Anaconda
7.7.3 CONNECTORS, LOGIC

Wago
Amp
Honda
Amphenol
7.7.4 CONNECTORS, GENERAL

Amphenol 97 Series
Cannon MS Series
7.7.5 ENCODERS, OPTICAL SHAFT

B.E.I.
Yaskawa
Fanuc
7.7.6 FUSES
Bussman FRN-R, FNM, & Class J
Gould-Shawmut Class CC - for branch supply/short circuit
protection
7.7.7 INDICATOR LIGHTS

G.E.
Telemechanique
Allen-Bradley
7.7.8 METER, PANEL MOUNT

Simpson
Weston
7.7.9 MOTORS, SERVO/SPINDLE
Page 32
Yaskawa
Fanuc
Baldor
Reliance
7.7.10 MOTORS, A.C.

Delco
G.E.
Bodine
Gusher, Graymill
Grundfos
7.7.11 MOTORS, PNEUMATIC

Gast
7.7.12 MOTOR STARTERS, CONTACTORS, MAGNETIC

Telemechanique with manufacturer's built in DC suppression
Klockner-Moeller
Siemens
7.7.13 PLUGS & RECEPTACLES

Brad Harrison
Amp
Cannon
7.7.14 POWER SUPPLIES

Power One
Condor
Deltron
7.7.15 PROGRAMMABLE CONTROLLERS

Fanuc I/O A
Fanuc 9030
7.7.16 PUSHBUTTONS
See Switches
7.7.17 RELAYS
Potter Brumfield
Allen-Bradley
Omron
Telemechanique
7.7.18 SWITCHES, LIMIT

Balluff
G.E.
Page 33
Telemechanique
Omron
Honeywell
7.7.19 SWITCHES, PUSHBUTTON

E.A.O.
G.E.
Allen-Bradley
Microswitch
Centralab
Baluff
7.7.20 SWITCHES, PROXIMITY

Effector Quadranorm
Turk
7.7.21 SWITCHES, MAGNETIC

No specific vendor required
7.7.22 TRANSFORMERS
Hevi-Duty
G.E.
Shape
7.7.23 WIREWAY, PLASTIC

Panduit
Taylor
7.7.24 WIRE
Alpha For Details see section 1.3.
Belden
Coleman
Brad Harrison
7.7.25 QUICK DISCONNECT JUNCTION BOXES

Brad Harrison
7.7.26 QUICK DISCONNECT CABLES, WIRE & CONNECTORS

Brad Harrison
7.7.27 SOLENOID VALVES

SMC NVJ700 series with built in suppression and
LED indicator
Asco
7.7.28 MAIN POWER DISTRIBUTION BLOCK
Page 34
G.E. Rated for 300V minimum
Allen-Bradley
7.7.29 GROUND BUS BAR

Square D
Wago
G.E.
Allen-Bradley
7.7.30 D.C. BUS BAR

Wago
G.E.
Square D
Allen-Bradley
7.7.31 END TERMINALS, WIRE SPLICES, ETC.

Panduit
H.H. Smith
Keystone
KSS
Page 35
8.0 OPERATING INSTRUCTION MANUALS AND DOCUMENTATION
This section describes the general requirements for documentation and manuals. Certain
items in this section may not be applicable to a contract manufacturer and such exceptions
shall be reviewed with the contract manufacturer and agreed in writing.
8.1 All instruction manuals and drawing documentation shall be in English.
8.2 Prior to machining, the contract manufacturer shall submit two sets of assembly
layouts, detail drawings and schematics of applicable pneumatic and electrical circuit
diagrams for review and approval of Hurco. Hurco shall return the approved
drawings within 10 working days after receiving these drawings. All assembly
drawings must include critical dimensions necessary to locate critical components.
8.3 The contract manufacturer shall provide one complete set of final drawings two
weeks after the shipment of the first machine. These final drawings (in English) shall
include all changes and corrections that may become necessary during the testing
and acceptance of the first machine. The complete drawing set will consist of
reproducible copy of all drawings and a disk with all CAD/Autocad drawings.
8.4 When the final drawings are released with all the agreed and approved changes, the
contract manufacturer WILL NOT make any changes to any drawings without
PRIOR WRITTEN approval of Hurco.
8.5 Hurco will have total control of modifications to the machine which is manufactured
for Hurco only, and no drawing changes can be made without written approval from
Hurco.
8.6 The contract manufacturer shall provide (5) complete sets of Operating and
Maintenance Instruction Manuals, written in English, at the time of shipping the first
machine. This instruction manual shall include:
8.6.1 Complete operating and maintenance instructions.

8.6.2 Lubrication diagram.
8.6.3 Pneumatic circuit diagram.
8.6.4 Spare parts list.
8.6.5 Reduced copies of assembly drawings.
8.6.6 Bill of material of all the parts used in the assembly.
8.6.7 A complete guide to preventive maintenance and trouble shooting of
problems.
8.6.8 ‘PPA’ for all purchased parts with supplier and manufacturer information
together with a Xerox copy of catalog information, in English.
8.7 The contract manufacturer must provide a document specifying individual machined
weight of large cast iron frames, large cast iron non-frame components and the
Page 36
major assembly weights. The major assemblies include the Head, Column Assembly
Base Assembly with Table and Saddle and Transmission assemblies.
8.8 The contract manufacturer shall provide drawings showing the machine layout with
all critical overall dimensions. These drawings shall include a top, side and front
view of each model of the Frame A machines. A separate drawing shall also be
provided showing the pallet and the shipping dimensions for each model.
8.9 The contract manufacturer shall provide a disk on CAD/Autocad of all drawings in
English. Hurco shall assign Hurco part numbers to these drawings and provide a
disk of completed and released drawings to the contract manufacturer.
Page 37
9.0 SURFACE PREPARATION AND PAINT
All cast surfaces of the main frame components must be prepared before painting to achieve
a GLASS SMOOTH finish.
9.1 Cast iron frames and components must be cleaned to remove sand and ground to
remove residual flashes.
9.2 The foundry also must clean all cast iron frames and components by shot/sand blast
process.
9.3 All surfaces of unmachined cast iron from the foundry must be well coated with a
primer /sealer. The primer/sealer must be allowed to dry thoroughly before any
handling and machining.
9.4 After all machining is complete, all components must be thoroughly cleaned to
remove chips, coolant/cutting oils and other surface contamination that might have
occurred during machining.
9.5 All visible cast surfaces must be prepared with "bando" (filler) to achieve a GLASS
SMOOTH surface. The filler must be allowed to dry thoroughly before sanding.
9.6 Each component will be painted with a primer and two finish coats of Hurco Gray
Paint as specified in document #701-0001-073. Before applying the first coat of
finish paint, the surfaces must be cleaned with a solvent to remove all grit and oils
from sanding the surfaces with filler. The surfaces must also be dry before applying
the first coat of finish paint. The first coat of paint must be thoroughly dry before
applying the second coat of the finish paint. The coolant tank, chip tray and other
pre-identified components shall be painted with Hurco Black as specified in
document # 701-0001-074
9.7 Contract manufacturer must comply with Hurco paint specification 716-7025-001.
9.8 After all finish painting is complete, all frame surfaces must be visually inspected for
surface defects and smoothness.
9.9 If touch-up painting is necessary before shipment of the machines, then the surfaces
requiring touch-up paint must be thoroughly cleaned with a solvent before applying
touch-up paint. Over spray spots and runs distinctly visible will not be acceptable.
9.10 The overall surface and paint quality must equal or exceed the quality of the sample.
Hurco shall provide paint chips to the contract manufacturer for matching of paint
color.
Page 38
10.0 MACHINE TESTS AND ACCEPTANCE
Cutting and non-cutting tests shall be performed on the prototype machines to measure the
performance of the Frame A design. These tests shall not be regarded as the final and the
only tests to validate the Frame A machines, but shall be regarded as the guidelines for the
basic tests. Additional tests as found necessary may be performed at either the contract
manufacturer’s facility or at Hurco. Initial tests shall be performed as specified in the Test
Specifications, Engineering Document 757-4002-045, Rev. A.
The contract manufacturer will test every spindle for all models of machines and
demonstrate the accuracies of each machine to comply with the specifications outlined in
Section 3.0 and the Performance and Accuracy requirements specified in this section. In the
event Hurco's engineers and technicians are not personally available to witness the tests and
accuracy checks, the contract manufacturer shall submit all test results and accuracy
measurements to Hurco for approval to ship the machines. Hurco will review these reports
within (3) working days.
Approval to ship the machines from the contract manufacturer's facilities does not constitute
the final acceptance of the machines received at Hurco. The final acceptance of the
machines shall be the successful measurement of accuracies either at Hurco, prior to
shipping the machines to Hurco's customers, or at Hurco's customers.
The following shall be the inspection and tests performed by the contract manufacturer
before a machine could be shipped to Hurco. A separate “Machine Acceptance to Ship”
document shall be provided for each machine.
The acceptance of the machines shall not be limited to tests and inspections described in this
section. Hurco may request the contract manufacturer to perform additional tests to certify
machines for long term reliability and quality compliance. At the same time the contract
manufacturer is encouraged to perform additional tests that may be necessary for in-process
inspection and certification of sub-assemblies to achieve overall accuracy and quality in the
products.
10.1 Visual Inspection. This inspection will verify aesthetics of the frame, overall
workmanship, surface finish and paint, mounting of pneumatic fittings and tubings,
lubrication system, location and mounting of switches, machine and power cabinet
wiring, machining quality, assembly practices, decals and warning labels.
10.2 Performance and Accuracy Checks. These checks and measurements will be
performed to verify and certify the geometric accuracies of all axes to meet the
required specifications. These checks and measurements must be performed for
each machine and serialized with the frame serial number. All checks, measurements
and visual inspection must be recorded in the "Machine Acceptance" document.
10.2.1 Spindle Testing
Page 39
10.2.1.1 Spindle run-in. Perform bench test as described in Table No. 2 and
the Vibration Analysis as described in section 10.2.5.
The spindle run-in and Vibration Analysis shall be performed on
ALL spindles and data submitted with each machine and
replacement spindles.
10.2.1.2 After spindle has been run-in, let spindle cool down for 4 hours.
10.2.1.3 Perform spindle and Head Growth test, as listed in section 10.2.2.
10.2.2 Spindle and Head Growth
This test shall be performed on the first (5) built units and thereafter
randomly, as requested by Hurco.
10.2.2.1 Spindle start-up from 1,000 to 8,000 RPM at 1,000 RPM

increments.
10.2.2.2 At 8,000 RPM, check temperature of front (2) bearing sets.
10.2.2.3 Monitor head and spindle growth.
2 (HEAD)
2 1
3
1
INDICATOR LOCATIONS
TEMPERATURE CHECKS
Page 40
Table No. 1
Bearing Temp. Head Growth Spindle Growth
Interval (min.) 1°° C 2°° C s1 s2 s3 s4
0 (Initial Reading)
15
30
45
60
75
90
105
120
135
150
165
180
195
210
225
240 (Final Reading)
10.2.3 Procedure for Checking Spindle Growth:
• At the start of 10.2.2.1 measure the spindle face from top of table.
(INITIAL READING IN CHART).
• Slide indicator away from spindle, without disturbing the setting.
• At the end of Spindle Temp and Head Growth Test, slide the indicator
below spindle and measure the spindle face from top of table. (FINAL
READING IN CHART).
• The difference between the final reading and initial reading is the spindle
growth.
• NOTE: Do not take s4 reading every 15 min. The spindle cannot be
stopped to take bearing temp readings 1, 2 and Head Growth readings
s1, s2 and s3.
• Record all measurements as shown in Table No. 1
Page 41
10.2.4 Spindle Taper test
10 MM
0.005 MM
MAX
250 MM
0.015 MM
MAX
PUSH END OF TAPER
GAGE TO MEASURE ERROR
PUSH WITH SMALL FORCE

TO KEEP TAPER ENGAGED.
CAUTION: PUSH END OF TAPER GAGE TO MEASURE

ERROR. PUSHING ON GAGE NEAR SPINDLE
CAN CAUSE GAGE TO BIND AND PREVENT
DETECTION OF ERROR.
Page 42
SPINDLE BEARING TEMPERATURE & SPINDLE GROWTH TEST
THIS TEST IS TO BE DONE ON THE BENCH WITHOUT SPINDLE IN THE HEAD.
1 2 3
SPINDLE FACE
(GAGE LINE)
Table No. 2
BEARING TEMPERATURE
TIME SPINDLE
INTERVAL GROWTH
(15 MIN.) 1 2 3 "A"
15
30
45
60
75
90
105
120
135
150
165
180
195
210
225
240
Page 43
10.2.4 Measure Noise Level at 8,000 RPM ________________ dbA.
10.2.5 Vibration Analysis
Spindle Vibration Analysis

Parameters Specification Measured
Displacement (mils) .08 mil
Velocity (in/sec) .04 in/sec
Acceleration (g’s) 1.0 g’s
Spindle Vibration Analysis

Parameters Specification Measured
Spike Energy (g-e-se) -------------- ---------------
4,000 RPM Spindle 1.0 g-se
10.2.6 Tool Retention Force
Spec 10.8 - 12.0 KN

Conversion: 1 KN = 224.81 lbs.
Measured: _______________
10.2.7 Geometry Checks. Perform all geometry checks illustrated in Table No. 3 for
every machining center. Record the measurements in Table No. 3 and submit
the measurements with each machining center. All measurements must
comply with the allowable specifications in Table No. 3.
The contract manufacturer must attempt to achieve the geometry in the mid-
range of the allowable tolerance rather than the upper or lower limits. No
deviations will be accepted from the allowable tolerances.
Page 44
Table No. 3
ALLOWANCE
NO. ITEM METHOD MEASURED INITIAL / DATE
INCHES METRIC
IN "X" DIRECTION
TIR=.0006 TIR=0.015
FULL LENGTH FULL LENGTH
OF TABLE OF TABLE
(UP TO 31.5) (UP TO 800)
TIR =
TIR=.001 TIR=0.025
OF TABLE OF TABLE
(OVER 31.5) (OVER 800)
TABLE SURFACE
TABLE
1 FLATNESS
(SEE SHT. 3) IN "Y" DIRECTION
TIR=.0004 TIR=0.010
FULL WIDTH FULL WIDTH
OF TABLE OF TABLE
(UP TO 19.7) (UP TO 500)
TIR =
TIR=.0008 TIR=0.020
FULL WIDTH FULL WIDTH
OF TABLE OF TABLE
(OVER 19.7) (OVER 500)
TABLE SURFACE
X =
PARALLELISM
OF TABLE X=.0006 X=0.015
2 MOVEMENT Y=.0006 Y=0.015
Y =
TO TABLE TOP
(FULL TRAVEL) TIR =
SQUARENESS
3 OF X AND Y .0006/12 0.015/300
MOVEMENT
"0-0" ON X AXIS
.0006 0.015
PARALLELISM (UP TO 19.7) (UP TO 500)
4 OF "T" SLOT
.0008 0.020 TIR =
AND X AXIS
(SEE SHT. 4 FOR FULL LENGTH FULL LENGTH
T-SLOT TEST (OVER 19.7) (OVER 500)
INFORMATION) DATUM EDGE
Page 45
ALLOWANCE
NO. ITEM METHOD MEASURED INITIAL / DATE
INCHES METRIC
Z - X 0
PLANE
.0006/12 0.015/300
SQUARENESS
5 OF HEAD
AND TABLE
Z - Y
PLANE
.0006/12 0.015/300
0
SPINDLE
6 SWEEP
.0006/12 0.015/300 TIR =
TIR TIR
0
"0"
A = .0002 A = 0.005
1"
RADIAL SPINDLE
RUNOUT OF FACE A
7 SPINDLE 12"
TAPER
ROTATE
B B = .0008 B = 0.020
SPINDLE
1"
PARALLELISM LEFT RIGHT
OF Z AXIS
8 TO SPINDLE
X
12"
.0006/12 0.015/300
Y
CENTERLINE
FRONT BACK
MOVE Z AXIS
SPINDLE
AXIAL FACE
9 RUNOUT OF .0004 0.010
SPINDLE ROTATE
SPINDLE
Page 46
PROCEDURE FOR CHECKING TABLE FLATNESS
-0- -0-
INDICATOR SLIDE BAR

J-BLOCK PARALLEL BAR
(BASE PLATE
FOR INDICATOR)
TABLE SURFACE TABLE SURFACE
PLACE 2 J-BLOCKS ON TABLE AND PLACE THE PARALLEL BAR ON J-BLOCKS.

SECURE INDICATOR ON SLIDING PLATE AND PLACE SLIDING PLATE WITH INDICATOR
ON PARALLEL BAR.
STARTING FROM ONE END, INITIALLY SETTING INDICATOR TO ZERO, TAKE
AT LEAST (4) READINGS IN "X" (5 IN CASE OF LARGE TABLE) ALONG A
STRAIGHT LINE IN "X". REPEAT THIS PROCESS FOR AT LEAST (4) STRAIGHT
LINE READINGS IN "X".
REPEAT THE SAME PROCESS FOR "Y".

RECORD ALL READINGS AND RECORD THE TIR FOR "X" & "Y".
EXAMPLE OF CHECKPOINTS:
13 14 15 16
9 10 11 12
5 6 7 8
1 2 3 4
IN "X" DIRECTION: RECORD READINGS IN "Y" DIRECTION: RECORD READINGS
1, 2, 3, 4, 1, 5, 9, 13,
5, 6, 7, 8, 2, 6, 10, 14,
9, 10, 11, 12, 3, 7, 11, 15,
13, 14, 15, 16 4, 8, 12, 16
Page 47
PROCEDURE FOR CHECKING TABLE T-SLOTS
CL CENTER
T-SLOT
A 0.020
A 0.020
-A-
A 0.020
SEE BELOW
-B-
ALL T- SLOTS MUST BE PARALLEL TO CENTER

T- SLOT AND EACH OTHER WITHIN 0.0008".
B 0.020
+0.027
-0.000
18.000
0.5
+2.0 20.0
-0.0
34.0
+2.0
-0.0
SEE ABOVE 12.0
Page 48
10.2.8 Ball Screw Growth. The ball screw growth shall be measured for all axis at
rapid traverse speeds as outlined below. These tests shall be performed on
all prototype models and randomly on production machines as necessary.
11.0 RUST PREVENTION AND PACKAGING FOR SHIPPING
All frames ready for shipment must be thoroughly cleaned and prepared for rust protection
just prior to packaging for shipment. The following guidelines shall be followed for rust
protection. The rust protection materials specified in this section are recommendations by
Hurco. The contract manufacturer can use other rust preventive materials if so desired, but
in any event, it shall be the contract manufacturer's responsibility to take all necessary
precautions to prepare the frames and apply proper rust protection to ensure that frames
arrive at Hurco without any rust and/or damage.
The head, table and the saddle must be properly secured to prevent any movement that may
cause damage to the machine during shipment.
11.1 All rust preventive oils must be applied to surfaces by spray. By spray application,
surfaces that are difficult to reach can be adequately protected, especially ballscrews.
11.2 The slideways and the ballscrews for all (3) axes shall be protected by applying way
lubricant using the auto lube system. Be sure all the lube lines are not pinched or
passages blocked.
11.2.1 Fill the lube pump with MELCOTE 87-X WAY LUBRICANT
(recommended). Cycle the auto lube pump to make sure all the lube lines are
full. Contract Manufacturer to provide information and MSDS sheets if a
substitute lube oil is used.
11.2.2 Slowly traverse all axes including the Knee while cycling the pump. All axes
must be traversed to full stroke several times to ensure way surfaces are well
coated with the way lubricant. As with all rust preventives, good application
will result in a no-rust frame while a poor application will result in a rusty
frame.
11.3 Position the saddle, table and the head for securing each axis for shipping.
11.4 Spray coat all exposed way surfaces and unpainted machined surfaces and table tops
with MELCOTE 50286-HF RUST PREVENTIVE (recommended). These surfaces
(could be protected with the way lubricant also) include way surfaces not covered by
the saddle, table, head, ballscrews, etc.
11.5 It is very important all surfaces must be clean and dry before spray coating the rust
preventive oils. A clean surface will give a longer lasting protection. Poor rust
protection and good packaging will not prevent rust, but good preparation and
Page 49
proper application of rust preventative materials will prevent rust, even in some
cases when packaging is poor.
11.6 Cover all exposed way surfaces and the table top with ZERUST or VCI (Volatile
Corrosion Inhibitor) paper.
11.7 Hang bags containing vapor/moisture absorbing material (desiccant bags) at various
locations on the machine.
11.8 Cover the entire machine with a plastic bag (with VCI-127 films) and tape open ends
to create a seal (not vacuum pack).
11.9 Secure the machines on wooden skids. Dry wood or metal tubings must be used for
skids.
11.10 All loose parts for each machine must be well packed in a box. A check list shall be
provided for all loose parts in a box. This list shall include the part number,
description and quantity.
11.11 Each machine must have its own box of loose parts. Do not mix loose parts for
more than one machine in a box.
11.12 All loose parts must be properly identified with a label or a tag. This identification
shall include the part number, description and the quantity.
11.13 All loose parts which have unpainted machined surfaces must also be protected from
rust.
11.14 Machines shall be arranged on skids to utilize the skid space very efficiently.
11.15 Skids ready for shipment shall be carefully placed in a closed well-sealed container.
Skids must be arranged in the container to accommodate maximum numbers of
skids.
11.16 All skids and machines must be well identified for inspection by U.S. Customs.
11.17 The contract manufacturer shall not ship any machines with part shortages. In an
event a machine has to ship with part shortages, the shortages must be identified at
the time of machine acceptance, with a copy of itemized shortages defined in the
section called “Correction List” in the Machine Acceptance Document. This list also
must be sent to Hurco prior to shipping the machine.
11.18 All defined and agreed shortages must be shipped by Air such that these shortages
arrive before or at the same time the machine is to arrive at the final destination.
Page 50
757-4002-283 CAD #D8700

VMX30

Mihai Leahu _________________ ________
Dan Ornelas_________________ ________ ____________________________ ________


.
DO

1.0 INTRODUCTION

of Linear Scales.

d) 003-1018-007, ASS’Y, LINEAR SCALES, VMX/VSX30 (OPTION)

38
19 406-5001-006 TIE WRAP, MEDIUM 34
4 110-5001-002 WASHER, M4 FLAT 33
4 101-5021-010 SHCS, M4 X 0.7 P X 25 LG. 32
3 FT 508-2001-011 TUBING, 12 mm O.D. NYLON 31
1 506-3009-049 UNION, ELBOW 30
1 506-3001-050 COUPLING MALE 28
1 506-6053-009 STREET TEE, 3/8” F X 3/8” F X 3/8” M PT 27
2 108-5004-004 BHSCS, M6 X 1.0 P X 16 LG. 26
2 101-5008-006 SHCS, M6 X 1.0 P X 20 LG. 25
1 803-1002-224 BRACKET, Z READER HEAD ADJUSTING 24
1 803-1002-164 BRACKET, Z READER HEAD 23
1 REF 416-0250-055 SEALED, LINEAR ENCODER, Z AXIS 22
1 803-1000-109 PLATE (2), Z LINEAR SCALES 21
1 803-1000-093 PLATE, (1), Z LINEAR SCALES 20
8 101-5008-004 SHCS, M6 X 1.0 P X 16 LG. 19
1 803-1003-092 COVER, Y LINEAR SCALE 18
1 803-1002-165 BRACKET, Y READER HEAD ADJUSTING 17
2 117-5013-001 NUT, M6 X 1.0 P 16
2 101-5008-012 SHCS, M6 X 1.0 P X 45 LG. 15
1 803-6001-052 BRACKET, Y READER HEAD 14
1 REF 416-0250-054 SEALED, LINEAR ENCODER, Y AXIS 13
3 REF 423-4401-409 HARNESS, AXIS SERVO DRIVE, SCALE 12
4 101-5007-003 SHCS, M5 X 0.8 P X 12 LG. 11

1 803-1000-113 PLATE, X LINEAR SCALE, RIGHT 10
1 803-1000-112 PLATE, X LINEAR SCALE, LEFT 9
26 110-5001-004 WASHER, M6 FLAT 8
22 101-5008-008 SHCS, M6 X 1.0 P X 25 LG. 6
1 803-1002-223 BRACKET, X READER HEAD ADJUSTING 5
1 803-1002-222 BRACKET, X READER HEAD 4
32 101-5007-008 SHCS, M5 X 0.8 P X 25 LG. 2
1 REF 416-0250-081 SEALED, LINEAR ENCODER, X AXIS 1
PARTS LIST

#003-1018-007.

Adjusting X Reader Head, item #5, Bracket X Reader Head, item #4,
Plate, X Linear Scale, Left, item #9 and Plate, X Linear Scale, Right
item #10 to locate the holes. Use also Table and Saddle details to
locate those holes.
4.1.9 Install Linear scale for X axis on Saddle.
4.1.10 Install items #9, #10, Plate, X Linear Scales Left/Right on Saddle.

mm.

holes have not been drilled and tapped, use Bracket, adjusting Y Reader Head,
item #17, Bracket Y Reader Head, item #14, to locate the holes. Use also
Saddle and Base to locate those holes.
5.1.8 Install Linear Scale for Y axis on Base.
with Y axis travel.
Y Axis – Third strip from (-) travel end (white, white, brown)
scale brackets, item #23, Bracket Z Reader Head, item #24, Bracket,
Adjusting, Z Reader Head, and item #20, 21, Plate Z Linear Scales, if
the mounting holes have not been drilled and tapped. Use also Column
and Head details to locate those holes.
6.1.4. Install item #20, 21, Plate Z Linear Scales.
6.1.6. Install Linear Scale for Z axis on Column.
mm.
Position.
Example: With leadscrew encoders the X, Y and Z axis CALIBRATE HOME

POSITION = 0. (Assumes 16.0 mm Limit Switch to Marker distance for all three
Axes).
8.5. For Z-Axis
value [-30.0 mm].
8.6. For X-Axis
value [20.5 mm].
8.7. For Y-Axis
8.7.1. With the Y-axis still on the Y- limit switch, slowly begin handwheel jogging Y-
axis in positive direction (x1 mode) and stop when Y- limit switch indication is
no longer displayed. Note Y-axis MACHINE POSITION on DRO [i.e. –
42.3]
8.7.2. Add 16 mm from current position [-42.3+16 = -26.3]
8.7.3. Multiply result by –1. This results in Y CALIBRATE HOME POSITION
value [26.3].
8.8. Note: Any machine specific dimensions (Tool Change Height, TPS Fixture Position,
TPS Access Position, etc.) will need to be redefined.
9.3 Reference HEIDENHAIN Mounting Instruction Manual for operation.

BMC4020
Res For Future Use

Res For Future Use
Res For Future Use
Res For Future Use
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Res For Future Use
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V*X50
D8701 757-4002-284 Installation Procedures for Heidenhain LS176 Linear Scales

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757-4002-284 CAD #D8701

VMX50

Mihai Leahu _________________ ________
Dan Ornelas _________________ ________ ____________________________ ________


.
DO

1.0 INTRODUCTION

of Linear Scales.

d) 003-2018-004, ASS’Y, LINEAR SCALES, VMX50 (OPTION)

38
37
36
35
25 406-5001-006 TIE WRAP, MEDIUM 32
4 110-5001-002 WASHER, M4 FLAT 31
4 101-5021-010 SHCS, M4 X 0.7 P X 25 LG. 30
1 REF 423-4401-444 HARNESS, Z-AXIS SERVO DRIVE, SCALES 29
1 REF 423-4401-410 HARNESS, Y-AXIS SERVO DRIVE, SCALES 28
1 REF 423-4401-409 HARNESS, X-AXIS SERVO DRIVE, SCALES 27
1 803-6003-042 PLATE, ADJUSTMENT, Z-AXIS 25
2 110-5001-003 WASHER, M5 FLAT 24
2 101-5007-004 SHCS, M5 X 0.8 P X 17 LG. 23
1 803-4102-009 BLOCK, DISTRIBUTION 22
1 506-0013-003 TEE, MALE RUN 3/8” PT X &6 TUBE 21
2 508-2001-010 TUBING, NYLON, &6 X 6800 mm 20
1 506-0012-002 ELBOW, MALE 3/8” PT X &12 mm TUBE 18
1 506-0012-003 ELBOW, MALE 3/8” PT X &6 mm TUBE 17
1 508-2001-011 TUBING, NYLON, &12 X 1500 mm 16
1 506-0014-001 CONNECTOR, MALE 3/8” PT X &12 mm TUBING 15
1 803-6001-136 BRACKET, ADJUSTMENT, Z-AXIS 14
1 REF 416-0250-080 SCALE LINEAR, Z-AXIS 13
1 803-6001-133 BRACKET, ADJUSTMENT, Y-AXIS 12
1 803-6003-041 PLATE, ADJUSTMENT, Y-AXIS 11

3 108-5003-003 BHSCS, M5 X 0.8 P X 10 LG. 10
1 803-6002-149 COVER, SCALE, Y-AXIS 9
1 REF 416-0250-079 SCALE LINEAR, Y-AXIS 8
14 110-5001-004 WASHER, M6 FLAT 7
14 101-5008-006 SHCS, M6 X 1.0 P X 20 LG. 5
1 803-6001-132 BRACKET, ADJUSTMENT, X-AXIS 4
39 101-5007-008 SHCS, M5 X 0.8 P X 25 LG. 2
1 REF 416-0250-078 SCALE LINEAR, X-AXIS 1
PARTS LIST

#003-2018-004.

Adjusting X Reader Head, item #4. Use Table and Saddle details
to locate those holes.
4.1.9 Install Linear scale for X axis on Saddle, item #1.

mm.

holes have not been drilled and tapped, use Bracket, adjusting Y Axis, item
#12, and item #11, Plate, Adjustment, Y-axis to locate the holes. Use Saddle
and Base to locate those holes.
5.1.8 Install Linear Scale for Y axis, item #8 on Base.
with Y axis travel.
Y Axis – Third strip from (+) travel end (white, white, brown)

scale brackets, item #14, Bracket Z, Adjustment, Z-axis and item #25,
Plate, Adjusting, Z-axis, if thr mounting holes have not been drilled
and tapped. Use Column and Head details to locate those holes.
6.1.4. Install item #25, Plate Adjustment, Z-axis.
6.1.6. Install Linear Scale for Z axis, item #13 on Column.
mm.

Position.
Example: With leadscrew encoders the X and Z axis CALIBRATE HOME

POSITION = 0, Y-axis CALIBRATE HOME POSITION = 660.4. (Assumes 16.0 mm
Limit Switch to Marker distance for all three axes).
8.5. For Z-Axis
value [-30.0 mm].
8.6. For X-Axis
value [20.5 mm].
8.7. For Y-Axis

8.7.1. With the Y-axis still on the Y+ limit switch, slowly begin handwheel jogging Y-
axis in positive direction (x1 mode) and stop when Y+ limit switch indication is
no longer displayed. Note Y-axis MACHINE POSITION on DRO [i.e.
+685.0]
8.7.2. Subract 16 mm from current position [685 - 16 = +669.0]
8.7.3. Subract Y AXIS TRAVEL LIMIT [669.0 – 660.4 = +8.6]
8.7.4. Subract result from Y AXIS TRAVEL LIMIT. This is the Y CALIBRATE
HOME POSITION value [660.4 – 8.6 = +651.8 mm]
8.8. Note: Any machine specific dimensions (Tool Change Height, TPS Fixture Position,
TPS Access Position, etc.) will need to be redefined.
9.3 Reference HEIDENHAIN Mounting Instruction Manual for operation
.

BMC 6434
D8611 757-4002-200 BMC6434 Machining Center Technical Specifications

D8596 757-4002-187 BMC6434 Chip Conveyor Installation Procedures
D8604 757-4402-193 BMC6434 Mech. Installation Procedures For Heidenhain LS-176 Scales
D8617 757-4002-205 BMC6434 10K Spindle Installation Procedure, Upgrade
D8632 757-4002-220 BMC6434 Installation of Coolant Through the Spindle
D8654 757-4002-239 BMC6434 40 Taper Head Thermal Comp. With Chiller and Fans
D8655 757-4002-240 BMC6434 Elec. Installation of Heidehain LS-176 Scales, Parameters
SPECIAL 704-0001-792 BMC6434 50T PLWD's, Rev. A
SPECIAL 003-6000-010 Machine Shipping Instructions
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R
757-4002-200 CAD # D8611
SUBJECT: BMC6434 MACHINING CENTER

TECHNICAL SPECIFICATIONS

RECORD OF CHANGES
757-4002-200
REV A CAD # D8611

A 14493 Original Release J. DILK 8DEC98
1.0
Machine Capacity
Table Working Surface 66” x 35” 1676mm x 889mm
T-Slots 7 x 0.71” 7 x 18mm
On 4.92” centers On 125mm centers
Maximum Load
With Uniform Distribution 4000 lb. 1814 kg
Enclosure Door Opening 68” 1727mm
Spindle Center To Column 38” 965mm
Spindle Nose To Table
Minimum/Maximum 6” / 36” 152mm / 914mm
(For table and machine clearances, please see attachment “B”)
2.0
Spindle
Type Cartridge, #40 Taper
Speeds 0-8000 rpm
Bearings ABEC Class 7 angular contact
Bearing Lubrication Grease packed

Spindle Motor AC Induction Motor, Dual winding, Fan cooled
Spindle Drive 200VAC, 3 Phase, 50/60 Hz, Regenerative Braking
Spindle Taper #40
Spindle HP 20 HP (15 kW) 30 minute rating *
15 HP (11 kW) continuous rating
Spindle Torque 175 lb-ft (237 Nm) at 600 RPM 30 minute rating *
129 lb-ft (175 Nm) at 600 RPM continuous
Drive Belt Ratio 1-1 Standard

Belt Type 8mm pitch, Poly Chain
Maximum Speed 8000 rpm Standard
Spindle Acceleration Time 0-8000 rpm in 5 seconds

Spindle Decelerate Time 8000-0 rpm in 4 seconds
Spindle Orientation Electronic - Spindle motor encoder
Spindle Air Blast Standard
Spindle Configuration Cartridge-type, flange mounted
(For spindle cross section, see attachment “C”. For motor and spindle HP, speed and torque curves, see attachment “E”)
Note:
* 30 minute rating: Motor can run at this power rating for 15 minutes and must be at no load for the remaining 15
minutes.
3.0
Movement and Ranges
Longitudinal (X) axis 64” 1625mm
Cross (Y) axis 34” 863mm
Vertical (Z) axis 30” 762mm
4.0
Position/Feed Rates
Rapid Feed Rate:
X axis 705 inches per minute 18m/minute
Y axis 705 inches per minute 18m/minute
Cutting Feed Rate:

X axis 300 inches per minute 7.6m/minute
Y axis 300 inches per minute 7.6m/mimute
Programming Resolution 0.0001” 0.002mm
5.0
Automatic Tool Changer
Number of Stations 24
Maximum Tool Diameter 3.2” 80mm
Maximum Tool Diameter (Adjacent Sides Empty) 5.0” 127mm
Tool Pocket Pitch 3.2” 81mm
Maximum Tool Length 11.8” 300mm
Maximum Tool Weight 15 lb. 6.8 kg
Adapter ANSI Standard V-Flange
ATC Time:
Tool to tool next station 3 seconds
Chip-to-Chip 2000 rpm 12” Z travel 7 seconds
Tool Selection System Random pot, bi-directional, swing arm
Retention Knob See attachment “D”
Note:
Tools to be loaded in the Automatic Tool Changer by using the spindle. Do not manually load tools directly into the Automatic Tool Changer.
6.0
Axis Movement
Axis Motors:
X AC 74 lb-in
Y AC 74 lb-in
Z AC 252 lb-in, with brake
Axis Thrust: Peak
X 4702lb. 20.9 kN
Y 4702 lb. 20.9 kN
Z 7155 lb. 31.8 kN
Axis Trust: Continuous

X 1682 lb. 7.5 kN
Y 1682 lb. 7.5 kN
Z 5727 lb. 25.4 kN
(For motor and spindle HP, speed and torque curves, see attachment “E”.)
Ball Screw Diameter

X 2.0” 50mm
Y 2.0” 50mm
Z 2.0” 50mm
Ball Screw Pitch

X .472” 12mm
Y .472” 12mm
Z .472” 12mm
Ball Screw Mounting
X, Y, and Z Double nut anchored on both ends
Ball Screw Drive System

X and Y Belt drive
Z Direct drive
Encoder Mounting Drive motor mounted
Guideway Systems:
X Precision linear ball rails
Y Precision linear ball rails and roller bearings
Z Hardened and ground box way
Bearing Trucks in X axis 4 total, 2 per rail Bearing Trucks in Y
axis 4 total, 2 per rail
Support Rollers in Y axis 2 total, 1 per rail
Distance between X axis ways (centers) 22.1” 561mm
Distance between Y axis ways (centers) 23.7” 603mm
Distance between Z axis ways (centers) 40” 1017mm
(Telescoping way covers used over all exposed ways)
7.0
Accuracy (at 68o F)
Positioning Accuracy (4 Pass VDI - 3441 method) -/+0.0002” -/+0.005mm
Repeatability (4 Pass VDI - 3441 method) -/+0.0001” -/+0.0025mm
( At final assembly, all machines are laser mapped, contour balanced with ball bar check, and run a capacity cutting test.. Therefore, the machine
is capable of producing these accuracies. If at installation, the machine cannot achieve these accuracies, Hurco will determine the reason for non-
attainment. If the reason is mechanical components, these will be replaced under the warranty. If the reason is improper transportation or rigging,
the customer will be charged at normal service rates. )
8.0
Draw Bar Actuation
Type Air/Oil Cylinder
Stroke 6.5mm
Maximum Force to Unclamp 3300 lb. (14.7 kN)
Air Supply 85-90 PSI (6 bar)
Maximum Clamping Force 2200 lb. (9.8 kN)
Draw Bar Type Gripper finger, Disc springs
9.0
Machine Dimensions
Table Size 66” x 35” 1676mm x 889mm
T-Slots
Number 7
Width x Spacing 0.71” @ 4.92” 18mm @ 125mm
(See attachment for slot and table dimensions)
Shipping Dimensions
Width 167” 4242mm
Depth 108” 2744mm
Height 133.9” 3400mm
Operating Dimensions
Width 249.5” 63380mm
Depth 173.3” 4400mm
Height 122” 3100mm
Machine Weight (approximate) 27000 lb. 12247 kg
Shipping Weight (approximate) 31000 lb. 14062 kg
(See attachment “A” for machine envelope dimensions)
10.0
Lubrication
Type Positive displacement by electric pump
Lubrication Type See Attachment `F’
Lubrication Volume 2 liter reservoir with float switch to maintain liquid level. Tank should last 80 hours
before refilling.
Lubrication pump 115 VAC, single phase, electric pump with maximum
discharge of 3-6 cc/cycle - 4 cycles per hour
Maximum pump pressure 42 PSI (2.9 bar)

11.0
Coolant Facilities
Coolant Tank Capacity 75 gallons 285 liters
Flood Pump Rating 40 gallons/minute 151 liters/minute

(same pump for flood and washdown)
Flood Pump Size 2 HP 1.56 kW
Full Chip and Coolant Enclosure Standard

Worklights Dual Standard
12.0
Machine Enclosure
Enclosure Door Opening 68” 1727mm
Left Side (ATC door)

Hinged Door (L x H) 45.5” x 49.5” 1156mm x 1257mm
Right Side
Hinged Door (L x H) 45.5” x 49.5” 1156mm x 1257mm
Dual Worklights Left side Right side
Chip Pan Side pull-out

Chip Conveyor Optional
Washdown System Standard
Enclosure Includes Top to Contain Chips and Coolant
(See attachment “G” for conveyor information)
13.0
Service Requirements
KVA Rating 33
Voltage Required 200-250 VAC / 60 Hz / 75 amp
Air Requirements 5 CFM @ 80-100 psi 0.14 M3/min. @ 6-8 bar
IMPORTANT:
As with all computer equipment, it is vital that the incoming power be free from high or low voltages, spikes, surges, and noise. The following
are the extremes from normal constant RMS sinusoidal supply voltages the system can tolerate:
Frequency.................................................................................. 47-63 Hz
Impulse Voltage ........................................................................ 200 percent peak voltage up to one msec duration.
One (1) pulse per half cycle maximum.
Voltage Drop............................................................................. Reduction of 20 percent for one cycle or reduction of 50 percent per half cycle. One
(1) drop per second maximum. Deviation from constant voltage will not ±10% of
input voltage. Failure to provide required power parameters may affect warranty.
List of Attachments
Machine Floor Layout ______________________________Attachment A
Table and Clearance _______________________________Attachment B
Spindle Assembly _________________________________Attachment C
Tool Holder and Retention Knob______________________Attachment D
Spindle Torque Charts______________________________Attachment E
Machine Oil Specifications_____________________ Attachment F
Chip Conveyor ______________________________ Attachment G
757-4002-187 CAD #D8596
CONVEYOR
BMC6434

Jeff Bitant _________________ ________
Mihai Leahu _________________ ________
Moe Whittemore _________________ ________ ____________________________ ________
Rev ECN # Revision Description Pg. # Date By App
. v.
Page 2
1.0 INTRODUCTION
This document is intended as a guideline to install The Conveyor Option on

BMC6434 series machines. This option can be ordered as one complete package
Conveyor. This procedure can be used for installing a complete option package
of Conveyor.

BILL OF MATERIAL FOR ASS’Y, 003-6011-001, ASS’Y, CONVEYOR, OPTION.
9
8
7
1 109-5011-004 PHMS, M5 X 12MM 5
3 101-5007-022 SHCS, M5 X 16MM 4
4 408-7501-030 CLAMP, ¾” BLACK NYLON 3
1 423-4400-017 HARNESS, CHIP CONVEYOR 2
1 003-6011-002 ASS’Y, CHIP CONVEYOR 1
QTY PART NUMBER ITEM DESCRIPTION ITEM
PARTS LIST
INSTALL PROCEDURE.
3.1 MECHANICAL INSTALL PROCEDURE FOR ASS’Y, CONVEYOR, OPTION, DRAWING #003-
6011-001.
+ PLEASE REFER TO FIGURE 1.
BMC6434 is designed to accept this option.
3.1.1. There is a plate located on the backside of the Chip Tank (above fluid level)
toward the rear of the machine. To remove this plate, slide the Chip Tank
out from Enclosure to allow access to mounting screws. Remove this plate.
3.1.2. Adjust the height of the Conveyor (by adjusting the height of the casters
or the casters mounting post) to align even with the opening in Chip Tank.
3.1.3. Slide the Conveyor into the Chip Tank, and together toward the machine
Base.
Page 3
FIGURE 1.
Note: Balloon numbers
correspond to items in BOM
listing for this assembly
1 Remove side plate in

the Chip Tank to slide
the Conveyor under the
machine Base.
2 Adjust caster to align the height of the Conveyor

to the opening in the Chip Tank.
Page 4
3.1.4. The main Conveyor wiring harness shall be routed as detailed

in Figure 2.
3 Harness routing.
Page 5
FIGURE 2.
There are (8) corelock hose clamps provided to secure the harness
(item 2) from Conveyor to the Electrical Cabinet.
NOTE: DO NOT drill any holes into the machine Enclosure!
Mount the clips to the Base, approximately 300-mm from the floor
level. Drill and tap (3) holes M5 x 0.8 P (see Figure 3 for location)
and install clips. Drill (1) 3.0-mm holes into the Electrical
Cabinet and install the clip.
4 Drill and tap holes to install clips.
Page 6
FIGURE 3.
3.2. ELECTRICAL INSTALLATION PROCEDURE FOR ASS’Y, CONVEYOR

DWG. #003-6011-001 & 423-4400-017.
**** IMPORTANT**** Ensure the Chip Conveyor motor voltage wiring is

configured for the proper machine type for which it is being installed.
For example, BMC4020 and BMC30s (Siemens) should be jumpered for
for 400VAC, while machines equipped with Yaskawa motors should have
their Conveyor motors jumpered for 230VAC.
Motor wiring configuration is identified either on the motor ID plate
or inside the terminal box, depending upon Chip Conveyor model.
3.2.1. Connect Harness, Chip Conveyor (dwg. #423-4400-017) to the mating

connector located on the underside of the Enclosure Ass’y, Chip Conveyor
Control Panel, dwg. #003-1005-004.
3.2.2. Provide a ¾” knockout in the bottom right hand corner of the Control
Cabinet to accommodate the Harness, Chip Conveyor dwg. #423-4400-017
entrance.
3.2.3. Connect the motor power conductors to circuit breaker CB-2 (6a),
terminals 2, 4 and 6. Connect the motor frame ground wire to a central ground
point. Finally, connect control voltage +24VDC SW to TB1-block 1 and the
machine ground and cable shield to TB1-block 3, as indicated on Harness
dwg. #423-4400-017.
Page 7
757-4402-193 CAD #D8604
SUBJECT: MECHANICAL, INSTALLATION PROCEDURES
BMC6434

Himat Patel _________________ ________
Mihai Leahu _________________ ________
_________________ ________ ____________________________ ________
757-4402-193 BMC6434 Linear Scales Installation Procedure Page1

Rev. A
.

Rev. A
1.0 INTRODUCTION

BMC6434 series machines. This option can be ordered as one complete package
of Linear Scales.

BILL OF MATERIAL FOR ASS’Y, 003-6005-006, ASS’Y, LINEAR SCALES.
34
33
1 803-6001-011 BRACKET, “Z” READER HEAD ADJUSTING 32
1 803-6001-053 BRACKET, “Z” READER HEAD 31
1 REF 416-0250-040 ENCLOSED LINEAR ENCODER, “Z” AXIS 30
2 101-5008-014 SHCS, M6 X 1.0 P X 55 LG. 29
1 REF 416-0250-039 ENCLOSED LINEAR ENCODER, “Y” AXIS 28
4 117-5013-001 NUT, M6 X 1.0 P HEX. 27
2 101-5008-012 SHCS, M6 X 1.0 P X 45 LG. 26
1 803-6001-003 BRACKET, “Y” READER HEAD ADJUSTING 25
8 101-5008-008 SHCS, M6 X 1.0 P X 25 LG. 24
1 803-6001-052 BRACKET, “Y” READER HEAD 22
1 REF 423-4401-302 HARNESS, AXIS SERVO DRIVE, SCALES 21
1 506-3001-052 COUPLING, MALE 20
43” 508-2001-012 TUBING, 10 MM O.D. NYLON 19
1 506-3009-046 UNION, ELBOW 18
1 REF 416-0250-033 UNIT COMPRESSED AIR 17
4 101-5008-004 SHCS, M6 X 1.0 P X 16 LG. 16
12 110-5001-004 WASHER, M6 FLAT 15
19 406-5001-006 TIE WRAPS MEDIUM 14
4 101-5021-010 SHCS, M4 X 0.7 P X 25 LG. 13
4 110-5001-002 WASHER, M4 FLAT 12
1 506-5058-005 STREET TEE, 3/8 PT 11
2 REF 423-4401-301 HARNESS, AXIS SERVO DRIVE, SCALES 10
3 103-8001-012 SSS, M5 X 0.8 P X 10 LG. FLAT PT 9
1 803-6000-026 PLATE, “X” READER HEAD ADJUSTING 8
44 101-5007-008 SHCS, M5 X 0.8 P X 25 LG. 7
1 REF 416-0250-038 ENCLOSED LINEAR ENCODER, “X” AXIS 6
4 110-5001-003 WASHER, M5 FLAT 5
2 101-5007-003 SHCS, M5 X 0.8 P X 12 LG. 4
1 803-6001-005 BRACKET, “X” READER HEAD 3
4 101-5007-022 SHCS, M5 X 0.8 P X 16 LG. 1
PARTS LIST
Rev. A

#003-6005-006.
+ PLEASE REFER TO FIGURE 1, 2, 3.
BMC6434 series machines, are designed to accept this option.

4.1.3. Remove the “X” axis limit switch and bracket. Limit switch does not
need to be disconnected.
mounting holes have not been drilled and tapped, use the “BRACKET,
“X” AXIS DOG” and “SADDLE” details to locate.
4.1.5 Install the reader head bracket on the “SADDLE”.
4.1.7 Install the scale mounting brackets to the scale.
4.1.8 Mount the assembly to the table “X” axis dog brackets.
reader head and mounting brackets are aligned.
4.1.11 “X” axis travel verification (BMC6434).
A) Software Limit 1625mm (64”)
B) Distance between hard stops 1651mm
4.1.12 Connect Air Purge to scale assembly. Reference the HEIDENHAIN
Mounting Instruction Manual.
NOTE:
Fig. 1.2.3. can be used as a guidance for “Y” & “Z” AXIS SCALE
INSTALL

Rev. A
FIGURE 1.
FIGURE 2.

Rev. A
FIGURE 3.
5. “Y” AXIS SCALE INSTALL
5.1.1. Disconnect the front and rear telescoping covers from the “SADDLE”.
5.1.2. Locate mounting holes for the reader head and scale brackets. If the
mounting holes have not been drilled and tapped, use the “SADDLE” and
the “BASE” details to locate.
5.1.3. Install the reader head bracket on the “SADDLE”.
5.1.4 Install the scale mounting brackets to the scale.
5.1.5 Mount the scale assembly to the “BASE” casting.
reader head and mounting brackets are aligned.
5.1.8 “Y” axis travel verification (BMC6434).
5.1.9 Connect Air Purge to scale assembly. Reference the HEIDENHAIN
Rev. A
6. “Z” AXIS SCALE INSTALL
6.1.1. Locate mounting holes for the reader head and scale brackets. If the
mounting holes have not been drilled and tapped, use the “COLUMN” and
“ASSEMBLY LINEAR SCALE” to locate.
6.1.2. Install the reader head bracket on the “HEAD” casting.
6.1.3. Install the scale mounting brackets to the scale.
6.1.4. Mount the scale assembly to the “COLUMN”.
the reader head and mounting brackets are aligned.
6.1.6. Reference the HEIDENHAIN Mounting Instruction Manual for
alignment of the scale and reader head.
6.1.7. “Z” axis travel verification (BMC6434).
6.1.8. Connect Air Purge to scale assembly. Reference the HEIDENHAIN
7.1. Locate and mount per the drawing “ASSEMBLY, LINEAR SCALE”.
7.2. Unlubricated Air Supply to scale filter/regulator.
7.3. Reference HEIDENHAIN Mounting Instruction Manual for operation.

Rev. A
757-4002-205 CAD #D8617
SUBJECT: INSTALLATION PROCEDURE

FOR KIT 10K SPINDLE, UPGRADE.
BMC6434

Himat Patel _________________ ________
Mihai Leahu _________________ ________
Scott Wrobleski _________________ ________ ____________________________ ________
Rev ECN # Revision Description Pg. # Date By Appv

.
A 14518 Original Issue 10/15/99 ML/ HP
SW
10000 RPM Spindle Option 757-4002-205 Rev. A Page 2

INSTALLATION PROCEDURE
1.0 INTRODUCTION
This document is intended as a guideline to install a new transmission on existing BMC6434 series
machines, in order to increase the Spindle speed from 8,000 RPM to 10000 RPM.
Please refer to Graphic 1 and Graphic 2, page 9 and page 10.
This procedure can be used for installing a complete option package for 10000-RPM Spindle.
BILL OF MATERIAL FOR ASS’Y, 003-6003-005, KIT 10K, SPINDLE UPGRADE.
1 450-3001-389 PROM, YASKAWA SPINDLE CONTROL PROGRAM 22

3 406-7001-043 BUTT SPLICE, 22-16AWG RED 21
1 423-4401-356 HARNESS, AUX, SPINDLE MOTOR ENCODER 20
2 103-5008-001 SHSS, M6 X 1.0 P X 6 LG. 18
1 108-5004-001 BHCS, M6 X 1.0 P X 10 LG. 17
1 418-5002-013 SWITCH, PROXIMITY, M5 NPN 16
1 803-6001-070 BRACKET, PROXIMITY SWITCH, M5 15
4 110-0046-007 LOCKWASHER, HELICAL M6 14
2 101-5008-003 SHCS, M6 X 1.0 P X 12 LG. 13
REF 110-0046-006 LOCKWASHER, M5 HELICAL SPRING 12
REF 101-5007-008 SHCS, M5 X 0.8 P X 25 LG. 11
REF 803-1012-003 RETAINER, PULLEY 10
1 204-0008-034 BELT, POLY-CHAIN GT 9
1 803-6005-066 PULLEY, SPINDLE MOTOR (10K) 8
REF 803-6000-007 PLATE, SPINDLE MOTOR 7
REF 803-1013-007 WASHER, FLAT M12 6
REF 101-5012-007 SHCS, M12 X 1.75 P X 50 LG. 4
REF 105-5051-003 HHCS, M14 X 2.0 P X 35 LG. 2
REF 402-6009-116 MOTOR, SPINDLE 1
QTY PART NUMBER ITEM DESCRIPTION ITEM REV
PARTS LIST

INSTALL PROCEDURE.
3.1 MECHANICAL INSTALL PROCEDURE FOR KIT, 10K SPINDLE UPGRADE

(OPTION), DRAWING #003-6003-005.
+ PLEASE REFER TO FIGURES: 1, 2.
BMC6434, series machines are designed to accept this option.
3.1.1. There are (11) SHCS, M6 X 1.0 P X 20 LG. screws, see Fig. 1, item #1, on the front and
right side of the Head, on Cover, Head Front, see Fig. 1, item #2, Cover Head R.H., see
Fig. 1, item #3 and Cover, Head R.R., see Fig. 1, item #4. Remove these (11) screws.
3.1.2. Lift all covers and set them outside of machine.
3.1.3. Lower Z-axis at your convenience for easier access to the Motor; see Fig. 2, item #1.
3.1.4. Remove (4) M12 X 1.75 P X 50 LG. screws, (4) lockwashers M12 and (4) flat washers,
from the Motor Mounting Plate, see Fig. 2, items 4, 5, 6.
3.1.5. Push the Motor forward, to remove all tension from Belt. See Fig. 2, item #9.
3.1.6. Disconnect the power and lock out.
3.1.7. Disconnect wires from Motor and remove the Motor. Set the Motor outside of machine.
3.1.8. Remove (3) SHCS, M5 X 0.8 P X 25 LG. screws and (3) lockwashers from the bottom
of Pulley, see Fig. 2, item #8.
3.1.9. Remove Retainer Pulley, see Fig. 2, item #10.
3.1.10. Remove Pulley using a puller, see Fig. 2, item #8, from Motor, dwg. no. 803-1046-003.
3.1.11. Install a new Pulley on Motor, dwg. no. 803-6005-066, using blue loctite on M5 screws.
3.1.12. Drill and tap new (4) holes M12 X 1.75 P, 80 mm to the back of machine from existing (4)
holes M12 X 1.75 P. See dwg. no. 003-6003-005 sheet 2.
Please refer to Fig. 3, item #3.2 on page 6 of this document, for mounting Proximity Switch.
3.1.13. Clean out all chips from Head.

3.1.14. Install new Encoder Harness, dwg. (423-4401-356).
3.1.15. Disconnect Original Encoder Harness from Spindle drive in Electrical Cabinet (3CN) and
Winding Select Contactor.
3.1.16. Connect new Encoder Harness to Spindle Drive (3CN) and Winding Select Contactor.
3.1.17. Connect new Encoder Harness to Spindle Motor, and Reconnect Spindle Power Harness.
3.1.18. Use butt splice (406-7001-043) connect Proximity Switch (418-5002-013) to new Encoder
Harness. (blue prox. wire – white wire) (black prox. wire – red/black wire) (brown prox wire
– white/black wire).
3.1.19. Reinstall new Belt, see Fig. 2, item #9, dwg. no. 204-0008-034.
3.1.20. Power up machine.

3.1.21. Verify and adjust pulley height alignment.
3.1.22. Adjust belt tension. Please refer to Fig. 4, page 7, item 3.3. of this document.
3.1.23. Change spindle parameters in Ultimax, using data from page 11, item #4.1., of this document,
Ultimax parameter changes.
3.1.24. Set orient zero mark with proximity sensor. Please refer to page 11, item #4.2., of this
document.
3.1.25. Reinstall front and right side Head covers in reverse order.
FIGURE 1. (Head, Covers)
FIGURE 2. (Pulley and Belt Installation)

3.2. MECHANICAL INSTALL PROCEDURE FOR PROXIMITY SWITCH.
+ PLEASE REFER TO FIGURE 3
FIGURE 3. (Proximity Switch)
3.2.1. Drill and tap (2) holes M6X1.0PX15LG. to install Bracket Proximity Switch, dwg. no.
803-6001-070, see Fig. 3, item #1. Location for these (2) holes is shown on dwg. no.
003-6003-005 sheet 1 and on Fig. 3.
3.2.2. Install (1) BHCS, M6 X 1.0 P X 10 LG., P/N 108-5004-001, see Fig. 3, item #4 and on
the opposite direction, install (2) SHSS M6 X 1.0 P X 6 LG., P/N 103-5008-001, to
compensate the weight of the BHCS, so that the Spindle should be balanced, see
Fig. 3, item #5. Use loctite to secure them.
3.2.3. Install Bracket Switch, see Fig. 3, item #1. Use (2) M6X1.0PX12LG. with (2) M6
lockwashers to secure it.

3.2.4. Install Proximity Switch, P/N 418-5002-013, see Fig. 3, item #3. Adjust the distance
between item #3 and item #4. This distance should be ~0.5 mm.
3.3. V-BELT TENSIONING METHOD.
FIGURE 4. (Belt Tension)
3.3.1. The best tension for a belt drive is the lowest tension under the highest load condition,
for optimum performance and life of the spindle.

3.3.2. Too much tension shortens belt and bearings life of the spindle. A spindle failure can
occur within a short period of time.
3.3.3. Keep belts and sheaves free from any foreign material, which may cause damage.
3.3.4. We recommend using a Gate Tension Tester to check the tension belt.
This procedure, using a Gate Tension Tester, is described below
and shown in fig. 4.
3.3.5. Push the motor using a jackscrew to tighten the belt, and secure it.
3.3.6. Position the lower of the two (2) “O” Rings using the following method.
Span Length
Machine Model Span Length (t) (in) Deflection (in)
BMC6434 (10K) 30.86 0.48
3.3.7. On the scale reading “Deflection Inches”, set the “O” Ring to show a deflection equal
to 1/64” per inch of span length (t). See chart for span length for machine model.
3.3.8. At center of span (t) apply force, with Gates Tension Tester perpendicular to the span,
large enough to deflect the belt on the drive until the bottom edge of the lower “O”
Ring is even with the top of the belt in initial position. A straight edge across the belt
top will assure accuracy of positioning.
3.3.9. Find amount of deflection force on upper scale of Tension Tester. The Sliding Rubber
“O” Ring slides down scale as tool compresses and stays down for accurate reading of
pound pressure. Read at top edge of ring. (Slide ring up before reusing).
3.3.10. See chart bellow for deflection distance and deflection force.
Deflection
Machine Model Deflection force (lb) Deflection distance (in)
BMC6434 (10K) 15-17 0.45~0.50
NOTE: If the measured force is less than minimum recommended deflection force, belt should
be tightened. If the measured force is more than maximum recommended deflection
force, drive is tighter than necessary. Run-in the spindle and perform a test cut. Verify
belt tension and reset if necessary.

GRAPHIC 1.
SPINDLE 8,000 RPM
26
24
22
20
18
Torque (10 x Ft*Lbs) / Power (hp)
16
14
12
10
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000
Motor R.P.M.
BMC 6434/40T-8K Torque / Horsepower Chart

Base Speed 600 RPM, Max. Speed 8000 RPM
1 Min. Power Rating 24 HP
1 Min. Torque Rating 210 Ft*Lbs

GRAPHIC 2.
SPINDLE 10000 RPM
26
24
22
20
18
16
MotorPower
( x) 14
Torque( x )
12
10
0
4
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 1 10
x
Motor R.P.M.
BMC 6434/40T-10K Torque / Horsepower Chart (Option)

1 Min Torque Rating 168 Ft*Lbs

4.1 ULTIMAX PARAMETERS
Change the Ultimax Parameters to match the table below.
<enter>, 100, <enter> **Integrator Support Services**
F1 - CNC Configuration Parameters
SPINDLE
Vertical Parameters Spindle

Maximum Spindle Motor Speed 8000
Maximum Spindle Tool Speed 10000
SPINDLE GEAR
Vertical Parameters Spindle Gear Parameters

Gear 0
Ratio 0.8000
Minimum RPM 1
Maximum RPM 10000
Tap Acceleration 100000
4.2 Yaskawa Eprom Installation/Verification
4.2.1 Verify Power is turned off.

4.2.2 Remove the four screws on the front of the Spindle Drive, and remove the front cover.
4.2.3 Remove the four screws holding the Orientation Card. It is the outer most card toward the bottom of
the drive, Approx 4.5” X 10”, and it’s ribbon cable may be disconnected.
4.2.4 Look for Prom U22 on the main PC board directly in front of you. If the number on the Prom is
NSN620208 or later (NSN620209, NSN620210…) then it does not need to be replaced. If it is
earlier, it must be replaced. Use Prom (450-3001-389).
4.2.5 Re-install the Orientation Card.
4.2.6 Reinstall the Front Cover.
4.2.7 Turn on Power.
4.3 Motor Encoder Orient
4.3.1 Calibrate machine, both axes and tool changer.

4.3.2 Enter Integration Support Services on the Hurco controller – AUX,Enter,100,Enter.
4.3.3 Enter “Machine Setup and Test” – F3.
4.3.4 Enter “Tool Changer Diagnostics” – F4.
4.3.5 Move Z-axis in positive direction until it stops at the software limit.
4.3.6 From the ATC Diagnostics screen command the “Spindle Orient” – F1
4.3.7 From the ATC Diagnostics screen command the ATC “Load Arm 60°” – F3.

4.3.8 From the ATC Diagnostics screen carefully and slowly jog Z-axis down (negative) until the spindle
nose is approximately 1.0” from top of ATC load arm.
4.3.9 Press the “Spindle OFF” button on console. Rotate the spindle by hand until the spindle key is aligned
with the ATC gripper key slot.
4.3.10 Record spindle motor position (counts) ________ from spindle drive display U2-03 (V2-03).
4.3.12 Push “Emergency Stop” on the control.
4.3.13 Set Spindle Drive Parameter C2-22 = 11010010.
4.3.14 Set Spindle Drive parameter C2-24 bit 0= 1
4.3.15 Set Spindle Drive parameter C2-01 to the number recorded in step #10.
4.3.16 Orient is now set, and may be commanded by Ultimax 4 Control.

757-4002-220 CAD #D8632

FOR KIT COOLANT THROUGH SPINDLE.
BMC6434 40 TAPER AND 50 TAPER.

Himat Patel _________________ ________
Mihai Leahu _________________ ________
Scott Wrobleski _________________ ________ ____________________________ ________

.
SW
Coolant Through Spindle, BMC6434 757-4002-220 Rev. A Page 2 of 9

1.0 INTRODUCTION
This document is intended as a guideline to install a Kit, Coolant Through Spindle on BMC6434 series
machines. This procedure can be used for installing a complete option package.
BILL OF MATERIAL FOR ASS’Y, 003-6003-009, KIT, COOLANT THRU SPINDLE (OPTION).
26
25
24
23
22
21
20
19
18
17
200” 4061245-007 CABLE, 2-COND, 24AWG SHLD 16
50” 406-2523-001 WIRE, 20AWG RED 15
1 117-5015-001 NUT, M8 HEX 11
1 408-1013-007 ELBOW, MALE 3/8”M X ¾”M 10
1 506-5060-012 FITTING, SWIVEL ¾” 9
1 510-0001-011 PRESSURE SWITCH 8
20ft. 508-2001-010 TUBE, 6 MM O.D. NYLON 7
1 506-3001-054 HALF UNION, ¼” X 6 MM O.D. TUBE 6
1 502-0241-010 NEEDLE VALVE 5
1 506-3014-020 MALE PIPE TEE ¼” 4
1 506-5005-027 REDUCER BUSHING 3/8”M X ¼”F 3
2 506-5018-008 STREET TEE, 3/8” 2
1 506-6051-038 ELBOW, MALE 3/8”M X 3/8”M 1
PARTS LIST

INSTALL PROCEDURE.
3.1 MECHANICAL INSTALL PROCEDURE FOR KIT, COOLANT THROUGH SPINDLE

+ PLEASE REFER TO FIG. 1 AND PICTURE FOR BMC6434 40-TAPER AND FIG. 2 FOR
50-TAPER
BMC6434 series machines are designed to accept this option.
3.1.1. Lower Z-axis at your convenience for easier access to the top of the Head.
3.1.2. Disconnect the power, air and lock out.
3.1.3. There are (6) M8 screws on top of the Head, which hold a Head Top Cover. Remove
these (6) screws.
3.1.4. Lift that Cover and set it outside of machine.
3.1.5. Disconnect the Hose, which goes to Rotary Union from fitting item #1.
3.1.6. Unscrew M8 X 1.25 P X 40 LG. from Manifold and set it outside of machine.
3.1.7. Unscrew item #1 from Manifold.
3.1.8. If necessary re-tap that open port of the Manifold, so that item #2 could be mounted into the
Manifold.
3.1.9. Make connections between item #2, item #3, item #4, item #5, item #6 and item #7. Please
refer to Fig. 1 and Picture.
3.1.10. Mount item #8, Pressure Switch to item #4. Please refer to Fig. 1 and Picture.
3.1.11. Mount fitting item #10 to the existing Valve.
3.1.12. After all connections are made and all the fittings are tightened, set the whole assembly back
on Head and mount item #1 to item #2. Re-tap item #2 if necessary.
3.1.13. Tighten the whole assembly on Head using existing M8 X 1.25 P x 40 LG. from Manifold and
make connection between item #9 and the high pressure hose.
3.1.14. High pressure hose and 6 mm drain tube should be routed through cable track.
3.1.15. Clean out all chips.
3.1.16. Reinstall the Head Top Cover.
NOTE:
Same procedure applies to BMC6434 50-Taper. However, a new location for this assembly is
needed. Fig. 2 shows the location for 50-Taper machines. In this case a clearance hole needs to be
drilled through the plate of Ass’y, Lube, Pneumatic & Coolant. Not to damage that plate, a M8 nut
and a M8 lockwasher have to be set under plate.

FIGURE 1. (Kit, Coolant Through Spindle Installation)

FIGURE 2. (Kit, Coolant Through Spindle Installation)

5 6 4 8
9 VALVE 3 2 1 HOSE

4.0 ELECTRICAL CONNECTIONS
FIGURE 4. (Electrical Installation)
4.0 PLEASE REFER TO FIGURE 4.
4.0.1 Make sure machine power is off.

4.0.2 Locate and remove the 1” hole plug in the bottom-right side of the electrical cabinet.
4.0.3 Locate the electrical cable supplied with the high pressure coolant system.
4.0.4 Remove the nut on the strain relief connector on the cable.
4.0.5 Install the cable through the 1” hole in the bottom of the cabinet and secure with the nut.
4.0.6 Route the dirty filter switch wires to the bottom side of terminal strip TB1.
4.0.7 Connect the wires to BLK3 terminal 5 and TB1-3 (MGND).
4.0.8 Route the Air solenoid wires to the bottom side of terminal strip TB1.
4.0.9 Connect one wire to BLK2 terminal 20 and the other to TB1-3 (MGND).
4.0.10 Install the 2-cond cable (406-1245-007) through the wireway, from the spindle to the electrical
cabinet.
4.0.11 Connect the Black wire from the 2 cond. Cable to TB1 terminal 2, the white wire to BLK1
terminal 22, and the SHLD to TB1-3 (MGND).
4.0.12 At the spindle head, cut the 110VAC HOT wire connected to the spindle unclamp solenoid.
4.0.13 Using the 20AWG Red wire and butt splice, connect one section of the wire that you just cut to
the Pressure Switch N/C 1.
4.0.14 Using the 20AWG Red wire and a butt splice connect the other section of the wire to the Pressure
Switch C1.

4.0.15 Using the 2 cond Cable, connect the black wire to the Pressure Switch N/C2, and the white wire
to C2.
4.1.1 Access the Integrator Support Services Screen. (AUX, <enter>,100,<enter>)

4.1.2 Access the Integrator Configuration Parameters. (F2)
4.1.3 Access the N95 Parameters. (F2)
4.1.4 Change the value of N95:241 (Coolant Through Tool Enable) to 1.
4.1.5 Change the value of N95:243 (CTT Max Spindle Speed w/o Coolant) to an appropriate value.
This depends on your spindle type and whether or not it can run at max speed without coolant
flowing through it.

757-4002-239 CAD #: D8654
BMC6434 40-taper
Head Thermal Compensation
with Chiller and Fans

Himat Patel___________________ __________
Mihai Leahu_________________ __________
Dan Ornelas___________________ __________ ____________________________ ________
Engineering Document 757-4002-239 CAD#: D8654
Rev. A
Rev. ECN # Revision Description Rev By Date Appd Date

By
A 14816 Original Release ML, DO 10-29-99 HP
Head Chiller, Fans Thermal Compensation 757-4002-239 Page 2 of 7

1.0 INTENT
To provide a standardized method of installation and configuration for Head ThermalCompensation with
Chiller and Fans.
2.0 APPLICABILITY
This procedure can be used for installing a complete option package, Head Thermal Compensation with
Chiller and Fans for BMC6434 40-Taper machining centers.
Machine Requirements: Spindle with O.D. grooves in cartridge.

Chiller Assembly
3.1 Turmoil (OCN-33 R) Operating Instruction Manual.

3.2 Dwg. # 003-1016-034 Assembly, Chiller Head Thermal Compensation.
3.3 Dwg. # 003-1016-043 Assembly, Fans Head Thermal Compensation.
3.4 Dwg. # 423-4401-128 Harness, Chiller Power.
3.5 Dwg. # 423-4401-126 Harness, Cooling Fan.
3.6 Dwg. # 423-4401-369 Harness, Fan Power.
4.0 INSTALLATION GUIDELINES
This document is intended as a guideline to install a Head Thermal Compensation Kit,

Dwg. # 003-1016-042 for BMC6434-40 Taper series machines. This Kit descrbes both the Chiller
Assembly and the Fan Assembly. Drawing Assembly # 003-1016-034 is intended for Chiller Assembly only,
for the Head Thermal Compensation. Drawing Assembly # 003-1016-043 is intended for Fan Assembly
only. This procedure can be used for installation of a complete Head Thermal Compensation Kit as well as
individual Chiller and Fan Assembly.

5.0 BILL OF MATERIAL FOR CHILLER ASSEMBLY DWG. # 003-1016-034.
1 506-0002-021 CONNECTOR STRAIGHT, MALE ½” T – ¼” NPT 16

1 402-0003-013 CONTACTER, 3-POLE, 24VDC COIL TELE LPK0901BW3 15
1 404-9081-062 CIRCUIT BREAKER, 10A, 2-POLE, 240V 14
1 403-5503-027 RELAY, OVERLOAD 5.5-8.0A TELE LR2K0314 13
8 406-0965-004 FERRULE, 18AWG RED 11
8 406-0965-005 FERRULE, 16AWG BLACK 10
15 ft 406-2005-020 WIRE, 18AWG BLACK 9
10 ft 406-2004-010 WIRE, 16AWG BLACK 8
1 423-4401-128 HARNESS, COOLER POWER 7
2 506-3009-015 MALE ELBOW, ½” T – ½” MP 6
1 504-5002-004 COOLER, TURMOIL OCN-33 R 5
50 ft 508-2001-006 TUBING, ½” O.D. X .062” WALL 4
15 406-5001-004 TIE, WRAP 3
2 506-3011-007 UNION ELBOW, ½” T 2
2 506-3009-013 MALE ELBOW, ½” T – ¼” NPT 1
-034 PARTS LIST
6.0 BILL OF MATERIAL FOR FAN ASSEMBLY DWG. # 003-1016-043.
1 409-1001-198 FUSE, 2A SLOW BLOW 18

1 406-4006-099 END/SEPARATOR PLATE, WAGO 280-312 17
1 406-4005-049 TERMINAL BLOCK, FUSED WITH NEON LAMP 16
1 403-2001-054 RELAY, MINIATURE DPDT 8A 15
1 403-5001-020 SOCKET, MINIATURE RELAY DIN RAIL MOUNT 14
2 110-5001-002 WASHER, M4 FLAT 13
2 108-5002-001 BHCS, M4 X 0.7 P X 8 LG. 12
2 423-4401-369 HARNESS, FAN POWER 11
2 423-4401-126 HARNESS, COOLING FAN 10
2 420-0001-013 115VAC AXIAL FLOW FAN 8
4 117-5011-001 HEX NUT, M4 X 0.7 P 7
4 110-5001-002 WASHER, M4 FLAT 6
4 108-5002-004 BHCS, M4 X 0.7 P X 14 LG. 4
2 803-6001-104 BRACKET, FAN 3
8 101-5008-003 SHCS, M6 X 1.0 P X 12 LG. 1
-043 PARTS LIST

7.0 CHILLER INSTALLATION PROCEDURE
MECHANICAL INSTALL PROCEDURE FOR ASS’Y, CHILLER HEAD THERMAL

COMPENSATION (OPTION), DWG. # 003-1016-034.
7.1 CHILLER INSTALLATION ON BMC6434
7.1.1 Modify the Head as described below in items # 7.1.2 through 7.1.7.
7.1.2 Reference: Ass’y, Chiller Head Thermal Compensation, dwg. # 003-1016-034.
7.1.3 Dwg. # 003-1016-034, sheet 1 and sheet 2, view A-A & A”-A”. Dwg.
# 003-1016-034, sheet 4 for electrical connections.
7.1.4 Raise the Head and drill a 43 DIA hole at the bottom of Head. See dwg. # 003-1016-034, sheet
1, view A-A and view A”-A” for location, to accommodate (2) items #2. Tighten these (2)
fittings with a tie wrap.
7.1.5 Lower Z-axis. In this position is easier to remove covers and drill holes on Head.
7.1.6 There are (11) SHCS, M6 X 1.0 P X 20 LG. screws, on the front and right side of the Head, on
Cover, Head Front, Cover Head R.H. and Cover, Head R.R. Remove these screws. Lift the
covers and set them outside of machine.
7.1.7 Drill a 30 DIA hole on the top of Head. See dwg. # 003-1016-034, sheet 1, view A-A and view
A”-A” for location, to accommodate (2) items #4.
7.1.8 Run the hoses, item #4 through Cable Carrier and through Housing, Z Axis Cable. Run them
between Column and Electrical Cabinet all the way back to Chiller, Turmoil, item #5.
7.1.9 Clean up all chips from Head.
7.1.10 Make all the necessary connections between Spindle, Hoses and Chiller, as shown on dwg. #
003-1016-034, sheet 1.
7.1.11 Reinstall all the covers in reverse order.
7.1.12 Chiller is turned ON/OFF with the control power. See Ass’y, Chiller Head Thermal
Compensation, dwg. # 003-1016-034, sheet 4.
7.1.13 Chiller Thermostat to be set at ambient temperature.Reference: Turmoil OCN-33 R, Operating
Manual.
7.1.14 Cycle Chiller. Check for leaks and make any necessary repairs. Verify if the INLET & OUTLET
are per drawings.
7.1.15 A rust inhibitor must be added to the water. A mixture of 30% DOWTHERM SRI to 70% clean
tap water is recommended. Chiller is turned ON/OFF with the Control Power.
7.1.16 Use cooling water (with rust inhibitor) and ethylene glycol only, with model OCN-33R. We do
not recommend automotive anti-freeze.
7.1.17.1 Recommended suppliers of Ethylene Glycol/Dowtherm SR-1
7.1.17.1.1 Ashland Chemical, phone # 317-895-2200.
7.1.17.1.2 Chem Central, phone # 317-876-0777.
7.1.17.1.3 Ulrich Chemical, phone # 317-898-8632.
7.1.17.1.4 Van Water & Rogers, phone # 317-547-4811.
Technical information is available from Dow at 800-447-4369.
8.0 FAN INSTALL PROCEDURE.
MECHANICAL INSTALL PROCEDURE FOR ASS’Y, FANS HEAD THERMAL

COMPENSATION (OPTION), DRAWING # 003-1016-043.
8.1 FANS INSTALLATION ON BMC6434 40-TAPER
8.1.1 Modify the Head Cover R.H. per the drawing # 003-1016-043.
8.1.2 Remove Head Cover R.H. P/N# 803-6002-033 and cut out two openings as
shown on dwg. # 003-1016-043, for Cover modifications.
8.1.3 Reference: dwg. # 003-1016-043, Ass’y, Fans Head Thermal Compensation details
for BMC6434 Head Cover modifications.
8.1.4 Modify the Head per drawing # 003-1016-043.
8.1.5 Drill and tap (8) holes M6 X 1.0 P, 15 mm deep as shown on dwg. #003-1016-043,
for Head holes loations.
8.1.6 Reference: dwg. # 003-1016-043, Ass’y, Fans Head Thermal Compensation for
fans installation.
8.1.7 Mount the Fans inside the Head using (2) brackets, P/N # 803-6001-104, as shown
on dwg. # 003-1016-043.
8.1.8 Fans are turned ON/OFF when the Spindle is enabled/disabled.
8.1.9 Refer to dwg. # 003-1016-043, sheet 2 and sheet 3, Ass’y, Fans Head Thermal
Compensation, for electrical connections.
8.1.10 Reinstall Head cover.

9.0 ELECTRICAL INSTALLATION PROCEDURE
9.1 COOLER POWER
NOTE: REFER TO DRAWING # 003-1016-034, SHEET 4.
9.1.1 Punch a 1/2” conduit knockout in the bottom of the control cabinet.
9.1.2 Install the Chiller Power Harness P/N # 423-4401-128 from the Cooler to the control
cabinet.
9.1.3 Connect the harness inside the Chiller to the terminal strip located just inside the 1/2” conduit
entrance.
9.1.4 Mount the circuit breaker, and cooler starter & overload, inside the electrical control cabinet on
the lower terminal strip.
9.1.5 Using #16 AWG wire, tap off existing 230VAC power and connect to contacts 1 and 3 on the
2-pole, 10A breaker.
9.1.6 Using #16 AWG wire, connect contacts 2 and 4 on the circuit breaker to contacts 1 and 3
respectively on the cooler starter.
9.1.7 Connect the Chiller Power Harness P/N # 423-4401-128 to the cooler starter overload contacts
2 and 4. Connect the ground wire to the existing grounding block.
9.1.8 Using #18 AWG wire, connect OCS-A1 to TB1-1 (+24V switched). Connect OCS-A2 to
TB1-3 (MGND).
9.2 FAN POWER
NOTE: REFER TO DRAWING # 003-1016-043, SHEET 2.
9.2.1 Connect a Cooling Fan Harness P/N # 423-4401-126 to each fan.

9.2.2 Install the Fan Power Harness P/N # 423-4401-369 from the spindle head assembly to the
machine control cabinet by pulling it through the spindle head cable track. Note: The two female
Mate-N-Lock connectors are to be installed at the spindle head.
9.2.3 Connect the two Cooling Fan Harness’s to the Fan Power Harness.
9.2.4 Using #18 AWG wire, connect TB2-1 (115V-Line) to the top of 2A-fused terminal block.
9.2.5 Using #18 AWG wire, connect the bottom of the 2A-fused terminal block to contact 11 of the
Fan Relay.
9.2.6 Using #18 AWG wire, connect TB2-2 (115V-Neutral) to contact 21 of the Fan Relay.
9.2.7 Connect the Fan Power Harness P/N # 423-4401-369 to contact 14 and 24 of the Fan Relay.
9.2.8 Connect the ground wire to an existing ground terminal block.
10.0 TEST AND VERIFICATION
When testing the Chiller Head Thermal Compensation circuits, check for the following control:
Chiller should run when control power is turned on. The Fans should run when the spindle is enabled.

R
757-4002-240 CAD #D8655
SUBJECT: ELECTRICAL, INSTALATION PROCEDURES

BMC6434
Originator: Date Mgr. Ultimax Products Group Date

RECORD OF CHANGES

By By
A 14481 Original Release RMN 11/9/99 DEO 11/11/99
B 15125 1) Was 832.0, 2) Was 863.0 DEO 11/15/00
I. INTENT
The purpose of this document is to document parameter changes and setup for Heidenhain linear scales application
on BMC 6434 machining centers.
II. SCOPE
This document is applicable to BMC 6434 Machining Centers equipped with Ultimax v2.xx and Heidenhain linear
scales. The procedure is meant for qualified Hurco personnel (or their agents) only. It is not meant for customer
use.
757-4002-240 BMC 6434 Linear Scales Installation Procedure Page 2

Rev. B
Installation
The linear scales are equipped with white plastic strips that mount in a slot along the length of the housing. A brown magnetic
strip is placed in the slot to invoke the reporting of the next marker pulse. The slot, which holds the strips, must be completely
filled, so as to prevent significant movement of the strips. The magnetic strips are to be placed as follows:
Y Axis – Third strip from (+) travel end (white, white, brown)

Rev. B
Calibration
Special Calibration procedures must be used when setting up the machine. Because the marker pulse location is not as near the
travel limit as is the case with encoders, the following technique should be used:
Example: With leadscrew encoders the X and Z axis CALIBRATE HOME POSITION =0, Y axis CALIBRATE HOME POSITION =
863.0 (assumes 12.0 mm Limit Switch to Marker distance for all three axes).
Change F96:0 X axis Limit Switch to Maker Distance (mm) = 50.0000

Change F96:1 Y axis Limit Switch to Maker Distance (mm) = 50.0000
Change F96:2 Z axis Limit Switch to Maker Distance (mm) = 65.0000
Perform (and allow to complete) machine calibration. All three linear axes should read 0.000 on DRO. Each axis will be positioned
at the linear scale marker position (aligned with brown/magnetic strip); this will be approximately 30 to 60 mm from the limit switch.
For Z axis:
1. Initiate another Calibration cycle.

2. While Z axis is still on Z+ limit switch (as displayed on DRO), abort the cycle with CYCLE STOP button.
3. Slowly begin handwheel jogging Z axis in negative direction (x1 mode) and stop when Z+ limit switch indication is no longer
displayed. Note Z axis MACHINE POSITION on DRO (= +53.5)
4. Subtract 12 mm from the current position [ 53.5 - 12 = +41.5 ]
5. Multiply result by –1. This is the Z CALIBRATE HOME POSITION value[ -41.5 mm].
For X axis:
1. Initiate another Calibration cycle.

2. After Z axis calibrates, watch for X- and Y+ limit switches to be “true” (as indicated on the DRO), abort the cycle with CYCLE
STOP button.
3. Slowly being handwheel jogging X axis in positive direction (x1 mode) and stop when X- limit switch indication is no longer
displayed. Note X axis MACHINE POSITION on DRO (= -42.5)
4. Add 12 mm to the current position [ -42.5 + 12 = -30.5]
5. Multiply result by –1. This is the X CALIBRATE HOME POSITION value [+30.5 mm].
For Y axis:
1. With the Y axis still on the Y+ limit switch, slowly begin handwheel jogging Y axis in negative direction (x1 mode) and stop
when Y+ limit switch indication is no longer displayed. Note Y axis MACHINE POSITION on DRO (= 906.2)
2. Subtract 12 mm from the current position [906.2 – 12 = +894.2].
3. Subtract Y AXIS TRAVEL LIMIT (863.0) from previous result [894.2 – 863 = +31.2]
4. Subtract result from Y AXIS TRAVEL LIMIT. This is the Y CALIBRATE HOME POSITION value [863 – 31.2 = +831.8 mm].
Any machine specific dimensions (Tool Change Height, TPS Fixture position, TPS Access position, etc.) will need to be
redefined.

Rev. B
AXES
Physical Parameters X Axis Y Axis Z Axis

Counts per Revolution 3000 3000 3000
Distance per Revolution (mm) 12.0000 12.0000 12.0000
In Position Tolerance 3 3 3
Positive Limit Switch Signal Logic 0 0 0
Negative Limit Switch Signal Logic 0 0 0
Maximum Feedrate (mmpm) 17900.0 17900.0 13462.0
Max DAC Volts 9.5 9.5 9.5
Vertical Parameters X Axis Y Axis Z Axis

Minus Direction Travel Limit (mm) 0.0000 0.0000 -762.0000
B1
Plus Direction Travel Limit (mm) 1625.0000 863.0000 0.0000
B2
Calibrate Home Position (mm) 30.5000 * 832.0000 * -41.5000 *
* Value determined on a per machine basis.
SPINDLE
Physical Parameters Spindle

Spindle Control Type Closed Loop Control
Number of Gears 1
Orient Mechanism Present Yes
Minimum Tap RPM 100
Maximum Tap RPM 2000
Maximum DAC Volts 9.500
Counts per Revolution 1024
In Position Tolerance 1024
Gear Table Manager CNC


Rev. B
F6 – Standard Servo Tuning
AXES/SPINDLE TUNE
Axis Tune Parameters X Axis Y Axis Z Axis Spindle
Integral 50 50 150 50
Proportional 2000 2000 2000 4000
Feedforward 1000 1000 1175 550
Derivative 250 250 250 250
Integral Limit 12 12 12 14
Output Loop Gain 1 1 1 1
Integral BW 200 200 200 1024
Max. Rapid Accel 3429000 3429000 3429000 300000
Max. Contour Accel 3429000 3429000 3429000 N/A
Maximum Abort Accel 6096000 6096000 6096000 300000
Following Error Halt 6.35 6.35 6.35 8.3333
Tuning Feedrate 3810.0 3810.0 3810.0 N/A
Z/S Tap Error N/A N/A N/A 1
F6/F3 - Alternate Servo Tuning
AXES/SPINDLE TUNE ALTERNATE PARAMETERS

Axis Tune Parameters X Axis Y Axis Z Axis Spindle
Integral 50 50 100 50
Proportional 1325 1325 1150 4000
Feedforward 100 100 100 550
Derivative 20 20 20 250
Integral Limit 12 12 12 14
Output Loop Gain 1 1 1 1
Integral BW 200 200 200 1024
Max. Rapid Accel 4015000 4015000 4015000 300000
Max. Contour Accel 4015000 4015000 4015000 N/A
Maximum Abort Accel 4015000 4015000 4015000 300000
Following Error Halt 12.7 12.7 12.7 8.3333
Tuning Feedrate 3810.0 3810.0 3810.0 N/A
Z/S Tap Error N/A N/A N/A 1

Rev. B
Yaskawa Servo Parameter Changes
Yaskawa Sigma servo drive parameter CN-04 must be changed as follows:
Axis Standard Value Linear Scale

(non-linear scale) Value
X 45 60
Y 45 60
Z 50 65

Rev. B
Hawk Bed Mills
D8564 757-4002-157 Setup and Test of Axis and Spindle Drive

D8657 757-4002-242 Setup & Test Procedures for Yaskawa Spindle and Axis Drives
Special Gib Adjustment on Hawk 30 and Hawk 40
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KNEEMILL
D8028 757-3012-015 Auto Spindle Controller PCB Setup Procedure

D8037 753-3010-001 Bore and Quill Dimension Sheet, KMB1
D8053 757-3011-003 KMB1 215 Spindle Motor Change Modification
(FS Only) (REF: 002-1841-001/002)
D8187 757-3012-016 Vari-Drive Adjustment, KM3, SM1
D8194 757-3012-007 CNC KMB1 Mill Build & Test Procedure
D8204 757-3013-003 R-8 Spindle Bore Check & Modification
D8210 757-3012-014 Clock Spring Removal & Install
RES FOR FUTURE USE
RES FOR FUTURE USE
RES FOR FUTURE USE
RES FOR FUTURE USE
RES FOR FUTURE USE
RES FOR FUTURE USE
RES FOR FUTURE USE
RES FOR FUTURE USE
RES FOR FUTURE USE
RES FOR FUTURE USE
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RES FOR FUTURE USE
RES FOR FUTURE USE
RES FOR FUTURE USE
RES FOR FUTURE USE
RES FOR FUTURE USE
757-3011-003 REV: B ECN #12447
R
02/04/93 CAD#D8053
SUBJECT: FIELD SERVICE KMB-1 215 SPINDLE MOTOR CHANGE

MODIFICATION (REF: 002-1841-001/002

B 12447 Retyped on Word for Windows 02/04/93
CUSTOMER: ___________________________________________________________
SERIAL NO.: ___________________________________________________________
COMPLETED BY: ______________________________________________________
DATE: ________________________________________________________________
NOTE: Be sure to return this procedure to Hurco with the service report.
I. MATERIAL
A. See 002-1841-001 (KMB-1) or 002-1841-002 (KMB-1S) for parts.
II. DRAWINGS AFFECTED BY THIS MODIFICATION
A. 002-1817 Z Axis Assembly KMB-1
B. 002-1814-002 Spline Coupling Assembly KMB-1
C. 002-1821-003 HDT Belt Drive Assembly KMB-1
D. 002-1827-001 Control Magnetic Schematic KMB-1
E. 002-1819-001 Relay Panel Assembly Diagram KMB-1
F. 002-1828-001 Relay Wiring Diagram
________________________________ _______ _______________________________ _______

III. TOOLS REQUIRED FOR INSTALLATION
A. Magnetic base electric drill (1/2 inch chuck)
B. Small electric hand drill (3/8 inch chuck)
C. .128 dia. drill
D. .404 dia. drill (letter Y)
E. M12 x 1.75 Tap
F. M4 x .7 Tap
G. Set of metric allen wrenches
H. Flat blade screwdriver
I. Loctite 242 compound
J. Jig fixture for new holes in KMB-1 overarm
K. Bearing puller
L. Wire strippers for insulation removal
M. Masking tape (1 inch wide x approximately 25 ft. long)
N. Oscilloscope
O. Data precision DVOM (True RMS) or EQUIVALENT TRUE RMS METER.
P. Digital tachometer
Q. Tap handle
IV. MODIFICATION PROCEDURE
_____1. Power down machine and move the Z axis spindle to the down position. Ensure
that spindle does not hit table. Power down machine.
_____2. Turn power disconnect on spindle drive cabinet to "off" (lock) position and if
possible disconnect power line going to machine. Remove input fuses.
_____3. Remove the Z axis front cover and the spindle motor cover. Be careful to
disconnect the fan cable/plug attached to fan in cover.
2
_____4. Remove the two screen/filters from the spindle motor cover and install with same
hardware on the new spindle motor cover. Do not remove cooling fan from old
cover because this modification obsoletes that part.
_____5. Disconnect spindle motor wiring and ground wire from motor. Remove brake
adjusting plate (caliper and solenoid) from motor support casting. Remove
conduit bracket and place to left side of mill head area to facilitate spindle
motor/support casting removal.
_____6. Remove drive belt by cutting this item with a knife or shears.
_____7. Remove spindle motor/motor support casting from mill. Place on work bench or
working surface to facilitate disassembly. Remove brake disc and sprocket from
motor shaft. Remove spindle motor from motor support casting.
_____8. Assemble new motor to motor support casting using M12 x 30 SHCS and same
washers used before.
_____9. Install new drive sprocket (not machined) on new motor. Install drive belt.
Install brake disc with existing hardware. Use Loctite 242 on all screws.
_____10. Secure jig fixture for new hole location for the motor support casting. These
holes will be drilled into the overarm of the mill. See Fig. 1 for particulars.
IMPORTANT
USE MASKING TAPE TO MASK OFF WITH NEWSPAPER OR OTHER

SUITABLE MATERIAL TO KEEP METAL CHIPS FROM GOING INTO THE
Z AXIS BALL SCREW ASSEMBLY AND OTHER CRITICAL
MOVING MECHANISM IN THE Z AXIS AREA.
_____11. Install new motor/motor support casting assembly on mill and use existing
hardware. Place spindle motor/motor support casting assembly all the
way forward to facilitate belt installation on spindle sprocket.
_____12. Mark upper bearing cap with scribe or marking pen to ensure proper orientation.
Remove the upper bearing cap and the spline coupling assembly.
_____13. Remove the bottom bearing retainer clip then remove the bottom bearing. Some of
these have been pressed on so an arbor press may be necessary to remove bearing. A
bearing puller may be substituted.
_____14. Remove the spindle sprocket and install new sprocket (machined). Position the
sprocket assembly on the spline coupling assembly where the previous sprocket
was located.
_____15. Install the new bearing on the bottom of the spline coupling assembly. Install
3
newbearing retainer on spline coupling assembly.
_____16. Slip drive belt past Z axis ball screw to quill spline shaft. Place belt over quill
spline shaft and ensure that grease does not contact new drive belt. If grease does
come in contact with belt, wipe the belt off with a shop cloth.
_____17. Install spline coupling assembly into place slipping belt onto sprocket and
ensuring that upper bearing cap is oriented in the same position as was
removed. Secure cap screws with Loctite 242.
_____18. Adjust spindle motor/motor support casting to proper belt tension.
_____19. Install brake adjusting plate (caliper and solenoid) on motor support casting.
Install air regulator on support casting. Install conduit
bracket onto the overarm. Use Loctite 242 on all screws.
_____20. Remove fan plug and cord from red and white twisted pair in mill head area.
Remove red and white twisted pair from conduit. Leave other end connected
through the spindle drive cabinet to the relay panel. Refer to wire list, wire
#301, 302. Three black wires will have to be run through the conduit that is
attached to the spindle drive cabinet6. Reconnect wiring on the spindle
motor and new wires for the spindle fan also. Refer to the wire list for
to-from information.
_____21. Drill and tap three M4 holes per Figure 2 on the spindle drive cabinet panel.
Mount the full voltage starter with M4 x 10 BHSS and #10 external star
lockwasher plus Loctite 242. Install heaters to contactor. MASK OFF
PARAJUST WHEN DRILLING & TAPPING.
_____22. REMOVE RED JUMPER WIRE FROM OL1 TO C2 ON THE

CONTACTOR.
_____23. Route wires per wire list from spindle drive cabinet thru transformer cabinet to
the main cabinet. Use wire list for wire to-from information.
4
V. MACHINE OPERATIONAL TEST
A. Preset these potentiometers in the spindle drive cabinet:
R65 Full CCW Isolation

R40 Full CCW Interface
R41 Full CCW PCB
ACCEL Mid Position Parajust
DECEL Mid Position Analog
SHEARPIN Full CW PCB
GAIN Full CCW Parajust Brake
THRESHOLD Full CCW, Back 1/4 turn CW Module
B. Switch power disconnect to on position, use new master tape to program machine,
check and operate.
C. Ensure that spindle motor fan is forcing air out the bottom and that the spindle is
turning in the direction programmed. If one or both are wiring,
power will have to be shut off and two phases of the spindle
motor fan will have to be swapped and/or also two phases of
the spindle motor will have to be swapped.
D. Repeat step B. Observe spindle motor fan air flow direction is down and spindle
direction is correct.
E. Check brake solenoid and caliper operation are correct.
F. Check belt alignment between the two sprockets for correct operation.
G. Parajust, isolation interface board, and DAC on interface board in card cage:
1. Position switch on isolation interface board to manual. Adjust R38 to 200-208

RPM at spindle using digital tachometer. Adjust boost
(parajust analog board) to develop 59-60 VAC measured with true RMS
DVOM across any two phases of the spindle motor.
2. Adjust R38 to 896-900 RPM at spindle. Adjust Volt/Hz pot (Parajust Analog
Board) to read 235-237 VAC measured across two phases of the spindle motor.
3. Repeat above steps 1 and 2 to achieve boost and Volt/Hz voltages.
4. Position switch on isolation interface board to auto. Connect scope TB7 1 and 2
on brake board. (300 VDC)
DANGER
ENSURE OSCILLOSCOPE IS ISOLATED FROM GROUND!
5
Program and run spindle at 2000 RPM, then press enter to stop, while watching
scope. 10% to 20% of DECEL time should be saturated brake signal; the signal
should them be pulse width modulated. (adjust threshold and gain)
5. Watching scope, sweep entire speed range from 1200 RPM to 150 in 16 RPM
increments. If "FALSE" braking signal is measured, re-adjust threshold and gain
slightly, then retest as per steps 4 and 5.
6. Position spindle speed pot on from panel to indicate 896 RPM on CRT. Adjust
DAC on card cage interface board to 2.20 - 2.21 VDC measured between IJ3-14
and IF3-15.
7. Position spindle speed pot on front panel to indicate 208 RPM on CRT. Adjust
R27 on isolation interface board to give 230-235 RPM at spindle.
8. Position speed pot to 3408 RPM on CRT. Adjust R36 for 3400 - 3415 RPM at
spindle.
9. Verify steps 7 and 8 as they affect each other.
10. Seal all potentiometers on the parajust analog and brake boards, isolation interface
board, and the card cage interface board using torque seal yellow.
H. Install the spindle motor cover with existing hardware. Clean up can be accomplished
and the machine released to it's owner.
V. DISPOSITION OF PARTS WITH THIS MODIFICATION
A. Disposition of parts replaced with this modification is at the discretion of the KMB-1
mill machine owner. Parts are NOT to be returned to Hurco Manufacturing.
B. Used Parts
1. Spindle motor
2. Spindle motor cover
3. Mill head cooling fan & plug/cable (Rotron)
4. Bearing
5. Bearing retainer
6
M1 TO MD
D8050 757-3011-001 MB1 ATC Arm Emergency Stop Switch

Modifications Procedure (REF: 002-1639-001)
D8054 757-3011-002 MB1 U215 Spindle Motor Change Modification (FS
Only) (REF: 002-1668-001/004)
D8325 757-3030-001 MB1 4 ATC Criteria for Reliable and Precise Tool
Changes
D8326 757-3030-002 MB1H and MD1 Tool Changer Operational Tests
and Tool Changer Sequence
757-3011-001 REV: B ECN #12447
R
12/04/92 CAD#D8050
SUBJECT: MB-1 ATC ARM EMERGENCY STOP SWITCH MODIFICATION

PROCEDURE (REF: 002-1639-001)

B 12447 Re-typed on Word for Windows 12/04/92
I. MATERIALS
A. Refer to 002-1639-001 for parts.
B. Equipment Qty
M5 Tap 1
#18 Drill 1
3/16" Drill 1
3/8" Drill 1
.125 Drill (Pilot) 1
Mounting Hole Fixture 1
Locktite 242 1
C-Clamps 5" 1
________________________________ _______ _______________________________ _______

II. INSTALLATION PROCEDURE
A. Remove and save existing limit switch from tool arm. Mount drill guide as shown on Page
3. Align edge of drill guide with oucnterbore outside diameter. Drill both holes
approximately 1" deep with a .125" drill. Remove drill guide and drill holes using No. 18
drill. Tap both holes with M5 tap. Install bracket Hurco P/N 902-0472-001 with M5 x 12
BHCS using Locktite 242. Ensure bracket is mounted square on tool changer arm.
Remove existing actuator and install new actuator plate Hurco P/N 902-0468-001 with
M5 x 16 BHCS using Locktite 242.
NOTE: Loosen tool arm clutch to ease switch installation and adjustment.
B. Install microswtiches as shown on PAge 4 and Page 5 using Locktite 242. Page 4 shows
the arm in.
IMPORTANT: Position switch to enable roller to roll on a actuator which is essential

for long microswitch life.
Ensure equal number of threads between jam nut and bracket on initial set up (See Page
5). Wire microswitches per schematic on Page 6.
C. Referring to Page 5, adjust limit swtiches using .020" and .025" feeler gauges. Using an
OHM meter, monitor microswitches. Adjust and verify that sliding the .020" feeler gauge
does NOT activate switch and sliding the .025" feeler gauge does activate switch.
NOTE: The top microswitch, LS8, may need more gap between actuator plate and
microswitch depending on spring tension of tool magazine. A larger gap
desensitized the microswtich operation so it is desirable to keep the gap at a
minimum.
After all adjustments are made, pin the actuator and switch bracket using a 3/16" drill and
a .187" dia. x .5 spring pin. Install cover over microswitches Hurco P/N 002-1644-001.
Use the 1/2" hole plug to close off old microswitch hole in tool changer arm.
III. TESTING
Cycle tool changer with tool magazine loaded 200 cycles and unloaded 100 cycles. This is
important to ensure there will be no nuisance Emeergency Stop activations. Ensure that both
microswitches, individually activated, "EMERGENCY STOP" machine.
2
757-3011-002 REV: B ECN #12447
R
01/25/93 CAD#D8054
SUBJECT: FIELD SERVICE MBI U215 SPINDLE MOTOR CHANGE

MODIFICATION (REF: 002-1668-001/002/003/004)

B 12447 Retyped into Word for Windows 01/25/93
CUSTOMER ________________________________________________________________________
SERIAL NO. ________________________________________________________________________
COMPLETED BY ____________________________________________________________________
DATE ______________________________________________________________________________
NOTE: Be sure to return this procedure to Hurco with service report.
I. MATERIAL
A. Refer to 002-1668-001/002/003/004 for parts
A. 002-1452-001/002/003 Z Axis Assembly
B. 002-1601-001/002/003/004 Main Mill Assembly MI/MBI
C. 002-1472-001 Control Magnetics Schematic
D. 002-1630-001 Control Magnetics Schematic (24VDC)
________________________________ _______ _______________________________ _______

III. TOOLS REQUIRED TO COMPLETE THIS MODIFICATION
A. Oscilloscope
B. Data precision DVOM (True RMS) or EQUIVALENT TRUE RMS METER!
C. Digital tachometer
D. An assortment of handtools
A. Step by step procedure
NOTE: Depending on the machine option, some of the following steps may be passed
over.
1. Power up machine and move the mill head assembly to the down position. Power
down the machine.
2. Throw power disconnect to off position and if possible disconnect power line
going to machine.
3. Remove mill front cover.
4. Cut tie-raps from cable tie downs in the mill head area.
5. Using masking tape and marker pen identify the spindle unclamp solenoid wires
(SV 3), shotpin in solenoid wires (SV 4), spindle unclamp position switch (LS 1),
and shotpin in switch (LS 2).
6. Disconnect switch wires and solenoid wires and save the hardware such as wire
nuts. Also disconnect limit switch cable connector and spindle optical switch
board connector (LS 7). Disconnect motor ground wire
and motor power wires.
7. Disconnect mill head fan leads and use a wire nut on each red and white wire
ends. This twisted pair will not be used.
8. Remove mill head/z axis top cover plate that will include fan, fan cover, and
Rotron cable and plug. Remove fan cover from top cover plate and install on
new top cover (902-0471-001) with hardware used on old assembly.. There are
M5 nuts and #10 lockwashers provided for this.
9. Disconnect the one inch conduit and wiring from the mill head casting. Be
careful when removing the wire and connectors, lugs, and etc. thru the threaded
casting hole.
2
10. Remove the air brake mounting bracket, spindle lock assembly, optical switch
assembly, limit switch brackets, and the mounting bolts that secure the
motor/unclamp cylinder to mill head area.
11. Remove the mill motor and place where disassembly will be easiest.
12. Transfer the spindle coupling, unclamp air cylinder from used motor to new
motor. Install new o-rings; M12 x 30 SHCS, Parker Seal (600-001-1/2), and new
coupling spider in this assembly. Also install new cylinder cap with tool
changer. The used one will most likely be damaged by split lockwashers.
13. Install new motor/unclamp cylinder into mill head area. Secure with same
hardware using Locktite 242. Install air brake mounting bracket, spindle lock
assembly, optical switch assembly, and the spindle unclamp limit switch bracket.
Use Locktite 242 when securing these items. On manual machines, use M12 x 40
SHCS for securing the motor.
14. Install one inch conduit previously removed from old top cover to new top cover.
Locate new 1/2 inch flexible conduit assembly and install from main cabinet to
new top cover. See view for clarification. Use existing hardware and install new
top cover on mill head area using Locktite 242.
15. Run the three nine foot long 14 ga. black wires and one green/yellow nine foot
long wire (12 ga.) thru the 1/2 inch conduit. Leave approximately 24 inches in
the main cabinet to be attached to the spindle fan contactor later.
16. Reconnect solenoid wires, limit switch wires, spindle optical switch connector,
and z axis limit switch connector. Refer to wire list to connect spindle fan
motor. Connect spindle motor wires per original wire list (page 5/6).
17. Remove ni-cad battery pack and mounting hardware if located below ACC
contactor. Drill hole in main cabinet per view supplied with this modification
procedure (page 4). Mount ni-cad battery pack per view.
18. Install new voltage contactor sub-plate with hardware and Locktite 242 per view
assembly. Then install full voltage contactor with hardware and Locktite 242 per
view.
19. Refer to wire list, 002-1668-001, for final wiring details and instructions. Refer
to BOM for parts.
20 BE SURE TO REMOVE THE RED JUMPER WIRE ON THE SPINDLE FAN

CONTACTOR THAT GOES FROM OL 1 TO C2. IF THIS IS NOT
PERFORMED, WHEN MILL POWER IS TURNED ON 115VAC WILL BE
DUMPED ON THE +24VDC RELAY LOGIC LINE. SEE VIEW OF
CONTACTOR DRAWING.
WIRELIST/PICTURES
3
A. Preset these potentiometers in the spindle drive cabinet:
R65 Full CCW Isolation

R40 Full CCW Interface
R41 Full CCW PCB
ACCEL Mid Position Parajust
DECEL Mid Position Analog
SHEARPIN Full CW PCB
GAIN Full CCW Parajust Brake
THRESHOLD Full CCW Module
B. Switch power disconnect to ON position, use new master tape to program the machine.
Check and operate.
C. Ensure that spindle motor fan is forcing air out the bottom and that the spindle is
turning is in the direction programmed. If one or both are wrong,
power will have to be shut off and two phases of the spindle motor
fan will have to be swapped and/or also two phases of the spindle
motor will have to be swapped.
D. Again power up machine and repeat step B. Observe that the spindle motor fan air
flow direction is down and that the spindle direction is correct.
E. Check that the brake solenoid and caliper operations are correct.
F. Parajust, isolation interface board, and DAC on card cage interface board:
1. Position switch on isolation interface board to manual. Adjust R38 to 200-208

RPM at spindle using digital tachometer. Adjust boost pot. (Parajust analog
board) to develop 59-60 VAC measured with data precision DVOM across any
two phases of the spindle motor.
2. Adjust R38 to 896-900 RPM at spindle. Adjust Volt/Hz Pot. (Parajust analog
board) to read 235-237 VAC measured across two phases of the spindle motor.
3. Repeat above steps 1 and 2 to achieve boost and Volt/Hz voltages.
4. Connect oscilloscope across TB7-1 & 2 of Parajust brake board. DANGER:

INSURE OSCILLOSCOPE IS ISOLATED FROM GROUND. Adjust R38
to 2000 RPM at spindle. Position switch on isolation interface board to center
or off. Watch oscilloscope for 10% to 20% saturation then pulse width
modulation.
5. Leave oscilloscope connected as in step 4 and position switch to auto on isolation

interface board. Adjust ACCEL and DECEL pots on Parajust analog board to
4
full CCW. Sweep entire speed range from front panel and verify proper braking
and that false triggering of brake board does not occur especially below 1000
RPM. Remove oscilloscope from brake board.
DAC on card cage interface to 2.20-2.21 VDC measured between IJ3-14 and IJ3-
15.
R27 on isolation interface board to give 230-235 RPM at the spindle.
8. Position spindle speed pot to 3408 RPM on CRT. Adjust R36 for 3400-3415
RPM at spindle.
9. Verify steps 7 & 8 as they affect each other.
10. On ATC mills only, adjust R40 on isolation interface board to give approximately
30 RPM at spindle during orient mode. (2-2.5 seconds per revolution)
11. Seal all potentiometers on the Parajust analog and brake boards, isolation
interface board, and the card cage interface board.
G. Completely cycle tool changer operation to insure spindle unclamp switch alignment is
proper, spindle optical switch alignment is proper, spindle lock or shotpin in assembly
alignment, and that operation is smooth and precise. (Refer to Technical Bulletin Issue
#3020, MBI T.C. Alignment & Adjustment)
H. Mill head front cover can be installed at this point and general clean-up can be
accomplished for this completes the MBI U215 spindle motor change modification.
VI. DISPOSITION OF PARTS REPLACED WITH THIS MODIFICATION
A. Disposition of parts replaced with this modification is upon the discretion of the MBI
mill machine owner. Parts are not to be returned to Hurco Manufacturing.
B. Used Parts:
1. Spindle Motor
2. Mill Head Top Cover
3. Mill Head Cooling Fan (Rotron)
5
M2 To MD3
D8052 757-3011-004 MB2 Servo Amplifier Change Modification

Randtronics (FS Only) (REF: 002-2048-001)
D8206 757-3021-001 MB3 Tool Change Sequence
D8207 757-3021-002 X-Axis Linear Scale Assembly Procedure
D8208 757-3021-003 Y-Axis Linear Scale Assembly Procedure
D8209 757-3021-004 MB3 Z--Axis Linear Scale Assembly Procedure
D8214 757-3021-005 MB3 Test, Alignment and Checkout Procedure
D8217 757-3021-007 MB3 Spindle Motor Pinion Assembly
D8218 757-3021-008 MB3 Z-Axis Servo Feed Motor Pinion Assembly
D8220 757-3022-001 X-Axis Linear Scale Assembly Procedure for MB2,
Level 2
D8221 757-3022-002 Y-Axis Linear Scale Assembly Procedure for MB2,
Level 2
D8222 757-3022-003 Z-Axis Linear Scale Assembly Procedure for MB2,
Level 2
D8224 757-3023-003 MD3 Tool Changer Sequence
D8381 758-3021-001 MB2/MB3/MD3 Leveling Procedure
757-3011-004 REV: B ECN #12447
R
02/05/93 CAD#D8052
SUBJECT: FIELD SERVICE MBII SERVO AMPLIFIER CHANGE

MODIFICATION (RANDTRONICS) REF: 002-2048-001)

A Original Issue
B 12447 Retyped on Word for Windows 03/06/91
CUSTOMER: ________________________________________________________
SERIAL NO.: ________________________________________________________
COMPLETED BY: ____________________________________________________
DATE: ______________________________________________________________
NOTE: Be sure to return this procedure to Hurco with service report.
I. MATERIALS
A. Refer to 002-2048-001 for parts.
A. 002-2033-002 Motor & Tachometer Schematic CNC MBII
B. 002-2023-001 Control Relay Panel Schematic MBII Mill
C. 415-0102-002 Axes Limits Switch Board Physical Schematic
D. 002-2027-002 X/Y/Z TM14 Schematic CNC MBII Mill
E. 002-2047-001 Servo Amplifier to Mill Schematic
________________________________ _______ _______________________________ _______

III. TOOLS REQUIRED TO COMPLETE THIS MODIFICATION
A. Metric allen wrenches
B. Wago terminal tool
C. Selection of screwdrivers (flat blade and phillips)
D. Jewelers screwdriver or pot adjusting tool (wand)
E. Crimping tool (ring tongue terminal and butt splice)
F. Volt/Ohmmeter
A. Step by step procedure
1. Power up machine and depress power on, check and operate push buttons.
Enter the servo amplifier test program located on pages 9 and 10 of this
specification. Before installing the new Randtronics servo amplifier, verify via
the machine test operational test on page 11 the following:
a. the milling machine operates in all three axes without binding
b. the limit switches are properly aligned and operating
c. there are not counting problems
If there are problems that can be directly traced to the Westamp servo amplifier,
proceed to step 2.
2. Remove power from the MBII by depressing emergency stop on the front panel,
turn the power disconnect switch to the off position.
3. Open access door to the main power cabinet. Remove the three input fuses
(power) to eliminate any shock hazard.
4. Locate the Westamp servo amplifier and the XJ1, YJ1, and ZJ1 connectors.
Insure that these connectors are marked. (This will help in wiring the
Randtronics servo amplifier)
5. Disconnect the red and white #16 twisted pair wires connected to TB6 of the
Westamp.
6. Label each #12 blue servo motor wires with the terminal location on the TB6 of
the Westamp. Now remove these wires from TB6.
7. Remove the two #10 black wires (72 VAC) from the Westamp servo amplifier.
8. Remove the Westamp servo amplifier by removing the four M6 SHCS bolts.
9. Carefully install the Randtronics servo amplifier per view on page 7 with the
terminal strip located at the top. Secure the new Randtronics servo
amplifier with the same hardware used on the Westamp servo amplifier plus
washers.
10. Locate the two #10 black wires and cut off the ring tongue
terminals. Install 1/4 quick disconnect 12-10 GA terminals on these two
wires.
NOTE: There is a spare terminal provided if a good, reliable crimp is not
made the first time.
11. Locate the twisted red and white #16 wires and cut off the ring tongue terminals
Install 1/4 quick disconnect 16-14 GA terminals on these two wires.
NOTE: There is a spare terminal provided if a good, reliable crimp is not
made the first time.
12. Locate the X and Y servo motor drive wires (#12 blue) and cut off the ring
tongue terminal. Install the 12-10 GA yellow butt splice on each of these wires.
Locate #12 blue wire Beldon #9912-6 and divide this 96 inch wire into four 24
inch sections. Crimp each of these wires into the free end of the butt splices
crimped earlier to the servo motor drive wires.
NOTES:
a. The Z axis motor drive wires are dressed in the correct direction and
will not have to be lengthened.
b. To aid in installing the wires, it may be necessary to remove the two end
screws that secure the wago terminal rail that holds RTB1 and TB2 on
the Randtronics servo amplifier.
c. The J1 connectors that were wired for Westamp drive (X/Y/Z) will be
cut off.
d. FOLLOW THE WIRE LIST EXACTLY, it is important to work on

only one axis at a time.
13. Now, refer to the wire list for point-to-point wiring information.
14. See view for the limit switch interface board located on the terminal strip panel
and modify as illustrated.
15. Perform the machine operational test on page 11.Pictures & wire lists

A. Ensure that the 72 VAC #10 black wires are connected to J5-1 and 2 respectively on
the fault logic board.
B. Ensure that the 120 VAC red and white twisted pair wires are connected to J4-1 and 2
on the fault logic board.
C. Using print 002-2047-002 and ohmmeter, perform continuity checks from RTB1 and 2
of the Randtronics servo amplifier to wherever terminated.
D. Using ohmmeter, check for approximately 160 OHMS between:
(X) RTB1-4 to RTB1-5
(Y) RTB1-12 to RTB1-13
(Z) RTB1-20 to RTB1-21
E. Using ohmmeter, check for 0 OHMS between RTB1-25 to RTB1-28.
F. Preset potentiometers on X, Y, and Z axes boards. (A5, A4 & A3) in the following
manner:
SIGNAL Full CW; Back 8 CCW
AUXILIARY Full CCW
TACH Full CW
BALANCE Center
GAIN Full CW; Back 5 CCW
CURRENT LIMIT Full CCW
G. Turn power disconnect on, power up machine, and depress power on, check and
operate push buttons. Verify that both fans on the Randtronics servo amplifier are
running and moving air across the boards.
H. Complete the following for all three axes, ONLY ONE AXIS AT A TIME.
1. Increase the current limit (CLM) CW. Ensuring the following:
a. polarity of the motor-tach combination
b. the CRT is counting in the correct direction
If the motor begins to "run-away", compare the motor and tach wires to the
wire list or servo-to-mill schematic.
2. Increase CLM full CCW.
3. Adjust signal pot to 0.90 volts at 25 IPM at:
(X) RTB1-2 to RTB1-3
(Y) RTB1-10 to RTB1-11
(Z) RTB1-18 to RTB1-19
4. Ensure difference between plus direction and minus is less than 50 MVDC at
same points shown in step 3.
5. With power applied to the servo amplifier and no command, adjust the gain pot
CW until the axis just begins to oscillate (buzz). Turn gain pot CCW three
turns.
6. Adjust balance until command is minimum and stable, 0.00 VDC ± 0.09 VDC.
Recheck signal if balance is not within this tolerance.
7. Table zero/tool cal. verify CRT is 0.000. If not, adjust balance pot.
8. With servos on, depress the emergency stop on the front panel. Verify axes
drift is not more than 0.010.
I. Enter the CNC program on pages 9 and 10 into the computer. Ensure that the limit
switches work, the table moves freely and without binding, and there are no counting
problems.
J. Close the access door to the main power cabinet and release the machine to the owner.
IV. DISPOSITION OF PARTS
A. Return the Westamp servo amplifier assembly to Hurco Manufacturing in the same
container that the new Randtronics servo amplifier was packed in.
B. Any spare 1/4 quick disconnect terminals are to be retained by Field Service personnel
for future crimp repairs.
757-3021-002 REV: C ECN #

R
04/06/84 CAD #D8207
SUBJECT: "X" AXIS LINEAR SCALE ASSEMBLY PROCEDURE FOR MB-3

& MD-3
I. INTENT
To provide controlled assembly procedures for the accurate installation of the X axis linear
scale assembly on the MB-3 & MD-3.
II. SCOPE
To be available for use by Manufacturing, Customer Service, and Quality personnel

applicable to the X axis scale assembly 002-2231-001 installed on the MB-3 main mechanical
assembly 002-2201-001 and 002-2801-001 on the MD-3 main mechanical assembly.
III. PROCEDURE
A. Reference Drawings: D002-2231-001 X Axis Scale Assembly and E002-2201-001

MB-3 Main Mechanical Assembly/E002-2801-001 MD-3 Main Mechanical Assembly.
B. Procedural Steps
1. Per 002-2231-001 and figure 1, remove paint, primer or dirt/grease where

indicated by shaded area. Surface must be clean to provide an accurate scale
installation.
2. Locate and center punch the six holes required to install the X axis linear scale
only. The reader head install will follow.. Refer to 002-2231-001 for
dimensions. Do not drill/tap holes at present time.
3. Position scale to center punched areas and ensure these are aligned before
drilling/tapping the holes per the drawing requirements.
4. Remove the four screws securing the reader head cover. Rotate the cover 180°
(cable exits toward the non-expansion joint mounting end)
and re-install the cover. CAUTION: Ensure the small insulated wires are not
pinched between the cover and housing during re-installation.
________________________________ _______ _______________________________ _______
5. Install the X scale with the expansion joint end to the right. Secure with the
hardware per the drawing. Ensure the two spherical washers are placed to each
side of the M5 screw on the left end of the scale and one spherical washer is
located in the center on the right end of the scale.
6. Loosen the mid-scale mounting support brackets where attached to the scale.
Secure the brackets to the mill first then secure scale end of brackets.
7. Locate and center punch holes for the reader head bracket. Ensure the center
punched holes align with the bracket/reader head before drilling/tapping the
required holes. Some grinding of the mating surface of reader head bracket to
achieve proper alignment per figure 2. Remove the red reader head shipping
retainers from the scale. Connect the scale connector to the Heidenhain enclosure
assembly 002-2233-001 X connector.
8. Using a .0005 inch dial indicator, align the scale per figure 2 and tolerance
indicated. Careful adjustment of the scale and tightening of the M5 screws with
the mounting support brackets affect the alignment.
9. Ensure the reader head is mounted flush to the scale and the desired .051 - .065
reader head gap to scale maintained. Refer to figure 2.
10. Per the 002-2201-001 and 002-2231-001 for MB-3 or 002-2801-001 and 002-
2231-001 for MD-3, install cable clamps as shown as install the scale cover.
Ensure the cover does not rest or contact the scale.
2
757-3021-003 REV: C ECN #

R
04/06/84 CAD #D8208
SUBJECT: "Y" AXIS LINEAR SCALE ASSEMBLY PROCEDURE FOR MB-

3 & MD-3
I. INTENT
To provide controlled assembly procedures for the accurate installation of the Y axis linear
scale assembly on the MB-3 & MD-3.
II. SCOPE
To be available for the use by Manufacturing, Customer Service, and Quality personnel
applicable to the Y axis scale assembly 002-2232-001 installed on the MB-3 main mechanical
assembly 002-2201-001 and MD-3 main mechanical assembly 002-2801-001.
III. PROCEDURE
A. Reference Drawings: D002-2232-001, Y Axis Scale Assembly and E002-2201-001

MB-3 Main Mechanical Assembly, or, D002-2232-001 Y Axis Scale Assembly and
MD-3 Main Mechanical Assembly 002-2801-001.
B. Procedural Steps
1. Per 002-2232-001, remove any paint or primer where the Y scale will be
installed. Surface must be smooth and clean to provide an accurate installation.
2. Locate and center-punch the two holes required to secure the Y axis linear
scale. The reader head install will follow later. Refer to 002-2232-001 for
dimensions. Do not drill/tap these holes at present time.
3. Position the scale to the center-punched areas and ensure these align with the
holes of the scale. If the locations are not accurate, correct same before
drilling/tapping these holes.
4. Remove the four screws that secure the reader head cover. Rotate the cover
180° (cable exits toward mounting end without expansion joint) and re-install
the reader head cover. CAUTION: Ensure the small insulated wires are not
pinched between the cover and housing during re-installation.
________________________________ _______ _______________________________ _______

5. Install the Y scale with the expansion joint end towards the right or front of the
machine. Secure with hardware per print. Ensure the spherical washers are
placed to each side of the M5 screw on the left scale end. One spherical washer
is positioned in the center of the expansion joint end where the M5 screw passes
through.
6. Locate and center punch holes for reader head brackets, items 8 and 12. These
should temporarily be installed to reader head to ensure correct bracket hole
locations. If correct, drill/tap holes per drawing then install brackets to reader
head. Refer to figure 1 for reader head shipping retainers. Connect cable
connector from scale to the Heidenhain enclosure assembly 002-2233-
001.
7. Using a .0005 inch dial indicator, align the scale per figure 1 tolerance
requirements. Y axis movement by machine control permissible.
8. Ensure the reader head is aligned per figure 1 requirements (view A-A).
9. Per 002-2201-001/002-2232-001 and 002-2801-001 install necessary clamps,

scale cover installed without contact to the scale, and dress remainder scale
cable.
2
757-3021-004 REV: C ECN #

R
04/20/84 CAD #D8209
SUBJECT: MB-3 & MD-3 Z AXIS SCALE ASSEMBLY PROCEDURES
I. INTENT
To provide controlled assembly procedures for the accurate installation of the "Z" axis linear
scale assembly on the MB-3 & MD-3 mills.
II. SCOPE
To be available for use by assembly personnel and Customer Service personnel applicable to
the "Z" axis scale assembly (Part number 002-2222-002) installed on Main Mechanical
Assembly (part number 002-2201-001 on MB-3 and 002-2801-001 on MD-3).
III. PROCEDURE
(Drawing - D002-2222-002 "Z" Axis Scale Assembly)

(Reference - E002-2201-001 MB-3 Main Mechanical Assembly &
002-2801-001 MD-3 Main Mechanical Assembly)
A. Reference drawings 002-2201-001 and 002-2222-002 for MB-3 and 002-2801-001 and
002-2222-002 for MD-3.
Become familiar with these drawings and the locating dimensions/holes required to
secure brackets, scale, and actuator. Please note particularly the dimensions are
relative to the top of the frame (column) and front of "Z" axis "way" surface (column).
All holes to be located within ±.015 (1/64) inch of the defined dimensions.
B. Clean all paint and foreign material from areas where brackets, Items 1, 20, and 22,
mount.
C. Locate drill and tap per drawing 002-2222-002 then (10) M6 and two (2) M8 holes.
D. Install brackets, Items 1, 20 and 22 onto the mill frame with hardware provided.
Finger tighten only to allow slight adjustment utilized later in this procedure. Install the
lower neoprene boot, Item 5.
________________________________ _______ _______________________________ _______

E. Install Item 20 to mill frame "Z" axis head per 002-2222-002 drawing. Install
Item 19 to Item 20. NOTE: These items shall be installed with hardware finger
tight.
F. Assembly Items 10, 12, 13, 26, 25, and 23 to Item 11. Refer to 002-2222-002
drawing. Item 10 shall be adjusted to protrude/extend per dimensions shown.
Route proximity switch hardware per print and secure.
G. Position the "Z" axis head to within 4 inches of tool changer height.
H. Verify the "Z°" axis stop block, located at the bottom of the "Z" axis ball
screw, reference 002-2201-001 for MB-3 and 002-2801-001 for MD-3, is
mounted in correct position to prevent head travel beyond physical limitations of
scale.
I. Remove the scale from the packing carton. CAUTION: Handling, install and
alignment will require careful thought. This is a precise instrument and should
be treated as same.
K. Loosen the hex retainer nut that secures the black conduit to the reader head.
NOTE: Use one open end wrench to hold the mating nut and one open end
wrench to remove the hex retainer. The black flexible conduit/retainer will slip
back. Position approximately 8 inches back from reader head.
L. Install the scale/reader head to Item 11 and secure. Carefully position cable
during this step to emerge to allow the gray cable to slip thru notch above
conduit. The round portion of the hex retainer (black conduit) will insert in the
notched area and be secured with Item 25. Remember - Handle with care.
Place the upper neoprene boot on the top end of the scale. Do not attach boot.
M. Attach the scale/reader head bracket assembly to the upper scale bracket with
hardware. Ensure there are two (2) spherical washers between the scale
mounting end and upper bracket. Finger tighten hardware only. Attach lower
scale end (expansion joint mounting end) to bottom bracket. There is one (1)
flat washer enter positioned between scale mounting end bracket. Tape
neoprene boot on top end of scale bracket, Item 1.
N. Secure reader head bracket, Item 11, it Item 19/20 support brackets. Route the
scale connector/black conduit per 002-2201-001 for MB-3 and 002-2801-001 for
MD-3 to the Heidenhein enclosure assembly and connect to the "Z" axis
connector on box. Remove the red shipping retainers from the reader head.
O. Alignment of scale to the axis movement to the column.
Using a .0005 inch graduated indicator and Figure 1 for reference tolerances,
align the scale. Tighten the top and bottom scale brackets, Items 1 and 22.
2
NOTE: The scale will only be as accurate as it is positioned/aligned. Exercise
care in handling and alignment. Scale to be positioned parallel to the axis
movement (AM) .0015 or less.
O. Align the reader head adjusting brackets, Items 19 and 20. Ensure front surface
of scale reader head and scale to be in same plane within .005 inch. Note also,
the .051-.065 inch space between reader head and scale body. Reference figure
1.
P. Jog "Z" axis head to tool changer height. By moving bracket Item 19 up/down;
align the scale reader head mark (scribed earlier) to scale scribed mark or
electrical "Z" axis marker output of Heidenhein PCB enclosure assembly.
Q. Connect 1/2" conduit between TB17 enclosure, reference 002-2222-002/002-

2201-001 for MB-3 and 002-2222-002/002-2801-001 for MD-3 drawings.
Three (3) proximity switch wires require connectors added and connected.
R. Install actuators for ± limit switch functions and tool changer height limit
switch. Ensure limit switches do not extend from reader head enclosure to
interfere with actuators during full travel.
T. Complete neoprene boots install and reader head bracket cover/gasket.
3
757-3021-007 REV: A ECN #

R
04/06/84 CAD #D8217
SUBJECT: MB-3 SPINDLE MOTOR-PINION ASSEMBLY
I. INTENT
To provide procedure for subject assembly.
II. AVAILABILITY
For initial and retrofit assembly personnel.
III. OPERATIONS
1. Place pinion and taper bushing loosely on motor shaft.
2. Position them to surface marked 2.89↓ with fixture held on motor mounting face.
3. Tighten taper bushing in this location.
________________________________ _______ _______________________________ _______

757-3021-008 REV: A ECN #

R
04/06/84 CAD #D8218
SUBJECT: MB-3 Z AXIS SERVO FEED MOTOR-PINION ASSEMBLY
I. INTENT
To provide procedure for subject assembly.
II. AVAILABILITY
For initial and retrofit assembly.
III. OPERATIONS
1. Position mounting plate over shaft to motor.
2. Position fixture MB-3Z, or .875 high spaced-up bar that clears centering ring as
shown.
3. Place pinion, clamping rings, and cap on shaft with lower pinion face touching fixture
or bar.
4. Tighten coupling mounting screws with pinion in above position.
________________________________ _______ _______________________________ _______

757-3022-001 REV: B ECN #

R
12/15/92 CAD #D8220
SUBJECT: "X" AXIS LINEAR SCALE ASSEMBLY PROCEDURE FOR MB2

LEVEL 2
I. INTENT
To provide controlled assembly procedures for the accurate installation of the X axis linear
scale assembly on the MB-2 Level 2 mill.
II. SCOPE
To be available for use by assembly personnel applicable to the X axis scale assembly (part
number 002-2236-001) installed on the MB-2 Level 2 retrofit assembly (part number
002-2239-001).
III. PROCEDURE
A. Reference Drawing 002-2236-001
1. Become familiar with this drawing and the locating dimensions for attaching
items 2, 3 and 5. Note particularly, the dimensions are relative to the mill table
and saddle. All holes to be located within ±.015 (1/64) inch of the defined
dimensions.
B. Procedural Steps
1. Clean all paint and foreign material from areas where brackets and scale mount.
2. Locate, drill, and tap the two (2) M5 holes per drawing 002-2236-001.
3. Remove the four screws securing the reader head cover. Rotate the cover 180°
(cable exits toward the non-expansion joint end) and re-install the reader head
cover. Caution: Ensure the small insulated wires do not become pinched
between cover and housing.
________________________________ _______ _______________________________ _______

4. Attach scale to mill table using screws (item 4) and spherical washers (reference
002-2236-001 drawing). Tighten finger tight.
Locate center - punch, drill, then tap (2) M6 holes to secure the center scale
support bracket.
5. Align the scale to the axis of movement. Use an .0005 inch graduated
indicator. Align the scale as shown on Figure 1 with the way surfaces and
tighten screws holding scale. Tighten screws holding scale and center scale
bracket.
Note: The scale will only be as accurate as it is positioned. Exercise care in

handling and alignment. Note: Scale is to be positioned parallel to the axis of
movement (AM) within .001 inch. Points A & B are located 0.5 inch from the
end caps of the scale as shown on sheet 3.
6. Attach reader head bracket, item 5, to the mill saddle with items 7 and 8.
7. Attach the scale reader head to the reader head bracket, item 5, with screws,
item 6, Remove the red plastic reader head shipping retainers.
It may be necessary to grind/remove material off reader head bracket mating
surface to ensure flush alignment as shown on sheet 3.
8. Install cable clamps and scale cover. Ensure cover does not contact or rest on
scale assembly.
2
757-3022-002 REV: B ECN #

R
12/15/92 CAD #D8221
SUBJECT: "Y" AXIS LINEAR SCALE ASSEMBLY PROCEDURE FOR MB-

2 LEVEL 2
I. INTENT
To provide controlled assembly procedures for the accurate installation of the Y axis linear
scale assembly on the MB-2 Level 2 mill.
II. SCOPE
To be available for use by assembly personnel and Customer Service personnel applicable to Y
axis scale assembly (part number 002-2235-001) installed on the MB-2 Level 2 retrofit
assembly (part number 002-2239-001).
III. PROCEDURE
1. Become familiar with this drawing and locating dimensions for attaching items 3
and 4. The dimensions are relative to the mill frame. All holes to be located
within ±.015 (1/64) inch of the defined dimensions.
B. Procedural Steps
1. Clean all paint and foreign material from areas where brackets, items 3 and 15
mount.
2. Locate, drill and tap the two (2) M5 holes per drawing 002-2235-001.
3. Remove the scale from the packing container. Remove the four screws securing
the reader head cover. Rotate the cover 180° (label exits toward non-expansion
joint end) and re-install the reader head cover.
CAUTION: Ensure the small insulated wires are not pinched between cover
and housing during re-install.
________________________________ _______ _______________________________ _______

4. Attach scale, item 4, and scale spacers, item 3 to mill frame. Spherical
washers, item 17, are to be in place per 002-2235-001 drawing.
5. Align the scale to the axis of movement using a .0005 inch graduated indicator
shown on figure 3 with these way surfaces and tighten the scale.
Note: The scale will be as accurate as it is positioned. Exercise care in

handling and alignment. Note, scale is to be positioned parallel to the axis of
movement (AM) within .001 inch. (Points A & B are located 0.5 inch from
each end and the distance in between shall meet the tolerance specified per
figure 3.)
6. Attach items 8, 12, and 15 to mill saddle and scale reader head. Carefully align
brackets to reader head and refer to figure 3 for reader head alignment. Be
careful to ensure front surface of scale and reader head to be in same place
within .005 inch. Note, also the .051 - .065 inch space between reader head
and scale body.
7. Install necessary clamps as shown. Drill/tap holes for cover. Ensure cover
does not contact scale.
8. Install spring pins, items 1 and 5, that will rigidize this assembly.
2
757-3022-003 REV: A ECN #

R
04/06/84 CAD #D8222
SUBJECT: "Z" AXIS LINEAR SCALE ASSEMBLY PROCEDURE FOR MB-2

LEVEL 2
I. INTENT
To provide controlled assembly procedures for accurate installation of the Z axis linear scale
assembly on the MB-2 Level 2 mill.
II. SCOPE
To be available for use by assembly personnel and Customer Service personnel applicable to Z
axis scale assembly (part number 002-2234-001) installed on MB-2 Level 2 retrofit assembly
(part number 002-2239-001).
III. PROCEDURE
1. Become familiar with this drawing and locating dimensions for attaching items
1, 11, and 19 which are the brackets required. Note particularly the dimensions
are relative to the top of frame (column), and front of Z axis way surface
(column). All holes to be located within ±.015 (1/64) inch of the defined
dimensions.
B. Procedural Steps
1. Clean all paint and foreign material from areas where brackets, items 1, 11, and
19, mount.
2. Locate, drill and tap the four (4) M6 holes per drawing 002-2234-001.
3. Install brackets, items 1, 11, and 19 onto frame with screws only finger tight
allowing slight movement between the mounting holes and screws.
4. Attach item 15 to item 11 again with screws finger tight.
5. Raise the head to within approximately 4 inches of tool change position.
________________________________ _______ _______________________________ _______

6. Verify the Z axis stop block, installed on the 002-2239-001 MB-2 Level 2
retrofit installation procedure. Ensure it is in the correct position. This will
prevent the head from moving to a position beyond the normal down travel of
the scale and thus damage the scale.
7. Place lower neoprene protector onto the lower scale bracket, item 19. Do not
attach at this time.
8. Place upper neoprene protector onto the upper scale bracket, item 1. Do not
attach, but retain with tape or similar.
9. Remove the scale from packing and insert through read head bracket, item 6.
Note read head towards front of machine and near
top end. Do not release the read head attaching screws. Remove the hex
retainer, approximately/8" hex from the reader head allowing the black
protective covering to slide back exposing the gray wire. Slip this gray wire
into the notch in front of reader head box and insert the hex member into the hole
provided.
10. Attach top end of scale to bracket, item 1, using screw, item 5, and spherical
washer, item 25, provided with scale. Washer is to be installed between scale
and bracket. Tighten finger tight.
11. Position and attach lower end of scale to lower bracket, item 19, same as top
end of step 10.
12. Position and attach reader head bracket, item 6, to reader head of scale. Do not
move reader head at this time.
13. Align the scale to the axis of movement. This is the front and side of the
column way. Use an .001 inch graduated indicator. Align the scale as shown
on sheet 4 with these way surfaces and tighten the brackets and scale. Note:
The scale will be as accurate as it is positioned. Exercise care in handling and
alignment. Note: Scale is to be positioned parallel to the axis of movement
(AM) within .0015 inch. Points A & B are located 0.5 inch from the end caps
on sheet 4.
14. Attach the reader head of scale to the reader head bracket, item 6, being careful
not to move reader head on scale.
15. Position and tighten all screws holding reader head to machine. Be careful to
ensure front surface of scale and reader head to be in same place within .005
inch. Note also the .051 - .065 inch space between reader head and scale body.
16. Remove the retainer strips used for packing and shipping of the scale.
17. Route wires - test, scale junction box. Complete the instructions.
2
MHP 20 and MHP 30
D8114 757-5000-009 MHP-20/30 Laser Measurement of Linear

Positioning
D8115 757-5000-010 Program Upload/Download, Dynapath Control
Procedure
D8120 757-5000-013 Jo Block Set-up Procedure
D8121 757-5000-014 Programming Changes for Spindle RPM
Options, MHP-30
D8122 757-4001-089 Leadscrew Mounted Encoder Assembly
D8123 757-5000-015 Procedure for MHP Firmware Chip Installation
D8152 757-4001-117 BMC and MHP Spindle Drive Belt Tensioning
Procedure
D8278 757-4001-066 Type “O” Automatic Tool Changer Setup
Procedure
D8279 757-4001-120 Type “1” Automatic Tool Changer Setup
Procedure
D8281 757-5000-018 MHP 20 Rigid Tapping Option Installation &
Adjustment Procedure
D8282 757-5000-019 MHP 30 Rigid Tapping Option Installation &
Adjustment Procedure
757-5000-009 REV: C ECN #12061

04/06/92 CAD#D8114
SUBJECT: MHP-20/30 LASER MEASUREMENT OF LINEAR POSITIONING
I. INTENT
To establish an accepted standard for testing of positional accuracy of a machine tool by direct
measurement to the measurement on the machine. Testing in accordance with these conditions
of acceptance serves mainly to provide information concerning the geometrical accuracy of
machine tools determined as a rule with the machine in the unloaded state. The effects of, for
example, cutting forces, play in bearings and imbalance which arise during machining of
workpieces, are under these circumstances only partly comprehended. Factors in the
assessment of positional accuracy with which a position can be attained are 1) Positional
Tolerance, 2) Positional Uncertainty, 3) Positional Deviation, 4) Reversal Error, and 5)
Positional Scatter. Based on this, positioning accuracy and repeat accuracy are calculated, and
electrically corrected for. The results of these tests form a solid base for establishing machine
specifications for positional accuracy.
II. APPLICABILITY
Applicable to all MHP-20/30 Machining Centers. This is the only procedure to be used by
Quality Control for confirming and acceptance of machine positioning accuracy and repeat
accuracy.
III. EQUIPMENT
Hewlett Packard Laser Measurement System, including:

Computer with I/O ROM, Printer/Plotter ROM
Printer Plotter
Associated Cabling
Metrology Software (Pullman & Associates Model 11085A or HP 55286A) or equivalent
Adaptor Plate AD-1
MHP Laser Program Disk
Greco Box with RS232 Cable.
________________________________ _______ _______________________________ _______

Accuracy (P): 0.0008 inches based upon 4 pass VDI 3441.

Repeatability (U) 0.0004 inches based upon 4 pass VDI 3441.
NOTE: That these specifications are based on full travel of the axis.
Positional Uncertainty (P): The total deviation on the selected test axis taking into account
the characteristic values determined in the individual positions; Positional
deviation, reversal error, and positional scatter. It consequently includes both system and
random deviations. At Hurco, this equates to the "Accuracy" Specification for the machine.
Reversal Error (U): The difference obtained from the mean values in both directions of
travel for each position on the chosen test axis. At Hurco, this equates to the "Repeatability"
Specification for the machine.
IV. MEASUREMENT PROCEDURE
A. Obtain all necessary equipment to perform the measurement on the desired axis (REF.
III).
B. Verify that the way lubricant is at an adequate level.
C. Reference the axes of the machine.
1. "Mode Select", "0 - Jog", "R - Reference Zero", then toggle the Z Jog switch.
After Z axis has referenced, toggle X and Y Jog switches (X and Y axes will
reference in the front right position).
D. Mount the adaptor plate to the mill table. Use a square to align the plate with the table
allowing sufficient room to mount the interferometer with 1 inch of clearance to the
retroreflector when the axis is at the end of its travel.
E. Insert tool holder into spindle.
1. Toggle the "Tool Changer" switch to the Manual position.
2. Press and release the "Tool Clamp/Unclamp" pushbutton located on the

machine ram of the MHP-30 or on the remote box of the MHP-20 (the
spindle will unclamp).
3. Insert the tool holder into the spindle.
3. Press and release the Tool Clamp/Unclamp" pushbutton (the spindle will
clamp).
2
F. Mount the interferometer to the mounting bracket. Place the reflector assembly over
the unused port of the interferometer. Mount the assembly to the rod in the tool
holder. Verify that the arrows on the interferometer are correctly
oriented with the axis being measured.
G. Position laser in line with the optics and beyond full travel of the axis. Level the
tripod. Connect the cabling between the laser, display, compensator, and computer.
Mount the temperature sensor on the table and the humidity sensor on the swing arm at
the same height as the table optics.
H. Attach the retroreflector to the adaptor plate using a magnetic base.
NOTE: On X axis, mount the interferometer to the adaptor plate and the retroreflector to
the machined surface on the front of the machine ram.
I. Jog the axis to be measured to its home position:
MHP-20 MHP-30
1. X= 0.0000 in. 0.0000 in.
Y= 16.0000 in. 20.0000 in.
Z= 0.0000 in. 0.0000 in.
J. Use a square to align the interferometer with the retroreflector in the plane of the axis
being measured (allow 1 of inch clearance between the optics at their closest position).
K. Perform the laser alignment by following the laser system users guide. Alignment
must be precise to minimize the cosine error.
NOTE: Insure that the beam indicator displays full strength the entire length of travel.
L. Download the following programs from the Greco box to the machine:
MHP-30 (columns) LASER X, LASER Y, LASER Z.
MHP-20 20LSRX, 20LSRY, 20LSRZ
1. These programs will position the mill in 1.0000 inch increments. Also, a move
beyond axis travel is included to allow backlash compensation to be determined.
2. If the initial laser pass indicates that the axis needs greater than 0.0004 inches
of compensation between consecutive moves, a problem with the axis
is indicated. The problem must be resolved before continuing with the laser
test.
3. The 4 pass run will use the VDI plot to determine machine acceptance.
Maximum total deviation of positioning is:
P - 0.0008 in.(Accuracy)
U - 0.0004 in. (Repeatability)
3
M. To enter axes offsets into the first event of the program:
1. <Mode Select>, "C-Catalog", "[Program I.D.]", <Enter>. The program

selected will be backlit.
2. <Mode Select>, "0-Jog". Write down the position of the axes not being
measured to load into the program.
3. <Mode Select>, "3-Program", Enter position data (Example: X 12.345

<Enter>).
N. Place the machine in a warm-up cycle.
1. <Mode Select>, "1-Auto", <Cycle Start>. Adjust the Axis Feedrate pot to
achieve 100 ipm.
NOTE: To restart a program at the beginning, the Event count must be reset; <Mode
Select>, "3-Program", <RESET>.
3. It takes between 45 and 60 minutes to achieve maximum thermal expansion

(growth) at 100 in/min. The axis must be allowed to warm-up to a stable
condition prior to taking readings.
O. Load the metrology software into the computer and select the program for linear
measurement.
P. Configure laser parameters:

Enter 6.5 for Expansion Coefficient.
Enter 5 for Resolution.
Q. Start machine in Single Event.
1. <Motion Stop> to stop cycling.
2. Reset event count.
3. <Mode Select>, "2-Single Event", <Cycle Start>.
R. Use <Cycle Start> to step through the backlash move till the machine is positioned at
0.0000 in.
S. Reset laser display to 0.00000 in.
T. Depress <Print> to take the reading on the laser.
U. Position the machine to the next position and take the reading. Repeat this step for the
length of the axis.
4
NOTE: This is a 2 pass run for leadscrew map data. If the data indicates a possible
problem with the axis, have the problem resolved and restart the laser test.
V. Enter the leadscrew mapping and backlash compensation (See Table 3), and presets
(See Table 4).
W. Repeat procedure until the axis falls within the specified range.
X. Repeat the procedure on the other two axes. Fill out a hard copy of mapping data
values and save mapping data on disk to go with the machine.
NOTE: MHP machines are lasered starting at the most negative position for the axis being
checked. Z must start at the bottom of travel. MHP-20 (-16.0"), MHP-30 (-
20.0"). Preset laser starting position and invert direction of system measurement.
V. APPENDIX A
A. Entering leadscrew mapping.
1. Depress <Emergency Stop>.
2. Toggle the <Write Protect> switch on the processor PCB to the down position
to enable the EEPROMs.
3. Press <Reset>, "P" to enter the parameter mode.
CAUTION: IN THIS MODE, ANY DATA THAT IS CHANGED WILL AFFECT THE
OPERATION OF THE MACHINE. BE ABSOLUTELY CERTAIN THAT THE PROPER
ADDRESS IS SELECTED PRIOR TO CHANGING THE DATA.
3. To select an address: "A", [address], <Enter>. <Next Event> will step to

next address.
4. The leadscrew mapping is cumulative. Compensation is calculated from move

to move. One pulse is added for each 0.00004 inches of deviation. A
maximum of 9 pulses is allowable per move. (see Table 1)
6. Enter leadscrew data per Table 2.
7. Calculate the largest and smallest backlash moves to calculate strapping into
Enter backlash compensation per Table 3.
Compensation is loaded in millimeters.
[Greatest BL move - ( Greatest BL - Smallest BL ) ] x 25.4 = Compensation in mm

2
5
8. After all data has been entered, toggle the <Write Protest> switch to the up
position to disable the EEPROMs.
9. Press <Reset>, THEN release <Emergency Stop>, <Mode Select>.
10. Clear the fault signals: <Fault/Status>, press <Reset> till faults have been
cleared.
11. Reference axes. Continue with laser.
VI. TABLE 1
DEVIATION MOVE TO MOVE DATA NOTE: The first digit of the data
0.000338 to 0.000374 19 indicates the sign of the data.
0.000299 to 0.000337 18 Negative compensation is added
0.000260 to 0.000298 17 with a 1 and positive compensation
0.000220 to 0.000259 16 is added with a 0.
0.000181 to 0.000219 15
0.000142 to 0.000180 14
0.000102 to 0.000141 13
0.000063 to 0.000101 12
0.000024 to 0.000062 11
-0.000023 to 0.000023 00
-0.000024 to -0.000062 01
-0.000063 to -0.000101 02
-0.000102 to -0.000141 03
-0.000142 to -0.000180 04
-0.000181 to -0.000219 05
-0.000220 to -0.000259 06
-0.000260 to -0.000298 07
-0.000299 to -0.000337 08
-0.000338 to -0.000374 09
6
VII. TABLE 2
MHP-20 MHP-30
X Pos. Addr. Data Y Pos. Addr. Data Z Pos. Addr. Addr. Data
0.0 106 0.0 206 -20.0 - 306
1.0 107 1.0 207 -19.0 - 307
2.0 108 2.0 208 -18.0 - 308
3.0 109 3.0 209 -17.0 - 309
4.0 10A 4.0 20A -16.0 306 30A
5.0 10B 5.0 20B -15.0 307 30B
6.0 10C 6.0 20C -14.0 308 30C
7.0 10D 7.0 20D -13.0 309 30D
8.0 10E 8.0 20E -12.0 30A 30E
9.0 10F 9.0 20F -11.0 30B 30F
10.0 110 10.0 210 -10.0 30C 310
11.0 111 11.0 211 -9.0 30D 311
12.0 112 12.0 212 -8.0 30E 312
13.0 113 13.0 213 -7.0 30F 313
14.0 114 14.0 214 -6.0 310 314
15.0 115 15.0 215 -5.0 311 315
16.0 116 16.0 216 -4.0 312 316
17.0 117 17.0 217 -3.0 313 317
18.0 118 18.0 218 -2.0 314 318
19.0 119 19.0 219 -1.0 315 319
20.0 11A 20.0 21A 0.0 316 31A
21.0 11B
22.0 11C
23.0 11D
24.0 11E
25.0 11F
26.0 120
27.0 121
28.0 122
29.0 123
30.0 124
7
VIII. TABLE 3 - BACKLASH
AXIS ADDRESS DATA NOTE: Values are loaded in millimeters (0.000)

X 048 Example: 0.014 mm backlash for X.
049
Y 04A X 048 00
04B 049 14
Z 04C Conversion factor from inch to millimeter is
04D 25.4 x inches = mm
IX. TABLE 4 - PRESET PARAMETERS:
DATA
ADDR MHP-20 MHP-30
0005 01 01
0047 01 01
0100 00 00
0101 00 00
0102 00 00
0103 02 02
0104 54 54
0105 00 00
0200 00 00
0201 00 00
0202 00 00
0203 02 02
0204 54 54
0205 00 00
0300 41 51
0301 06 06
0302 00 00
0303 02 02
0304 54 54
0305 00 00
8
757-5000-010 REV: B ECN #12061

04/14/92 CAD#D8115
SUBJECT: PROGRAM UPLOAD/DOWNLOAD, DYNAPATH CONTROL

PROCEDURE
I. INTENT
To upload and download part programs, tool charts, and system parameters of MHP
machines using a Greco box.
II. REQUIREMENTS
1. Greco Box
3. RS232 cable
4. Formatted 5.25" floppy disk
III. SET-UP
1. Plug in AC the power cord from the Greco box.

2. Connect the RS232 cable from Port 0 on the Greco box to the RS232 port on the
machine.
3. Remove the disk from the drive.
4. Turn power "On" on the Greco box.
5. Select 40 # to view port set-up.
Use # to step through the parameters.
Channel: 0 (49 # 0 #)
Protocol: X on/X off (47 # 1 #)
Baud: 9600 (43 # 9600 #)
Data bits: 7 (65 # 7 #)
Stop bits: 1 (61 # 1 #)
Parity: Even (45 # 2 #)
________________________________ _______ _______________________________ _______

Command Function
# Enter, invokes the selected command
* Erases one entry on the display
1 Define file (write file to disk)
2 Select file (read file from disk)
3 Close file
5 Directory (# advances to next file)
40 Display parameter
42 Store parameter
43 Channel 0 baud rate (9600)
45 Channel 0 parity (even)
47 Channel 0 protocol (X on/X off)
49 Selected channel 0
51 Text file type (enabled)
52 Line feed output (disabled)
55 Convert line feed to carriage return (enabled)
61 Channel 0 stop bits (1)
65 Channel 0 data bits (7)
98 Delete file (98 # "file number " #)
6. Turn power "On" on the machine.

7. Reference axes.
IV. DOWNLOAD PART PROGRAM OR TOOL CHART FROM GRECO BOX
1. On the machine, select:

Mode Select
9 - Load
R6 - RS232 9600 Baud
P1 - Parity On
X1 - Ctr Chr On
E0 - Echo Off
2. Select :Load Progrm softkey to load a part program
Load Tools softkey to load a tool chart.
"Busy Loading" will appear on the screen, the machine is waiting to receive data.
3. On the Greco box, select: 2 # (file number) #
The File Open led will begin flashing and the Activity led will come on. When the
Activity led goes out, the transfer is complete.
2
V. DOWNLOAD PART PROGRAM FROM THE MACHINE TO THE GRECO BOX.
1. On the Greco box, select 5 # Directory. Use # to step through the directory.
2. Choose a file number that is not being used.
3. Select: 1 # (new file number) #
The File Open led will begin flashing, the Greco box is waiting to receive data.
NOTE: If all programs are to be transferred, disregard steps 4 and 5.
4. On the machine, select: Mode Select, C- Catalog.

5. Select the program to be transferred.
6. Select:
Mode Select
8 - Record
R6 - RS232 9600 Baud
P1 - Parity On
X1 - Ctr Chr On
7. Select: Record Progrm to transfer one program.
All Progrm to transfer entire directory.
Record Tools to transfer tool chart.
"Busy Recording" will appear on the screen, when "Done" appears on the screen, the
transfer is complete.
8. On the Greco box, select: 3 # to close the file.
9. Record the file number on the description on the disk.
VI. DOWNLOAD PARAMETERS FROM THE GRECO BOX INTO THE MACHINE.
1. Depress Emergency Stop on the machine.

2. Toggle the Write Protect Switch on the processor PCB down to enable EEPROMs.
3. Select: Parameter Mode - Reset, P
PIC Editor Mode - Reset, E
Load/Record softkey
R6 - RS232 9600 Baud
P1 - Parity On
X1 - Ctr Chr On
E0 - Echo Off
Load Program/Load Progr.
"Busy Loading" will appear on the screen.
4. On the Greco box, select: 2 # (file number) #
The File Open led will flash and the Activity led will come on. When the Activity led
goes out, the transfer is complete.
5. On the machine, select: Exit.
6. Toggle the Write Protect Switch up to disable the EEPROMs.
7. Select: Parameter - Reset, then release Emergency Stop.
PIC Editor - Reset, Cycle Power OFF then ON.
3
VII. DOWNLOAD PARAMETERS FROM THE MACHINE TO THE GRECO BOX.
1. On the Greco box, select: 5 # Directory. Use # to step through the directory.
2. Choose a file number that is not being used.
3. Select: 1# (new file number) #
The File Open led will begin to flash, the Greco box is waiting to receive data.
4. On the machine, depress Emergency Stop.
5. Toggle the Write Protect Switch on the processor PCB down to enable the
EEPROMs.
6. Select: Parameter Mode - Reset, P
PIC Editor Mode - Reset, E
Load/Record softkey
R6 - RS232 9600 Baud
P1 - Parity On
X1 - Ctr Chr On
E0 - Echo Off
Record Param/Record Progr.
"Busy Recording" will appear on the screen. When "Done" appears, the transfer is
complete.
7. Toggle the Write Protect Switch up to disable the EEPROMs.
8. Select: Parameter - Reset, then release Emergency Stop.
PIC Editor - Reset, then cycle power OFF then ON.
9. On the Greco Box, select: 3 # to close the file.
10. Record the file number and description on the disk.
VIII. DISCONNECTING THE GRECO BOX.
1. Remove the disk.

2. Turn power "Off".
3. Disconnect the RS232 cable.
4. Unplug AC power cord.
2 -------------------------- 3
3 -------------------------- 2
7 -------------------------- 7
RS232 Cable
4
757-5000-013 REV: B ECN #12061

04/13/92 CAD#D8120
SUBJECT: JO BLOCK SET-UP PROCEDURE
I. INTENT
To provide a standardized procedure for testing and compensating for leadscrew and backlash
error.
II. APPLICABILITY
Applicable to all MHP Kneemills. This procedure is to be the only procedure to be used
within HURCO facilities and should be used at customer installations to help achieve factory
proven performance.
III. EQUIPMENT
Obtain the following equipment required to perform Jo Block test:
19.5 inch Jo Block

10 inch Jo Block
3 End Blocks
2 Toe Clamps
2 Tee Nuts
2 Bolts
________________________________ _______ _______________________________ _______

IV. X AXIS PROCEDURE
1. Load program XJB.

2. Reference the machine.
3. Mount the 19.5 inch Jo Block with end blocks attached in the center slot using the toe
clamps to hold the Jo Block in place.
4. Install the tool holder and indicator in the spindle.
5. Zero the indicator on the outside left surface of the left end block, centered
1/8 inch from top of block.
6. Back X off of the block 0.0030 inches and ZERO SET X, Y, and Z.
7. Run the program in Single Event. (The first part of the program is backlash)
8. Press CYCLE START until the indicator touches off to the Jo Block and check the
indicator for zero.
9. Continue with the program until the indicator touches off to the Jo Block again. Take
the first reading and record it.
___________________inches
10. Continue with the program. Backlash is rechecked for verification.
11. Continue with the program until the indicator touches off to the right end block.. Take
and record the reading. This reading is the leadscrew error.
___________________inches
12. Continue with the program. The program repeats to verify the reading.
13. Load presets per Table 1.
14. Load the compensation into the parameters. (Table 2 for MHP-3/3S, Table 4 for MHP-5)
15. Load backlash into the parameters. (Table 6 for MHP-3/3S, Table 7 for MHP-5)
14. Repeat the procedure to verify compensation is accurate.
V. Y AXIS PROCEDURE
1. Load program YJB.

3. Mount the 10 inch Jo Block, with one end block attached, in the center of the table
situated with the end block toward the column and 1/2 inch of the Jo Block extending
over the front table pad. Use the toe clamp to hold the Jo Block in position.
4. Zero the indicator on the front surface of the Jo Block, centered 1/8 inch from top of
block.
5. Back Y off of the block 0.0030 inches and ZERO SET X, Y, and Z.
6. Run the program in Signal Event. (The first part of the program is backlash)
7. Press CYCLE START until the indicator touches off to the Jo Block and check the
indicator for zero.
8. Continue with the program until the indicator touches off to the Jo Block again. Take
the first reading and record it.
___________________inches
9. Continue with the program. Backlash is rechecked for verification.
10. Continue with the program until the indicator touches off to the end block. Take and
record the reading. This reading is the leadscrew error.
___________________inches
2
11. Continue with the program. The program repeats to verify the reading.
12. Load the compensation into the parameters. (Table 3 for MHP-3/3S, Table 5 for MHP-5)
13. Load backlash into the parameters. (Table 6 for MHP-3/3S, Table 7 for MHP-5)
14. Repeat the procedure to verify compensation is accurate.
VI. LOADING PARAMETERS
1. Depress EMERGENCY STOP.

2. Toggle the WRITE PROTECT SWITCH on the Processor PCB to the DOWN position
to enable the EEPROMs.
NOTE: ANY DATA THAT IS CHANGED WILL AFFECT THE OPERATION OF

THE MACHINE. BE EXTREMELY CAREFUL WHEN SELECTING THE ADDRESS
TO BE CHANGED.
3. Press RESET, "P" to enter the Parameter mode.

4. Select the address to be changed by typing "A", then the address number, ENTER.
NEXT EVENT will move to the next address.
5. After all parameters are changed, toggle the WRITE PROTECT SWITCH to the UP
position. Press RESET, then release the EMERGENCY STOP BUTTON.
TABLE #1 - Presets:
MHP-3/3S MHP-5
ADDR. DATA DATA
0005 01 01
0047 01 01
100 00 00
101 00 00
102 00 00
103 01 02
104 00 54
105 00 00
200 14 35
201 00 60
202 00 00
203 01 02
204 00 54
205 00 00
3
TABLE # 2: STRAPPING TABLE FOR MHP-3/3S X AXIS
Error is in ten thousandths of an inch (0.0001)

ADDR +1 +2 +3 +4 +5 +6 +7 +8 +9 +10 +11 +12 +13 +14 +15 +16 +17 +18 +19 +20 +21 +22 +23 +24 +25
0106 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
0107 00 00 00 11 11 11 11 11 11 11 11 12 12 12 12 12 12 12 12 12 12 12 13 13 13
0108 00 00 00 00 00 00 11 11 11 11 11 11 11 11 11 11 12 12 12 12 12 12 12 12 12
0109 00 00 00 11 11 11 00 11 11 11 11 11 11 12 12 12 11 12 12 12 12 12 12 12 13
010A 00 00 11 00 00 11 11 11 11 11 11 11 12 11 11 12 12 12 12 12 12 12 12 13 12
010B 00 11 00 00 11 00 11 00 11 11 11 11 11 11 12 11 12 11 12 12 12 12 12 12 12
010C 11 00 00 11 00 11 00 11 00 11 12 12 11 12 11 12 11 12 11 13 12 13 13 12 13
010D 00 00 11 00 11 00 11 11 11 11 11 11 12 11 12 11 12 12 12 12 12 12 12 13 12
010E 00 00 00 11 00 11 11 11 11 11 11 11 11 12 11 12 12 12 12 12 12 12 12 12 13
010F 00 00 00 00 11 11 00 11 11 11 11 11 11 11 12 12 11 12 12 12 12 12 12 12 12
0110 00 11 11 00 00 00 11 00 11 12 12 11 12 12 12 12 12 12 12 12 13 13 12 13 13
0111 00 00 00 11 11 11 11 11 11 11 11 12 11 12 12 12 12 12 12 12 12 12 13 12 13
0112 00 00 00 00 00 00 11 11 11 11 11 11 11 11 11 11 12 12 12 12 12 12 12 12 12
0113 00 00 11 11 11 11 00 11 11 11 11 11 12 12 12 12 11 12 12 12 12 12 12 13 13
0114 00 00 00 00 0 11 11 11 11 11 11 11 11 11 11 12 12 12 12 12 12 12 12 12 12
0115 00 11 00 00 11 00 11 00 11 11 11 11 11 11 12 11 12 11 12 12 12 12 12 12 12
0116 11 00 00 11 00 11 00 11 00 11 12 12 11 12 11 12 11 12 12 13 12 13 13 12 13
0117 00 00 11 00 11 00 11 11 11 11 11 11 12 11 12 11 12 12 12 12 12 12 12 13 12
0118 00 00 00 11 00 11 11 11 11 11 11 11 11 12 11 12 12 12 12 12 12 12 12 12 13
0119 00 00 00 00 11 11 00 11 11 11 11 11 11 11 12 12 11 12 12 12 12 12 12 12 12
011A 00 11 11 00 00 00 11 00 11 11 11 11 12 11 11 11 12 11 12 12 12 12 12 13 12
011B 00 00 00 11 11 11 11 11 11 11 11 12 11 12 12 12 12 12 12 12 12 12 13 12 13
011C 00 00 00 00 00 00 00 11 11 11 11 11 11 11 11 11 12 12 12 12 12 12 12 12 12
011D 00 00 11 11 11 11 11 11 11 11 11 11 12 12 12 12 12 12 12 12 12 12 12 13 13
011E 00 00 00 00 00 11 11 11 11 11 11 11 11 11 11 12 12 12 12 12 12 12 12 12 12
5
TABLE #2: MHP-3/3S X AXIS (continued)

ADDR -1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25
0106 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
0107 00 00 00 01 01 01 01 01 01 01 01 02 02 02 02 02 02 02 02 02 02 02 03 03 03
0108 00 00 00 00 00 00 01 01 01 01 01 01 01 01 01 01 02 02 02 02 02 02 02 02 02
0109 00 00 00 01 01 01 00 01 01 01 01 01 01 02 02 02 01 02 02 02 02 02 02 02 03
010A 00 00 01 00 00 01 01 01 01 01 01 01 02 01 01 02 02 02 02 02 02 02 02 03 02
010B 00 01 00 00 01 00 01 00 01 01 01 01 01 01 02 01 02 01 02 02 02 02 02 02 02
010C 01 00 00 01 00 01 00 01 00 01 02 02 01 02 01 02 01 02 01 03 02 03 03 02 03
010D 00 00 01 00 01 00 01 01 01 01 01 01 02 01 02 01 02 02 02 02 02 02 02 03 02
010E 00 00 00 01 00 01 01 01 01 01 01 01 01 02 01 02 02 02 02 02 02 02 02 02 03
010F 00 00 00 00 01 01 00 01 01 01 01 01 01 01 02 02 01 02 02 02 02 02 02 02 02
0110 00 01 01 00 00 00 01 00 01 02 02 01 02 02 02 02 02 02 02 02 03 03 02 03 03
0111 00 00 00 01 01 01 01 01 01 01 01 02 01 02 02 02 02 02 02 02 02 02 03 02 03
0112 00 00 00 00 00 00 01 01 01 01 01 01 01 01 01 01 02 02 02 02 02 02 02 02 02
0113 00 00 01 01 01 01 00 01 01 01 01 01 02 02 02 02 01 02 02 02 02 02 02 03 03
0114 00 00 00 00 00 01 01 01 01 01 01 01 01 01 01 02 02 02 02 02 02 02 02 02 02
0115 00 01 00 00 01 00 01 00 01 01 01 01 01 01 02 01 02 01 02 02 02 02 02 02 02
0116 01 00 00 01 00 01 00 01 00 01 02 02 01 02 01 02 01 02 02 03 02 03 03 02 03
0117 00 00 01 00 01 00 01 01 01 01 01 01 02 01 02 01 02 02 02 02 02 02 02 03 02
0118 00 00 00 01 00 01 01 01 01 01 01 01 01 02 01 02 02 02 02 02 02 02 02 02 03
0119 00 00 00 00 01 01 00 01 01 01 01 01 01 01 02 02 01 02 02 02 02 02 02 02 02
011A 00 01 01 00 00 00 01 00 01 01 01 01 02 01 01 01 02 01 02 02 02 02 02 03 02
011B 00 00 00 01 01 01 01 01 01 01 01 02 01 02 02 02 02 02 02 02 02 02 03 02 03
011C 00 00 00 00 00 00 00 01 01 01 01 01 01 01 01 01 02 02 02 02 02 02 02 02 02
011D 00 00 01 01 01 01 01 01 01 01 01 01 02 02 02 02 02 02 02 02 02 02 02 03 03
011E 00 00 00 00 00 01 01 01 01 01 01 01 01 01 01 02 02 02 02 02 02 02 02 02 02
5
TABLE #3: MHP-3/3S Y AXIS

ADDR +1 +2 +3 +4 +5 +6 +7 +8 +9 +10 +11 +12 +13 +14 +15 +16 +17 +18 +19 +20 +21 +22 +23 +24 +25
0206 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
0207 00 00 00 11 11 11 11 11 11 12 12 12 12 13 13 13 13 13 13 14 14 14 14 15 15
0208 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15
0209 00 00 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15
020A 00 11 11 00 11 11 11 12 12 12 12 13 13 12 13 13 13 14 14 14 14 15 15 14 15
020B 11 00 11 11 11 12 12 12 12 12 13 12 13 13 13 14 14 14 14 14 15 14 15 15 15
020C 00 00 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15
020D 00 11 11 11 11 11 12 12 11 12 12 13 13 13 13 13 14 14 13 14 14 15 15 15 15
020E 00 00 00 00 11 11 11 12 12 12 12 12 12 12 13 13 13 14 14 14 14 14 14 14 15
020F 00 11 11 11 11 11 11 11 12 12 12 13 13 13 13 13 13 13 14 14 14 15 15 15 15
0210 11 00 11 11 11 12 12 12 12 12 13 12 13 13 13 14 14 14 14 14 15 14 15 15 15
0211 00 00 00 11 11 11 11 12 12 12 12 12 12 13 13 13 13 14 14 14 14 14 14 15 15
0212 00 11 11 00 11 11 12 11 12 12 12 13 13 12 13 13 14 13 14 14 14 15 15 14 15
0213 00 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15
0214 00 00 00 11 11 11 12 11 11 12 12 12 12 13 13 13 14 13 13 14 14 14 14 15 15
6
TABLE #3: MHP-3/3S Y AXIS (continued)

ADDR -1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25
0206 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
0207 00 00 00 01 01 01 01 01 01 02 02 02 02 03 03 03 03 03 03 04 04 04 04 05 05
0208 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05
0209 00 00 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05
020A 00 01 01 00 01 01 01 02 02 02 02 03 03 02 03 03 03 04 04 04 04 05 05 04 05
020B 01 00 01 01 01 02 02 02 02 02 03 02 03 03 03 04 04 04 04 04 05 04 05 05 05
020C 00 00 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05
020D 00 01 01 01 01 01 02 02 01 02 02 03 03 03 03 03 04 04 03 04 04 05 05 05 05
020E 00 00 00 00 01 01 01 02 02 02 02 02 02 02 03 03 03 04 04 04 04 04 04 04 05
020F 00 01 01 01 01 01 01 01 02 02 02 03 03 03 03 03 03 03 04 04 04 05 05 05 05
0210 01 00 01 01 01 02 02 02 02 02 03 02 03 03 03 04 04 04 04 04 05 04 05 05 05
0211 00 00 00 01 01 01 01 02 02 02 02 02 02 03 03 03 03 04 04 04 04 04 04 05 05
0212 00 01 01 00 01 01 02 01 02 02 02 03 03 02 03 03 04 03 04 04 04 05 05 04 05
0213 00 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05
0214 00 00 00 01 01 01 02 01 01 02 02 02 02 03 03 03 04 03 03 04 04 04 04 05 05
7
TABLE # 4: MHP-5 X AXIS

ADDR +1 +2 +3 +4 +5 +6 +7 +8 +9 +10 +11 +12 +13 +14 +15 +16 +17 +18 +19 +20 +21 +22 +23 +24 +25
0106 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
0107 00 11 11 11 11 11 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 15
0108 00 00 11 11 11 11 11 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15
0109 00 00 00 11 11 11 11 11 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15
010A 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 15
010B 00 00 00 00 11 11 11 11 11 12 12 12 12 13 13 13 13 13 14 14 15 15 14 15 16
010C 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15
010D 00 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 15 14 14 15 15 15
010E 00 00 00 11 11 11 11 11 12 12 12 12 12 13 14 13 13 13 14 14 14 14 15 15 15
010F 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 15
0110 00 00 00 00 11 11 11 11 11 13 12 12 12 12 13 13 13 13 13 14 14 14 14 14 16
0111 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15
0112 00 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15
0113 00 00 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15
0114 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 15 15 15 15 15 15
0115 00 00 00 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 14 14 14 14 14 15 16
0116 00 11 11 11 11 11 12 12 12 12 12 13 13 13 14 13 14 14 14 14 14 15 15 15 15
0117 00 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15
0118 00 00 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15
0119 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 15
011A 00 00 00 00 11 11 11 11 11 13 12 12 12 12 13 13 13 13 13 14 14 14 14 15 16
011B 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 15 14 15 15 15 15
011C 00 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15
011D 00 00 00 11 11 11 11 11 12 12 12 12 12 13 13 14 13 14 14 14 15 14 15 15 15
011E 11 11 11 11 11 12 12 12 12 12 13 13 13 13 14 14 14 14 14 14 15 15 15 15 15
011F 00 00 00 00 11 11 11 11 12 12 12 12 12 13 13 13 14 13 14 14 14 15 14 15 16
0120 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15
0121 00 00 11 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15
0122 00 00 00 11 11 12 12 12 12 12 13 13 13 13 13 14 14 14 14 15 15 15 15 15 15
0123 11 11 11 11 12 12 12 12 12 12 13 13 13 13 13 14 14 14 14 14 15 15 15 15 15
8
TABLE # 4: MHP-5 X AXIS (continued)

ADDR -1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25
0106 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
0107 00 01 01 01 01 01 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05 05
0108 00 00 01 01 01 01 01 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05
0109 00 00 00 01 01 01 01 01 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05
010A 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05 05
010B 00 00 00 00 01 01 01 01 01 02 02 02 02 03 03 03 03 03 04 04 05 05 04 05 06
010C 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05
010D 00 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 05 04 04 05 05 05
010E 00 00 00 01 01 01 01 01 02 02 02 02 02 03 04 03 03 03 04 04 04 04 05 05 05
010F 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05 05
0010 00 00 00 00 01 01 01 01 01 03 02 02 02 02 03 03 03 03 03 04 04 04 04 04 06
0011 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05
0002 00 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05
0003 00 00 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05
0004 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 05 05 05 05 05 05
0005 00 00 00 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 04 04 04 04 04 05 06
0006 00 01 01 01 01 01 02 02 02 02 02 03 03 03 04 03 04 04 04 04 04 05 05 05 05
0017 00 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05
0018 00 00 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05
0019 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05 05
001A 00 00 00 00 01 01 01 01 01 03 02 02 02 02 03 03 03 03 03 04 04 04 04 05 06
001B 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 05 04 05 05 05 05
001C 00 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05
001D 00 00 00 01 01 01 01 01 02 02 02 02 02 03 03 04 03 04 04 04 05 04 05 05 05
001E 01 01 01 01 01 02 02 02 02 02 03 03 03 03 04 04 04 04 04 04 05 05 05 05 05
001F 00 00 00 00 01 01 01 01 02 02 02 02 02 03 03 03 04 03 04 04 04 05 04 05 06
0020 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05
0021 00 00 01 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05
0022 00 00 00 01 01 02 02 02 02 02 03 03 03 03 03 04 04 04 04 05 05 05 05 05 05
0023 01 01 01 01 02 02 02 02 02 02 03 03 03 03 03 04 04 04 04 04 05 05 05 05 05
9
TABLE # 5: MHP-5 Y AXIS

ADDR +1 +2 +3 +4 +5 +6 +7 +8 +9 +10 +11 +12 +13 +14 +15 +16 +17 +18 +19 +20 +21 +22 +23 +24 +25
0206 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
0207 00 11 00 11 11 11 11 12 12 12 12 12 12 12 12 13 13 13 13 13 14 14 14 14 15
0208 00 00 11 11 11 11 11 11 11 12 12 12 13 13 13 13 13 14 14 14 14 14 14 15 14
0209 11 00 00 11 11 11 12 11 12 12 12 13 12 12 13 13 13 13 14 13 14 14 14 14 15
020A 00 11 11 00 11 11 11 12 12 12 12 12 12 13 12 13 13 13 13 14 13 14 14 14 14
020B 00 00 11 11 00 11 11 11 11 11 12 12 12 12 13 12 13 13 14 14 14 14 15 15 15
020C 00 00 00 11 11 11 12 12 12 12 12 12 13 13 13 13 13 13 13 13 14 14 14 14 14
020D 00 11 11 11 11 12 11 11 11 12 12 13 12 12 12 13 13 14 13 14 14 14 14 14 15
020E 11 00 00 00 11 11 11 11 12 12 12 12 12 13 13 13 13 13 14 13 13 14 14 14 14
020F 00 00 11 11 00 11 12 12 12 11 12 12 13 12 13 12 13 13 13 14 14 14 15 15 15
0210 00 11 11 11 11 11 11 11 11 12 12 12 12 13 12 13 13 13 13 14 14 14 14 14 14
0211 00 00 00 11 11 11 11 12 12 12 12 12 12 12 13 13 13 14 14 13 14 14 14 14 15
0212 00 00 11 00 11 11 12 11 12 12 12 13 12 13 13 13 13 13 13 14 13 14 14 14 14
0213 11 11 11 11 11 11 11 11 11 12 12 12 13 12 12 13 13 13 14 13 14 14 14 15 15
0214 00 00 00 11 11 11 11 12 12 12 12 12 12 13 13 13 13 13 13 14 14 14 14 14 14
10
TABLE # 5: MHP-5 Y AXIS (continued)

ADDR -1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16 -17 -18 -19 -20 -21 -22 -23 -24 -25
0206 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00
0207 00 01 00 01 01 01 01 02 02 02 02 02 02 02 02 03 03 03 03 03 04 04 04 04 05
0208 00 00 01 01 01 01 01 01 01 02 02 02 03 03 03 03 03 04 04 04 04 04 04 05 04
0209 01 00 00 01 01 01 02 01 02 02 02 03 02 02 03 03 03 03 04 03 04 04 04 04 05
020A 00 01 01 00 01 01 01 02 02 02 02 02 02 03 02 03 03 03 03 04 03 04 04 04 04
020B 00 00 01 01 00 01 01 01 01 01 02 02 02 02 03 02 03 03 04 04 04 04 05 05 05
020C 00 00 00 01 01 01 02 02 02 02 02 02 03 03 03 03 03 03 03 03 04 04 04 04 04
020D 00 01 01 01 01 02 01 01 01 02 02 03 02 02 02 03 03 04 03 04 04 04 04 04 05
020E 01 00 00 00 01 01 01 01 02 02 02 02 02 03 03 03 03 03 04 03 03 04 04 04 04
020F 00 00 01 01 00 01 02 02 02 01 02 02 03 02 03 02 03 03 03 04 04 04 05 05 05
0210 00 01 01 01 01 01 01 01 01 02 02 02 02 03 02 03 03 03 03 04 04 04 04 04 04
0201 00 00 00 01 01 01 01 02 02 02 02 02 02 02 03 03 03 04 04 03 04 04 04 04 05
0202 00 00 01 00 01 01 02 01 02 02 02 03 02 03 03 03 03 03 03 04 03 04 04 04 04
0203 01 01 01 01 01 01 01 01 01 02 02 02 03 02 02 03 03 03 04 03 04 04 04 05 05
0204 00 00 00 01 01 01 01 02 02 02 02 02 02 03 03 03 03 03 03 04 04 04 04 04 04
TABLE #6: MHP-3/3S BACKLASH TABLE #7: MHP-5 BACKLASH
AXIS ADDR DATA NOTE: Values are AXIS ADDR DATA NOTE: Values are
X 0048 loaded in inches. X 0048 loaded in millimeters
0049 Example: 0.0014" 0049 Example: 0.014mm
Y 004A X 0048 00 Y 004A X 0048 00
004B 0049 14 004B 0049 14
11
757-5000-014 REV: A ECN #11668

01/06/91 CAD#D8121
SUBJECT: PROGRAMMING CHANGES FOR SPINDLE RPM OPTIONS,

MHP-30
I. PIC PROGRAMMING CHANGES
A. Entering PIC Edit Mode.
1. Depress <E-Stop>.
2. Toggle the EEPROM write protect switch down to enable the EEPROMs.
3. <Reset>, "E" to enter the PIC Edit Mode.
NOTE: Any numbers changed in this mode will change the programming for the
machine and effect the operation of the machine.
B. Changing the programming.
1. <Line Select> softkey to select address (The screen will not indicate the
button has been pushed).
2. Enter the address number to be changed, then <Enter>.
3. Type in the data corresponding to that address, then <Enter>.
ADDRESS 4K DATA 6K DATA 10K DATA

2617 LDI 01300 LDI 02000 LDI 03300
2626 LDI 01299 LDI 01999 LDI 03299
2733 LDI 03300 LDI 02000 LDI ?
________________________________ _______ _______________________________ _______

C. Exiting the PIC Edit Mode.
1. Toggle the write protect switch up to disable the EEPROMs.
2. Cycle the machine power off then on to reset the PIC processor.
II. PARAMETER PROGRAMMING CHANGES
A. Entering the Parameter Mode.
1. Depress <E-Stop>.
2. Toggle the write protect switch down to enable the EEPROMs.
3. <Reset>, "P" to enter the parameter mode.
B. Entering data.
1. Type "A" then the address to be changed, then <Enter>.
2. Enter the data corresponding to that address, then <Enter>.
ADDRESS 4K DATA 6K DATA ADDRESS 10K DATA

0052 12 20 0450 00
0053 99 00 0451 00
0054 40 60 04AF 01
0055 00 00 1AC0 00
0056 40 60 1AC1 01
0057 00 00 1AC2 00
0058 40 60 1AC3 00
0059 00 00 1AC4 33
1AC5 00
1AC6 00
C. Exiting the Parameter Mode. 1AC7 32
1AC8 99
1. Toggle the write protect switch 1AC9 01
up to disable the EEPROMs. 1ACA 00
1ACB 00
2. <Reset>, then release <E-Stop>. 1ACC 00
1ACD 32
1ACE 99
1ADF 01
1AD0 00
1AD1 00
757-4001-089 REV: B ECN #11668

01/23/92 CAD#D8122
SUBJECT: LEADSCREW MOUNTED ENCODER ASSEMBLY
I. INTENT
To provide a procedure and tooling requirements for properly installing the leadscrew
mounted encoders on the BMC/MHP 30-50 machining centers.
II. TOOLING REQUIREMENTS
A. Magnetic Base
B. .001 inch Indicator
C. Straight Blade Screwdriver
D. M6 Allen Wrench
E. M8 Allen Wrench
F. 7/64 Allen Wrench
III. PROCEDURE
A. Remove clamp plate from the leadscrew pulley.
B. Install driver 802-2511-001 with 4 M6 X 16 SHCS over the leadscrew shaft to the
pulley using Loctite 242.
C. Ensure that the belt tension on each axis is snug to reduce the physical backlash in the
belt tension.
________________________________ _______ _______________________________ _______

D. Indicate the driver shaft by turning the ballscrew by hand to be within .001 inch T.I.R.
E. Install the housing cover 802-2503-002 with 4 M10 x 20 SHCS using Loctite 242.
DO NOT tighten fasteners.
F. Install set-up plate 802-2500-009 over drive shaft and fasten to the housing cover with
3 M6 x 16 SHCS. This aligns the housing cover to the drive shaft. Tighten housing
cover fasteners.
G. Remove set-up plate.
H. Install hub clamp 205-0004-006 over the drive shaft.
I. Install flex coupling 205-0004-007 over the drive shaft between hub clamp and shaft.
Tighten the hub clamp down to the shaft.
J. Install hub clamp over flex coupling at encoder end. DO NOT TIGHTEN.
K. Install encoder adapter 802-2514-002 over flex coupling and mount to the housing
cover with 4 M6 x 60 SHCS using Loctite 242.
L. Line up tightening bolt on hub clamp with access hole in encoder adapter.
NOTE: Remove the play from the flex coupling. Loosen retainer cap on front end of
coupling. Pull coupling towards ballscrew to reduce end play and re-tighten
retainer cap.
M. Install encoder 416-0248-044 into flex coupling.
N. Tighten hub clamp to encoder and flex coupling.
O. Install mounting cleats 604-0002-001 to the encoder adapter using Loctite 242, and
tighten down to hold the encoder in position.
P. Install connector to the encoder.
Q. Install encoder cover over the encoder assembly into the housing cover using 2 M6 x
16 SHCS and 2 M6 flat washers. Use Loctite 242.
2
NOTE: Upon completion of the laser test, the housing cover must be pinned using two 1/4"
x 1 1/4" spring pins 112-5008-004.
PRECAUTION: DO NOT pry against the housing cover for increasing the belt tension
during the laser test. This will misalign the encoder assembly.
This procedure is written for BMC 40/50 machines. The same procedure applies for the
BMC/MHP-30 except for some part differences. The following is a materials list for all
BMC/MHP 30-50 assemblies.
PART NUMBER DESCRIPTION WHERE USED
205-0004-006 Hub Clamp 30/40/50

205-0004-007 Flex Coupling 30/40/50
416-0248-044 Encoder 30/40/50
604-0002-001 Mounting Cleat 30/40/50
802-2503-002 Housing Cover 40/50
802-2511-001 Driver 30/40/50
802-2514-002 Adapter 40/50
802-2503-005 Cover 40/50
802-2503-001 Housing Cover 30
802-2514-001 Adapter 30
802-2503-004 Cover 30
BMC/MHP-30 Assembly 002-3839-001
BMC 40/50 Assembly 002-3839-002
Set-up Plate BMC/MHP-30 802-2500-010
Set-up Plate BMC 40/50 802-2500-009
3
757-5000-015 REV: A ECN #11668

01/08/92 CAD#D8123
SUBJECT: PROCEDURE FOR MHP FIRMWARE CHIP INSTALLATION
I. SCOPE
All MHP machines that require a firmware change.
II. PURPOSE
To provide a systematic process to install MHP firmware chips.
III. TOOLS REQUIRED
Small flat blade screwdriver

Static pad to lay board on
Installation Procedure
NOTE: When removing the auxiliary board or the processor board it is necessary to
back up any programs or tool tables that you want to keep. Removal of these
boards deprives memory of the required voltage to maintain programs.
IV. PROCEDURE
A. Turn the main power off and lock out if possible.
B. Place static wrist strap on wrist.
C. Remove the cover on the Dynapath card rack located in the power cabinet.
D. Locate the Delta processor using the Diagram on the control cover.
________________________________ _______ _______________________________ _______

E. Remove J11, located on the lower edge of the board.
F. Remove the ground directly under J11.
G. Remove the processor board and lay on the static protection mat.
H. With the board on the mat and orientated so that the plastic thumb tabs are facing up,
locate the letters A through S on the bottom of the board. Looking to the right edge of
the board locate the Numbers 1 through 4. The firmware chips are at locations 1H and
1L.
I. Using the small flat blade screw driver carefully remove the firmware chips.
J. Place the chips in their respective sockets paying careful attention to the orientation of
the pin one location, refer to the drawing furnished.
K. Replace the board in the cage by reversing the steps 1-7.
L. Turn main power on.
M. CRT should indicate firmware version number:
1. Delta 10 Control PB5708
2. Delta 20 Control PB5211
2
757-4001-117 REV: B ECN #12367

R
09/18/92 CAD#D8152
SUBJECT: BMC AND MHP SPINDLE DRIVE BELT TENSIONING

PROCEDURE
I. INTENT
To provide a standardized procedure for spindle drive belt tensioning. This will allow
maximum power and torque to be transferred from the motor to the spindle and prevent
premature spindle bearing failure due to excessive belt tensioning.
II. APPLICABILITY
Applicable to only the spindle drive systems listed in this document. This procedure is to be
used whenever tensioning one of the listed spindle drive belts.
III. EQUIPMENT
A. Magnetic Base Indicator Holder.
B. Dial Test Indicator with .0001 Inch Graduation.
IV. BELT TENSIONING PROCEDURE
A. Tension needs to be released from the spindle drive belt.
B. Position indicator and magnetic base to indicate off the spindle magnetic sensor adaptor
(as close to the back end of the adaptor as possible). Do not move the spindle.
Moving the spindle can change the indicator reading because the adaptor may not be
concentric with the spindle shaft. See Figure 1.
C. Tighten Spindle Drive Belt to the proper spindle shaft deflection. See Chart 1.
D. Only tension HTD spindle drives enough to take out belt slack.
E. Tighten motor mounting plate screws.
F. Remove magnetic base and indicator.
________________________________ _______ _______________________________ _______

CHART 1:
MACHINE SPINDLE MAX. DRIVE BELT MOTOR POWER SPINDLE DEFLECTION

TYPE SPEED (RPM) (HP) (INCHES)
20 6,000 JB V-BELT 10 .0006
6,000 HTD 10 0
10,000 J V-BELT 10 .0005
25/30/40 4,000 HTD 15 0
6,000 JB V-BELT 15 .0008
10,000 J V-BELT 15 .0008
50 4,000 HTD 20 0
6,000 JB V-BELT 20 .0008
Page 2 of 3
FIGURE 1: DIAL INDICATOR PLACEMENT
Page 3 of 3
757-4001-066 REV: C ECN #11978

R
03/10/92 CAD#D8278

I. INTENT
Automatic Tool Changers (ATC) used on BMC-20/50 and MHP-20 type Machining Centers.
II. APPLICABILITY
III. FORMAT


________________________________ _______ _______________________________ _______

is pushed out by the spindle by 0.005 inches to 0.020 inches while unclamped. Tighten
the set screw, apply Loctite #271 to the jam nut and tighten.
alignment bars, one to the mill column and one to the base plate of the tool
changer.
sweep fixture.
quiet operation. NOTE: Some change to the Spindle/Tool Magazine alignment
may be made by moving the Gearbox and Motor.
2
B. Jog the Z axis so that the distance from the bottom of the Spindle face to the
"ATC Height SW".
F. For Software version 7.24 and earlier, set switch positions 1 thru 6 of switch
is displayed for the Z axis. The switch positions are a Binary input with
S1-1 being the least significant bit and S1-6 being the most significant bit. Reference
"Store 2 Position"
G. Move the Magazine Down and place a tool in it under the Spindle. Using a
straight edge, check from the Spindle Key to the Tool Slot. Adjust the "Bias" and
"L-Bias" potentiometers on the Orient Card to insure precise mating of tool to the
Spindle.
Off", and turn the aluminum sensor mount on the spindle, then re-tighten. Press
"Spindle Orient" "Start" to switch between L-G and H-G, recheck and fine tune
using the "Bias" and the L-Bias" potentiometers.
3
_________________millimeters
a straight slot. Adjust the "Bias" and the "L-Bias" potentiometer on the Orient
Card to insure precise mating of tool to the spindle.
potentiometer to mid range, turn Orient OFF by selecting "M19" CODE "Cycle
Start", and turn the aluminum sensor mount on the spindle, then re-tighten.
Using "M40 and M41" CODES' switch between L-G and H-G, recheck and fine
tune using the "Bias" and "L-Bias" potentiometers.

for details.
A. Adjust Right, Left, Up, Down, and reference ATC micro switches as shown
below:
4
Roller Type Switch
Actuator
unclamp action.
B. Magazine Out of Position Proximity switch - Set for 0.015" to 0.025" gap
between end of switch and actuator.
Diagnostics, through several tool changes. Minor adjustments to the flow control
valves, air cushions, and limit switches may be necessary.
make two complete cycles of all tools in the magazine. Verify the pneumatic oiler is
set for 1 drop per every two tool changes.
4. Insure the ATC tool to tool time (from orient complete to magazine left, thru one
change of adjacent tools) is equal to the advertised specifications.
MACHINE SECONDS
BMC-20 6
BMC-30 8
BMC-40 8
BMC-50 8
MHP-20 6
5
757-4001-120 REV: A ECN #11978

R
03/11/92 CAD#D8279

I. INTENT
ATCs used on BMC-25, 30, 30K 40SLV and MHP-30 machining centers.
II. APPLICABILITY
Applicable to all BMC-25, 30 40SLV, and MHP-30 machining centers. This

procedure is the only procedure to be used within Hurco facilities and should be used at
III. FORMAT

IV. EQUIPMENT
ATC Sweep Fixture

________________________________ _______ _______________________________ _______

cylinder.
valves or smooth and consistent movement. Movements left and right should be
equal in time duration.
travel. Adjust the needle valves to eliminate any bounce or noise at the end of
travel.
sweep fixture.
E. Using the alignment bars, adjust the sweep (front to back) to be less than 0.010
centerline. The tool pot and the spindle nose must be concentric to make a
smooth tool change.
2
I. Loosen the (4) set screws on the top of the right/left cylinder mounting
brackets.Use the machine control to move the ATC to the right.
Align the tool holder to the tool changer pot and move the cylinder to
mate the tool changer to the tool holder securely. Tighten the set screws and move
the ATC to the left. Remove the tool holder.
holders.
"Start" button.
"101", "Enter".
Jogwheel, jog Z axis so that the distance from the bottom of the spindle nose to

a straight edge, check from the spindle key to the tool slot. Adjust the "Bias and
spindle.
is not within the range of adjustment of the potentiometer,
then set the potentiometer to mid range, turn Orient OFF by pressing "Spindle Off",
and turn the aluminum sensor mount on the spindle, then switch between L-G and
H-G, recheck and fine tune using the "Bias" and "L-Bias" potentiometers.
E. Remove the tool from the magazine and move the magazine "Left".

3

__________________ millimeters
F. Move the machine head up, place a tool in the magazine under the spindle. Using
a straight edge, check from the spindle key to the tool slot. Adjust the "Bias" and
"L- Bias" potentiometer on the Orient card to insure precise mating of tool to
the spindle.
potentiometer to the mid range, turn Orient OFF by selecting "M19" CODE
"Cycle Start", and turn the aluminum sensor mount on the spindle, then re-
tighten. Using "M40 and M41" CODES, switch between L-G and H-G, recheck
and fine tune using the "Bias" and "L-Bias" potentiometers.
1. Verify tool retention force is set properly. Reference 757-4001-091 or 757-5000-007 for
details.
4
Roller Type Switch
Actuator
Adjust the Unclamp switch so that when actuated the plunger is depressed to the edge
of the rivet hole in the roller to allow the spindle to be fully unclamped before the next
tool change movement.
MACHINE SECONDS
BMC-25 12
BMC-30 12
BMC-30K 12
BMC-40SLV 12
MHP-30 12
5
757-5000-018 REV: A ECN #12469
R
12/03/92 CAD#D8281
SUBJECT: MHP-20 Rigid Tapping Option Installation and Adjustment Procedure

I. INTENT
To provide a standardized procedure for the installation and adjustment of the Rigid
Tapping Option on MHP-20 machining centers.
II. APPLICABILITY
This procedure applies to all MHP-20 machining centers and is the only procedure to be used in
the installation of the MHP-20 Rigid Tapping Option on the manufacturing floor and in the
field.
III. EQUIPMENT
1. Digital Tachometer 12. M10 Tap
2. #2 Phillips Screwdriver 13. 3mm Hex Key
3. Drill 14. 4mm Hex Key
4. #9 Drill Bit 15. 5mm Hex Key
5. 9/16" Drill Bit 16. 6mm Hex Key
7. (2) 19mm Open End Wrenches 18. 1/8" Hex Key
8. Loctite 271 19. Jig Saw
9. Test Part and Base(802-9001-001/002) 20. 10mm Wrench
10. Tooling - See Chart A. 21. (4) 1/2-13 X 2 1/2" SHCS
11. M6 Tap 22. Honda Pin Extractor
________________________________ _______ _______________________________ _______

IMPORTANT: COPY ALL OF THE CUSTOMER PART PROGRAMS AND TOOL FILES
ONTO DISK OR CASSETTE PRIOR TO INSTALLATION OF THE RIGID TAPPING
OPTION. ALL FILES WILL BE LOST WHEN THE PROCESSOR PCB IS REMOVED FROM
THE CARD RACK.
IV. PROCEDURE FOR MHP-20
A. Installation
1. Remove Head Cover, Unclamp Cylinder Magnetic Sensor, Magnet Collar and Orient
Harness.
2. Locate, drill and tap two (2) 9/16" holes for the Encoder Mounting Bracket on the side
of the ram per drawing# 002-4144-003.
3. Install the Spindle Pulley with the gear facing down and place the timing belt over the
pulley.
4. Install the Unclamp Cylinder.
5. Assemble the Encoder to the Encoder Bracket, attach the Encoder Pulley and install the
assembly to the ram.
6. Install the Rigid Tapping Encoder Harness and wire per drawing # 423-6716-001
7. Install the Encoder Orientation PCB in place of the Magnetic Sensor Orientation PCB.
8. Connect the 6CN and 7CN cables to the Orient Card and wire the S/TJ9 Connector per
drawing# 423-6716-002.
B. Presets
1. Set S5 as follows: 0 = Off; 1 = On
1 2 3 4 5 6 7 8
1 0 0 0 0 0 0 1
2. Set A/B jumper on B.

3. Turn Power On.
4. In the Machine Parameters verify the following.
Depress E-STOP and toggle the Write Protect Switch on the Processor PCB Down to
enable the EEPROMs. Then <RESET> "P".
Select an address by entering A, (address), <ENTER>. <NEXT EVENT> to move to
the next address. Enter data by entering (data) <ENTER>.
ADDR DATA ADDR DATA ADDR DATA ADDR DATA

04A8 09 1ADB 00 1AE3 00 1AEB 00
04A9 05 1ADC 50 1AE4 12 1AEC 50
1AD5 02 1ADD 00 1AE5 06 1AED 00
1AD6 00 1ADE 39 1AE6 66 1AEE 63
1AD7 40 1ADF 99 1AE7 02 1AEF 50
1AD8 00 1AE0 00 1AE8 50 1AF0 09
1AD9 01 1AE1 40 1AE9 01 1AF1 50
1ADA 00 1AE2 96 1AEA 00
5. Toggle the Write Protect Switch Up to disable the EEPROMs, then <RESET>, and
release E-STOP.
<MODE SELECT>, "0 - Jog Mode", "R", <START>.
7. Set Control Constants on the orient card as follows:
S4 select control constants F-00 to F-0F

S5 1 ON - Test Mode
S5 1 OFF - Normal Mode
S5 7 selects between 00-0F and 10-1F
S5 8 ON allows control constants to be changed
S6 S9 selects control constant data
SET display data of S6 - S9
STO Store data of S6 - S9 in nonvolatile RAM
CAN Test Mode - Start setup motion
CAN Normal Mode - Cancels setting of control constant
To adjust data, turn S4 to FN# desired, press SET turn S6 - S9 to required data
number, press STO (store) to store. When all data has been changed, set S4 to F to
monitor the spindle speed, and turn S6 - S9 to 0.
FN- S5-7 S4 Description Data Unit

0 Off 0 I/O Signal state Note
1 Off 1 Spindle origin 0000 pulse
2 Off 2 Position control H gear 99.99
3 Off 3 Position control M gear 99.99
4 Off 4 Position control L gear 99.99
5 Off 5 End detection width 0010 pulse
6 Off 6 End cancellation width 0020 pulse
7 Off 7 Orientation speed 0300 rpm
8 Off 8 BCD command resolution 001.0
9 Off 9 Stop position bias width 0000 pulse
D Off D Spindle position monitor read out pulse
E Off E Spindle stop position command 0000 pulse
F Off F Spindle speed monitor read out rpm
4 On 4 Decel rate of orientation speed 0000
6 On 6 Reducing rate of orientation speed 0000
Note: FN-00 will display signals as shown below:
Spindle origin signal (Home Pos)
Orient End
Flashes if CPU is normal Orient Signal
High Gear if Lit Incremental Signal

Medium Gear if Flashing
Low Gear if Out
8. Set control constant CN-26 on spindle drive for 06A4.

The LED display should read zero. Depress the NO./DATA key. Now press the
Mode key 2 times. The display should have CN-01, which stands for control constant
one. Press the ñ key and the MODE/ð ð key to select CN-26 display. Press the DATA
key to read the data. If the constant needs to be changed, use the MODE / ð key to
position to the digit which needs to be changed. When you have positioned to the digit
which requires changing, it will start blinking. Use the ñ key to change the value of the
preset value. Once you have the correct value programmed press and hold the HOME
/ SET key until all the numbers have quit flashing. Press NO. / DATA key and
HOME/SET key to return to spindle speed monitor.
C. Set-up Procedure
1. Jog Z axis to 0, then orient the spindle.

<Mode Select> "0 - Jog" "2 - Fast" then move Z to proper height.
<Mode Select> "3 - Program" "N" "." <Enter>
<Event Type> "9 - M Codes" "M" "19" <Enter>
<Cycle Start>, the control will output the orient command.
2. On the Orient Card, press the CAN button. The spindle will automatically find Home
Position as the spindle encoder marker pulse by searching CW and CCW analyzing the
encoder pulses.
3. When the spindle has stopped, press <RESET> on the control to cancel the orient
command.
4. Align the spindle nose balance key with the ATC tool pot key.
5. Read the data from the orient card in control constant FN-0D and copy that data into
control constant FN-01.
6. Orient the spindle by selecting:
"N" "." <Enter>
7. Turn Tool Change Select Switch to MAN and move the ATC magazine under the
spindle. Select one of the following (M-Codes), <ENTER> then <START> to make an
ATC motion.
MHP-20
M 60 Right
M 61 Unclamp
M 62 Down
M 63 Up
M 64 Clamp
M 65 Left
8. In the Jog Mode, SLOWLY move Z down close to the ATC, then repeat steps 3 - 5.
9. Turn S5 - 8 Off, S4 to F, and S6 - S9 to 0000.
10. Adjust the Spindle DAC Offset, CN - 40 for a window of 5 RPM between CW and
CCW at 1000 RPM.
Run the spindle CW and CCW at 1000 RPM measuring the RPM in both directions.
"N", ".", <ENTER>
M51, <ENTER>, <START> (feedrate lock-out)
M3, <ENTER>, <START>. measure (CW)
M4, <ENTER>, <START>. measure (CCW)
M5, <ENTER>, <START> (stop)
11. Adjust CN - 40 on the spindle drive to bring the CW and CCW speeds closer together.
The more negative the number in CN -40, the faster the spindle will run in the CW
direction and the slower it will run in the CCW direction.
D. Testing
1. Enter the following program:
N Event Type
0001 9 M 19 S 1000
0002 0 X 10 Y 10 Z -2 F 25 G 8 W 1
0003 9 M 30
2. Run in Auto Mode.

<MODE SELECT>, "1 - Auto", <RESET>, <START>
The machine will run a rigid tap cycle at 1000 RPM, observe the accel and decel of the
spindle and of Z axis, both should start and stop at the same time.
3. Enter the following test part program:
Name: RIGIDTAP
N Event Type
0001 9 M7
0002 9 M3 T1 S2600
0003 0 X8.5 Y5.5 Z-1.0 G3 F4.0 K0.2 Q0.05
0004 0 X0.5/ Y5.5 Z-1.0 G3 F4.0 K0 2 Q0.05
0005 9 M6 T2
0006 9 M3 S2000
0007 0 X8.5 Y5.5 Z-0.75 G8 F-0.7 NOTE
0008 0 X0.5/ Y5.5 Z-0.75 G8 F-0.7 NOTE
0009 9 M6 T3
0010 9 M3 S900
0011 0 X8.5 Y5.0 Z-1.0 G3 F4.0 K0.2 Q0.05
0012 0 X0.5/ Y5.0 Z-1.0 G3 F4.0 K0 2 Q0.05
0013 9 M6 T4
0014 9 M3 S1500
0015 0 X8.5 Y5.0 Z-0.75 G8 F-0.7 NOTE
0016 0 X0.5/ Y5.0 Z-0.75 G8 F-0.7 NOTE
0017 9 M9
0018 9 M30
NOTE: Negative F indicates metric Thread Pitch value.
Chart A
Tool # Tool Holder Collet Bit
1 Sandvik 40MM - VF4 - C3 C3 - 1/8 #30 Drill Bit
2 Sandvik 40MM - VF4 - C3 C3 - 11/64 M4 Tap
3 Sandvik 40MM - VF4 - C8 C8 - 13/32 #Y Drill Bit
4. Assure Table Top and bottom of Base Plate are clean and free from chips, then mount
Base Plate to Machine Table with four (4) 1/2-13 X 2 1/2" SHCS. Assure that Base
Plate is centered on table and visually square to table before tightening bolts.
5. Reference Axes.
6. Manually insert Tool #1 into the Spindle. Calibrate the tool to top of test part. Remove
Tool #1 and calibrate Tool #s 2, 3 and 4 in the same manner.
7. Put machine into the Auto Mode, ATC into Auto, verify the tool in the spindle is Tool#
1, the magazine slot facing the spindle is empty, and Tool #s 2, 3 and 4 are in the proper
slots.
8. After the machine changes to Tool #s 2 or 4, press Motion Stop and clean the test part.
Press cycle start to continue the program.
9. After the part program is completed, use a shop vacuum and brush to clean the .
machine.
NOTE: Do not use compressed air to clean off part, the air could force chips under the machine
covers.
10. If any problems occur, analyze and repair the problem and repeat the test part
procedure.
11. Remove the test part and tooling from the machine
12. Using the Template# 888-3574-001, cut the clearance hole and mounting holes for the
encoder cover in the side of the head cover.
13. Mount the encoder cover, sealing it with RTV.
SHT.
SIZE DRAWING REV.
1 PROPRIETARY INFORMATION
C 423-6716-001 OF
1
INFORMATION CONTAINED HEREIN IS THE PROPERTY OF HURCO MANUFACTURING COMPANY, INC. NO REPRODUCTION OR
DISCLOSURE OF THIS INFORMATION SHALL BE MADE BY THE RECIPIENT TO ANY OTHER PERSON OR ORGANIZATION WITHOUT
THE PRIOR WRITTEN CONSENT OF HURCO MANUFACTURING COMPANY, INC.
1.0" TYP
BOTH ENDS 8
CLAMP MUST FIT SNUGLY 7

AROUND CABLE AND BOOT 5 1.5" TYP 6
BOTH ENDS
1 2
3 4
SPINDLE ENCODER
OUTSIDE
KEY
144"
1.5"
146"
NOTES:
1. BLACK WIRE OF GREEN/BLACK WIRE NOT USED, CUT OFF
BOTH ENDS
RED
H 4 2. SOLDER SHIELD TO GREEN WIRE AND COVER WITH #7
BLACK
K 1
WHITE
H 5
BLACK
K 2
SPINDLE BROWN ORIENT 11 406-0811-009 CONTACT, MALE GOLD PLATED 8
A 11
ENCODER BLACK CARD 2" 406-6481-004 SHRINK TUBE, 1/8 BLK 7
N 12 6 CN
YELLOW 3" 406-6481-005 SHRINK TUBE, 3/8 BLK 6
C 14
BLACK 146" 406-1485-001 CABLE, 6 PAIR 22 AWG SHIELD 5
R 15
BLUE 1 406-0561-011 SLEEVE, CABLE CLAMP .541 4
B 7
BLACK 1 406-0401-020 CONNECTOR, CIRCULAR MS3108B20-295 3
P 8
GREEN 1 406-0561-012 SLEEVE, CABLE CLAMP .438 2
E 16
BLACK 1 406-0521-028 ASS’Y, CABLE CLAMP 1
QTY. PART NUMBER ITEM DESCRIPTION ITEM
PARTS LIST
SURFACE TREATMENT
EXCEPT AS NOTED:
~
ALL DIMENSIONS
HURCO HURCO MANUFACTURING COMPANY, INC.
IN INCHES
TOLERANCE INDIANAPOLIS, IN U.S.A.
R
DECIMAL
.0 –.0300
HEAT TREATMENT
.00 –.0150 DESCRIPTION
.000 –.0050
~
FIRST USED ON
.0000 –.0005
ANGULAR – 0ANGULAR 30’
BREAK ALL
SHARP EDGES
THIRD ANGLE
PROJECTION
HARNESS, MHP 6CN/ENCODER RIGID TAPPING
DRAWN
SCALE
NONE
DRA
DATE
11-23-92
SIZE
CHECKED
KGS
DRAWING
DATE
11-24-92
APPROVED
SHT.
1
DATE
REV.
C.N.
7059
A
REV
12469 REL
P.I.N.
NO.
REVISION DESCRIPTION REV
BY
DATE CHK
BY
DATE APPD
BY
DATE DF MHP-30
UNIT OF MEAS.
EA C 423-6716-001 OF
1
SHT.
SIZE DRAWING REV.
C 423-6716-002 OF
1
1 2 3 4 5
7CN
PIN 16
71"
1.5"
73"
NOTES:
1. FILL REMAINING SLOTS IN #2 WITH
REMAINING #1
RED 2. USE 2" OF #8 TO CONNECT

11 25 SHIELDS TO PIN 1, AND COVER WITH #7
BLACK
12 26
WHITE
ORIENT 14 27 SERVO TRANSDUCER PCB
BLACK 2" 406-1688-010 WIRE, 22AWG BLACK 8
CARD 15 28 S/T J9
GREEN 1" 406-6481-002 HEAT SHRINK, 1/8 BLACK 7
7CN 7 29
BLACK 6 406-0803-022 PIN, AMP 20, 5089-1 CONNECTOR 6
8 30
3" 406-6481-004 HEATSHRINK, 1/4 BLACK 5
1
72" 406-1244-002 CABLE, 3 PAIR INDIV. SHIELD 22 AWG 4
1 406-0811-039 CASE, VERTICAL MR-16L 3
1 406-0811-041 INSULATOR, CRIMP TYPE FEMALE MRP-16F01 2
16 406-0811-011 FEMALE CONTACT GOLD 1
PARTS LIST
SURFACE TREATMENT
EXCEPT AS NOTED:
~
ALL DIMENSIONS
IN INCHES
R
DECIMAL
.0 –.0300
HEAT TREATMENT
.000 –.0050
~
FIRST USED ON
.0000 –.0005
BREAK ALL
SHARP EDGES
THIRD ANGLE
PROJECTION
HARNESS, MHP STJ9/7CN
DRAWN
SCALE
NONE
DRA
DATE
11-23-92
SIZE
CHECKED
KGS
DRAWING
DATE
11-24-92
APPROVED
SHT.
1
DATE
REV.
C.N.
7060
A
REV
12469 REL
P.I.N.
NO.
BY
DATE CHK
BY
DATE APPD
BY
DATE DF MHP-30
UNIT OF MEAS.
EA C 423-6716-002 OF
1
757-5000-019 REV: A ECN #12469
R
12/03/92 CAD#D8282
SUBJECT: MHP-30 Rigid Tapping Installation and Adjustment Procedure

I. INTENT
To provide a standardized procedure for the installation and adjustment of the Rigid Tapping
Option on MHP-30 machining centers.
II. APPLICABILITY
This procedure applies to all MHP-30 machining centers and is the only procedure to be used in
the installation of the MHP-30 Rigid Tapping Option on the manufacturing floor and in the
field.
III. EQUIPMENT
1. Digital Tachometer 11. M6 Tap
2. #2 Phillips Screwdriver 12. M10 Tap
3. Drill 13. 3mm Hex Key
4. #9 Drill Bit 14. 4mm Hex Key
7. (2) 19mm Open End Wrenches 17. 8mm Hex Key
8. Loctite 271 18. 1/8" Hex Key
9. Test Part and Base(802-9001-001/002) 19. 10mm Wrench
10. Tooling - See Chart A. 20. (4) 1/2-13 X 2 1/2" SHCS
21. Honda Pin Extractor
________________________________ _______ _______________________________ _______

IMPORTANT: COPY ALL OF THE CUSTOMER PART PROGRAMS AND TOOL FILES
ONTO DISK OR CASSETTE PRIOR TO INSTALLATION OF THE RIGID TAPPING
OPTION. ALL FILES WILL BE LOST WHEN THE PROCESSOR PCB IS REMOVED FROM
THE CARD RACK.
IV.PROCEDURE FOR MHP-30
A. Installation
1. Remove Head Cover, Unclamp Cylinder, Magnetic Sensor, Magnet Collar and Orient
Harness.
2. Locate and drill two (2) 1/2" holes for coolant lines through the top of the ram per
drawing# 002-4144-002. Reroute oil cooler lines.
3. Locate and drill two (2) 9/16" holes and tap with 8mm thread for the Encoder Mounting
Bracket per drawing# 002-4144-002.
4. Replace the Push Stud with the 70mm Push Stud in the Unclamp Cylinder rod.
5. Install the Spindle Pulley with the gear facing down and place the timing belt over the
pulley.
6. Install the Unclamp Cylinder using the Risers and M10 X 60mm SHSCS.
7. Assemble the Encoder to the Encoder Bracket attach the Encoder Pulley and install the
assembly to the top of the ram.
8. Install the Rigid Tapping Encoder Harness and wire per drawing # 423-6716-001
9. Install the Encoder Orientation PCB in place of the Magnetic Sensor Orientation PCB.
10. Connect the 6CN and 7CN cables to the Orient Card and wire the STJ9 Connector per
drawing# 423-6716-002.
11. Install the new software PAL chip on the processor PCB and return old chip through
Hurco for credit.
B. Presets
1. Set S5 as follows: 0 = Off; 1 = On
1 2 3 4 5 6 7 8
1 0 0 0 0 0 0 1
2. Set A/B jumper on B.

3. Turn Power On.
4. In the Machine Parameters verify the following.
Depress E-STOP and toggle the Write Protect Switch on the Processor PCB Down to
enable the EEPROM'S. Then <RESET> "P".
Select an address by entering A, (address), <ENTER>. <NEXT EVENT> to move to
the next address. Enter data by entering (data) <ENTER>.
ADDR DATA ADDR DATA ADDR DATA ADDR DATA

04A8 09 1ADB 00 1AE3 00 1AEB 00
04A9 05 1ADC 50 1AE4 12 1AEC 50
1AD5 02 1ADD 00 1AE5 06 1AED 00
1AD6 00 1ADE 39 1AE6 66 1AEE 63
1AD7 40 1ADF 99 1AE7 02 1AEF 50
1AD8 00 1AE0 00 1AE8 50 1AF0 09
1AD9 01 1AE1 40 1AE9 01 1AF1 50
1ADA 00 1AE2 96 1AEA 00
5. Toggle the Write Protect Switch Up to disable the, then<RESET>, and release E-
STOP.
<MODE SELECT>,"0 - Jog Mode", "R", <START>.
7. Set Control Constants on the orient card as follows:
S4 select control constants F-00 to F-0F

S5 1 ON - Test Mode
S5 1 OFF - Normal Mode
S5 7 selects between 00-0F and 10-1F
S5 8 ON allows control constants to be changed
S6 S9 selects control constant data
SET display data of S6 - S9
STO Store data of S6 - S9 in nonvolatile RAM
CAN Test Mode - Start setup motion
CAN Normal Mode - Cancels setting of control constant
To adjust data, turn S4 to FN# desired, press SET turn S6 - S9 to required data number,
press STO (store) to store. When all data has been changed, set S4 to F to monitor the
spindle speed, and turn S6 - S9 to 0.
FN- S5-7 S4 Description Data Unit

0 Off 0 I/O Signal state Note
1 Off 1 Spindle origin 0000 pulse
2 Off 2 Position control H gear 99.99
3 Off 3 Position control M gear 99.99
4 Off 4 Position control L gear 99.99
5 Off 5 End detection width 0010 pulse
6 Off 6 End cancellation width 0020 pulse
7 Off 7 Orientation speed 0300 rpm
8 Off 8 BCD command resolution 001.0
9 Off 9 Stop position bias width 0000 pulse
D Off D Spindle position monitor read out pulse
E Off E Spindle stop position command 0000 pulse
F Off F Spindle speed monitor read out rpm
4 On 4 Decel rate of orientation speed 0000
6 On 6 Reducing rate of orientation speed 0000
Note: FN-00 will display signals as follows:
Spindle origin signal (Home Pos)
Orient End
Flashes if CPU is normal Orient Signal
High Gear if Lit Incremental Signal

Medium Gear if Flashing
Low Gear if Out
8. Set control constant CN-26 on spindle drive for 06A4.
The LED display should read zero. Depress the NO./DATA key. Now press the
Mode key 2 times. The display should have CN-01, which stands for control constant
one. Press the ñ key and the MODE/ð ð key to select CN-26 display. Press the DATA
key to read the data. If the constant needs to be changed, use the MODE / ð key to
position onto the digit which needs to be changed. When you have positioned to the
digit which requires changing, it will start blinking. Use the ñ key to change the value.
Once you have the correct value programmed press and hold the HOME / SET key
until all the numbers have quit flashing. Press NO. / DATA key and HOME/SET key
to return to spindle speed monitor.
C. Set-up Procedure
1. Jog Z axis to 0, then orient the spindle.

<Mode Select> "0 - Jog" "2 - Fast" then move Z to proper height.
<Mode Select> "3 - Program" "N" "." <Enter>
2. On the Orient Card, press the CAN button. The spindle will automatically find Home
Position as the spindle encoder marker pulse by searching CW and CCW analyzing the
encoder pulses.
3. When the spindle has stopped, press <RESET> on the control to cancel the orient
command
4. Align the spindle nose balance key with the ATC tool pot key.
5. Read the data from the orient card in control constant FN-0D and copy that data into
control constant FN-01.
6. Turn Power On.
7. Orient the spindle by selecting:
"N" "." <Enter>
8. Turn Tool Change Select Switch to MAN and move the ATC magazine under the
spindle. Select one of the following (M-Codes), <ENTER> then <START> to make an
ATC motion.
MHP-30
M 60 Right
M 61 Unclamp
M 62 Clamp
M 63 Left
9. In the Jog Mode, SLOWLY move Z down close to the ATC, then repeat steps 3 - 5.
10. Move the ATC left and turn S5 - 8 Off, S4 to F, and S6 - S9 to 0000.
11. Adjust the Spindle DAC Offset, CN - 40 for a window of 5 RPM between CW and
CCW at 1000 RPM.
Run the spindle CW and CCW at 1000 RPM measuring the RPM in both directions.
"N", ".", <ENTER>
M51, <ENTER>, <START> (feedrate lock-out)
M3, <ENTER>, <START>. measure (CW)
M4, <ENTER>, <START>. measure (CCW)
M5, <ENTER>, <START> (stop)
12. Adjust CN - 40 on the spindle drive to bring the CW and CCW speeds closer together.
The more negative the number in CN -40, the faster the spindle will run in the CW
direction and the slower it will run in the CCW direction.
D. Testing
1. Enter the following program:
N Event Type
0001 9 M 19 S 1000
0002 0 X 10 Y 10 Z -2 F 25 G 8 W 1
0003 9 M 30
2. Run in Auto Mode.

<MODE SELECT>, "1 - Auto", <RESET>, <START>
The machine will run a rigid tap cycle at 1000 RPM, observe the accel and decel of the
spindle and of Z axis, both should start and stop at the same time.
3. Enter the following test part program:
Name: RIGIDTAP
N Event Type
0001 9 M7
0002 9 M3 T1 S2600
0003 0 X8.5 Y5.5 Z-1.0 G3 F4.0 K0.2 Q0.05
0004 0 X0.5/ Y5.5 Z-1.0 G3 F4.0 K0 2 Q0.05
0005 9 M6 T2
0006 9 M3 S2000
0007 0 X8.5 Y5.5 Z-0.75 G8 F-0.7 NOTE
0008 0 X0.5/ Y5.5 Z-0.75 G8 F-0.7 NOTE
0009 9 M6 T3
0010 9 M3 S900
0011 0 X8.5 Y5.0 Z-1.0 G3 F4.0 K0.2 Q0.05
0012 0 X0.5/ Y5.0 Z-1.0 G3 F4.0 K0 2 Q0.05
0013 9 M6 T4
0014 9 M3 S1500
0015 0 X8.5 Y5.0 Z-0.75 G8 F-0.7 NOTE
0016 0 X0.5/ Y5.0 Z-0.75 G8 F-0.7 NOTE
0017 9 M9
0018 9 M30
NOTE: Negative F indicates metric Thread Pitch value.
Chart A
Tool # Tool Holder Collet Bit
1 Sandvik 40MM - VF4 - C3 C3 - 1/8 #30 Drill Bit
3 Sandvik 40MM - VF4 - C8 C8 - 13/32 #Y Drill Bit
4. Assure Table Top and bottom of Base Plate are clean and free from chips, then mount
Base Plate to Machine Table with four (4) 1/2-13 X 2 1/2" SHCS. Assure that Base
Plate is centered on table and visually square to table before tightening bolts.
5. Reference Axes.
6. Manually insert Tool #1 into the Spindle. Calibrate the tool to top of test part. Remove
Tool #1 and calibrate Tool #s 2, 3 and 4 in the same manner.
7. Put machine into the Auto Mode, ATC into Auto, verify the tool in the spindle is Tool#
1, the magazine slot facing the spindle is empty, and Tool #s 2, 3 and 4 are in the proper
slots.
8. After the machine changes to Tool #s 2 or 4, press Motion Stop and clean the test part.
Press cycle start to continue the program.
9. After the part program is completed, use a shop vacuum and brush to clean the
machine.
NOTE: Do not use compressed air to clean off part, the air could force chips under the machine
covers.
10. If any problems occur, analyze and repair the problem and repeat the test part
procedure.
11. Remove the test part and tooling from the machine
12. Replace the head cover.
SHT.
SIZE DRAWING REV.
C 423-6716-001 OF
1
1.0" TYP
BOTH ENDS 8
CLAMP MUST FIT SNUGLY 7

AROUND CABLE AND BOOT 5 1.5" TYP 6
BOTH ENDS
1 2
3 4
SPINDLE ENCODER
OUTSIDE
KEY
144"
1.5"
146"
NOTES:
1. BLACK WIRE OF GREEN/BLACK WIRE NOT USED, CUT OFF
BOTH ENDS
RED
H 4 2. SOLDER SHIELD TO GREEN WIRE AND COVER WITH #7
BLACK
K 1
WHITE
H 5
BLACK
K 2
SPINDLE BROWN ORIENT 11 406-0811-009 CONTACT, MALE GOLD PLATED 8
A 11
ENCODER BLACK CARD 2" 406-6481-004 SHRINK TUBE, 1/8 BLK 7
N 12 6 CN
YELLOW 3" 406-6481-005 SHRINK TUBE, 3/8 BLK 6
C 14
BLACK 146" 406-1485-001 CABLE, 6 PAIR 22 AWG SHIELD 5
R 15
BLUE 1 406-0561-011 SLEEVE, CABLE CLAMP .541 4
B 7
BLACK 1 406-0401-020 CONNECTOR, CIRCULAR MS3108B20-295 3
P 8
GREEN 1 406-0561-012 SLEEVE, CABLE CLAMP .438 2
E 16
BLACK 1 406-0521-028 ASS’Y, CABLE CLAMP 1
PARTS LIST
SURFACE TREATMENT
EXCEPT AS NOTED:
~
ALL DIMENSIONS
IN INCHES
R
DECIMAL
.0 –.0300
HEAT TREATMENT
.000 –.0050
~
FIRST USED ON
.0000 –.0005
BREAK ALL
SHARP EDGES
THIRD ANGLE
PROJECTION
HARNESS, MHP 6CN/ENCODER RIGID TAPPING
DRAWN
SCALE
NONE
DRA
DATE
11-23-92
SIZE
CHECKED
KGS
DRAWING
DATE
11-24-92
APPROVED
SHT.
1
DATE
REV.
C.N.
7059
A
REV
12469 REL
P.I.N.
NO.
BY
DATE CHK
BY
DATE APPD
BY
DATE DF MHP-30
UNIT OF MEAS.
EA C 423-6716-001 OF
1
SHT.
SIZE DRAWING REV.
C 423-6716-002 OF
1
1 2 3 4 5
7CN
PIN 16
71"
1.5"
73"
NOTES:
1. FILL REMAINING SLOTS IN #2 WITH
REMAINING #1
RED 2. USE 2" OF #8 TO CONNECT

11 25 SHIELDS TO PIN 1, AND COVER WITH #7
BLACK
12 26
WHITE
ORIENT 14 27 SERVO TRANSDUCER PCB
BLACK 2" 406-1688-010 WIRE, 22AWG BLACK 8
CARD 15 28 S/T J9
GREEN 1" 406-6481-002 HEAT SHRINK, 1/8 BLACK 7
7CN 7 29
BLACK 6 406-0803-022 PIN, AMP 20, 5089-1 CONNECTOR 6
8 30
3" 406-6481-004 HEATSHRINK, 1/4 BLACK 5
1
72" 406-1244-002 CABLE, 3 PAIR INDIV. SHIELD 22 AWG 4
1 406-0811-039 CASE, VERTICAL MR-16L 3
1 406-0811-041 INSULATOR, CRIMP TYPE FEMALE MRP-16F01 2
16 406-0811-011 FEMALE CONTACT GOLD 1
PARTS LIST
SURFACE TREATMENT
EXCEPT AS NOTED:
~
ALL DIMENSIONS
IN INCHES
R
DECIMAL
.0 –.0300
HEAT TREATMENT
.000 –.0050
~
FIRST USED ON
.0000 –.0005
BREAK ALL
SHARP EDGES
THIRD ANGLE
PROJECTION
HARNESS, MHP STJ9/7CN
DRAWN
SCALE
NONE
DRA
DATE
11-23-92
SIZE
CHECKED
KGS
DRAWING
DATE
11-24-92
APPROVED
SHT.
1
DATE
REV.
C.N.
7060
A
REV
12469 REL
P.I.N.
NO.
BY
DATE CHK
BY
DATE APPD
BY
DATE DF MHP-30
UNIT OF MEAS.
EA C 423-6716-002 OF
1
40 SLV
D8147 757-4001-116 ELECTROCRAFT MAX 400 SERVO AMPLIFIER

SET-UP PROCEDURE
D8279 757-4001-120 HURCO TYPE "1" AUTOMATIC TOOL CHANGER
(ATC) ALIGNMENT AND SET-UP PROCEDURE
D8376 757-4001-121 40SLV High Torque Spindle Setup Procedure

757-4001-116 REV: B ECN #

R
09/08/92 CAD #D8147
SUBJECT: ELECTROCRAFT MAX 400 SERVO AMPLIFIER SET-UP

PROCEDURE

A Original Issue
B Updated to current specs, Added MHP 09/08/92
I. INTENT
To provide a standardized set-up and adjustment procedure for the Electrocraft MAX 400
amplifiers for the BMC-40 SLV.
II. APPLICABILITY
Applicable to all BMC-40SLV and MHP-20/30 Machining Centers. This procedure is to be

used within Hurco facilities by Manufacturing during the manufacture of all BMC-40SLV and
MHP-20/30 Machining Centers.
Digital Voltmeter (DVM)

IV. FORMAT
Pages 2 to 3: BMC-40SLV Procedure

Pages 4 to 5: MHP-20/30 Procedure
________________________________ _______ _______________________________ _______

V. PROCEDURE FOR BMC-40SLV
A. SET UP
ILIM - Full CW
VCS - Full CW
P8 1 to 2 - Isolates drive common from chassis ground.

3. Turn power on and calibrate machine: select <EXIT> softkey,

<MANUAL>, <POWER>, <START>, <CALIBRATE MACHINE>
softkey, <START>, <START> again when prompted to calibrate the ATC.
4. Move axes to mid travel.
5. Adjust axis DAC offset pots:
a. Select <CHANGE TOOL OR DIAGNOSTICS> softkey, <ATC

AND MACHINE DIAGNOSTICS> softkey, <ENTER>, 101,
<ENTER> to display the Spindle/Axis Diagnostic Setup Screen.
b. Select <AXIS BALANCE ADJUSTMENT>, (X, Y or Z axis),

<START>. The Dual Axis PCB will output an open loop DAC
command voltage of approximately 9.7 mV, alternating plus and
minus at three (3) second intervals.
c. Connect the DVM to P1-1 and P1-2 (DAC) of the appropriate

amplifier with the meter set on the millivolt scale.
d. Adjust the corresponding pot on the Dual Axis PCB's to achieve the
same voltage reading in the plus and minus directions, usually 9.7 mV
but voltage varies between amplifiers.
e. Return machine to the closed-loop servo mode in Manual Mode, press

<EXIT>, <MANUAL>.
f. Adjust the BALANCE pot on the amplifier to 0.0000 mV +/-

0.0002 mV.
2
g. Repeat for other axes.
6. Adjust the LAG pot CW until the axis motor begins to oscillate, then
CCW until the oscillation stops, and an additional
two (2) turns CCW. An oscilloscope may be used to view
the transition between stable and unstable.
7. With the voltmeter set on the 2 Volt scale and connected across P1-1 and
P1-2, jog the axis at 40 ipm plus and minus. Adjust the TACH pot to
0.951 Volts +/- 0.001 Volt. An adjustment to the BALANCE pot may be
necessary to get the same reading in both directions.
B. AXIS CURRENTS
2. With the DVM set on the 10 Amp DC scale, connect the meter in series
with the motor wire from P3-4 of the amplifier. Verify meter lead
connections.
3. Release <EMERGENCY STOP>. Run the axes in both directions at

100 ipm over full axis travel. Record results below:
LOWEST HIGHEST MAX ALLOWABLE

X+
X-
Y+
Y-
Z+
Z-
NOTE: Currents greater than the MAX ALLOWABLE indicate a mechanical

problem causing the axis to bind.
VI. PROCEDURE FOR MHP-20/30
A. SET UP
3
ILIM - Full CW
VCS - Full CW
P8 2 to 3 - Low Impedance Isolation. Drive common is isolated from

chassis ground through a 15 ohm resistor.
Replace the amplifier covers.
3. Turn power on.
3. Change display to show axis lag: release <EMERGENCY STOP>,

select <MODE SELECT>, 5, <RESET>, <RESET>, TM4,
<ENTER>, <MODE SELECT>, 0. Axis lag is displayed on the
bottom right of the screen.
5. Adjust BALANCE on the amplifiers to get 0.0000 +/- 0.0002 on the Lag
Display. This adjustment will allow the axes to reference.
6. Reference machine: select R, <CYCLE>.
7. Adjust the LAG Pot: turn the LAG pot CW until the motor begins to
oscillate, then CCW until the oscillation stops, and then an additional three
(3) turns CCW. An oscilloscope may be used to view the transitions
between stable and unstable.
8. Adjust the Lag Display: select 1, turn the Axis Feedrate Pot full CW.
Jog the axis plus (+) and minus (-) and observe the Lag Display. Adjust
the TACH and/or VCS to obtain 0.0150 +/- 0.0001 on the Lag Display.
(May require a slight BALANCE Pot adjustment to achieve the same
reading in both directions.)
9. Repeat for all 3 axes.
9. Run axis at 400 ipm full travel to verify proper operation and smoothness
of axes. Reset Lag Display on the drive if axis does not operate smoothly
4
at 400 ipm.
B. AXIS CURRENTS
2. Set the DVM to the 10 Amp DC scale, connect the meter in series with the
motor wire from P3-4 of the amplifier. Verify
meter lead connections.
3. Release <EMERGENCY STOP>. Run axes in both directions at 100

ipm over full axis travel.
MACHINE AXIS TOLERANCE

MHP-20 X&Y 3-5 AMPS
Z+ 6-8 AMPS
Z- 3-5 AMPS
MHP-30 X&Y 5-7 AMPS
Z+ 6-10 AMPS
Z- 3-7 AMPS
If necessary, adjust gibs to achieve above specifications and record results

in the table below.
LOWEST HIGHEST
X+
X-
Y+
Y-
Z+
Z-
NOTE: Currents that do not fall within the tolerances specified indicate a
mechanical problem.
COMPLETED BY: ______________________________ DATE:
5
757-4001-120 REV: A ECN #11978

R
03/11/92 CAD#D8279

I. INTENT
To provide a standardized procedure for consistency in the setup and adjustment of the ATCs
used on BMC-25, 30, 30K 40SLV and MHP-30 machining centers.
II. APPLICABILITY
Applicable to all BMC-25, 30 40SLV, and MHP-30 machining centers. This procedure is the
only procedure to be used within Hurco facilities and should be used at customer installations
to help achieve factory proven performance.
III. FORMAT

IV. EQUIPMENT
ATC Sweep Fixture

________________________________ _______ _______________________________ _______

cylinder.
valves for smooth and consistent movement. Movements left and
right should be equal in time duration.
travel. Adjust the needle valves to eliminate any bounce or noise at the end of travel.
sweep fixture.
C. Using the alignment bars, adjust the sweep (front to back) to be less than 0.010
centerline. The tool pot and the spindle nose must be concentric to make a smooth
tool change.
2
I. Loosen the (4) set screws on the top of the right/left cylinder mounting brackets.
Use the machine control to move the ATC to the right. Align the
tool holder to the tool changer pot and move the cylinder to mate the tool changer
to the tool holder securely. Tighten the set screws and move the ATC to
the left. Remove the tool holder.
holders.
"Start" button.
"101", "Enter".
Jogwheel, jog Z axis so that the distance from the bottom of the spindle nose to

a straight edge, check from the spindle key to the tool slot. Adjust
the "Bias and "L-Bias" potentiometer on the Orient
card to insure precise mating of tool to the spindle.
potentiometer to mid range, turn Orient OFF by pressing "Spindle Off", and turn
the aluminum sensor mount on the spindle, then switch between L-G and H-G,
recheck and fine tune using the "Bias" and "L-Bias" potentiometers.
F. Remove the tool from the magazine and move the magazine "Left".

3
Mode in the "Set-up" screen. Orient the spindle using
the "M19" CODE in the PROGRAM
mode and the "Cycle Start" button.

__________________ millimeters
a straight edge, check from the spindle key to the tool slot. Adjust
the "Bias" and "L-Bias" potentiometer on the Orient card to insure precise mating of
tool to the spindle.
potentiometer to the mid range, turn Orient OFF by selecting "M19" CODE "Cycle
Start", and turn the aluminum sensor mount on the spindle, then re-tighten. Using
"M40 and M41" CODES, switch between L-G and H-G, recheck and fine tune using
the "Bias" and "L-Bias" potentiometers.

for details.
4
Roller Type Switch
Actuator
Adjust the Unclamp switch so that when actuated the plunger is depressed to the edge of
the rivet hole in the roller to allow the spindle to be fully unclamped before the next tool
change movement.
MACHINE SECONDS
BMC-25 12
BMC-30 12
BMC-30K 12
BMC-40SLV 12
MHP-30 12
5
757-4001-121 REV: A ECN #12355

R
08/31/92 CAD #D8376
SUBJECT: BMC-40SLV HIGH TORQUE SPINDLE OPTION SET-UP

PROCEDURE

I. INTENT
To provide a standardized set-up and adjustment procedure for the Yaskawa 626VM3
Varispeed Drive for the BMC-40SLV Machining Center with High Torque Option.
II. APPLICABILITY
Applicable to all BMC-40SLV Machining Centers with the High Torque Spindle Option. This
procedure is to be used within Hurco facilities by Manufacturing during the manufacture of all
BMC-40SLV Machining Centers with the High Torque Spindle Option.
Digital Tachometer Heat Gun

Honda Pin Extractor 2" of 1/8" Shrink Tubing
4 mm Hex Key #1 Phillips Screwdriver
IV. FORMAT
Pages 2 thru 5: Drive Set-up Procedure

Pages 6 thru 8: Orient Set-up Procedure
Kevin Sermersheim 09/01/92 Wayne E. Hawkins 09/01/92

V. PROCEDURE
A. PRESETS
1. Remove the Orient Card and verify that the double shunt jumper is in the VCOM
position. This position connects the 0 volt common of the
drive to be used by the Hurco control for inputs to the drive. Verify that the
Spindle Dual Axis and the CRP PCBs are set as follows:
1 2 3 4 5 6 7 8
Z-S SW1 0 0 0 0 0 1 1 0
Z-S SW2 0 0 0 0 1 0 1 0
CRP SW1 1 1 0 0 1 0 0 0
2. Install the Orient card, rewire the CN5 connector as per Orient Procedure. Turn
power ON.
3. The LED display will read 0 (Motor Speed Display).
4. Preset the Control Constants
Press the DISPLAY key twice. The display will read C1-01
(Control Constant 01).
Press the DATA/ENTER key to view data. If the data needs to be changed, use
the > RESET key to select the digit to be changed and the ARROW UP or
ARROW DOWN key to change that digit.
Press and hold the DATA/ENTER key for (2) seconds to transfer the data to the
control.
Press DISPLAY, > RESET, the ARROW UP or ARROW DOWN to select
another Control Constant.
DRIVE/PROG - No operation
DSPL - Selects between U-Data Display and C-Control Constants
DATA/ENTER - When displaying an item - will display the data in that
location
When displaying data - transfers displayed data into the
control.
UP ARROW - Increases the selected digit by one (1)
DOWN ARROW- Decreases the selected digit by one (1)
> RESET - Selects digit one (1) position to the right Alarm reset
RUN - Run command
STOP - Stop command
FWD/REV - Selects direction of motor rotation
JOG - Jog command
2
C1-01 Speed control P (H-gear) 030 1 - 255
C1-02 Speed control P (L-gear) 030 1 - 255
C1-03 Speed control P (H-gear, ORT) 030 1 - 255
C1-04 Speed control P (L-gear, ORT) 030 1 - 255
C1-05 Speed control P (Servo mode) (H-gear) 030 1 - 255
C1-06 Speed control P (Servo mode) (L-gear) 030 1 - 255
C1-07 Motor speed adjustment 1.0250 0.9 - 1.56
C1-08 Speedometer signal level adjustment 1.00 0.9 - 1.5
C1-09 Load meter signal level adjustment 0.90 0.9 - 1.5
C1-10 Load meter full scale 120 120 - 350
C1-11 External operation torque limit 010 5 - 150
C1-12 Soft start time of speed reference 00.1 0.1 - 25.5
C1-13 Speed control I (H-gear) 0100 10 - 1000
C1-14 Speed control I (L-gear) 0100 10 - 1000
C1-15 Speed control I (H-gear, ORT) 0100 10 - 1000
C1-16 Speed control I (L-gear, ORT) 0100 10 - 1000
C1-17 Speed control I (Servo mode) (H-gear) 0100 10 - 1000
C1-18 Speed control I (Servo mode) (L-gear) 0100 10 - 1000
C1-19 Operation level of speed detection signal 017 0- -100
C1-20 Hysteresis width of speed detection signal 01.00 0.0 - 10.00
C1-21 Operation level of torque detection signal 010 5 - 120
C1-31 Motor rated speed 06000 1000-MAXRPM
C1-32 H-gear ratio (Spindle speed/Motor speed) 1.6700 0.5 - 2.5
C1-33 M-gear ratio (Spindle speed/Motor speed) 1.6700 0.5 - 2.5
C1-34 L-gear ratio (Spindle speed/Motor speed) 1.6700 0.5 - 2.5
C1-35 Motor code selection 75 01H - FFH
C1-36 Torque limit level (motor side) 120 50 - 150
C1-37 Torque limit level (brake side) 120 50 - 150
C1-38 I2 rate limit 00.0 0.0 - 20.0
C1-39 Magnetic flux lower level 030 15 - 100
C1-40 Magnetic flux compensation level 50 25 - 50
C1-41 Magnetic flux upper level 100 60 - 120
C1-42 Magnetic flux lower level of servo mode 070 50 - 100
C1-43 Base speed of servo mode 1.00 1.00 - 5.00
C1-44 Speed agree signal width 15 10- 50
C1-45 Zero speed detection level 30 3 - 60
C1-46 DB interval 000 0 - 100
C1-81 Speed reference offset adjustment (preset) *SETTING +/- 800
C1-82 Torque reference offset adjustment (preset) *SETTING +/- 800
C1-87 Control signal adjusted value 5 (preset) *SETTING -0.9 - 1.1
C1-90 Control signal adjusted value 8 (preset) 10.0 0.0- 25.5
*SETTING - Factory setting, will vary
3
B. SET-UP
1. Turn spindle on in Manual Mode, verify proper spindle rotation (CW)and

operation, select <EXIT> softkey, <MANUAL>, <POWER>,
<START>, SPINDLE <ON> and <START>.
2. Calibrate machine, <CALIBRATE MACHINE> softkey, <START>, then

<START> again when prompted to calibrate the ATC, and run a repeating
tapping program at 500 RPM. Adjust bottom pot on the Z-Spindle PCB, while
observing the display on the drive, to obtain 5 RPM window between
3. Run spindle CW at 1000 RPM. Use a Digital Tachometer to verify RPM is

correct RPM.
NOTE: C1-07 may be changed while spindle is running.
4. Run spindle CCW at 1000 RPM. Use a Digital Tachometer to verify RPM is
correct RPM.
NOTE: C1-81 may not be changed while spindle is running.
5. Repeat steps 3 and 4 until both readings are within specification.
6. Run MACHINE WARM UP CYCLE in MANUAL MODE.
7. Record spindle speeds on following chart:
MACHINE PROGRAMMED ACTUAL SPEED ACCEPTABLE

TYPE SPEED CW CCW SPEED RANGE
BMC40SLV 100 RPM 95 - 105 RPM
1000 RPM 950 - 1050 RPM
10K RPM 3000 RPM 2850 - 3150 RPM
6000 RPM 5700 - 6300 RPM
SPINDLE 8000 RPM 7600 - 8400 RPM
10000 RPM 9500 - 10500 RPM
4
VI. CONTROL DATA DISPLAY
Display Description Data at Power On Unit

U1-01 Motor Speed 0 RPM
U1-02 Speed Command 0.00 %
U1-04 Torque Command 0.0 %
U1-05 Spindle Speed 0 RPM
U1-06 Primary Frequency Command 0.0 Hz
U1-07 Primary Current Signal 0.0 %
U1-08 DC Bus Voltage varies V
U1-16 Internal State varies HEX
U2-04 Motor Temperature varies DEG C
U1-17 BIT DISPLAY U1-18 BIT DISPLAY

== == == == == == == == == ==
RDY EMGL FOR REV THL ZSPD AGR NDET TDET TLE
== == == == == == == == == ==
TLL SSC RST CHW PPI IP ORE CHWE ALMA ALM
== == == == == == == == == ==
ORT LGR MGR DAS CHWA AC0 AC1 AC2 AC3
F-Code Alarm Code Description

AC3 AC2 AC1 AC0
F - 000* 1 1 1 1 Winding changeover error***
F 001 1 1 1 1 Emergency stop error
F 100 1 1 1 0 Inverter over current
F 200 1 1 0 1 MCON error
F 300 1 1 0 0 Converter over current
F 400 1 0 1 1 Over voltage
F 500 1 0 1 0 Over speed
F 602 1 0 0 1 Under voltage
F 603 1 0 0 1 Power supply frequency error
F 700 1 0 0 0 Overload
F 800 0 1 1 1 Excessive speed deviation
F 901 0 1 1 0 Motor overheat
F 902 0 1 1 0 Thermo detector disconnection
F 904 0 1 1 0 Controller overheat
F b00 0 1 0 0 AD defective
F b01 0 1 0 0 CPU-AD defective
F C00 0 0 1 1 PG disconnection error
F E01 0 0 0 1 NVRAM error
CPF00** 0 0 0 0 CPF (Control function failure)
1 = ON, 0 = OFF
* A dash (-) after the F indicates the first malfunction.
** If Control Function Failure (CPF) occurs, cycle power OFF then ON to reset. If CPF
continues, replace the Control Board.
5
***This code applicable to winding select systems only.VII. ORIENT
A. PRESETS
1. Preset drive at following settings:

C1-01 Spindle Origin P0.00 +/- 2.00
C1-02 Position Control Proportional Gain (H) 010 1 - 99
C1-03 Position Control Proportional Gain (M) 010 1 - 99
C1-04 Position Control Proportional Gain (L) 010 1 - 99
C1-05 Positioning End Detection Width 00.5 0 - 20
C1-06 Positioning End Cancellation Width 05.0 0 - 20
C1-07 Orientation Speed 150 30 - 600
C1-09 Stop Position Bias Width 001.0 0.5 - 180
C1-10 ---------- 000 ----------
C1-11 ---------- 00 ----------
C1-12 ---------- 00000 ----------
C1-18 Magnetic Flux Level at Orientation 080 15 - 100
C1-19 ---------- 000 ----------
C1-20 Selection Code 4 (Auto Tuning) varies ----------
C1-21 Magnetic Sensor Window Width 15 5 - 20
C1-22 9.990 ----------
2. Adjust the gap between the Magnet and the Magnetic Sensor for
1/5 mm +/- 0.5 mm.
3. Rewire CN5 of the magnetic sensor cable as follows:
a. Remove blank pins from 7, 9, 12 and 13. Discard the male pin from 13.
b. Remove the White and Black wires from 17 and 16. Fold pins back and
apply shrink tubing over individual wires to insulate them.
c. Remove Red wire from 15 and insert into 13.

Remove Green wire from 19 and insert into 1.
Remove Shield wire from 20 and insert into 7.
d. Fill empty positions with female pins.
6
Black *
A 12 (+) Position Command
Red *
D 13 (-) Position Command
Green +
B 1 DC Return
Black +
C 9 +15 Volts
7 Ground
*/+ - Indicates twisted pairs
B. SET-UP
1. Turn power ON.
3. Select <EXIT>, <MANUAL>, <POWER>, <START>,

<CALIBRATE MACHINE> softkey, <START>, then <START> again
when prompted to calibrate the ATC.
3. Verify C3-01 data is 0.00. Change C3-13 data Bit 4 to 0. Display will read
11000000.
4. After the machine has calibrated, select <CHANGE TOOL OR

DIAGNOSTICS> softkey, <ATC AND MACHINE DIAGNOSTICS> softkey,
<ENTER>, 101, <ENTER>, <SPINDLE ORIENT DIAGNOSTICS> softkey,
<START>.
NOTE: The spindle will orient but the system will not look for an Orient
Complete signal, so Oriented display will not be back lit on the screen.
5. On the drive an error message F-d14 will appear, press the <STOP> and the
<RESET> buttons at the same time and the error will reset. The drive will
initialize the Auto Tune program. The spindle will rotate 3-5 revolutions at
35 RPM then slow to 5 RPM for 3-5 revolutions. When the spindle stops, the
orient position will be set.
NOTE: This spindle drive uses the spindle motor encoder in conjunction with
the magnetic sensor to orient the spindle. The drive looks for the relationship
of the magnetic sensor position to the encoder marker pulse and records the
position as the number of tics offset from the marker. If any one of the
variables, magnetic sensor, magneto collar, spindle, or spindle motor, is
moved or replaced the Auto Tune must be reset.
NOTE: The Automatic Tool Changer (ATC) must be aligned and leveled prior to
setting the ATC HEIGHT and making the fine adjustments to the orient position.
5. Exit to Manual Mode, press <MANUAL>, and orient the spindle, press
7
<SPINDLE ORIENT> softkey, <START>.
7. Jog Z axis to where the spindle nose is above the ATC tool seat.
8. Move the ATC magazine right, select <CHANGE TOOL OR

DIAGNOSTICS> softkey, <ATC AND MACHINE DIAGNOSTICS> softkey,
<MAGAZINE RIGHT> softkey, <START>.
9. Verify the centerline of the spindle nose keys is within +/-2.00 degrees of the
centerline of the ATC tool seat.
a. If yes, continue to step 10.
b. If not, turn Spindle Orient off, press SPINDLE <OFF>, loosen the
magneto collar, turn the collar to
achieve proper alignment, then retighten
the collar. Move the ATC magazine left, press <MAGAZINE
LEFT> softkey, <START>.
Repeat steps 3 through 9.
10. To offset the orient position, select C3-01 on the drive and access the data,
change and enter the data to move the orient position, the drive allows for
+/- 2.00 degrees of compensation.
11. To set ATC height, enter machine diagnostics, select <CHANGE TOOL OR
DIAGNOSTICS> softkey, <ATC AND MACHINE
DIAGNOSTICS> softkey, <ENTER>, 101,
<ENTER>.
12. Select Z axis, using the hand wheel, jog Z to where the nose of the spindle is
/32 inches (0.53 inches) from the bottom inner edge of the ATC tool seat
flange. Press <STORE Z POSITION>, verify the Z AXIS position is the
same as the TARGET position displayed on the screen.
a. If yes, move ATC magazine left, press <MAGAZINE LEFT>

softkey, <START>. Spindle drive set up complete.
b. If not, move ATC magazine left, press <MAGAZINE LEFT>

softkey, <START>, move Z axis
limit switch dogs up or down 10mm to achieve
proper alignment, calibrate machine, move the ATC magazine right and
repeat step 12.
8
Control Options
D8448 757-4002-070 Installation of 12” Color Monitor w/ 110 VAC

D8474 757-4002-094 Installation of Industry Standard NC Hardware
D8523 757-4002-130 Pentium Installation for Ultimax, Ver. 2.xx
D8529 757-4002-135 Ultimax Pentium Field Reference Documents
D8538 757-4002-140 Hardware Install Procedure for ULTINET
D8544 757-4002-145 Version 2.xx Machine Type Selection Procedure
D8581 757-4002-172 MAX 4 Print and Document Holder Installation
D8582 757-4002-173 MAX 4 Keyboard Drawer Installation
D0000
D8650 757-4002-236 Procedure, RS232 Serial Card Install
D8651 757-4002-237 Procedure, RS232 Serial Card Test
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757-4002-070 REV: A ECN #13507
11/14/95 CAD #D8448
SUBJECT: Installation of 12” Color Monitor w/110VAC Power
I. INTENT:
The purpose of this document is to provide instructions for field installation of the 12” Color
Monitor (425-0001-023) with 110VAC power. It is intended to provide instruction when replacing the
+24VDC Color Monitor (425-0001-012) where no 110VAC console power is available.
II. SCOPE:
This document is applicable for Hurco machines with MAX3 Console as follows: BMC30/M,
BMC30HT/M, BMC40/M, BMC40/50M, and BMC50/50/M.
III. MATERIALS:
The following list of materials should be included with the 12” Color Monitor Retrofit Kit (002-
4107-008):
1 425-0001-023 1PC Monitor, 12” Color VGA, 110VAC.
2 802-2212-012 1PC Bracket, Interface, 12” Color Monitor w/110VAC.
3 109-5010-010 4PC PPHMS, M4x0.7x25mm.
4 110-5001-002 4PC M4 Flatwasher.
5 423-4401-057 1PC Harness, Color Monitor, 110VAC Pwr, 442”.
6 406-5001-008 6PC Ty-wrap, SST25-M, 7” Standard.
7 406-5001-003 6PC Ty-wrap, SST1M-M, 4” Miniature.
8 406-7001-008 3PC #10 Ring Tongue, 18/22 AWG.
9* 423-4401-059 1PC Harness, Video Adapter, 110V Clr Mon
*Note: Item 9 is included in the retrofit kit to allow connection between the old shielded ribbon
cable and the High Density DB-15 connector on the monitor.
In addition to these materials and some basic hand tools (i.e. phillips and flathead screwdrivers,
metric socket set, etc...), a fish tape and pull string is required for successful completion of this
installation.
IV. PROCEDURE:
A. Disassemble the Console (reference figure 1).
1. Remove power from the machine by switching the main power disconnect to the off position.
2. Remove the CRT top cover by loosening the M4 PPHMS’s.
3. Remove the Heat Exchanger by loosening the M4 PPHMS’s. Disconnect the Heat Exchanger
power leads and ground wire.
4. Disconnect the VGA signal cable, power harness, and ground wire from the Text and
Graphics Monitors.
5. Remove the Text and Graphics Monitors by loosening the three M4 PPHMS’s that secures
each monitor to the Console CRT Base.
6. Disconnect the signal harness and ground wire from the Softkey Keyboard PCB.
7. Remove the Console CRT Base and Bezel by loosening the two M10 hex bolts.
8. Remove the two hinge pins from the Console Keyboard.
9. Remove the Console Cover by loosening the M4 PPHMS’s.
______________________ _______ ______________________ _______ ______________________ _______

757-4002-070 REV A
B. Install the 110VAC Power Harness in the CNC to Console Harness Assembly (reference figure 3).
Note 1: It may be necessary to disconnect the 1-1/2” conduit nipple on the CNC to Console
Harness Assembly from the Control Cabinet. This is particularly true for the BMC30 machines
with the 90-degree elbow. In that case, separate the 90-degree elbow from the 1-1/2” corlock,
pull the cable through the corlock, then finger-feed the cable through the elbow.
Note 2: Before feeding the fish tape through the CNC to Console Harness, wrap electrical tape
around the fish tape hook. This will prevent the hook from snagging on the woven sleeving in
case it is necessary to back the fish tape out.
1. Feed the fish tape through the CNC to Console Harness Assembly from the Console cable
entry to the control cabinet.
2. Secure a pull string to the end of the fish tape and pull through the CNC to Console Harness
Assembly by back feeding the fish tape.
3. Remove the end of the pull string from the fish tape and secure the pull string to the 110VAC
Power Harness.
4. Feed the Power Harness through the CNC to Console Harness Assembly by backfeeding the
pull string. Pull the remainder of the Power Harness Cable through leaving enough slack at the
console end to reach the monitors (approx. 24”).
C. Terminate the 110VAC Power Harness inside the Control Cabinet.

1. BMC30/M, reference drawings 003-1007-002/003, 003-1022-002, and 423-4401-057.
a) Applicable Parts List:
i) Harness, 12” Color Monitor, 110VAC, 442”, dwg 423-4401-057.
ii) Item 19, dwg 003-1007-002/003, 6A 2-Pole Circuit Breaker.
iii) Item 21, dwg 003-1007-002/003, 4A 1-Pole Circuit Breaker.
iv) Item 35, dwg 003-1007-002/003, 12P Ground Terminal.
b) Terminate the live (brown) conductor at the load side of the 4A Circuit Breaker.
c) Terminate the neutral (light blue) conductor at the neutral pole on the line side of the
6A Circuit Breaker.
d) Using the #10 Ring Tongue, terminate the ground (green/yellow) conductor at the 12P
Ground Terminal.
2. BMC40/M, reference drawings 002-4105-011,002-4122-029, and 423-4401-057.
ii) Item 31, dwg 002-4105-011, 8A 2-Pole Circuit Breaker.
iii) Item 43, dwg 002-4105-011, Gray Terminal Block.
b) Terminate the live (brown) conductor at the live pole on the load side of the 8A Circuit
Breaker.
c) Terminate the neutral (light blue) conductor at the neutral pole on the load side of the
8A Circuit Breaker.
d) Terminate the ground (green/yellow) conductor at the ground terminal of the 8P
Terminal block.
3. BMC40/50/M and BMC50/50/M, reference drawings 002-4105-012/013, 002-4122-029, and
423-4401-057.
ii) Item 31, dwg 002-4105-012/013, 8A 2-Pole Circuit Breaker.
iii) Item 43, dwg 002-4105-012/013, Gray Terminal Block.
b) Terminate the live (brown) conductor at the live pole on the load side of the 8A Circuit
Breaker.
c) Terminate the neutral (light blue) conductor at the neutral pole on the load side of the
8A Circuit Breaker.
d) Terminate the ground (green/yellow) conductor at the ground terminal of the 8P
Terminal block.
2
757-4002-070 REV A
D. Reassemble the Console (reference figures 1 and 2).

1. Replace the Console Cover using M4 PPHMS’s and insert the Console Keyboard hinge pins.
2. Replace the Console CRT Base using two M10 hex bolts.
3. Connect the ground wire and signal cable to the Softkey Keyboard.
4. Install the 12” Color Monitor Interface Bracket to the Console CRT Base using three M4
PPHMS’s.
5. Set the 12” Color Monitor on the Interface Bracket and align the four obround thru holes with
the four M4 nutserts in the Interface Bracket.
6. Using four M4x20mm PHMS’s and four M4 Flatwashers, insert through the obround holes and
screw into the nutserts. Do not tighten at this time.
7. Slide the 12” Color Monitor forward until flush with the Console CRT Bezel and tighten the
four M4x20mm PHMS’s.
8. Connect the ground wire to the ground screw located at the back of the 12” Color Monitor
chassis base bracket.
9. Connect the ISA Video Signal Harness to the female DB-15 connector on the Monitor.
10. Connect the Color Monitor 110VAC Power Harness to the male IEC 320 plug on the Monitor.
E. Check and Test

1. Restore power to the machine by switching the main power disconnect to the on position.
2. Adjust the Contrast, Brightness, Horizontal Position, and Height as required.
3. Remove power to the machine by switching the main power disconnect to the off position.
F. Complete the Installation

1. Secure the 110VAC Power Harness in the control cabinet using the ty-wraps supplied.
2. Connect the power leads and ground wire to the Heat Exchanger and replace using M4
PPHMS’s.
3. Replace the CRT Cover using M4 PPHMS’s.
4. Restore power to the machine.
G. Parts Listing for Figures 1-3

Parts Listing
Item Description Hurco Part No. Qty.
1 Console, Bottom Plastic Part 802-2130-002 Ref
2 Console, Cover Plastic Part 802-2130-003 Ref
3 Console, Keyboard Plastic Part 802-2130-004 Ref
4 Console, CRT Base Plastic Part 802-2130-005 Ref
5 Console, CRT Cover Plastic Part 802-2130-006 Ref
6 Console, CRT Bezel Plastic Part 802-2130-007 Ref
7 Heat Exchanger 420-0003-006 Ref
8 Monitor, 12” Color VGA, 110VAC 425-0001-023 1
9 Bracket, Interface, 12” Color Monitor 802-2212-012 1
10 M4x0.7x25mm PPHMS 109-5010-010 4
11 M4 Flatwasher 110-5001-002 4
12 PPHMS, M4x0.7x10mm 109-5024-004 Ref
13 Harness, 12” Color Monitor, 110VAC, 442” 423-4401-057 1
14 Ty-wrap, SST25, 7” Standard 406-5001-008 6
15 Ty-wrap, SST1M-M, 4” Miniature 406-5001-003 6
3
757-4002-070 REV A
2
7
4 3
Figure 1. Console, Plastic Parts.
4
757-4002-070 REV A
10
11
12
Figure 2. 12" Color Monitor - Mounting Detail.
5
757-4002-070 REV A
442"
(L) BRN
110VAC CRT PWR
(G) GRN/YEL
(N) LT. BLU
13
9"
Figure 3. Harness, 12" Color Monitor, 110VAC, 442".
6
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757-4002-094 CAD No: D8474
SUBJECT: Installation of Industry Standard NC Hardware
Responsible Review and Approved
__Ron England_________________________ _6/7/96_ __Mike Caron_________________________ _6/7/96_

757-4002-094 REV C
Revisions:
Date ECN Rev Description Rev By Date Appd By Date

6/7/96 13669 A RELEASE
8/28/96 13804 B 1) Changed Paragragh B to Paragraghs RME 8/28/96 MFC 8/28/96
B.1 and B.2 to include Multibus systems,
2) added FPC-to-Keyboard harness, 423-
6824-006, to BOM, 3) added figures 3
and 4.
12/18/96 13929 C 1) Page 4, Section IV step C added DEO 12/18/96
procedure to include keyboard cover.
2) Page 5, Section V changed item 2 part
number was 419-1001-002 and added
item 12.
2
757-4002-094 REV C
I. INTENT:
The intent of this document is to provide instructions for installing the hardware
included with the Industry Standard NC Option. The hardware consists of an AT compatible
keyboard, keyboard cover, keyboard drawer assembly and keyboard extension cable. See
section V of this document for a complete BOM listing.
II. SCOPE:
These instructions are applicable for mounting the keyboard drawer assembly to
the dual screen console. The installation instructions contained within this document
are applicable to the MAX3 dual screen console with ISA and Multibus control.
III. TOOLS:
A. Drill
B. 1/4” drill bit
C. Metric allen wrenches
D. Measuring Tape
E. Fish Tape
IV. PROCEDURE:
A. Mount the Keyboard Drawer Assembly (see figure 1).
Note: As you face the front of the console, the Keyboard Drawer Assembly
should be mounted flush with the bottom right hand side of the console.
1. Using the dimensions shown in figure 1, mark the hole locations for the
front right and two rear through holes in the bottom of the console.
2. Using the 1/4” drill bit, drill the three through holes marked in step 1
above.
3. Mount the keyboard drawer assembly using two (2) M5x25mm screws
for the two rear mounting holes and one (1) M5x20mm screw for the front
mounting hole.
4. Mark the location of the front left mounting hole using the keyboard
drawer assembly as a template.
5. Remove the keyboard drawer assembly.
6. Drill a 1/4” through hole at the location marked in step 4 above.
7. Mount the keyboard drawer assembly again using two (2) M5x25mm
screws for the rear mounting holes and two (2) M5x20mm screws for the
front mounting holes.
B1
B.1 Install the Keyboard Extension Harness (ISA machines only).
1. Disconnect all of the CNC/CONS Harness cables at the console end
(i.e. CRT cables, FDD cable, Canbus cable, etc...).
2. Remove the CNC/CONS Harness from the pendant arm.
3
757-4002-094 REV C
3. Pull the keyboard extension harness (423-4401-109) through the

CNC/CONS Harness assembly insuring the female panel mount
connector is at the console end of the harness.
4. Reinstall the CNC/CONS Harness assembly in the pendant arm and
reconnect the cables removed in step 1.
5. Remove the old keyboard connector from the remote jog access panel.
6. Using two M3x8mm screws and M3 hexnuts, mount the keyboard
extension cable panel mount connector to the remote jog access panel in
the bottom of the console.
7. At the control cabinet, connect the keyboard extension harness to the
keyboard port on the ISA card cage assembly (figure 2). Coil up any
excess cable and lay neatly in the bottom of the control cabinet.
B1
B.2 Install the FPC-to-Keyboard Harness (Multibus Systems Only, see figures
3 & 4)
1. Some MAX3 Multibus systems may require reconnection of the
existing keyboard harness. If so, connect this harness to P6 of the CPU
and J2 of the FPC inside the console.
2. If required, install the FPC-to-Keyboard Harness (423-6824-006)
included in the install kit. Terminate the ferrules at FPC-TB9 per figure 4.
Install the keyboard panel mount connector on the Remote Jog access
panel using two M3x8mm screws and two M3 hexnuts.
C1
C. Keyboard and Cover Assembly
1. Place viewseal cover over keyboard assembly. Ensure cover fits
properly over all keys, then remove adhesive strips and secure
viewseal cover to keyboard assembly.
2. Set the keyboard in the drawer feeding the signal cable through the 1”
through hole in the rear of the drawer.
3. Plug the keyboard cable into the keyboard extension cable at the
remote jog access panel in the bottom of the console.
4
757-4002-094 REV C
V. Bill of Material:
Parts List (002-4312-001)

Item Part Number Item Description Quantity
1 002-4312-002 Assy, Keyboard Drawer, Dual Screen Console 1
C2
2 419-1001-003 Keyboard, PC-AT 1
3 423-4401-109 Harness, ISA Keyboard Extension Cable, 1
300”
4 614-0002-111 Box, 24” x 24” x 12” 1
5 108-5003-008 BHSCS, M5x20mm, BL Oxide 2
6 108-5003-010 BHSCS, M5x25mm, BL Oxide 2
7 110-0046-006 M5 Lockwasher 4
8 108-5001-002 BHSCS, M3x8mm 2
9 117-5009-001 Hexnut, M3 2
10 757-4002-094 Installation of Industry Standard NC Hardware 1
B2
11 423-6824-006 Harness, FPC-to-Keyboard 1
C2
12 419-1001-004 Cover, Keyboard Viewseal 1
5
757-4002-094 REV C
Figure 1. Keyboard Drawer Assembly Mounting Details.
6
757-4002-094 REV C
Figure 2. ISA Card Cage
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757-4002-094 REV C
B3
Figure 3. Multibus Systems
3
Figure 4. FPC-to-Keyboard Harness Connections
8
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757-4002-130 CAD# D8523
Pentium Field Installation

Procedure for Ultimax,
For Version 2.xx
Scott Wrobleski
Originator Mgr. Control Systems Engineering
Date Date
RECORD OF CHANGES


I. INTENT
To provide a standardized method to retrofit and install Pentium Motherboard and

Processor assembly in existing machining centers.
II. APPLICABILITY
As required on all machines equipped with 486 based motherboard and CPU.
1) 757-4002-105, Setup Procedure for Hunter Industrial Pentium Motherboard.

2) Manufacturing Notice 3997 for Canbus Controller Modification.
3) Manufactuiring Notice 4057 for M-code wiring Modification.
IV. INDEX

Page 4 Installation Instructions
Page 6 Canbus Controller Modification
V. KIT DEFINITION
Pentium compatible motherboard and Pentium processor.

Hunter Motherboard & CPU 007-3003-001 1


3. Locate the Card Rack and disconnect and label all harnesses.
Note: all harnesses will be reconnected to the same boards in the Card Rack.
4. Disconnect and label all harnesses to the Power Supply.
5. Remove the Card Rack from the Cabinet by removing the four bolts at each corner of the Card Rack
base.
6. At a flat table with plenty of workspace, remove the top cover of the Card Rack by loosening the four
spring screws.
NOTE: the following steps have the Card Rack positioned so that the Power Supply is to the left, the
I/O Interface and DC I/O flyer cards to the right, and the Card Rack connectors nearest you. PC
Slots are numbered one through seven, right to left. Use static strap when motherboard and cards.
7. Disconnect and label the harnesses to the DSP Board in slot 1 (the right-most PC board) of the Card
Rack.
8. Disconnect and label the harnesses to the CANbus Controller Board in slot 3 of the Card Rack.
9. Remove the Hard Drive by loosening the spring screw on the left-side of the Card Rack; disconnect
and label the Hard Drive power harness and disconnect and label the IDE Harness. Store the Hard
Drive in a safe place.
10. Disconnect and label the J6 harness from the DSP Board to the Breakout Board.
11. Remove the Breakout Board (covers slots 2 and 3) by removing the two screws.
12. Remove the DSP Board from slot 1(remove the hold-down screw and carefully pull board from slot).
13. Remove the CANbus Controller Board from slot 3 (remove the hold-down screw and carefully pull
board from slot).
14. Remove the VGA Card from slot 7 (remove the hold-down screw and carefully pull board from slot).
15. Remove Disk Drive.
16. Remove Parallel Port Connector.
17. Remove Speaker wire, the black wire should be to the right.
18. Disconnect and label all harnesses plugged into the CPU. Note that the two, 6-terminal power
harnesses are removed by pulling the connectors straight up and then tilting them forward (almost 90
degrees).
19. Remove the CPU motherboard (remove nine screws). May need to loosen all wires routed inside the
Card Rack. Lower right corner has guide that may hold board.
20. Inspect nylon spacers on Card Rack base and resecure if necessary.
21. Verify all jumper settings on Pentium CPU motherboard per Engineering Document 757-4002-105.
22. Install 3 nylon spacers.
23. Carefully install the Pentium CPU motherboard with the slots aligned to the bottom right (ten
screws). Reroute and secure all wires removed in previous step and secure board
24. Reconnect all harnesses to the Pentium CPU, using new harnesses provided where necessary.
25. Install serial port.
26. Install parallel port.
27. Install floppy drive card.
28. Install the VGA Card in slot 7 (note that Dual VGA cards will come very close to the Pentium CPU
Fan Assembly; if there is interference from the Fan Assembly, do not install in slot 7 but use slot 4
instead).

29. Install the Breakout Board with the connector through the slot 3 opening (or slot 2 if CANbus
Controller has to be in slot 3). Install the DSP Board in slot 1.
30. Install the DSP Board in slot 1.
31. Modify CANbus controller board. See Attached.
32. Install the CANbus Controller Board in slot 4 (or slot 3 if Dual VGA has to be in slot 4).
33. Reconnect the Breakout harness to J6 of the DSP Board.
34. Reconnect the Hard Drive power harness and the Hard Drive IDE harness to the Hard Drive.
35. Install the Hard Drive on the left-side of the Card Rack.
36. Reconnect the harnesses to the CANbus Controller Board.
37. Reconnect the harnesses to the DSP Board.
39. Reinstall the Card Rack inside the Control Cabinet (four bolts).
40. Reconnect all harnesses to the Power Supply and the Card Rack.
41. Cycle the Machine Power On for 10 seconds (allows the Pentium CPU BIOS to reset).
44. Attach an AT Keyboard to the DIN Keyboard Port of the Card Rack.
45. Cycle the Machine Power On. Press and hold the Delete key on the AT Keyboard to access the
CMOS BIOS setup utility (may require several attempts by cycling the Machine Power Off and On).
46. Verify and set all BIOS settings per Engineering Document 757-4002-105 with the following
exception:
In Standard Setup, do not set Pri Master Type to Auto. Need to manually set the Hard Drive’s
Cylinders and Heads as taken from the label on the Hard Drive. However, for V1.6x software,
Sectors should be set to 50.
47. Save and Exit the changes.
The system will reboot and should load the Ultimax Executive.

CanBus Controller Modification
This modification is necessary for all Pentium based systems to correct an ISA bus conflict, caused by
the I/F circuit responding to non-specific addressing.
Modification: U36, pin 1 is to be cut at the PCB and pulled out perpendicular to the side of the IC.
Using ¾ “ 30 GA. Wire (insulated wierwrap wire), solder one end to the floating pin 1 on
U36, and the other end to the via as shown below. Change the revision letter from B to C.
U36 U37
Ground
Verification: Continuity between gold finger A11(AEN) and U36 pin 1, and no continuity between
U36 pin 1 and ground.

R
757-4002-135 CAD #D8529
SUBJECT: Ultimax Pentium Field Reference Documents
5/5/97
Originator Date Mgr, Control Systems Engineering Date
RECORD OF CHANGES

By

2
I. INTENT
The purpose of this document is to provide information for field installation of the Ultimax Pentium CPU board on
ISA based Hurco machines. This information is to supplement the Pentium installation procedure.
II. SCOPE
This document is applicable to machines with ISA card racks.
III. Documents
The following documents are included:
• 007-3002-001 thru 004 (CAD #8451) ASSY, ISA/P CARD CAGE

• 415-0247-007 thru 008 (CAD #8455) PCB ASSY, MX4 CNC++
• 007-3003-001 (CAD #8456) ASSY, ISA PENTIUM CPU STD

3
4
5
6
R
757-4002-140 CAD# D8538
Subject: Hardware Installation Procedure

for Ultinet Networking Option.

RECORD OF CHANGES

Network Card Installation, Ultinet 757-4002-140 Page 2

I. INTENT
To provide a standardized method to retrofit and install the Ultinet Network Option,
including the Network Card, the Cabling, and the Comm Panel.
II. APPLICABILITY
As required on all machines equipped with V2.0 or greater software, Pentium based
motherboard and CPU.
1) 007-3002-001, Assy, ISA/P Card Cage.

2) 802-2901-002, Cabinet, Knee Mill Control.
IV. INDEX

Page 4 ISA Network card installation instructions
Page 4 BMC comm panel installation Instructions
Page 5 Knee Mill network connector installation Instruction
V. KIT DEFINITION
Ultinet Hardware and Cabling.

PCB Assy, Etherlink III Network Card 415-0600-004 1
Connector, BNC -Y Type 406-0804-049 1
Cable, Cat-4 w/RJ-45 Connectors 406-1663-001 1
Cable, Coax w/BNC Connectors 406-1663-002 2
Assy, Comm Port w/Network Connectors 007-0021-001 1
V. TOOLS NEEDED
AT Keyboard with Extension Cable.

ISA NETWORK CARD INSTALLATION

3. Locate the ISA Card Rack and remove cover.
4. Locate an open ISA slot amongst the existing cards. (should be an open slot near canbus
controller)
5. Remove ISA blank bracket from the slot, and discard, retain mounting screw for use on
Network Card Installation.
6. Install Network (415-0600-004) card in the chosen slot.
7. Fasten with mounting screw from step 5.
8. Replace cover on ISA Rack.
9. Locate two black coax cables (406-1663-002).
10. Locate BNC Y-type connector (406-0804-049).
11. The BNC connector has a “board side” with one connection point, and a “cable side” with
two connection points.
12. Attach one end of each of the two coax cables, to each of the connection points on the
cable side of the BNC connector.
13. Connect the board side of the connector to the matching BNC connection point on the
newly installed Network Card.
14. Locate the cable with RJ-45 connectors, telephone type (406-1663-001)
15. Install one end of the cable into the telephone jack on the newly installed Network Card.
BMC COMM PANEL INSTALLATION

16. Locate the comm panel mounted in the left-side door of the main electrical cabinet.
17. Remove the components from the existing comm panel and set aside, retain all mounting
screws, they will be used to reinstall components on new panel:
The two DB-9 comm port connectors (PORT 1 and PORT2)
The hour meter.
The indexer connector.
The light switch (if applicable)
18. Remove the existing comm panel and discard, retain the mounting screws, they will be
used to mount the new comm panel.
19. Install the new comm panel. Refer to (007-0021-001) for proper orientation, and secure
with screws from step 18.
20. Install all components that were removed in step 17. Refer to (007-0021-001) for proper
location.
21. Use button plug (408-8001-027) for light switch hole, if light switch is not present.
22. Locate the existing comm cables and their routing from the ISA rack to the comm panel.
23. Locate the three new cables that are attached to the new network card, keeping the cables
together; route them with the existing Comm cables up to the comm panel.
24. Connect the telephone type cable to the telephone type plug, and connect the coax cables
to the BNC type connectors. (Either BNC cable can connect to either BNC connector)
25. Insert a DOS bootable disk into the floppy drive.
27. Remove the DOS disk and replace it with the 3-Comm EtherDisk.
28. At the A: prompt, type “3C5X9CFG.EXE”, press ENTER
29. A menu comes up and says Configure NIC. Press ENTER

30. Press the TAB key 5 times to highlight the “NIC CONFIGURE” box.
31. Press the DOWN ARROW key 6 times to highlight the “PLUG AND PLAY” field.
32. Press the ENTER key, “DISABLE” should now be selected.
33. Press ENTER again.
34. Press TAB key 4 times to highlight the “OK” box on the lower menu bar.
35. Press ENTER again. The following message will pop-up. “The specified configuration is
now being saved to the NIC.”
36. Press ESC, then press ENTER. This will exit the program.
37. Cycle the Machine Power Off, then back On Again.
38. Verify machine operation.
KNEE MILL NETWORK CONNECTOR INSTALLATION

39. Locate the comm ports (PORT 1and PORT 2) on the side of the main electrical cabinet.
This is the area that the new network connectors will be installed.
40. Drill or punch all of the holes for the BNC feed thru connectors, and the RJ-45 feed thru
connector. Refer to (802-2901-002) Knee Mill Cabinet Drawing.
41. Install the new network connectors.
42. Locate the existing comm cables and their routing from the ISA rack to the comm ports.
43. Locate the three new cables that are attached to the new network card, keeping the cables
together; route them with the existing Comm cables up to the network connectors.
44. Connect the telephone type cable to the telephone type plug, and connect the coax cables
to the BNC type connectors. (Either BNC cable can connect to either BNC connector)
45. Insert a DOS bootable disk into the floppy drive
46. Cycle the Machine Power On
47. Remove the DOS disk and replace it with the 3-Comm EtherDisk.
48. At the A: prompt, type “3C5X9CFG.EXE”, press ENTER
49. A menu comes up and says Configure NIC. Press ENTER
50. Press the TAB key 5 times to highlight the “NIC CONFIGURE” box.
51. Press the DOWN ARROW key 6 times to highlight the “PLUG AND PLAY” field.
52. Press the ENTER key, “DISABLE” should now be selected.
53. Press ENTER again.
54. Press TAB key 4 times to highlight the “OK” box on the lower menu bar.
55. Press ENTER again. The following message will pop-up. “The specified configuration is
now being saved to the NIC.”
56. Press ESC, then press ENTER. This will exit the program.
57. Cycle the Machine Power Off, then back On Again.
58. Verify machine operation.

R
757-4002-145 CAD #D8544
SUBJECT: Ultimax v2.xx Machine Type Selection Procedure
Michael Dupont
RECORD OF CHANGES

By By
B 14547 Added MCDs for machines with Yaskawa
Sigma drives and VTC40. Removed the
Siemens drive machines from the table.
Also, added the serial number graphic
(B1); Added the old Yaskawa, new
Yaskwaw and Siemens drive machines
to table along with the serial number
graphic. This table was blank. (B2). BVP 2/18/99
Added the machine revision field to the
table for better machine identification
(B3)

757-4002-145 Rev. B Page 2
I. INTENT
The purpose of this document is to provide instructions for the selection of the proper machine type when installing
the Ultimax control on a machine tool equipped with version 2.00 or above. This procedure can also be used to
reselect a machine type if the incorrect type has been selected.
II. SCOPE
The procedure is meant for qualified Hurco machine tool assembly and field service personnel only. It is not meant
for customer use.
This document is divided into the following sections:
• Prerequisites
• Production machine type selection procedure
• Reselecting a machine type
• Field retrofit machine type selection procedure
III. PREREQUISITES
The following is necessary for successful selection of the correct machine type:
1) Ultimax control successfully installed on machine tool.

2) Successful installation of the v2.00 or greater Ultimax software (ref. 757-4002-129)
3) Serial number of machine tool.

757-4002-145 Rev. B Page 3
IV. PRODUCTION MACHINE TYPE SELECTION PROCEDURE
Serial number
<machine type> Description S/N Prefix S/N Suffix

2416Y BMC2416 with Yaskawa Sigma drives B24S B
3017Y BMC3017 with Yaskawa Sigma drives B3SM, B3M B
3017HY BMC3017HT with Yaskawa Sigma drives B3HM B
4020Y BMC4020 with Yaskawa Sigma drives B42S, B42M B
5050Y BMC5050 with Yaskawa drives B5M B
6434Y BMC6434 with Yaskawa Sigma drives B64T B
VTC40 VTC40 with Siemens drives VTC4 C
B1
________7. The prompt “There are machine boot config files in the selected MCD. Do you want to copy these to
the configuration directory?” will appear. Select the “YES” softkey.
________9. Following procedures for setting up servo drives and tool changer, enter the MAXIMUM DAC VOLTS
and TOOL CHANGE POSITION.

757-4002-145 Rev. B Page 4
V. RESELECTING MACHINE TYPE
________1. Apply power to the control.
________7. Write down the maximum DAC voltage _________________.
________16. Write down the tool change position ___________________.
________21. Follow the procedure described in MACHINE TYPE SELECTION section above starting at step 4 to
select the new machine type. Use the logged values for the specified fields or use new values if
necessary.

757-4002-145 Rev. B Page 5
VI. FIELD RETROFIT MACHINE TYPE SELECTION
Serial number
<machine type> Description S/N Prefix Mach RevB3 S/N Suffix

30SSMY BMC30SSM with Yaskawa spindle B3SM Thru F A
30MY BMC30M with Yaskawa drives B3M, QAM Thru F B
30HTMY BMC30HT/M with Yaskawa drives B3HM, QHT Thru F B
30SSMS BMC30SSM with Siemens spindle B3SM Thru F D
30MS BMC30M with Siemens drives B3M Thru F C
30HTMS BMC30HT/M with Siemens drives B3HM Thru F C
4020SSM BMC4020SSM with Siemens drives B42S Thru F C
4020HT BMC4020HT with Siemens drives B42M Thru F C
4050MY BMC4050 with Yaskawa drives B45M Thru C B
5050MY BMC5050 with Yaskawa drives B5M Thru B B
(pre-v1.08 ladders)
2416Y BMC2416 with Yaskawa Sigma drives B24S B B
3017Y BMC3017 with Yaskawa Sigma drives B3SM, B3M E B
3017HY BMC3017HT with Yaskawa Sigma drives B3HM E B
4020Y BMC4020 with Yaskawa Sigma drives B42S, B42M E B
5050Y BMC5050 with Yaskawa drives B5M C B
(v1.08 ladders & later)
6434Y BMC6434 with Yaskawa Sigma drives B64T A B
VTC40 VTC40 with Siemens drives VTC4 A C
B2
NOTE: Some SSM machines may have been converted to dual screen. Use the SSM machine type.

757-4002-145 Rev. B Page 6
________14. Type the maximum DAC voltage and press <ENTER>.
________23. Type the tool change position using metric units (mm) and press <ENTER>.
________29. Now the control will display the Auxiliary screen. The machine is now functional.

757-4002-145 Rev. B Page 7
757-4002-147 CAD #D8548

FOR COOLANT AND NON-COOLANT THROUGH
8000/12000 RPM SPINDLE
EQUIPPED WITH HYDRAULIC POWER DRAWBAR.

Jeff Bitant _________________ ________
Mihai Leahu _________________ ________
Scott Wrobleski _________________ ________ ____________________________ ________

.
SW
B 14241 1) ITEM 24 WAS QTY. 1 3 3/98 ML HP
2) WAS M8X1.0P, NPN 7
3) WAS M8,NPN 8
C 14256 (1)CHANGED NAME, (27)ADDED: #43, (28)ADDED:#44, (29)ADDED: #45, 3 6/98 ML HP
(30)ADDED: #46, (31)ADDED: #47, (32)ADDED: #48, (33)CHANGED
P.P.A. AND QTY., (34)CHANGED P.P.A. AND QTY., (35)CHANGED
P.P.A. AND QTY. (37)DELETED ITEM #28
(2)WAS:2, (3)WAS:8, (4)WAS:6, (5)WAS: 26, (6)WAS: 22, (7)WAS:117- 4
1002-003
(8)WAS:117-1002-004, (9)WAS: LOOSEN, (10)AD.: REMOVE MOT., 4
(11)ADDED: PUT BACK MOT., (18)WAS: 101-5008-011., (36)CHANGED
QTY.
(12)WAS: LOOSEN, (13)ADDED: REMV. MOT., (14)ADDED: DRILL AND 5
TAP HOLES FOR PROX. SWITCH BRACKETS AND SPACER PUMP
MOUNTING.
(15)ADDED: VACUUM AND CLEAN UP THROUGHOUT THE HEAD, 5
(16)ADDED: MOTOR BACK.
(17)CHANGED HARNESS ROUTING. 6
(19)ADDED: M12X1.0P, (20)ADDED: AND TAP TEN., (21)WAS: 2, 7
(22)ADDED:
SPACER PUMP MOUNTING, ITEM #6 AND BRACKET ROTARY UNION, 7
ITEM #7., (23)WAS: 4, (24)ADDED POINT 3.3.4.
(25)CHANGED FIG. 3. 8
(38) CHANGED ELECTRICAL INSTALL PROCEDURE (39-42) ADDED 3
D 14390 1-3) Added specific Ultimax parameter values for spindle 14 9/22/98 SAW DEO
and machine type. 4) Changed parameter P-146 was 15
-500. 5) Added specific P-131 parameter values for spindle 15
and machine type. 6) Added note about error message 15
FP02.
E 14510 (1) Revised Installation Procedure, pages: 4, 5, 6, 7, 8. 4~8 12/98 ML HP
(2) Added pct. 3.4. V-Belt Tensioning Method. 10
(3) Added pct. 3.5. Spindle Run-In. 12
F 14532 (1) Added Table for High Speed Spindle 14 1/21/99 SAW
(2) Added Coolant Through Tool 16
G 14719 REVISED INSTALLATION PROCEDURE, ACCORDING TO ROTARY 3~4 7/23/99 ML HP
UNION MANUFACTURER. (1)DELETED # 1,2,3,4,5 (2)ADDED # 42
(3)WAS QTY. 2
8000/12000 RPM Spindle Option 757-4002-147 Rev. G Page 2 of 16

1.0 INTRODUCTION
This document is intended as a guideline to install a new 12,000/8,000 RPM., Spindle

option on BMC30 and BMC4020 series machines. This procedure can be used for installing a complete option
package.

BILL OF MATERIAL FOR ASS’Y, 003-1020-003/004, ASS’Y, INSTALL KIT (12K/8K OPTION)
4 4 406-7001-043 BUTT SPLICE, 22-16AWG, RED 52 C42

200” 200” 406-1245-004 CABLE, 10/COND. 24AWG SHLD 51 C41
2 2 406-0811-008 CONTACT, MALE, SILVER 50 C40
50” 50” 406-2523-001 WIRE, 20AWG, RED 49 C39
1 - 510-0001-011 PRESSURE SWITCH 48 C32
1 - 506-3025-039 PIPE CONNECTOR 47 C31
1 - 502-0241-010 NEEDLE VALVE 46 C30
25ft 25ft 508-2001-010 TUBING, 6MM O.D. NYLON 45 C29
1 - 506-3001-055 HALF UNION 44 C28
1 1 506-0001-059 MALE CONNECTOR, ¼” TUBE TO ¼” NPT 43 C27
1 - 506-5060-020 MALE PIPE SWIVEL 90B 11L43-4-4 42 G2
1 1 757-4002-147 INSTALLATION KIT 41
1 1 614-0002-070 CONSOLE BOX 28 X 247/8 X 245/8 40
1 1 803-1002-073 BRACKET, PROXIMITY SWITCH 39
1 - 502-0130-009 CHECK VALVE 38
1 1 502-5202-009 VALVE 120 VAC, 2-POSITION, 3-WAY 37
3 3 506-5009-017 ADAPTER, SAE070220 36 C1
1 1 506-5009-018 ADAPTER, MALE, 90º ELBOW 35
6 5 506-5060-019 FITTING, SAE(JIC) 37º SWIVEL 34
2 - 506-3001-054 HALF UNION 33 C35
2 - 506-3014-020 MALE PIPE TEE 32 C34
1 - 506-6008-003 PIPE THREAD REDUCER 31 C33
1 - 502-0130-008 CHECK VALVE 30
1 - 506-5009-022 MALE ADAPTER 29
28 C37
1 - 506-3014-021 MALE BRANCH TEE 27
1 - 506-5060-012 FITTING, 20630 37º SWIVEL 26
1 - 506-5060-010 MALE PIPE SWIVEL 25 G3
REF REF 803-1014-008 COLLAR, CLAMP POSITION 24 B1
1 1 803-1042-028 SPACER, PUMP MOUNTING 23
100” 100” 406-2017-006 WIRE, 24AWG BLUE 22
200” 200” 406-1245-008 CABLE, 4/COND. 24AWG SHLD 21
2 2 110-0066-004 STAR WASHER, M3 20
2 2 108-5001-001 BHSCS, M3 X 6 LG. 19
1 1 406-4001-069 WAGO TERMINAL STRIP 18
1 1 803-1002-074 BRACKET, PUMP MOUNTING 17
1 1 503-0002-005 HASKEL, LIQUID PUMP 16
4 3 504-0001-016 HOSE, (1 PIECE OF 5 FEET + 3 PIECES OF 2.5 FEET) 15 C36
1 - 506-5031-005 FITTING, MALE ELBOW 14
- 1 506-5060-011 METRIC SWIVEL FEMALE 13
3 3 803-1002-072 BRACKET, PROXIMITY SWITCH 12 C2

3 3 418-5002-017 PROXIMITY SWITCH, M8X1.0 P PNP 11 C2
10 10 101-5008-003 SHCS, M6 X 1.0 P X 12 LG. 10 C3,C4
11 8 101-5008-006 SHCS, M6 X 1.0 P X 20 LG. 9
26 22 110-0046-007 LOCKWASHER, M6 HELICAL SPRING 8 C5,C6
13 10 117-5047-001 NUT M6 X 1.0 P 7 C7
4 4 101-5008-013 SHCS, M6 X 1.0 P X 50 LG. 6 C18
5 G1
4 G1
3 G1
2 C8 G1
1 G1
QTY QTY PART NUMBER ITEM DESCRIPTION ITEM REV
-003 -004 PARTS LIST
E1
INSTALL PROCEDURE.
3.1 MECHANICAL INSTALL PROCEDURE FOR ASS’Y, INSTALL KIT (12K/8K OPTION),
DRAWING #003-1020-003 @ #003-1020-004.
+ PLEASE REFER TO FIGURES 1, 2, 3, 4, 5, 6, 7.
Both the BMC30 and BMC4020 are designed to accept this option.
3.1.1. There are (2) M5 screws on front of the Head door. Remove these (2) screws.
3.1.2. Open the door. Cut tye wraps from inside Head door, which hold the wires for tool
release switch.
3.1.3. Unplug tool release switch.
3.1.4. Lift the door out of hinges and set it outside of machine.
3.1.5. Remove (3) M6 screws from side cover and set it outside of machine. Remove (6) M5 screws
from front belt access plate. There is a cover at the bottom of the Head, held by (2) M6
screws. Remove this cover and disconnect air purge hose.
3.1.6. Remove (4) M12X1.75PX50LG. screws, from the motor mounting plate, see Fig. 1.
NOTE: For 8K Spindle, don’t remove (4)M12 screws. Just loosen them.
3.1.7. Push the motor forward, to remove all tension from belt. See Fig. 1, item #4.
3.1.8. Support Spindle, fig.1 item #6, on outer bearing cap. Don’t support Spindle on spindle shaft.
3.1.9. Remove (6) M12X1.75PX35LG. screws, from spindle flange, Fig.1, item #5.
3.1.10. Raise Z-axis, until the Head clears the top of the Spindle
3.1.11. Remove the Spindle and set it outside of machine.
3.1.12. Lower Z-axis. In this position is easier to drill and tap holes on Head.
3.1.13. Disconnect the power, air and lock out.
3.1.14. Remove (4) nuts, HEX 12X1.75P, Fig.1, item #2, from Ass’y Unclamp Cylinder, Fig.1, item
#1. Remove Unclamp Cylinder and Standoff Cylinder, Fig.1, item #1 and item #3.
3.1.15. Disconnect wires from Motor and remove Motor.
3.1.16. Remove belt from Head, Fig.1, item #4.

3.1.17. Remove (3) M5 screws and one M16 screw from the bottom of pulley, on spindle motor.
remove Pulley using a puller, from motor, Fig.1, item #7.
E1
3.1.18. Install a new Pulley on motor, Fig. 1, item #4. Use blue loctite on M5 screws and red loctite
on M16 screw. Pulley for BMC4020, dwg. no. 803-1046-028 and for BMC30, dwg. no.
803-1046-027. If the new pulley has an interference fit, heat the pulley to 200LF. Don’t use
flame to heat the pulley.
3.1.19. On the right side of the Head, there is an Unclamp Solenoid. Remove the fitting from port “A”
and plug “A” with a pipe plug.
3.1.20. Layout, drill and tap holes for proximity switch brackets, dwg. no. 803-1002-072/073, pump
bracket, dwg. no. 803-1002-074. Please refer to page 7, item #3.2., Fig. 2, of this document.
You can use dwg. no. 003-1020-003/004-sheet 2 as a template for holes location.
3.1.21. Clean out all chips.
3.1.22. Install the new belt. Belt dwg. no. 204-0010-025 for BMC4020 and belt dwg. no. 204-
0010-024 for BMC30.
3.1.23. Reinstall spindle motor and wires. Reinstall electrical covers back on motor.
NOTE: If you have to install 8K-Spindle Coolant Through, don’t perform the following
operations: 3.1.15. - 3.1.16. – 3.1.17. – 3.1.18. – 3.1.22. – 3.1.23.
3.1.25. Install new Spindle and air purge hose.

3.1.27. Adjust belt tension.
NOTE: For V-belt tensioning method for 12K-Spindle, please refer to page 10, item #3.4.
Fig. 5 and Fig 6, of this document.
3.1.28. Install Hydraulic Pump and proximity switches on machine and complete all plumbing. Use
dwg. no. 003-1020-003/004. Use tye wraps to hold high pressure hose to cabletrac.
Use existing hole in Coolant Tank for the drain hose. Route the drain line down and out to the
right and to the back of the Head.
3.1.29. Install Rotary Union on arbor using a twisting motion. Please refer to page 9, Fig. 4, for
Runout check.
3.1.30. For cable installation, please refer to page 13, item #4.0 of this document. You can also use
dwg. no. 003-1020-003/004-sheet 3.
document.
3.1.33. If Coolant Through Spindle is also being used, please refer to page 15, item #4.4. of this
document to wire and plumb.
NOTE: If you have to install Non-Coolant Through Spindle, don’t perform the following
operations: 3.1.28. – 3.1.29. – 3.1.33.

3.1.34. Run Spindle in. Please refer to page 12, item #3.5., Fig. 7, of this document.
3.1.35. Reinstall front belt access plate.
3.1.36. Reinstall side head cover, air purge cover and door in reverse order.
E1
FIGURE 1. (Spindle Installation)
(4) M12X1.75P50LG
1 2 3
4 5 6 7 8

E1
3.2 MECHANICAL INSTALL PROCEDURE FOR SWITCH LAYOUT.
FIGURE 2. (Switch Layout)
3.2.1 Use existing (4) holes, M6X1.0P, Fig.2, item #5, to install Pump bracket.
3.2.2. Drill and tap (2) holes M6X1.0PX15LG, as shown in Fig. 2, item #4 and
install bracket switch, dwg. no. 803-1002-073, Fig. 2, item #3, for orientation
proximity switch, M5X0.5P. Use (2) M6X1.0PX12LG screws with M6
3.2.3 Drill and tap (8) holes M6X1.0PX15LG, Fig.2, item #2 and install (3) brackets,
Fig.2, item #1, for proximity switches, M8X1.0P-PNP, spacer pump mounting, Fig. 2,
item #6. Use dwg no. 003-1020-003/004-sheet 2 as a template for holes listed above.
3.2.3. Vacuum and clean up throughout the Head.

E1
3.3. MECHANICAL INSTALL PROCEDURE FOR PUMP AND VALVE.
3.3.1. Pump and valve wiring harness should be routed as detailed in Fig. 3.
3.3.2. There are four holes, M6X1.0PX20LG on the right side on the top of
Assembly “HEAD”, see Fig. 2 and Fig. 3. Use these holes to install item 3,
“BRACKET, PUMP MOUNTING”.
FIGURE 3. (Pump and Valve Installation)

3.3.3. Make connections between item 2, 3-way hydraulic valve and air over
oil intensifier pump, item 4, using 90 degree fittings and items 1, as shown
in Fig. 2.
Mount valve and pump on item 3, “BRACKET, PUMP MOUNTING”.
3.2.4. Install valve, pump, pump mounting plate and hoses on assembly head.
Use four M6X1.0PX20LG with M6X1.0P nut and M6 lockwasher to
secure the pump, item 4, to pump mounting plate, item 3. Use two
M6X1.0Px40LG with M6X1.0P nut and M6 lockwasher to secure item 2,
valve, to item 3, “BRACKET, PUMP MOUNTING”.
3.2.5. Coolant hose going to Rotary Union must have a loop and for connection between
hoses and Rotary Union must use 90B fittings.
FIGURE 4. (Rotary Union. Runout check)
ROTARY UNION INDICATOR
The runout on Rotary Union, Rotary Union must be checked for runout and
while Spindle is rotating, must not cannot exceed .001” while Spindle is rotating.
exceed .001”. Place indicator on Rotary Union with no hoses

Damage could occur. connected. Check runout.
Place all hoses on Union and check one last
time that runout does not exceed .001”.
3.4. V-BELT TENSIONING METHOD. E2
FIGURE 5. (Belt Tension I)
3.4.1. The best tension for a V-belt drive is the lowest tension at which the belts will not slip
under the highest load condition, for optimum performance and life of the spindle.
3.4.3. Keep belts and sheaves free from any foreign material, which may cause slip.
3.4.4. Put the indicator base on the head and its tip on the end of the spindle shaft, as
shown in fig. 5.
3.4.5. Push the motor using a jackscrew until the indicator shows 0.0004” shaft deflection.
Secure the motor and perform a cut test.
3.4.6. If the belt slips, tighten the belt. We recommend tightening the belt up to maximum
0.00045” shaft deflection.
3.4.7. If available, we recommend using a Gate Tension Tester to check the above
procedure. This procedure, using a Gate Tension Tester, is described below
Span Length

BMC4020 11.65 0.182
BMC30 10.3 0.16
“O” Ring slides down scale as tool compresses - stays down for accurate reading of
Deflection
Machine Model Deflection force (ld) Deflection distance (in)
BMC4020 6.0~7.0 0.14~0.18
BMC30 4.5~5.5 0.12~0.16
FIGURE 6. (Belt Tension II)

Spindle performance testing. Aluminum
Trial Depth of cut Feedrate Cutter dia. Removal rate Horse power Spindle
inches in/min inches in^3/min measured rpm
1 0.125 95 2.5 29.5 15 8500
2 0.125 50 3 19 15 12000
3.5. SPINDLE RUN-IN.E3
Although spindles are tested and run-in during manufacturing, all spindles must be run-in after
installation.
Transportation and fastening of the spindle in the head can affect the performance and life of the
spindle.
There are three (3) holes M4 on the spindle. See fig. 6 for hole location.
Remove (2) set screws, position 1 and 2 and (1)SHCS, position 3.
Use these three holes 1, 2, 3, for probe temperature.
Reinstall those (3) bolts, after test temperature.
FIGURE 7. (Spindle Temperature Test)
Spindle run-in
TIME BEARING TEMPERATURE SPINDLE
INTERVAL SPEED
(15MIN.) 1 2 3 (RPM)
0 500
15 1000
30 2000
45 3000
60 4000

75 6000
90 8000
105 10000
120 12000
3.5.1. Spindle run-in. Perform test as described in the above table. Perform this test every
time a spindle is removed and re-installed in a machine.
Belt tension will affect the temperature of the spindle bearings.
3.5.2. Spindle start-up at 500 RPM and increase the speed in increments shown in the chart
above. If the bearing temperature have not stabilized within the increment, run the
Spindle until the temperature stabilizes before increasing the speed to the next level.
3.5.3. If the temperature at any bearing location exceeds 120LF (48.8LC) stop the spindle, let the
the spindle cools for 1hour and restarts the test. If same results are obtained contact
Technical support/QC department.
3.5.4. The difference in temperature, between the upper bearing and the lower set of bearings
should not exceed 5LF (2.8LC). The upper bearing temperature will be slightly higher
than the lower bearing. If the difference in bearing temperature is more than 5LF (2.8L),
stop the spindle and contact Technical support/QC department.
3.5.5. After spindle has been run-in, let spindle cool down for two (2) hours.
3.5.5. It is recommended at this point to recheck the belt tension.
ATTENTION: 1) Do not run the Spindle-Coolant-Through beyond 10,000RPM, if you do not have
coolant through spindle running.
2) Do not run any spindle beyond 500 RPM if you do not have tool into spindle.
4.0 ELECTRICAL INSTALL PROCEDURE FOR ASS’Y, SPINDLE (8K/12K OPTION),

DRAWING #003-1020-003, #003-1020-004.
4.1 ELECTRICAL INSTALLATION

1. Install 10/C cable (406-1245-004) and 4/C cable (406-1245-008) through wire way, from the
spindle to the Electrical cabinet.
2. Locate Terminal Strip TB2 in the Electrical Cabinet.
3. Disconnect the cable that connects the Unclamp Switch to TB2 Terminals 3, 18, and 26.
4. Disconnect the cable that connects the Clamp Switch to TB2 Terminals 3, and 17.
5. Use 24AWG Blue wire to connect TB2-3 to TB2-26.
6. Use 24AWG Blue wire to connect TB2-36 to CRP4 Board TB9-1.
7. Cut a piece of the 24AWG Blue wire long enough to go from DCIO#1 J1 to TB2-35 and Crimp a
Male Honda Pin (406-0811-008) to one end.
8. Install the Honda Pin and wire in DCIO#1 J1-23, and connect other end to TB2-35.
9. Connect 10/C cable (406-1245-004) to Terminal strip TB2. Refer to Drawing (003-1020-003/004) Section A.
10. Connect 4/C cable (406-1245-008) to the Siemens Drive. Refer to Drawing (003-1020-003/004) Section
B.
Note: The following connections are to be made on Terminal Strip TB5 located in the Spindle Head.

Refer to Drawing (003-1020-003/004) Section A
11. Disconnect the wires from the existing Drawbar Clamp and Unclamp limit switches.
12. Connect the new 10/C cable (406-1245-004) to Terminal strip TB5.
13. Disconnect the wires from the Pneumatic Unclamp Solenoid, connect them to TB5-1 and 4.
14. Use 20AWG Red wire to connect a jumper between TB5-2 and TB5-3.
15. Use 20AWG Red wire to connect existing Pneumatic Unclamp solenoid to TB5-1 and 2.
16. Connect new Hydraulic Assist solenoid wires to TB5-1 and 2.
17. Use 20AWG Red wire to connect Pressure Switch N/C1 to TB5-3.
18. Use 20AWG Red wire to connect Pressure Switch C1 to TB5-4.
19. Use 20AWG Red wire to connect Pressure Switch N/C2 to TB5-5.
20. Use 20AWG Red wire to connect Pressure Switch C2 to TB5-12.
Note: Refer to Prox. Switch documentation for proper wire colors.
21. Connect the Drawbar Clamp No Tool (signal) wire to TB5-6.

22. Connect the Drawbar Clamp No Tool (+24V) wires to TB5-9.
23. Connect the Drawbar Clamp No Tool (MGND) wires to TB5-11.
24. Connect the Drawbar Clamp w/Tool (signal) wire to TB5-7.
25. Connect the Drawbar Clamp w/Tool (+24V) wires to TB5-9.
26. Connect the Drawbar Clamp w/Tool (MGND) wires to TB5-11.
27. Connect the Drawbar Unclamped (signal) wire to TB5-8.
28. Connect the Drawbar Unclamped (+24V) wires to TB5-10.
29. Connect the Drawbar Unclamped (MGND) wires to TB5-12.
4.2ULTIMAX PARAMETER CHANGES

1. Access the Integrator Support Services Screen. (AUX, <enter>, 100, <enter>)
2. Access the CNC Configuration Parameters Screen. (F1)
3. Access the Spindle Parameters Screen. (F4)
4. Access the Vertical Parameters Screen. (F6)
5. Change the Maximum Spindle Tool Speed. D1
• BMC30, 8K with coolant = 8,125.
• BMC30, 12K with or without coolant = 12,038.
6. Access the Gear Table Screen. (F4)
7. Change the Gear Ratio. D2
• BMC30, 8K with coolant = 0.8000.
• BMC4020, 8K with coolant = 0.8000.
• BMC30, 12K with or without coolant = 0.6646.
• BMC4020, 12K with or without coolant = 0.5391.
8. Change the Maximum RPM. D3

9. Access the Integrator Configuration Parameters Screen. (F2)
10. Access the Integer (N95) Parameter Screen. (F2)
11. Set values as follows:
Parameter Number Description Value

F1
N95:240 High Speed Spindle Enable 1
F1
N95:242 Max Spindle Speed w/o Tool 500
4.3 SIEMENS ORIENT ZERO MARK SETUP WITH PROXIMITY SENSOR
1. In order to change machine specific parameters disable write protection by changing parameter
“P-051” to “4H”.
2. Toggle + or - through each parameter as required.
3. Repeat this procedure whenever a change is necessary.
4. Following procedure will work properly with motor encoder and proximity switch when spindle has
a 1:X.XX ratio. To achieve an orient zero mark proceed as follows:
5. When using a proximity switch, the spindle is set for single direction approach. This is
accomplished by setting parameter “P1-149” to “29H”.
6. Set parameter “P1-138”, orient P-Gain to “100H”.
7. Set parameter “P1-146”,Search Speed for Spindle Positioning, “-100”. D4
8. Parameter “P-131” defines the number of encoder counts between two reference signals taking
into account the gear ratio. When the drive unit is powered up, the position counter is checked
during the first one or two revolutions of the spindle. Set Maximum Pulse Number between 2
Zero Marks. D5
9. Parameter “P-141” set to “2H”, assigns proximity switch with motor encoder evaluation when
10. Request transfer of switching parameters “P-141” for position by setting parameter “P-143” to
“1”. The parameter is automatically reset to “0”.
11. Remove the tool drive key.
12. Move Z-axis to the proper tool change height.
13. Rotate the spindle at least one complete revolution by hand to a position so the drive key may be
re-installed.
14. Move ATC to “right” position from the Ultimax Control.
15. Determine the correct orientation position for machine with tool drive key re-installed.
16. Record the position actual value for zero mark offset from parameter “P-140”
17. Store the value from parameter “P-140” as the new Zero Mark Offset in parameter “P-130”.

18. After all parameter value settings have been incorporated and verified transfer the data into the
drives EPROM by changing the value or parameter “P-052” to “1” to store the changes. Once
the data has been stored parameter “P-052” will return to “0”.
19. Finally enable write protection parameter “P-051” to “0H” so that changes cannot be made
inadvertently.
NOTE: During a positioning sequence (command to orient) the position loop performs a position
counter check. Should the count be greater than the number in “P-131”, the error FP02 is displayed
on the spindle drive. This error is most likely caused by spindle belt slippage and can be corrected
to synchronize the spindle and motor pulleys by tightening the belt as required. D6

4.4 THROUGH SPINDLE COOLANT OPTION
1. Locate and remove the 1” hole plug in the bottom-right side of the electrical cabinet.
2. Locate the electrical cable supplied with the high pressure coolant system.
3. Remove the nut on the strain relief connector on the cable.
4. Install the cable through the 1” hole in the bottom of the cabinet and secure with the nut.
5. Route the dirty filter switch wires to the bottom side of the CRP4 board and connect them to
Connector TB2 terminals 1(GND) and 4 (INP2). Refer to Drawing (003-1020-003/004) Section C
6. Route the Air solenoid wires to the top side of the CRP4 board and connect them to TB1
terminals 6 (GND) and 7 (+24v). Refer to Drawing (003-1020-003/004) Section C
7. Access the Integer (N95) Parameter Screen. (F2)

8. Set values as follows:
Parameter Number Description Value

N95:241 F2 Coolant Through Tool Enable 1
N95:243 F2 Max Spindle Speed w/o Coolant 10,000

Other Options
D8464 757-4002-085 Procedure, Hawk 5 SSM Work Light Installation

D8472 757-4002-093 Hawk 5SSM Heat Exchanger Installation
D8494 757-4002-109 Installation Procedures / Parameter Settings for
Heidenhein LS406 Linear Scales
D8495 757-4002-110 Installation of Head Growth Compensation Kit
D8509 757-4002-119 Chip Conveyor and Washdown Installation
Procedure
D8510 757-4002-120 Heat Exchanger Retrofit Procedure, Bed Mills
D8543 757-4002-144 Spindle Fan Retrofit Procedure for Siemens
Machines
D8548 757-4002-147 12,000 RPM Spindle and Thru The Tool Coolant
D8617 757-4002-205 Installation Procedure for BMC6434 10K Spindle Upgrade
D8649 757-4002-235 Installation Of Head Thermal compensation Chiller and Fans
D8694 757-4002-277 V*X 12,000 RPM Coolant Through Spindle Procedure
D8697 757-4002-280 VMX CTS with 20 Bar Pump
D8693 757-4002-276 Head Thermal Compensation with Chiller for VMX24/30/40/50
D8695 757-4002-278 Installation Procedure, 8K High Torque Spindle, VMX24 - VMX50
D8660 757-4002-245 Installation Procedure for BMC6434 8K Spindle Upgrade
D8698 757-4002-281 Installation Procedure, 10K Spindle, VMX64 / 40T
D8702 757-4002-285 Installation Procedure, 8K Spindle, VMX64 / 50T
D0000
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D0000
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757-4002-235 CAD #: D8649

with Chiller and Fans

Himat Patel___________________ __________
Mihai Leahu_________________ __________
Dan Ornelas___________________ __________ ____________________________ ________
Rev. A

By

1.0 INTENT
Chiller and Fans.
2.0 APPLICABILITY
Chiller for BMC6434 and a complete option package, Head Thermal Compensation both with Chiller and
Fans for BMC30/4020 machining centers.
Machine Requirements: Cooled Spindle

Cooler Assembly
A) Turmoil (OCN-33 R) Operating Instruction Manual.

B) 003-1016-034 Assembly, Chiller Head Thermal Compensation.
C) 003-1016-035 Assembly, Fans Head Thermal Compensation.
D) 423-4401-128 Harness, Cooler Power.
E) 423-4401-126 Harness, Cooling Fan.
F) 423-4401-127 Harness, Fan Power.
This document is intended as a guideline to install a Cooler, Turmoil OCN-33 R, option on BMC30,
BMC4020 and BMC6434 series machines, please refer to dwg. #003-1016-034 and Fans on BMC30,
BMC4020, please refer to dwg. #003-1016-035. In case of using both Chiller and Fans, for electrical
connections, please refer to dwg. #003-1016-034/4, #003-1016-035/3, #003-1016-035/4. This procedure
can be used for installing a complete option package.

BILL OF MATERIAL FOR ASS’Y, 003-1016-034, ASS’Y, CHILLER HEAD THERMAL

COMPENSATION.
1 506-0002-021 CONNECTOR STRAIGHT, MALE ½” T – ¼” NPT 16
1 404-9081-062 CIRCUIT BREAKER, 10A, 2-POLE, 240V 14
8 406-0965-004 FERRULE, 18AWG RED 11
15 ft 406-2005-020 WIRE, 18AWG BLACK 9
10 ft 406-2004-010 WIRE, 16AWG BLACK 8
2 506-3009-015 MALE ELBOW, ½” T – ½” MP 6
15 406-5001-004 TIE, WRAP 3
2 506-3011-007 UNION ELBOW, ½” T 2
2 506-3009-013 MALE ELBOW, ½” T – ¼” NPT 1
-034 PARTS LIST
BILL OF MATERIAL FOR ASS’Y, 003-1016-035, ASS’Y, FANS HEAD THERMAL

COMPENSATION.
1 409-1001-198 FUSE, 2A SLOW BLOW 20

1 406-4006-099 END/SEPARATOR PLATE, WAGO 280-312 19
1 406-4005-049 TERMINAL BLOCK, FUSED WITH NEON LAMP 18
1 403-2001-054 RELAY, MINIATURE DPDT 8A 17
1 403-5001-020 SOCKET, MINIATURE RELAY DIN RAIL MOUNT 16
2 110-5001-002 WASHER, M4 FLAT 15
2 108-5002-001 BHCS, M4 X 0.7 P X 8 LG. 14
2 423-4401-127 HARNESS, FAN POWER 13
2 423-4401-126 HARNESS, COOLING FAN 12
2 420-0001-040 FAN, 115mm DIA 115V 11
1 803-1008-006 ENCLOSURE, FAN 10
2 420-0001-039 GUARD, FAN FINGER 9
8 117-5009-001 HEX NUT, M3 X 0.5 P 8
8 110-0066-004 LOCKWASHER, M3 7
16 110-5001-001 WASHER, M3 FLAT 6
8 101-5006-010 SHCS, M3 X 0.5 P X 25 LG. 5
8 117-5012-001 NUT, HEX M5 X 0.8 P 4
8 110-5001-003 WASHER, M5 FLAT 2
8 101-5007-003 SHCS, M5 X 0.8 P X 12 LG. 1
-035 PARTS LIST

7.0 CHILLER INSTALL PROCEDURE

COMPENSATION (OPTION), DRAWING #003-1016-034.
7.1 CHILLER INSTALLATION ON BMC6434
7.1.1 Modify the Head.

7.1.2 Reference: Head, dwg. #803-6004-005.
7.1.3 Reference: Ass’y, Chiller Head Thermal Compensation, dwg. #003-1016-034
7.1.4 Sheet-1/4, view A-A & A”-A”and Sheet-2/4. Sheet-4/4 for electrical connections.
7.1.5 Raise the Head and drill a 43 DIA hole at the bottom of Head. See dwg. 003-1016-034, Sheet-
1/4, view A-A and view A”-A” for location, to accommodate (2) items #2. Tighten these (2)
fittings with a tie wrap.
7.1.6 Lower Z-axis. In this position is easier to remove covers and drill holes on Head.
7.1.7 There are (11) SHCS, M6 X 1.0 P X 20 LG. screws, on the front and right side of the Head, on
Cover, Head Front, Cover Head R.H. and Cover, Head R.R. Remove these screws. Lift the
covers and set them outside of machine.
7.1.8 Drill a 30 DIA hole on the top of Head. See dwg. 003-1016-034, Sheet-1/4, view A-A and
view A”-A” for location, to accommodate (2) items #4.
7.1.9 Run the hoses, item #4 through Cable Carrier and through Housing, Z Axis Cable. Run them
between Column and Electrical Cabinet all the way back to Cooler, Turmoil, item #5.
7.1.10 Clean up all chips from Head.
7.1.11 Make all the necessary connections between Spindle, Hoses and Cooler.
7.1.12 Reinstall all the covers in reverse order.
7.1.13 Chiller turned ON/OFF with the control power. See Ass’y, Chiller Head Thermal Compensation,
dwg. #003-1016-034, Sheet-4/4.
7.1.14 Chiller Thermostat to be set at ambient temperature.Reference: Turmoil OCN-33 R, Operating
Manual.
7.1.15 Cycle Chiller. Check for leaks and make any necessary repairs. Verify if the INLET & OUTLET
are per drawings.
7.1.16 A rust inhibitor must be added to the water Is recommended a mixture of 30% DOWTHERM
SRI to 70% clean tap water, or something similar. Cooler ON/OFF with the Control Power.
7.2 CHILLER INSTALLATION ON BMC30/4020
7.2.1 Modify the Bracket, Head Main Cover Mounting.

7.2.2 Reference: Bracket, Head Main Cover Mounting, dwg. #803-1002-024.
7.2.3 Reference: Ass’y, Head Thermal Compensation With Chiller, dwg. #003-1016-034 Sheet-3/4,
view D-D. See Sheet-4/4 for electrical connections.
7.2.4 Drill a 40 DIA hole at the bottom of Bracket, Head Main Bracket. See dwg. 003-1016-034,
Sheet-3/4, view D-D for location, to accommodate (2) items #2. Tighten these (2) fittings with a
tie wrap.
7.2.5 Run the ½” oil lines, item #4 through the Bracket, Head Main Cover Mounting and through the Z
axis catrac. Run them between Column and Electrical Cabinet all the way back to Cooler,
Turmoil, item #5.

7.2.6 Make all the necessary connections between Spindle, Oil lines and Cooler.
dwg. #003-1016-034, Sheet-4/4.
7.2.8 Chiller Thermostat to be set at ambient temperature.
7.2.9 Reference: Turmoil OCN-33 R, Operating Manual.
7.2.10 Cycle Chiller. Check for leaks and make any necessary repairs. Verify if the INLET &
OUTLET are per drawings.
7.2.11 A rust inhibitor must be added to the water Is recommended a mixture of 30%
7.2.12 DOWTHERM SRI to 70% clean tap water, or something similar. Cooler ON/OFF with the
Control Power.
8.0 FAN INSTALL PROCEDURE.
MECHANICAL INSTALL PROCEDURE FOR ASS’Y, FANS HEAD THERMAL

COMPENSATION (OPTION), DRAWING #003-1016-035.
8.1 FANS INSTALLATION ON BMC30/4020
8.1.1 Verify the distance between the Head cover and the right Enclosure door track to ensure there is
room available for the Fan enclosure, should be approx. 27 mm.
8.1.2 Reference: dwg. # 003-1016-035, Ass’y, Fans Head Thermal Compensation, sheet 1/4, detail
B.
8.1.3 Note: If there is not enough room for the Fan enclosure to clear the right door track when the
Head is in the “up” position, the door track mounting location will have to be moved forward
(front of machine), to make room available.
8.1.4 Modify the Head cover per the drawing.
8.1.5 Reference: dwg. # 003-1016-035, Ass’y, Fans Head Thermal Compensation, sheet 2/4, details
for BMC30 & BMC4020 Head cover modifications.
8.1.6 Assemble the Fan enclosure.
8.1.7 Reference: dwg. # 003-1016-035, Ass’y, Fans Head Thermal Compensation, sheet 1/4, detail
B.
8.1.8 Center the assembled Fan enclosure on the Head cover cut out, transfer the mounting hole
locations, then drill and tap.
8.1.9 Install the Fan enclosure and seal it with RTV.
8.1.10 Locate the Clamp/Unclamp switch under the Fan enclosure. Transfer the mounting hole locations,
then drill and tap.
8.1.11 Install the Clamp/Unclamp switch.
8.1.12 Fans to be turned ON/OFF with Spindle.
8.1.13 Reference: please refer to dwg. # 003-1016-035, Ass’y, Fans Head Thermal Compensation,
sheet 3/4, for electrical connections.
8.1.14 Reinstall Head cover.

9.1 COOLER POWER
NOTE: REFER TO SHEET 4/4 ON DRAWING (003-1016-034).
9.1.2 Install the Cooler Power Harness (423-4401-128) from the Cooler to the control cabinet.
9.1.3 Connect the harness inside the Cooler to the terminal strip located just inside the 1/2” conduit
entrance.
9.1.4 Mount the circuit breaker, and cooler starter & overload, inside the electrical control cabinet on
the lower terminal strip.
2-pole, 10A breaker.
9.1.6 Using #16 AWG wire, connect contacts 2 and 4 on the circuit breaker to contacts 1 and 3
9.1.7 Connect the Cooler Power Harness (423-4401-128) to the cooler starter overload contacts 2
and 4. Connect the ground wire to the existing grounding block.
TB1-3 (MGND).
9.2 FAN POWER
9.2.1 Connect a Cooling Fan Harness (423-4401-126) to each fan.

9.2.2 Install the Fan Power Harness (423-4401-127) from the spindle head assembly to the machine
control cabinet by pulling it through the spindle head cable track. Note: The two female Mate-N-
Lock connectors are to be installed at the spindle head.
9.2.3 Connect the two Cooling Fan Harness’s to the Fan Power Harness.
9.2.4 Using #18 AWG wire, connect TB2-1 (115V-Line) to the top of 2A-fused terminal block.
9.2.5 Using #18 AWG wire, connect the bottom of the 2A-fused terminal block to contact 11 of the
Fan Relay.
9.2.6 Using #18 AWG wire, connect TB2-2 (115V-Neutral) to contact 21 of the Fan Relay.
9.2.7 Connect the Fan Power Harness (423-4401-027) to contact 14 and 24 of the Fan Relay.
9.2.8 Connect the ground wire to an existing ground terminal block.
Cooler should run when control power is turned on. The Fans should run when the spindle is enabled.

757-4002-277 CAD #D8694
SUBJECT: INSTALLATION PROCEDURES FOR

COOLANT AND NON-COOLANT THROUGH
12,000 RPM SPINDLE FOR VMX24/30/40 MACHINES.

Mihai Leahu _________________ ________
Dan Ornelas _________________ ________ ____________________________ ________

.
DEO
B 15218 1) Added control parameters N95:214, 240, 242, 2) text 14/15 2/21/01 DEO
was “motor encoder orient”
12000 RPM VMX Spindle Option 757-4002-277 Rev. B Page 2 of 2

1.0 INTRODUCTION
This document is intended as a guideline to install a new 12,000 RPM. Spindle coolant through or non-coolant
option, on VMX/VSX24/30/40 series machines. This procedure can be used for installing a complete option
package.
BILL OF MATERIAL FOR ASS’Y, 003-1020-007/008, ASS’Y, INSTALL KIT (12K OPTION)
3 - 417-6001-011 SUPPRESSOR, RC NETWORK 58
1 - 417-0001-047 SUPPRESSOR + INDICATOR DIODE MODULE 57
1 - 403-5001-020 SOCKET, MINIATURE RELAY, DIN RAIL MOUNT 56
1 - 403-2001-054 RELAY, MINIATURE, DPDT, 8A 55
6 - 406-0965-007 FERRULE, 14AWG, YLW 54
10 - 406-0965-014 FERRULE, 24AWG, LT YLW 53
4 4 406-7001-043 BUTT SPLICE, 22-16AWG, RED 52
2 2 406-0811-008 CONTACT, MALE, SILVER 50
50” 50” 406-2523-001 WIRE, 20AWG, RED 49
1 - 510-0001-011 PRESSURE SWITCH 48
1 - 506-3025-039 PIPE CONNECTOR 47
1 - 502-0241-010 NEEDLE VALVE 46
25ft 25ft 508-2001-010 TUBING, 6MM O.D. NYLON 45
1 - 506-3001-055 HALF UNION 44
1 1 506-0001-059 MALE CONNECTOR, ¼” TUBE TO ¼” NPT 43
1 - 506-5060-020 MALE PIPE SWIVEL 90B 11L43-4-4 42
1 1 757-4002-277 INSTALLATION KIT 41
1 1 614-0002-070 CONSOLE BOX 28 X 247/8 X 245/8 40
1 - 502-0130-009 CHECK VALVE 38
1 1 502-5202-009 VALVE 120 VAC, 2-POSITION, 3-WAY 37
3 3 506-5009-017 ADAPTER, SAE070220 36
1 1 506-5009-018 ADAPTER, MALE, 90º ELBOW 35
6 5 506-5060-019 FITTING, SAE (JIC) 37º SWIVEL 34
2 - 506-3001-054 HALF UNION 33
2 - 506-3014-020 MALE PIPE TEE 32
1 - 506-6008-003 PIPE THREAD REDUCER 31
1 - 502-0130-008 CHECK VALVE 30
1 - 506-5009-022 MALE ADAPTER 29
100” - 406-2003-010 WIRE, 14AWG BLK 28
1 - 506-3014-021 MALE BRANCH TEE 27
1 - 506-5060-012 FITTING, 20630 37º SWIVEL 26
2 - 506-5060-010 MALE PIPE SWIVEL 25
REF REF 803-1014-008 COLLAR, CLAMP POSITION 24
1 1 803-1042-028 SPACER, PUMP MOUNTING 23
150” 100” 406-2017-006 WIRE, 24AWG BLUE 22
2 2 110-0066-004 STAR WASHER, M3 20
2 2 108-5001-001 BHSCS, M3 X 6 LG. 19
1 1 406-4001-069 WAGO TERMINAL STRIP 18

1 1 803-1002-074 BRACKET, PUMP MOUNTING 17
1 1 503-0002-005 HASKEL, LIQUID PUMP 16
4 3 504-0001-016 HOSE, (1 PIECE OF 5 FEET + 3 PIECES OF 2.5 FEET) 15
1 - 506-5031-005 FITTING, MALE ELBOW 14
- 1 506-5060-011 METRIC SWIVEL FEMALE 13
3 3 418-5002-017 PROXIMITY SWITCH, M8X1.0 P PNP 11
10 10 101-5008-003 SHCS, M6 X 1.0 P X 12 LG. 10
11 8 101-5008-006 SHCS, M6 X 1.0 P X 20 LG. 9
26 22 110-0046-007 LOCKWASHER, M6 HELICAL SPRING 8
13 10 117-5047-001 NUT M6 X 1.0 P 7
4 4 101-5008-013 SHCS, M6 X 1.0 P X 50 LG. 6
1 1 423-4401-507 HARNESS, AUX. SPINDLE MOTOR ENCODER 5
1 - 423-4401-545 HARNESS, CTS PUMP POWER 4
1 - 423-4401-544 HARNESS, COOLANT FILTER DIRTY 3
1 - 403-5503-015 OVERLOAD, RELAY, 12.0A-18.0A 2
1 - 403-5502-038 CONTACTOR, 3-POLE, 24VDC COIL, 32A 1
QTY QTY PART NUMBER ITEM DESCRIPTION ITEM
3.0 INSTALL PROCEDURE
3.1 MECHANICAL INSTALL PROCEDURE FOR ASS’Y, INSTALL KIT, 12K OPTIONS,
DRAWING #003-1020-007 NO COOLANT & #003-1020-008 COOLANT THROUGH.
+ PLEASE REFER TO FIGURES 1, 2, 3, 4, 5, 6, and 7.
VMX24, VMX30 and VMX40 are designed to accept this option.
3.1.1 There are (2) M5 screws on front of the Head door. Remove these (2) screws.
3.1.2 Open the door. Cut tye wraps from inside Head door, which hold the wires for tool release switch.
3.1.3 Unplug tool unclamp (release) switch.
3.1.4 Lift the door out of hinges and set it outside of machine.
3.1.5 Remove (3) M6 screws from side cover and set it outside of machine. Remove (6) M5 screws
from front belt access plate. There is a cover at the bottom of the Head, held by (2) M6 screws.
Remove this cover and disconnect air purge hose.
3.1.6 Remove (4) M12X1.75PX50LG. screws, from the motor mounting plate, see Fig. 1.
3.1.7 Push the motor forward, to remove all tension from belt. See Fig. 1, item #4.
3.1.8 Support Spindle, fig.1 item #6, on outer bearing cap. Don’t support Spindle on spindle shaft.
3.1.9 Remove (6) M12X1.75PX35LG. screws, from spindle flange, Fig.1, item #5.
3.1.10 Raise Z-axis, until the Head clears the top of the Spindle
3.1.11 Remove the Spindle and set it outside of machine.
3.1.12 Lower Z-axis. In this position is easier to drill and tap holes on Head.
3.1.13 Disconnect the power, air and lock out.
3.1.14 Remove (4) nuts, HEX 12X1.75P, Fig.1, item #2, from Ass’y Unclamp Cylinder, Fig.1, item #1.
Remove Unclamp Cylinder and Standoff Cylinder, Fig.1, item #1 and item #3.
3.1.15 Disconnect wires from Motor and remove the Motor.
3.1.16 Remove the belt from Head, Fig.1, item #4.

3.1.17 Remove (6) M6 screws from the bottom of pulley, on spindle motor. Remove Pulley using a puller,
from motor, Fig.1, item #7.
3.1.18 Install a new Pulley on motor, Fig. 1, item #4. Use blue loctite on M6 screws. Pulley for
VMX24/30/40, dwg. No. 803-6005-105. If the new pulley has an interference fit, heat the pulley
to 200LF. Don’t use flame to heat the pulley.
3.1.19 On the right side of the Head, there is an Unclamp Solenoid. Remove the fitting from port “A” and
plug “A” with a pipe plug.
3.1.20 Layout, drill and tap holes for proximity switch brackets, dwg. No. 803-1002-072/073, and pump
bracket, dwg. No. 803-1002-074. Please refer to page 7, item #3.2, Fig. 2, of this document.
You can use dwg. No. 003-1020-007/008-sheet 2 as a template for holes location.
3.1.21 Clean out all chips.
3.1.22 Install the new belt. Belt dwg. No. 204-0010-030 for VMX24 and VMX30 and belt dwg.
No. 204-0010-032 for VMX40.
3.1.23 Reinstall spindle motor and wires. Reinstall electrical covers back on motor.
3.1.24 Power up machine.
3.1.25 Install new Spindle and air purge hose.
3.1.26 Verify and adjust pulley height alignment.
3.1.27 Adjust belt tension.
NOTE: For V-belt tensioning method for 12K-Spindle, please refer to page 10 and
page 11, item #3.4. Fig. 5 and Fig 6, of this document.
NOTE: If you have to install Non-Coolant Through Spindle, don’t perform the following
operations: 3.1.28. – 3.1.29. – 3.1.30. - 3.1.35.
3.1.28 Install Hydraulic Pump and proximity switches on machine and complete all plumbing. Use dwg.
No. 003-1020-007/008. Use tee wraps to hold high-pressure hose to cabletrac.
3.1.29 Use existing hole in Coolant Tank for the drain hose. Route the drain line down and out to the right
and to the back of the Head.
3.1.30 Install Rotary Union on arbor using a twisting motion. Make a loop on 5-foot coolant hose to
Rotary Union. Please refer to page 9, Fig. 4, for Runout check.
3.1.31 For cable installation, please refer to page 13, item #4.0 of this document. You can also use dwg.
No. 003-1020-007/008-sheet 3.
3.1.32 Change spindle parameters in Ultimax, using data from page 14, item #4.2, of this document,
3.1.33 Set orient zero mark with proximity sensor. Please refer to page 15, item #4.3, of this document.
3.1.34 If Coolant Through Spindle is also being used, please refer to page 16, item #4.4. of this document
to wire and plumb.
3.1.35 Run Spindle in. Please refer to page 12, item #3.5, Fig. 7, of this document.
3.1.36 Reinstall front belt access plate.
3.1.37 Reinstall side head cover, air purge cover and door in reverse order.

FIGURE 1. (Spindle Installation)
(4) M12X1.75P50LG
1 2 3
4 5 6 7 8

FIGURE 2. (Switch Layout)
3.2 MECHANICAL INSTALL PROCEDURE FOR SWITCH LAYOUT.
3.2.1 Use existing (4) holes, M6X1.0P, Fig.2, item #5, to install Pump bracket.
3.2.2 Drill and tap (2) holes M6X1.0PX15LG, as shown in Fig. 2, item #4 and install bracket switch,
dwg. No. 803-1002-073, Fig. 2, item #3, for orientation proximity switch, M5X0.5P. Use (2)
M6X1.0PX12LG screws with M6 lockwashers to secure it.
3.2.3 Drill and tap (8) holes M6X1.0PX15LG, Fig.2, item #2 and install (3) brackets, Fig.2, item #1,
for proximity switches, M8X1.0P-PNP, spacer pump mounting, Fig. 2, item #6. Use dwg no.
003-1020-007/008-sheet 2 as a template for holes listed above.
3.2.4 Vacuum and clean up throughout the Head.

FIGURE 3. (Pump and Valve Installation)
3.3. MECHANICAL INSTALL PROCEDURE FOR PUMP AND VALVE.
3.3.1 Pump and valve non-electrical harnesses should be routed as detailed in Fig. 3.
3.3.2 There are four holes, M6X1.0PX20LG on the right side on the top of Assembly “HEAD”, see
Fig. 2 and Fig. 3. Use these holes to install item #3,“BRACKET, PUMP MOUNTING”.
3.3.3 Make connections between item #2, 3-way hydraulic valve and air over oil intensifier pump, item
#4, using 90 degree fittings and items #1, as shown in Fig. 2.
3.3.4 Mount valve and pump on item #3, “BRACKET, PUMP MOUNTING”.
3.3.5 Install valve, pump, pump mounting plate and hoses on assembly head. Use four (4)
M6X1.0PX20LG with M6X1.0P nut and M6 lockwasher to secure the pump, item #4, to pump
mounting plate, item #3. Use two M6X1.0Px40LG with M6X1.0P nut and M6 lockwasher to
secure item #2, valve, to item #3, “BRACKET, PUMP MOUNTING”.
3.3.6 Coolant hose going to Rotary Union must have a loop and for connection between hoses and
Rotary Union must use 90B fittings.

FIGURE 4. (Rotary Union. Runout check)
ROTARY UNION INDICATOR
The run out on Rotary Union, Rotary Union must be checked for runout and
exceed .0005” Place indicator on Rotary Union with no hoses
Damage could occur connected. Check runout. Place Rotary Union
Holding Bracket, on Union and check runout
has not changed. Place all hoses on Union and
check one last time that runout does not exceed
.0005”.

FIGURE 5. (Belt Tension I)
3.4.1 The best tension for a V-belt drive is the lowest tension at which the belts will not slip under the
highest load condition, for optimum performance and life of the spindle. Too much tension
shortens belt and bearings life of the spindle. A spindle failure can occur within a short period of
time.
3.4.2 Keep belts and sheaves free from any foreign material, which may cause slip.
3.4.3 Put the indicator base on the head and its tip on the end of the spindle shaft,
as shown in fig. 5.
3.4.4 Push the motor using a jackscrew until the indicator shows 0.0004” shaft deflection. Secure the
motor and perform a cut test.
3.4.5 If the belt slips, tighten the belt. We recommend tightening the belt up to maximum 0.00045” shaft
deflection.
3.4.6 If available, we recommend using a Gate Tension Tester to check the above procedure. This
procedure, using a Gate Tension Tester, is described below and shown in fig. 6.
3.4.7 Position the lower of the two (2) “O” Rings using the following method.
Span Length
VMX40 11.78 0.184
VMX24/30 9.8 0.152

3.4.8 On the scale reading “Deflection Inches”, set the “O” Ring to show a deflection equal to 1/64” per
inch of span length (t). See chart for span length for machine model.
3.4.9 At center of span (t) apply force, with Gates Tension Tester perpendicular to the span, large
enough to deflect the belt on the drive until the bottom edge of the lower “O” Ring is even with the
top of the belt in initial position. A straight edge across the belt top will assure accuracy of
positioning.
3.4.10 Find amount of deflection force on upper scale of Tension Tester. The Sliding Rubber “O” Ring
slides down scale as tool compresses - stays down for accurate reading of pound pressure. Read
at top edge of ring. (Slide ring up before reusing).
3.4.11 See chart bellow for deflection distance and deflection force.
Deflection
Machine Model Deflection force (ld) Deflection distance (in)
VMX40 6.0~7.0 0.14~0.18
VMX24/30 4.5~5.5 0.13~0.16
NOTE: If the measured force is less than minimum recommended deflection force, belt should be
tightened. If the measured force is more than maximum recommended deflection force,
drive is tighter than necessary. Run-in the spindle and perform a test cut. Verify belt
tension and reset if necessary.
FIGURE 6. (Belt Tension II)

Spindle performance testing. Aluminum
Trial Depth of cut Feedrate Cutter dia. Removal rate Horse power Spindle
inches in/min inches in^3/min measured rpm
1 0.125 95 2.5 29.5 15 8500
2 0.125 50 3 19 15 12000
3.5. SPINDLE RUN-IN.
Although spindles are tested and run-in during manufacturing, all spindles must be run-in after installation.
Transportation and fastening of the spindle in the head can affect the performance and life of the spindle.
FIGURE 7. (Spindle Temperature Test)
Spindle run-in
TIME BEARING TEMPERATURE SPINDLE
INTERVAL SPEED
(15MIN.) 1 2 3 (RPM)
0 500
15 1000
30 2000
45 3000
60 4000
75 6000
90 8000
105 10000
120 12000
3.5.1 There are three (3) holes M4 on the spindle. See fig. 7 for hole location.
3.5.2 Remove (2) set screws, position 1 and 2 and (1) SHCS, position 3.

3.5.3 Use these three holes 1, 2, 3, for probe temperature.
3.5.4 Reinstall those (3) bolts, after test temperature.
3.5.5 Spindle run-in. Perform test as described in the above table. Perform this test every time a spindle
is removed and re-installed in a machine. Belt tension will affect the temperature of the spindle
bearings.
3.5.6 Spindle start-up at 500 RPM and increase the speed in increments shown in the chart above. If
the bearings temperature has not stabilized within the increment, run the Spindle until the
temperature stabilizes before increasing the speed to the next level.
3.5.7 If the temperature at any bearing location exceeds 120LF (48.8LC) stop the spindle, let the spindle
cools for 1hour and restart the test. If the same results are obtained contact Technical support/QC
department.
3.5.8 The difference in temperature, between the upper bearing and the lower set of bearings should not
exceed 5LF (2.8LC). The upper bearing temperature will be slightly higher than the lower bearing.
If the difference in bearing temperature is more than 5LF (2.8L), stop the spindle and contact
Technical support/QC department.
3.5.9 After spindle has been run-in, let spindle cool down for two (2) hours.
3.5.10 It is recommended at this point to recheck the belt tension.
ATTENTION: 1) Do not run the Spindle-Coolant-Through beyond 10,000RPM, if you do not have
coolant through spindle running.
2) Do not run any spindle beyond 500 RPM if you do not have tool into spindle.
4.0 ELECTRICAL INSTALL PROCEDURE FOR ASS’Y, SPINDLE 12K OPTION, DRAWING #003-
1020-007, #003-1020-008.
4.1 ELECTRICAL INSTALLATION

4.1.1 Install 10/C cable (406-1245-004), and new Encoder Harness (423-4401-507) through wire
way, from the spindle to the Electrical cabinet.
4.1.2 Disconnect original Encoder Harness (423-4401-507) from Spindle drive (2CN) and Winding
Select Contactor in Electrical Cabinet.
4.1.3 Connect new Encoder Harness to Spindle Drive (2CN) and Winding Select Contactor.
4.1.4 Locate terminal strip TB1 in the electrical cabinet.
4.1.5 Disconnect the cable that connects the unclamp switch to BLK1 terminal 32, TB1
terminal 2.
4.1.6 Disconnect the cable that connects the clamp switch to BLK1 terminal 31, and TB1 terminal 2.
4.1.7 The new spindle configuration uses proximity switches instead of limit switches for the spindle
clamp/unclamp status. The proximity switch does not accommodate a normally closed unclamp
switch in series with the Spindle Enable circuit. This N.C. switch will be replaced with a jumper
from 2CR-11 (SER) to TB1-2 (+24VDC).

NOTE: Refer to Drawing (003-1020-007/008)
4.1.8 Connect new Encoder Harness (423-4401-507) to Spindle Motor.

4.1.9 Connect the new 10/C cable (406-1245-004) from Terminal strip TB5 to BLK1, BLK2, BLK3,
TB1-2, and TB1-3 as shown on page 3 of drawing 003-1020-007/008.
4.1.10 Disconnect wires from the Pneumatic Unclamp Solenoid; connect them to TB5-1 and 4.
4.1.11 Use 20AWG Red wire to connect a jumper between TB5-2 and TB5-3.
4.1.12 Use 20AWG Red wire to connect existing Pneumatic Unclamp solenoid to TB5-1 and 2.
4.1.13 Connect new Hydraulic Assist solenoid wires to TB5-1 and 2.
4.1.14 Use 20AWG Red wire to connect Pressure Switch N/C1 to TB5-3.
4.1.15 Use 20AWG Red wire to connect Pressure Switch C1 to TB5-4.
4.1.18 Connect the Drawbar Clamp No Tool (signal) wire to TB5-6.
4.1.19 Connect the Drawbar Clamp No Tool (+24V) wires to TB5-9.
4.1.20 Connect the Drawbar Clamp No Tool (MGND) wires to TB5-11.
4.1.21 Connect the Drawbar Clamp w/Tool (signal) wire to TB5-7.
4.1.22 Connect the Drawbar Clamp w/Tool (+24V) wires to TB5-9.
4.1.23 Connect the Drawbar Clamp w/Tool (MGND) wires to TB5-11.
4.1.24 Connect the Drawbar Unclamped (signal) wire to TB5-8.
4.1.25 Connect the Drawbar Unclamped (+24V) wires to TB5-10.
4.1.26 Connect the Drawbar Unclamped (MGND) wires to TB5-12.
4.2 ULTIMAX PARAMETER CHANGES


SPINDLE
Maximum Spindle Motor Speed 10,000
Maximum Spindle Tool Speed 12,025
SPINDLE GEAR
Gear 0
Ratio 0.8316
Minimum RPM 1
Maximum RPM 12,025
Tap Acceleration 120,250
B1
F2 - Integrator Configuration Parameters
INTEGER
N95:214 (NOTE 1) Force Rotate Before Orient 1
N95:240 (NOTE 2) High Speed Spindle Enable (opt.) 1
N95:242 (NOTE 2) HSS Max. Spindle Speed w/o Tool (opt.) 500

NOTE 1: Requires V2.17/1.13 for field to appear on screen and function to be operational.
NOTE 2: Set N95:240 and N95:242 with three position (3-prox. Sensor) drawbar configuration ONLY.
4.3 EXTERNAL PROXIMITY SENSOR ORIENT B2
4.3.1 Calibrate machine axis and tool changer.
4.3.5 Move Z-axis in positive direction until it stops at the software limit (0.0000).
4.3.6 Depress the More key twice” – F7.
4.3.7 Depress Set T/C Height key” – F3 to store.
4.3.8 Depress the More key again” – F3. (The screen returns to a single sequence mode)
4.3.9 Depress Orient Spindle key” – F1. and press Start.
4.3.10 Depress Tool Pocket Down key” – F2. and press Start.
4.3.11 Depress Load Arm 60° key” – F3. and press Start.
4.3.12 Carefully and slowly jog Z-axis down (negative) until the spindle nose is approximately 1.0” from
top of ATC load arm.
4.3.13 Press the “Spindle OFF” button on console. Rotate the spindle by hand until the spindle balance
key is aligned with the ATC gripper key slot. If you have removed the keys because of clearance
issues, remember that you have made a mark for drive key location so the unmarked notch in the
spindle is the balance key side of the spindle.
4.3.14 Record spindle motor position (counts) from spindle drive display U2-03 ________ (V2-03).
Depress DSPL repeatedly on keypad until U1-XX is displayed, with the Up–Down arrow keys
change display to U2-XX, now with the “>, Reset” key, scroll to the far right changing the display
to U2-03 and depress Data key to view the counts.
4.3.15 Set spindle drive parameter C2-22 = 11010010.
4.3.16 Set spindle drive parameter C2-24 bit 0 =1.
4.3.17 Set spindle drive parameter C2-01 to the number recorded in step 4.3.14.
4.3.18 Reset C2-24 bit 0 = 0.
4.3.19 Check to make sure there is NO belt slip.
4.3.20 Orient is now set and may be commanded from Ulimax 4 console.

4.4.1 Mount contactor, 10MS (403-5502-038), overload device (403-5503-015), relay socket (403-
5001-020), suppressor (417-0001-047), and relay, 15CR (403-2001-054) on DIN rail where
space is available.
4.4.2 Remove existing hole plugs from electrical cabinet bottom panel assembly to secure and route
harnesses CTS Pump Power (423-4401-545) and Coolant Filter Dirty (423-4401-544). If no
hole access position is available drill/punch a 3/8” and 1/2” hole in bottom of cabinet near ISA
card rack.
4.4.3 Terminate CTS Pump Power (423-4401-545) harness at CTS pump utility box end along with
safety ground wire. Secure locking nut and utility box cover. Connect other end to 3-phase AC
power overload device (10MS) load side. Also connect power suppressors (417-6001-011)
delta configuration to load side of overload device.
4.4.4 Terminate Coolant Filter Dirty (423-4401-544) harness at pump switch assembly. Secure with
locking nut. Connect other end, IOIF INP5, at BLK3-5 and MGND at TB1-3.

4.4.5 Using 24AWG blue wire and ferrules furnished with kit connect CTS coolant, OUTP20, from
BLK2-20 to relay 15CR-A1. Terminate other end of relay 15CR-A2 to MGND at TB1-3.
4.4.6 Using 14AWG black wire and ferrules furnished with kit connect 3-phase AC power to contactor
device (10MS CTS pump) line side from flood coolant pump contactor 8MS. Ensure consistent
wire phasing so that pump rotates in the proper direction. If rotation is not correct simply swap
any two-phase wires and reconnect.
4.4.7 Using 20AWG red wire furnished with kit connect control power for CTS system. Add wire from
TB2-1 (115VAC) to 15CR-11. Add wire from 15CR-14 to M10-A1. Add wire from M10-A2
to M10-96, N.C. overload contact. Add wire from M10-95, N.C. overload contact to TB2-2
(115V GND).
4.5 THROUGH SPINDLE COOLANT ULTIMAX PARAMETERS

4.5.5 Change the value of N95:243 (CTT Max Spindle Speed w/o Coolant) to 500.

757-4002-280 CAD #D8697
SUBJECT: INSTALLATION PROCEDURES FOR

COMPLETE SYSTEM, CTS, 20 BAR
FOR VMX24/30/40/50/64 MACHINES.

Mihai Leahu _________________ ________
Dan Ornelas _________________ ________ ____________________________ ________

.
DEO
B 15143 (1) ADDED ITEMS #65, #66. 3 12-1-00 ML
(2) ADDED ITEM #1, (3) WAS QTY. 4, (4) WAS 406-2523-001. 5
C 15208 1) Was 403-5502-038, 24VDC; 2) Paragraph 6.2.5 6, 21 2/7/01 DEO
parameter N95:243, was 500.
Complete System, CTS, 20 Bar 757-4002-280 Rev. C Page 2 of 2

1.0 INTRODUCTION
This document is intended as a guideline to install a new Draw Bar KIT, which is used for coolant through the
spindle, KIT Pressure Switch and 20 Bar Coolant System, on VMX24/30/40/50/64 series machines. This
procedure can be used for installing a complete option package, 20 Bar, Coolant Through the Spindle.
BILL OF MATERIAL FOR ASS’Y, 003-1016-061, KIT, DRAW BAR, CTS (OPTION) FOR VMX24/30/40.
50” 406-2523-001 WIRE, 20AWG, RED 66 B1
2 406-7001-043 BUTT SPLICE, 22-16AWG, RED 65 B1
1 506-6053-009 RUN TEE, 3/8” PT 64
1 506-6050-002 NIPPLE, 3/8” M X 3/8” M HEX 63
8 101-5012-006 SHCS, M12 X 1.75 P X 45 LG. 61
1 803-4100-075 SPACER, TOOL CYLINDER 60
1 506-6053-008 TEE, 3/8” PT F 59
1 510-0001-011 SWITCH, PRESSURE (604GM11) 58
1 506-6051-070 ELBOW, ADAPTER 90º- 3/8” PT M X ¼” NPT M 57
1 506-6050-035 NIPPLE, HEX, REDUCING 56
1 502-0241-010 NEEDLE VALVE 55
1 506-3001-054 HALF UNION, ¼” X 6 mm O.D. TUBE 54
20FT 508-2001-010 TUBE, 6.0 mm O.D. NYLON 53
1 803-1065-006 DRAW BAR (CTS 10K) 52
1 113-0001-038 RING, RETAINING STW -25 51
1 803-4100-077 SPACER, UPPER DRAW BAR 50
1 803-4106-076 NUT, CYLINDER 49
1 803-4102-005 COVER, CYLINDER UPPER 48
1 101-5012-024 SHCS, M12 X 1.75 P X 85 LG 47
4 101-5007-010 SHCS, M5 X 0.8 P X 35 LG 46
1 803-4100-019 SPACER, CYLINDER 45
1 211-2014-015 BEARING, NEEDLE 44
1 608-2003-061 RING, SNAP 43
1 506-6050-005 NIPPLE 42
1 803-4102-066 DOG, NO TOOL 41
6 103-5007-005 SHSS, M5 X 0.8 P X 10.0 LG. 40
2 803-6001-083 SUPPORT, INNER 39
2 608-2003-076 O-RING 38
2 101-5008-009 SHCS, M6 X 1.0 P X 30 LG 37
1 803-6001-082 SUPPORT OUTER 36
35
1 608-2003-051 O-RING 34
2 803-4100-076 STANDOFF, UNION 33
1 803-4101-021 HOUSING, BEARING 32
8 101-5010-007 SHCS, M8 X 1.25 P X 25 LG 31
4 103-5165-021 SHSS, M8 X 1.25 P X 10.0 LG. 30
1 803-4101-022 RING, HOUSING SUPPORT 29
1 803-4101-020 BRACKET, CYLINDER 28
3 418-5002-017 SWITCH, PROXIMITY M8 X 1.0 P, PNP 27
1 803-4101-019 BRACKET, SWITCH 26

2 110-5001-004 WASHER, M6 FLAT 25
2 110-0046-007 LOCK WASHER, M6 HELICAL SPRING 24
2 101-5008-003 SHCS, M6 X 1.0 P X 12 LG 23
1 608-2003-060 SEAL 22
1 803-4106-012 PISTON, CYLINDER 21
1 803-4106-014 CYLINDER 20
2 608-7001-016 SEAL 19
2 608-2003-059 O-RING 18
1 803-4102-004 COVER, CYLINDER, LOWER 16
8 101-5012-006 SHCS, M12 X 1.75 P X 45 LG 15
1 506-6052-049 ADAPTER, STRAIGHT, 3/8” PT M X ¼” PT M 14
1 506-0005-023 UNION ROTARY 13
1 501-0151-007 CYLINDER BOOSTER, PRESSURE, CTS 12
1 506-3009-062 ELBOW, 90º, 1/4” PT M X 6.0 O.D. TUBE 11
3 506-6051-061 ELBOW, 90º, 3/8” PT M X 9/16-18 UNF M 10
2 507-1206-102 HOSE, PRESSURE, 3/8” I.D. X 700 LG. 9
2 506-3009-050 ELBOW, 3/8” PT M X 12.0 mm O.D. TUBE 8
1 506-5009-022 ADAPTER, 3/8” PT M X ¾ ”-16 M 7
1 506-6053-009 TEE, 3/8” F X 3’8” F X 3’8” M PT 6
1 803-1029-012 MANIFOLD, COOLANT, CTS 5
1 506-6052-050 ADAPTER, STRAIGHT, 3/8” PT M X 9/16-18 UNF M 4
4 803-6006-016 STANDOFF, CYLINDER 3
1 506-3009-061 ELBOW, 90º, 3/8” PT M X 6.0 O.D. TUBE 2
2 502-0130-013 VALVE, CHECK, 3/8” PT 1
-061 PARTS LIST
BILL OF MATERIAL FOR ASS’Y, 003-1016-048 (60 Hz) AND 003-1016-060 (50 Hz), KIT, COOLANT
SYSTEM, 20 BAR FOR CTS (OPTION), FOR VMX24/30/40/50/64.
1 1 757-4002-280 INSTALLATION PROCEDURE 31

1 1 507-1206-101 HOSE PRESSURE, ¾” I.D. X 700 LG 30
1 1 513-0281-012 FILTER, CTS 29
28
27
26
25
24
23
22
2 2 101-5010-005 SHCS, M8 X 1.25 P X 20 LG 21
1 1 803-1002-213 BRACKET, FILTER, CTS 20
2 2 506-6051-062 ELBOW, 90º, 3/4” PT M X 1 1/16”-12 UNF M 19
2 2 506-6055-011 BUSHING, PIPE, 1 ½” PT M X ¾” PT F 18
1 1 506-6051-064 ELBOW, 90º, 3/4” PT M X ¾”-16 UNF M 17
2 2 110-0046-010 LOCK WASHER, M12 HELICAL SPRING 16
2 2 101-5012-001 SHCS, M12 X 1.75 P X 20 LG 15
1 1 506-6055-010 BUSHING, PIPE, 1 ¼” PT M X ¾ ” PT F 14
4 4 101-5010-007 SHCS, M8 X 1.25 P X 25 LG 12
1 - 803-1002-212 BRACKET, PUMP, CTS, 50Hz 11

- 1 803-1002-211 BRACKET, PUMP, CTS, 60 Hz 11
6 6 101-5008-008 SHCS, M6 X 1.0 P X 25 LG 9
1 - 509-0007-053 PUMP, CTS, 50 Hz 8
- 1 509-0007-052 PUMP, CTS, 60 Hz 8
1 1 507-1206-111 HOSE, PRESSURE, ½ ” I.D X 6096 LG. 7
6
5
4
3
2
1 1 003-1016-064 KIT, ELECTRICAL, CTS 1 B2
QTY QTY PART NUMBER ITEM DESCRIPTION ITEM
BILL OF MATERIAL FOR ASS’Y, 003-5002-001, KIT, PRESSURE SWITCH, FOR VMX50/64.
50” 406-2523-001 WIRE, 20AWG RED 17
1 506-6051-073 ELBOW, 90º, ¼” PT M X ¼” -18 NPT M 15
1 117-5015-001 NUT, M8 HES 13
20ft 508-2001-010 TUBE, 6.0 mm O.D. NYLON 12
1 506-3001-054 HALF UNION, ¼” X 6 mm O.D. TUBE 11
1 502-0241-010 NEEDLE, VALVE 10
1 506-6050-061 NIPPLE, 3/8” PT M X ¼-18 NPT M HEX 9
2 506-6050-002 NIPPLE, 3/8” PT M HEX 8
1 506-6053-008 TEE, 3/8” X 3/8” X 3/8” PT F 7
1 506-6055-022 BUSHING REDUCER ¾ ” PT M X 3/8” PT F 6
1 506-6055-023 BUSHING, REDUCER ¾ ” PT M X 9/16”-18 UNF M 5
1 506-6053-001 TEE, ¾”X¾ ”X¾ ” PT F 4
1 506-6055-021 BUSHING, REDUCER ¾ ” PT M X ¼” PT F 3
1 506-6050-060 NIPPLE, ¼” PT M X ¼-18 NPT M 2
1 510-0001-011 PRESSURE SWITCH (604GM11) 1
-001 PARTS LIST
BILL OF MATERIAL FOR ASS’Y, 003-1016-064, KIT, ELECTRICAL, CTS, FOR VMX24/30/40/50/64.
3 417-6001-011 SUPPRESSOR, RC NETWORK 18
1 417-0001-047 SUPPRESSOR + INDICATOR DIODE MOUNT 17
1 403-5001-020 SOCKET, MINIATURE RELAY, DIN RAIL MOUNT 16
1 403-2001-054 RELAY, MINIATURE, DPDT, 8A 15
6 406-0965-007 FERRULE, 14AWG, YLW 14
10 406-0965-014 FERRULE, 24AWG, LT YLW 13
2 406-7001-043 BUTT SPLICE, 22-16AWG, RED 12
200” 406-1245-004 CABLE, 10/C, 24AWG, SHLD 11 B3
10 B4
100” 406-2003-010 WIRE, 14AWG, BLACK 9
150” 406-2017-006 WIRE, 24AWG, BLUE 8

2 110-0066-004 STAR WASHER, M3 7
2 108-5001-001 BHSCS, M3 X 6 LG 6
1 406-4001-069 TERMINAL STRIP, WAGO 5
1 423-4401-545 HARNESS, CTS PUMP POWER 4
1 423-4401-544 HARNESS, COOLANT FILTER DIRTY 3
1 403-5503-015 OVERLOAD, RELAY, 12.0A-18.0A 2
1 403-5502-050 CONTACTOR, 3-POLE, 110VAC COIL, 18A 1 C1
PARTS LIST

3.0 INSTALL PROCEDURE FOR KIT, DRAW BAR, CTS.
3.1 MECHANICAL INSTALL PROCEDURE FOR ASS’Y, KIT, DRAW BAR, CTS,
DRAWING #003-1016-061 FOR VMX24/30/40.
+ PLEASE REFER TO FIGURES 1, 2, 3.
VMX24, VMX30 and VMX40 are designed to accept this option.
FIGURE 1. (Draw Bar and Rotary union for CTS)

FIGURE 2. (Rotary union and Cylinder Booster CTS)

FIGURE 3. (Pressure Switch, Needle Valve, Cylinder Booster)
3.1.1 There are (2) screws on front of the Head door. Remove those (2) screws.
3.1.2 Open the head door.
3.1.3 Unplug E-Stop and clamp/unclamp switches.
3.1.4 Lift the head door out of hinges and set it outside of machine.

3.1.5 Remove (6) screws from belt cover plate. Remove the belt cover plate from front of the head. Do
not remove the fitting or the tube for Top Air Purge.
3.1.6 Loosen (4) Motor mounting bolts and slide the Motor forward to remove all tension from belt.
3.1.7 Support Spindle, on outer bearing cap. Don’t support Spindle on spindle shaft.
3.1.8 Remove (6) M12X1.75PX35LG. screws, from spindle flange.
3.1.9 Raise Z-axis, until the Head clears the top of the Spindle
3.1.10 Remove the standard Spindle, which does not have CTS capabilities and set it outside of machine.
3.1.11 Disconnect the power, air and lock out. Disconnect air hoses from Unclamp Cylinder.
3.1.12 Remove (4) nuts, HEX 12X1.75P, from Ass’y Unclamp Cylinder. Remove Unclamp Cylinder and
(4) Standoffs Cylinder.
3.1.13 Install Spacer Tool Cylinder for CTS Unclamp Cylinder, items #60, #61, Fig. 1. Drill and tap (4)
holes M12, if those four holes are not already there.
3.1.14 Install Hydraulic Cylinder items #15~#30, on Spacer Tool Cylinder, Fig. 1. Hydraulic Cylinder will
come as a complete assembly.
3.1.15 Install item #12, Cylinder Booster, Pressure, CTS, Fig. 2, 3. Drill and tap (4) holes M10 for the
Standoffs Cylinder, item #3, Fig. 3, if those four holes are not already there.
3.1.16 Locate drill and tap (2) M6 holes for the Manifold, Coolant CTS, if the two holes are not already
there. Please, refer to Fig. 3, item #5. Install the Manifold for coolant and air blast.
3.1.17 For Draw Bar change, see Section 3.2. Take out the Draw Bar with no capabilities for CTS,
from the standard Spindle.
3.1.18 Install the new Draw Bar for CTS, item #52, Fig. 1, into existing Spindle. In reverse order, install
the Spindle with the new Draw Bar back in machine Head. Adjust the Belt tension and secure the
Motor with existing screws.
3.1.19 Make all the necessary connections of the existing air lines to the new Cylinder Booster and new
Hydraulic Cylinder.
3.1.20 Install hydraulic line item #9, Fig. 2, from the bottom of Cylinder Booster item #12, Fig. 2, to the
top of the Hydraulic Cylinder.
3.1.21 Install the coolant line, item #9, Fig. 2 from item #4, Fig. 3, to item #10, Fig. 2, on top of the
Rotary Union. See Fig. 4 for Rotary Union run out check.
3.1.22 Connect the air to machine.
3.1.23 With no tool in Spindle, loosen (4) screws M5, item #46, Fig. 1, that lock the Nut Cylinder, item
#49, Fig. 1.
3.1.24 Turn the screws down until the Nut hits the Draw Bar Spacer, item #50, then turn back
approximative 1.5 turns.
3.1.25 Install a tool into the Spindle and adjust tool push out to 2 mm. When setting tool push out do not
turn further down the Nut than was backed off in 3.1.24, Draw Bar Spacer must not make contact
with the Cylinder adjustment Nut with no tool in Spindle.
3.1.26 Install a tool in Spindle.
3.1.27 Install Needle Bearing assembly, items #31, 32, 43, 44. Adjust the run out of the Draw Bar to
0.0005”.
3.1.28 Install (2) Standoffs Union, item #33, Fig. 1. Install Rotary Union stabilizer, items #36~40.
3.1.29 Install Rotary Union, item #13. Rotary Union has left hand threads. Install item #9, Fig. 2, Coolant
Hose from the top of Rotary Union to item #4, Fig. 3. Item #11 on Rotary Union and the nylon
tube are for draining the coolant. That tube should go down hill.
3.1.30 Wire and set the correct height for (3) Proximity Switches item #27, Fig. 10. The bottom switch
will come on for Unclamp position, the middle switch will come on for Clamp with Tool position

and the top switch will come on for Clamp without Tool position. The middle switch and the top
switch will come on together for bad clamp position.
3.1.31 Install Pressure Switch item #58, and Needle Valve item #55, Fig. 3 and Picture 1, between
Manifold, item #5 and Coolant Hose item #9. Use items #4, 64, 63, 56, 57, 59 for connections,
see Fig. 3 and Picture 1. Install items #53 and #54 to Needle Valve, item #55, Fig. 3 and Picture
1. Item #53 should be routed through Cable Track to the Coolant Tank.
3.1.32 Set the pressure for the Pressure Switch to 75~80 psi 5~5.5 bars.
3.1.33 See Section 4 for KIT, 20 Bar installation. Install Coolant Hose from Valve item #1, in Cable
Carrier.
3.1.34 Adjust Belt tension and secure the Motor on Head using existing mounting bolts.
3.1.35 Put back the Belt Head Cover. Plug in the E-Stop and unclamp switch. Put back the Front Head
Cover.
3.1.36 Set Spindle orientation.
3.1.37 Check the tool change height and tool change operation.
FIGURE 4. (Rotary Union. Run out check)
Rotary Union Indicator
The run out on Rotary Union, Rotary Union must be checked for run out and
exceed .0005” Place indicator on Rotary Union with no hoses
Damage could occur connected. Check run out. Place the coolant hose on
Rotary Union and check one more time, that run out

does not exceed 0005”.
3.2 MECHANICAL INSTALL PROCEDURE FOR DRAW BAR CHANGE FROM NON-CTS TO
DRAW BAR CTS.
3.2.1 Remove Spindle from machine, see Section 3.1.

3.2.2 Loosen Collet Tool Retention (gripper) using No. 8 Allen Wrench in the gripper hexagon and No.
19 open-end wrench on the flat portion of the top of Draw Bar. Loosen only.
3.2.3 Remove (4) M5 screws from Collar Locking. Remove Collar Locking. Remove a Retaining Ring
from the Draw Bare bore. Those components are on the top of the Spindle.
3.2.4 Put the Spindle in a press. Press down on top of the Draw Bar, until Draw Bar Nut turns freely.
Press approximately ½” (12 mm).
3.2.5 Unscrew the Draw Bar Nut completely.
3.2.6 Unscrew the Collet Tool Retention from Draw Bar and release the press.
3.2.7 Remove the Draw Bar from Spindle.
3.2.8 Install the new CTS Draw Bar by pressing on Draw Bar Upper Spacer, item #50.
Note: Do not press on top of the Draw Bar. That will damage the Draw Bar
3.2.9 In reverse order install the Tool Retention Collet.
3.2.10 Install a tool into the Spindle and release the press.
3.2.11 Install the Draw Bar Nut. Make adjustments by screwing down until the Draw Bar Nut touches
the top of the Draw Bar. Unscrew 1.5 turns.
3.2.12 In reverse order, install the Retaining Ring and Collar Locking.
3.2.13 Secure the Draw Bar Nut and the Collar Locking by using (4) screws M5.
3.2.14 Remove the tool from the Spindle, and check retention force.
4.0 INSTALL PROCEDURE FOR KIT, 20 BAR, COOLANT SYSTEM.
4.1 MECHANICAL INSTALL PROCEDURE FOR ASS’Y, KIT, 20 BAR, COOLANT SYSTEM
DRAWING #I003-1016-048 (60 Hz) and #003-1016-060 (50 Hz) FOR VMX24/30/40/50/64.
+ PLEASE REFER TO FIGURES 5, 6.
VMX24, VMX30, VMX40, VMX50, VMX64 are designed to accept this option.
4.1.1 Remove (4) screws from the Cover Plate located on Coolant Tank. Remove the Cover
Plate as well.
4.1.2 Mount the Pump Bracket, item #11, Fig. 5, by using (4) screws M8, items #12, 13.
4.1.3 Mount the CTS Pump, item #8 and secure it to item #11, using (4) screws M6, by using
items #9, 10, Fig. 5.
4.1.4 Mount Bracket Filter item #20 and secure it to item #11, by using items #13, 21, Fig. 6.
4.1.5 Mount the Filter, item #29, Fig. 5, to the Bracket Filter, item #20, Fig. 6, by using (2)
M12 screws, items #15, 16.
4.1.6 Make connection between Filter and Pump by using the Coolant Hose item #30 and
fittings, items #14, 18, 19, Fig. 6.
4.1.7 Connect the Filter to existing Manifold Coolant CTS on machine, through Coolant

Hose, item #7, Fig. 5, by using fittings, items #17, 18.
4.1.8 Route the Coolant Hose through the Cable Track.
4.1.9 Run the coolant through Spindle and check all connections.
FIGURE 5. (20 Bar Coolant System)

FIGURE 6. (20 Bar Coolant System)

5.0 INSTALL PROCEDURE FOR PRESSURE SWITCH FOR VMX64 AND VMX50.

5.1 MECHANICAL INSTALL PROCEDURE FOR ASS’Y, PRESSURE SWITCH FOR VMX50/64
DRAWING #003-5002-001.
+ PLEASE REFER TO FIG. 7, 8 FOR VMX64 AND FIG. 9 FOR VMX50
VMX64 40-Taper and VMX64 50-Taper are design to accept this option, see Fig. 7, 8.
FIGURE 7. (VMX64 40-Taper)
FIGURE 8. (VMX64 50-Taper)

PRESSURE SWITCH INSTALLATION FOR VMX64, FIG 7, 8.
5.1.1 Lower Z-axis at your convenience for easier access to the top of the Head.
5.1.3 There are (6) M8 screws on top of the Head, which hold a Head Top Cover. Remove
these (6) screws.
5.1.4 Lift that Cover and set it outside of machine.
5.1.5 Disconnect the Hose (which goes to Rotary Union) and the fitting from Manifold.
5.1.6 Unscrew M8 X 1.25 P X 40 LG. from Manifold and set it outside of machine.
5.1.7 Do not dis-connect the Hose from Rotary Union.
5.1.8 If necessary re-tap that open port of the Manifold, so that item #8 could be mounted into the
Manifold.
5.1.9 Make connections between item #3, item #4, item #5, item #6, item #7, item #8, item #9, item
#10, item #11, item #12 and item #15. Please refer to Fig. 7.

5.1.10 Mount item #1, Pressure Switch to item #15. Please refer to Fig. 7.
5.1.11 Refer to Fig. 10 for electrical connection using (406-2523-001), Wire, 20AWG, Red and
(406-7001-043), Butt Splices.
5.1.12 After all connections are made and all the fittings are tightened, set the whole assembly back
on Head and connect the Rotary Union Hose to item #5.
5.1.13 If there is no space to mount the Manifold in the old position, drill and tap a M8 hole and
mount the Manifold where is space available.
5.1.14 Tighten the whole assembly on Head using existing M8 X 1.25 P x 40 LG. from Manifold and
make connection between Manifold, Valve and the Coolant Tank Hose, which come from
CTS Filter, see Fig. 5 item #7.
5.1.15 The Hose from Coolant Tank should be routed through Cable Track.
5.1.16 Item #12, 6 mm drain tube, should be routed through Cable Track to Coolant Tank.
5.1.17 Reinstall the Head Top Cover.
5.1.20 Verify coolant through Spindle function.
NOTE:
Same procedure applies to VMX64 50-Taper. However, a new location for this assembly is needed.
Fig. 8 shows the location for 50-Taper machines. In this case a clearance hole needs to be drilled
through the plate of Ass’y, Lube, Pneumatic & Coolant. Not to damage that plate, a M8 nut and a M8
lockwasher have to be set under plate.
5.2 PRESSURE SWITCH INSTALLATION FOR VMX50, FIGURE 9.
FIGURE 9. (VMX50)

PICTURE 1. (VMX24/30/40, PRESSURE SWITCH)
To Rotary Needle Air Pressure 56 59

Union Valve Blast Switch
To Coolant 4 63 64 Manifold 57 6 7
Tank
5.2.1 Lower Z-axis at your convenience for easier access to the right side of the Head.
5.2.3 Take out existing screws for the right hand side Head Cover and open that door.
5.2.4 Disconnect the Hose, which goes to Rotary Union from existing fitting in Manifold.
5.2.5 Unscrew M8 X 1.25 P X 40 LG. from Manifold and set it outside of machine.
5.2.6 Unscrew existing fitting, which is between Coolant Hose and Manifold.
5.2.7 If necessary re-tap that open port of the Manifold, so that item #8 could be mounted into
the Manifold.
5.2.8 Make connections between existing Manifold and existing Coolant Hose, by using items #2, 3,
4, 5, 6, 7, 8, 9, Fig. 9.
5.2.9 Mount item #1, Pressure Switch to item #2. Please refer to Fig. 9.

5.2.10 Refer to Fig. 10 for electrical connection using (406-2523-001), Wire, 24AWG, Red and
(406-7001-043) , Butt Splices.
5.2.11 Mount Needle Valve item #10 to item #9.
5.2.12 Mount fitting item #11 to Needle Valve and tubing item #12 to item #11.
5.2.13 Item #12, 6 mm drain tube, should be routed through Cable Track to the Coolant Tank.
5.2.14 After all connections are made and all the fittings are tightened, set the new assembly back on
Head.
5.2.15 If there is no space to mount the Manifold in the old position, drill and tap a M8 hole and
mount the Manifold where is space available.
5.2.16 Tighten the whole assembly on Head using existing M8 from Manifold and make connection
between Coolant Tank Hose, which come from the CTS Filter item #7, see Fig. 5 and existing
fitting and valve, see Fig. 9.
5.2.17 Coolant hose should be routed through Cable Track.
5.2.18 Close the Head Cover.
5.2.21 Verify coolant through Spindle function.
6.0 ELECTRICAL CONNECTIONS, CTS
FIGURE 10. (Electrical Installation)

6.0.1 Install 10/C cable (406-1245-004), and new Encoder Harness (423-4401-507) through wire
way, from the spindle to the Electrical cabinet.
6.0.2 Disconnect original Encoder Harness (423-4401-507) from Spindle drive (2CN) and Winding
Select Contactor in Electrical Cabinet.
6.0.3 Connect new Encoder Harness to Spindle Drive (2CN) and Winding Select Contactor.
6.0.4 Locate terminal strip TB1 in the electrical cabinet.
6.0.5 Disconnect the cable that connects the unclamp switch to BLK1 terminal 32, TB1
terminal 2.
6.0.6 Disconnect the cable that connects the clamp switch to BLK1 terminal 31, and TB1 terminal 2.
6.0.7 The new spindle configuration uses proximity switches instead of limit switches for the spindle
clamp/unclamp status. The proximity switch does not accommodate a normally closed unclamp
switch in series with the Spindle Enable circuit. This N.C. switch will be replaced with a jumper
from 2CR-11 (SER) to TB1-2 (+24VDC).
NOTE: Refer to Fig. 10

6.0.8 Connect new Encoder Harness (423-4401-507) to Spindle Motor.
6.0.9 Connect the new 10/C cable (406-1245-004) from Terminal strip TB5 to BLK1, BLK2, BLK3,
TB1-2, and TB1-3 as shown on page 3 of drawing 003-1020-007/008.

6.0.10 Disconnect wires from the Pneumatic Unclamp Solenoid; connect them to TB5-1 and 4.
6.0.11 Use 20AWG Red wire to connect a jumper between TB5-2 and TB5-3.
6.0.12 Use 20AWG Red wire to connect existing Pneumatic Unclamp solenoid to TB5-1 and 2.
6.0.13 Connect new Hydraulic Assist solenoid wires to TB5-1 and 2.
6.0.18 Connect the Drawbar Clamp No Tool (signal) wire to TB5-6.
6.0.19 Connect the Drawbar Clamp No Tool (+24V) wires to TB5-9.
6.0.20 Connect the Drawbar Clamp No Tool (MGND) wires to TB5-11.
6.0.21 Connect the Drawbar Clamp w/Tool (signal) wire to TB5-7.
6.0.22 Connect the Drawbar Clamp w/Tool (+24V) wires to TB5-9.
6.0.23 Connect the Drawbar Clamp w/Tool (MGND) wires to TB5-11.
6.0.24 Connect the Drawbar Unclamped (signal) wire to TB5-8.
6.0.25 Connect the Drawbar Unclamped (+24V) wires to TB5-10.
6.0.26 Connect the Drawbar Unclamped (MGND) wires to TB5-12.
6.1.1 Mount contactor, 10MS (403-5502-038), overload device (403-5503-015), relay socket
(403-5001-020), suppressor (417-0001-047), and relay, 15CR (403-2001-054) on DIN rail
where space is available.
6.1.2 Remove existing hole plugs from electrical cabinet bottom panel assembly to secure and route
harnesses CTS Pump Power (423-4401-545) and Coolant Filter Dirty (423-4401-544). If no
hole access position is available drill/punch a 3/8” and 1/2” hole in bottom of cabinet near ISA
card rack.
6.1.3 Terminate CTS Pump Power (423-4401-545) harness at CTS pump utility box end along with
safety ground wire. Secure locking nut and utility box cover. Connect other end to 3-phase AC
power overload device (10MS) load side. Also connect power suppressors (417-6001-011)
delta configuration to load side of overload device.
6.1.4 Terminate Coolant Filter Dirty (423-4401-544) harness at pump switch assembly. Secure with
locking nut. Connect other end, IOIF INP5, at BLK3-5 and MGND at TB1-3.
6.1.5 Using 24AWG blue wire and ferrules furnished with kit connect CTS coolant, OUTP20, from
BLK2-20 to relay 15CR-A1. Terminate other end of relay 15CR-A2 to MGND at TB1-3.
6.1.6 Using 14AWG black wire and ferrules furnished with kit connect 3-phase AC power to contactor
device (10MS CTS pump) line side from flood coolant pump contactor 8MS. Ensure consistent
wire phasing so that pump rotates in the proper direction. If rotation is not correct simply swap
any two-phase wires and reconnect.
6.1.7 Using 20AWG red wire furnished with kit connect control power for CTS system. Add wire from
TB2-1 (115VAC) to 15CR-11. Add wire from 15CR-14 to M10-A1. Add wire from M10-A2
to M10-96, N.C. overload contact. Add wire from M10-95, N.C. overload contact to TB2-2
(115V GND).

6.2 THROUGH SPINDLE COOLANT ULTIMAX PARAMETERS
6.2.5 Change the value of N95:243 (CTT Max Spindle Speed w/o Coolant) to 10,000. C2

757-4002-276 CAD #: D8693

with Chiller for VMX24/30/40/50 Machines.

Mihai Leahu___________________ __________
Dan Ornelas___________________ __________ ____________________________ ________

By
Head Thermal Compensation with Chiller 757-4002-276 Page 2 of 2

1.0 INTENT
Chiller.
2.0 APPLICABILITY
Chiller for VMX24/30/40/50 machining centers.
Machine Requirements: Cooled Spindle

Cooler Assembly
A) Turmoil (OCN-33 R) Operating Instruction Manual.

B) 003-1016-045 Assembly, Chiller Head Thermal Compensation.
C) 423-4401-128 Harness, Cooler Power.
This document is intended as a guideline to install a Cooler, Turmoil OCN-33 R, option on VMX24,
VMX30, VMX40 and VMX50 series machines, please refer to dwg. 003-1016-045.
This procedure can be used for installing a complete option package.

BILL OF MATERIAL FOR ASS’Y, 003-1016-045, ASS’Y, CHILLER HEAD THERMAL

COMPENSATION.
2 409-1001-253 FUSE, 10A, TIME DELAY, 13/32 x 1 ½ 17
1 506-0002-021 CONNECTOR STRAIGHT, MALE ½” T– ¼” NPT 16
1 409-2001-057 FUSE HOLDER, 2-POLE, CLASS CC SERIES 14
8 406-0965-004 FERRULE, 18AWG RED 11
15 ft 406-2005-020 WIRE, 18AWG BLACK 9
10 ft 406-2004-010 WIRE, 16AWG BLACK 8
2 506-3009-015 MALE ELBOW, ½” T– ½” MP 6
15 406-5001-004 TIE, WRAP 3
2 506-3011-007 UNION ELBOW, ½” T 2
2 506-3009-013 MALE ELBOW, ½” T– ¼” NPT 1
-045 PARTS LIST
6.0 CHILLER INSTALL PROCEDURE

COMPENSATION (OPTION), DRAWING 003-1016-045.
6.1 CHILLER INSTALLATION ON VMX24/30/40/50
6.1.1 Modify the Bracket, Head Main Cover Mounting.

6.1.2 Reference: Bracket, Head Main Cover Mounting.
6.1.3 Reference: Ass’y, Head Thermal Compensation With Chiller, dwg. 003-1016-045,
Sheet-1/2, view A-A. See Sheet-2/2 for electrical connections.
6.1.4 Drill a 40 DIA hole at the bottom of Bracket, Head Main Bracket. See dwg. 003-1016-045,
Sheet-1/2, view A-A for location, to accommodate (2) items #2. Tighten these (2) fittings with a
tie wrap.
6.1.5 Run the ½” oil lines, item #4 through the Bracket, Head Main Cover Mounting and through the Z
axis catrac. Run them between Column and Electrical Cabinet all the way back to Cooler,
Turmoil, item #5.
6.1.6 Make all the necessary connections between Spindle, Oil lines and Cooler.
dwg. 003-1016-045, Sheet-2/2.
6.1.8 Chiller Thermostat to be set at ambient temperature.
6.1.9 Reference: Turmoil OCN-33 R, Operating Manual.
6.1.10 Cycle Chiller. Check for leaks and make any necessary repairs. Verify if the INLET &
OUTLET are per drawings.
6.1.11 A rust inhibitor must be added to the water Is recommended a mixture of 30%
DOWTHERM SRI to 70% clean tap water, or ETHYLENE GLYCOL and water. Cooler
ON/OFF with the Control Power.
7.1 COOLER POWER
7.1.2 Install the Cooler Power Harness (423-4401-128) from the Cooler to the control cabinet.
7.1.3 Connect the harness inside the Cooler to the terminal strip located just inside the 1/2” conduit
entrance.
7.1.4 Mount the fuse holder, 10A fuses , and cooler starter & overload, inside the electrical control
cabinet on the lower terminal strip.
2-pole, 10A fuse holder.
7.1.6 Using #16 AWG wire, connect contacts 2 and 4 on the 10A fuse holder to contacts 1 and 3
7.1.7 Connect the Cooler Power Harness (423-4401-128) to the cooler starter overload contacts 2
and 4. Connect the ground wire to the existing grounding block.
TB1-3 (MGND).
Cooler should run when control power is turned on.

757-4002-278 CAD #D8695

FOR KIT, SPINDLE, 8K, HIGH TORQUE
VMX24, VMX30, VMX40, VMX50

Mihai Leahu _________________ ________
Dan Ornelas _________________ ________ ____________________________ ________


.
A 15092 Original Issue 10/17/00 ML, HP
DO
B 15218 Added control parameters N95:214, 240, 242 12 2/21/01 DEO
Kit, Spindle, 8K, High Torque (Option) 757-4002-278 Rev. B Page 2

1.0 INTRODUCTION
This document is intended as a guideline to install a new transmission (new pulley) on existing
VMX24, VMX30, VMX40, VMX50 series machines, in order to increase the Spindle Torque.
Please refer to Graphic 1, Graphic 2, and Graphic 3 page 9, 10 and 11.
This procedure can be used for installing a complete option package for VMX24/30/40/50.
BILL OF MATERIAL FOR ASS’Y, 003-1016-065, KIT, SPINDLE, 8K, HIGH TORQUE.
25
24
23
22
21
20
19
18
17
15
14
13
12
11
2 103-5008-001 SHSS, M6 X 1.0 P X 6 LG. 9
1 108-5004-001 BHCS, M6 X 1.0 P X 10 LG. 8
2 110-5001-003 WASHER, FLAT, M5 6
2 110-0046-006 LOCKWASHER, HELICAL SPRING, M5 5
2 101-5007-005 SHCS, M5 X 0.8 P X 18 LG. 4
1 404-9300-003 SWITCH, PROXIMITY, M5 PNP 3
1 803-6005-109 PULLEY, SPINDLE MOTOR, 8K, OPTION 1
PARTS LIST A

INSTALL PROCEDURE.
3.1 MECHANICAL INSTALL PROCEDURE FOR KIT, SPINDLE, 8K, HIGH TORQUE.
VMX24/30/40/50, series machines are designed to accept this option.
3.1.1. There are (2) SHCS, M6 X 1.0 P X 20 LG. screws, see Fig. 1, item #2, on the front of
the Head, for VMX24/30/40. There are (4) screws M6 on the front of Head for VMX50
and (2) screws on top of the Head. These screws are located on front Head Cover, item
#1. For VMX50 there are also (2) screws on the right side of the Head, mounted on
Cover Front Right hand side, see Fig. 1, item #3. Remove these screws.
3.1.2. For your convenience, lift those covers and set them outside of machine.
3.1.3. On VMX24/30/40, after the Front Cover is removed, you will find a Plate in front of the
Head, which covers a casting hole in Head. This Plate is attached to the Head by (4)
screws. You will find a similar Plate on VMX50, but this Plate is on the right hand side
of the Head. Remove these Plates.
3.1.4 Lower Z-axis at your convenience for easier access to the Motor; see “Motor”, Fig. 2.
3.1.5 Remove (4) M12 X 1.75 P X 50 LG. screws, (4) lockwashers M12 and (4) flat washers,
from the Plate Spindle Motor, see “Plate, Spindle Motor”, Fig. 2.
3.1.6 Push the Motor forward, to remove all tension from Belt. See “Belt”, Fig. 2.
3.1.7 Disconnect the power and lock out.
3.1.8 Disconnect wires from Motor and remove the Motor. Set the Motor outside of machine.
3.1.9 Remove (6) SHCS, M6 X 1.0 P X 35 LG. screws.
3.1.10 Remove Retainer Pulley, see “Retainer Pulley”, Fig. 2.
3.1.11 Remove Pulley, P/N 803-6005-068, using a puller if necessary, see Fig. 2, item #1, from
Motor. Remove Locking Elements as well.
3.1.12 Install a new Pulley on Motor, dwg. no. 803-6005-109, using blue loctite on M6 screws.
3.1.13 Reuse the Belt, Screws, Retainer Pulley and Locking Elements from previous Pulley.
3.1.14 Drill and tap new (4) holes M12 X 1.75 P, 20 mm to the back of machine from existing
(4) holes M12 X 1.75 P. See dwg. no. 003-1016-065.
3.2. MECHANICAL INSTALLATION PROCEDURE FOR PROXIMITY SWITCH.

(Please refer to Dwg. P/N 003-1016-065)
3.2.1. For VMX24/30/40, drill and tap (2) holes M5 X 0.8 P Thru, left hand side of the Head, to
install Bracket Proximity Switch, dwg. no. 803-6001-164. Location for these (2) holes
for VMX24/30/40, is shown on dwg. no. 003-1016-065.
3.2.2. For VMX50, drill and tap (2) holes M5 X 0.8 P Thru, in front of the Head, to install

Bracket Proximity Switch, dwg. no. 803-6001-164. Location for these (2) holes, for
VMX50, is shown on dwg. no. 003-1016-065.
3.2.3. Install Bracket Switch, see dwg. 003-1016-065, item #2. Use (2) M5 X 0.8 P X 18 LG.
with (2) M5 lockwashers flat washers and locktite to secure the bracket.
3.2.4. Install Proximity Switch, P/N 404-9300-003, see dwg. 003-1016-065, item #3. Adjust the
distance between Proximity Switch and Wheel Balance. That distance
should be ~0.5 mm. Target the slot on Wheel Balance for the Proximity Switch.
3.3 ELECTRICAL INSTALLATION PROCEDURE FOR PROXIMITY SWITCH.

3.3.1 Disconnect Original Encoder Harness from Spindle drive in Electrical Cabinet (2CN)
and Winding Select Contactor.
3.3.5. Reinstall existing Belt, see Fig. 2.
3.3.10. Set orient zero mark with proximity sensor. Please refer to pages 12 & 13, item #4.2., of this
document.


3.4 V-BELT TENSIONING METHOD.
3.4.1 The best tension for a belt drive is the lowest tension under the highest load condition,

Span Length
VMX24/30/50 10.86 0.168
VMX40 12.91 0.201
Deflection
VMX24/30/50 4.5~5.5 0.13~0.16
VMX40 6.0~7.0 0.14~0.18

GRAPHIC 1.
15
14
13
12
11
10
0
4
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000 8500 9000 9500 1 10
Motor R.P.M.
VMX24-10K Torque / Horsepower Chart

1 Min. Power Rating 12.5 HP

16
15
14
13
12
11
10
0
0 400 800 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800 5200 5600 6000 6400 6800 7200 7600 8000
Motor R.P.M.
VMX24-8K (Option) Torque / Horsepower Chart

GRAPHIC 2.
22
20
18
16
14
12
10
0
4
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000 8500 9000 9500 1 10
Motor R.P.M.
VMX30-10K Torque / Horsepower Chart


24
22
20
18
16
14
12
10
0
0 400 800 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800 5200 5600 6000 6400 6800 7200 7600 8000
Motor R.P.M.
VMX30-8K (Option) Torque / Horsepower Chart

GRAPHIC 3.
15 min, 30% cycle
26
24
22
20
Torque(10 x Ft*Lbs) / Power (hp)
18
16
14
12
10
0
4
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000 8500 9000 9500 1 10
Motor R.P.M.
VMX40/VMX50-10K Torque / Horsepower Chart

1 Min. Power Rating/Torque Rating = 25 HP/219 Ft*Lbs
Speed 600-750 RPM, 15 min, 30% cycle, Power Rating/Torque Rating = 20 HP/175 Ft*Lbs

15 min, 30% cycle
30
28
26
24
22
20
18
16
14
12
10
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000
Motor R.P.M.
VMX40/VMX50-8K (Option) Torque / Horsepower Chart



SPINDLE
SPINDLE GEAR
Gear 0
Ratio 1.2000
Minimum RPM 1
Maximum RPM 8333
B1
INTEGER

4.2 External Proximity Sensor Orient

4.2.12 Carefully and slowly jog Z-axis down (negative) until the spindle nose is approximately 1.0” from top
of ATC load arm.
4.2.13 Press the “Spindle OFF” button on console. Rotate the spindle by hand until the spindle balance key
is aligned with the ATC gripper key slot. If you have removed the keys because of clearance issues,
remember that you have made a mark for drive key location so the unmarked notch in the spindle is the
balance key side of the spindle.
Depress DSPL repeatedly on keypad until U1-XX is displayed, with the Up–Down arrow keys change
display to U2-XX, now with the “>, Reset” key, scroll to the far right changing the display to U2-03 and
depress Data key to view the counts.
4.2.18 Reset C2-24 bit 0 = 0.

R
757-4002-085 REV: A ECN #13600
01/10/96 CAD #D8464
SUBJECT: PROCEDURE, HAWK 5 SSM WORKLIGHT INSTALLATION
I. INTENT:
Provide brief instruction on 110V worklight installation.
II. SCOPE:
Applies to Hawk 5 SSM Knee Mills as well as those upgraded to Dual Screen. This worklight
should only be used on the assembly where the transformer is inside the cabinet enclosure.
III. PROCEDURE:
A. Bill of Materials. Ensure the following parts are included in the worklight option kit.
PART DESCRIPTION QTY

408-8501-011 LOCKNUT, 3/8" CONDUIT 1
408-8003-038 CORD GRIP, STD TYPE 1
406-0965-004 FERRULE, 18 AWG RED 4
406-6481-005 HEAT SHRINK, 3/8" BLACK 2”
406-4006-082 HORZ JUMPER, GRAY 284-4 1
406-4005-089 TERM, #284-101 GRAY 1
713-0011-094 WORKLIGHT, MAGBASE 110VAC 1
406-4006-006 WAGO TRM BLK LBL#11-20 1
406-4005-049 TERMINAL, RAIL MOUNT FUSE 1
409-1001-192 FUSE, 1A 3AG SLO-BLO, MDL, MDA 2
406-2004-010 WIRE, 16AWG BLACK 4”
406-0965-005 FERRULE, 16 AWG BLACK 3
406-5001-006 TIE WRAP, MEDIUM 10
406-5001-002 TIE MOUNT 5
B. Installation
Option A: Plug worklight into 110VAC outlet.
Option B: Connect worklight to machine. Proceed as follows...
1. After shutting down machine power, prepare interior of cabinet for drilling by
covering servo chassis with a cloth or sheet of plastic.
2. Drill 0.675 hole as indicated:
______________________ _______ ______________________ _______

Originator Date Engineering Manager Date
757-4002-085 REV A
3. Cut off molded plug from worklight power cord. Install 408-8003-038 cord grip
on worklight cord. Feed cable into cabinet. Fasten cord grip to cabinet with 408-
8501-011.
4. Terminate worklight cord with 406-0965-004 ferrules and 406-6481-005
heat shrink.
5. Loosen the left end stop with a screwdriver. Slide to the left & add 406-4005-
089 gray terminal. Install #11 label 406-4006-006. Add horizontal jumper 406-4006-
082 between terminals 10 and 11.
6. Install 409-1001-192 fuse into 406-4005-049 fuse terminal. Install fuse terminal
assembly on DIN rail.
7. Prepare a 2” length of 406-2004-010 16 awg black wire and terminate with 2 pcs
406-0965-005 16 awg ferrules.
8. Wire as shown:
9. Tighten end stop.

10. Dress worklight cable neatly from terminal strip to cord grip. Allow adequate
length for easy relocation of lamp. Use tie wraps 406-5001-006 and/or tie
mounts 406-5001-002 as required.
11. Clean & close power cabinet.
12. Mount worklight magbase to spindle head or power cabinet. Install bulb.
13. Route cable away from moving parts. Secure with tie wraps if necessary.
14. Power up machine to test light.
2
R
757-4002-109 CAD #D8494
SUBJECT: Installation Procedures and Parameter Settings

for HEIDENHAIN LS406 Linear Scales.
Brian Atterson 11/15/96 Jeff Bitant 1/7/97

Originator Mgr. Machine Tool
Date Date
Rev. C 757-4002-109 Page
1
RECORD OF CHANGES

By
B 14004 Added Servo Drive Adjustments and Tuning DEO 3/31/97 MFC 4/2/97
as Sections IV-F and V-F.
C 14128 1) Pages 5 & 7, added E2 reference. 2) Pages 5 DEO 10/27/97
& 8, revised drive adjustment procedure for
fine-tuning. 3) Pages 10 & 11, added Table 2
for version 2.x software compatibility.
Rev. C 757-4002-109 Page

2
I. INTENT
To provide a standardized method of installation and configuration for Heidenhain linear

scales.
II. APPLICABILITY
Specific to all BMC30 and BMC4020 machining centers.
III. REFERENCE DOCUMENTS/DRAWINGS
1) HEIDENHAIN Mounting Instruction Manual

2) 003-2018-001, ASS’Y OPTION LINEAR SCALES
3) 003-2018-002, KIT, LINEAR SCALES
4) 003-2018-003, ASS’Y LINEAR SCALES (COVERS AND MOUNTING BRACKETS)
5) 423-4401-115, HARNESS AXIS SERVO DRIVE
Rev. C 757-4002-109 Page

3
IV. BMC30 SCALE INSTALLATION
A. X AXIS SCALE INSTALL
1) Remove the front table guard.

2) Remove the left and right X-axis telescoping way covers.
3) Remove the X-axis limit switch and bracket. Limit switch does not need to be
disconnected.
4) Locate mounting holes for the read head and scale brackets. If the mounting holes have
not been drilled and tapped, use the “BRACKET, X AXIS DOG” and “SADDLE”
details to locate.
5) Install the read head bracket on the saddle.
6) Install limit switch mounting bracket.
7) Install the scale mounting brackets to the scale.
8) Mount the assembly to the table X-axis dog brackets.
9) With the scale assembly installed, verify that the mounting holes for the read head and
mounting bracket are aligned.
10) Reference the HEIDENHAIN Mounting Instruction Manual for alignment of the scale
and read head.
11) Axis Travel Verification (BMC30)
A) Software Limit 762mm(30”)
B) Distance between hard stops 768mm(30.25”)
12) Connect Air Purge to scale assembly. Reference the HEIDENHAIN Mounting
Instruction Manual.
B. Y AXIS SCALE INSTALL
1) Disconnect the front and rear telescoping covers from the saddle.
not been drilled and tapped, use the “SADDLE” and “BASE” details to locate.
5) Mount the scale assembly to the base casting.
and read head.
Instruction Manual.
10) Install front and rear scale shields.
Rev. C 757-4002-109 Page

4
C. Z AXIS SCALE INSTALL
not been drilled and tapped, use the “COLUMN” and “ASSEMBLY, SCALE BMC30”
to locate.
2) Install the read head bracket on the head casting.
4) Mount the assembly to the column.
6) Reference the HEIDENHAIN Mounting Instruction Manual for the alignment of the scale
and read head.
Instruction Manual.
9) Install Z-axis scale shield, there should be approximately 1 to 2mm gap between the edge
of the shield and the head casting.
D. AIR PURGE ASSEMBLY
1) Locate and mount per the drawing.

ASSEMBLY, SCALE BMC30
2) Unlubricated Air supply to scale filter/regulator.
3) Reference HEIDENHAIN Mounting Instruction Manual for operation.
E.C1 SYSTEM PARAMETERS
1) Enter the appropriate parameters from Table 1 attached, through Axis Tune Screen “103”
and Machine Configuration Screen “100”, for specific machine type using version 1.6x
software.
2) Enter the appropriate parameters from Table 2 attached, through AUXILIARY, “100”,
ENTER, “100” for specific machine type using version 2.x software.
F.C2 SERVO DRIVE ADJUSTMENTS AND TUNING
1) Siemens axis default amplifier “Proportional Gain Adjustment”

a) Adjust X, Y, and Z-axis potentiometer labeled “Kp” until the motor starts to
oscillate, then back off until it stops. After it stops, turn the pot slightly 10%
CCW.
2) Siemens axis default amplifier “Integral Gain Adjustment”.
a) Adjust X and Y-axis potentiometer labeled “TN” to approximately 35 % from zero
detent in a CW direction.
Rev. C 757-4002-109 Page
5
b) Adjust Z-axis potentiometer labeled “TN” to approximately 50 % from zero
3) Connect a digital voltmeter (DVM) to drive test point “W” (positive lead) and test point
4) Program the given axis to move back and forth at 50 IPM and observe the stability of
5) Fine adjust the “Integral Gain Adjustment” potentiometer labeled “TN” until the voltage
measured at drive test points becomes stable, typically +/-10mV fluctuation is adequate.
V. BMC4020 SCALE INSTALLATION
A. X AXIS SCALE INSTALL
1) Remove the front table guard.

2) Remove the left and right X-axis telescoping way covers.
3) Remove the X-axis limit switch and bracket. Limit switch does not need to be
disconnected.
not been drilled and tapped, use the “BRACKET, X AXIS DOG” and “SADDLE”
details to locate.
6) Install limit switch mounting bracket.
7) Install the scale mounting spar and brackets to the scale.
8) Mount the assembly to the table X-axis dog brackets.
and read head.
B) Distance between hard stops
12) Connect Air Purge to scale assembly. Reference the HEIDENHAIN Mounting Instruction
Manual.
B. Y AXIS SCALE INSTALL
1) Disconnect the front and rear telescoping covers from the saddle.
not been drilled and tapped, use the “SADDLE” and “BASE” details to locate.
5) Mount the scale assembly to the base casting.
Rev. C 757-4002-109 Page
6
and read head.
B) Distance between hard stops
Manual.
10) Install front and rear scale shields.
C. Z AXIS SCALE INSTALL
1) Disconnect Z-axis telescoping cover from the head casting

not been drilled and tapped, use the “COLUMN” and “ASSEMBLY, SCALE
BMC4020” to locate.
2) Install the read head bracket on the head casting.
4) Mount the assembly to the column.
6) Reference the HEIDENHAIN Mounting Instruction Manual for the alignment of the scale
and read head.
Manual.
9) Install Z-axis scale shield.
D. AIR PURGE ASSEMBLY
1) Locate and mount per the drawing.

ASSEMBLY, SCALE BMC4020
2) Unlubricated Air supply to scale filter/regulator.
3) Reference HEIDENHAIN Mounting Instruction Manual for operation.
E.C1 SYSTEM PARAMETERS
1) Enter the appropriate parameters from Table 1 attached, through Axis Tune Screen “103”
and Machine Configuration Screen “100”, for specific machine type using version 1.6x
software.
2) Enter the appropriate parameters from Table 2 attached, through AUXILIARY, “100”,
ENTER, “100” for specific machine type using version 2.x software.
Rev. C 757-4002-109 Page
7
F.C2 SERVO DRIVE ADJUSTMENTS AND TUNING
1) Siemens axis default amplifier “Proportional Gain Adjustment”

a) Adjust X, Y, and Z axis potentiometer labeled “Kp” until the motor starts to
oscillate, then back off until it stops. After it stops, turn the pot slightly 10%
CCW.
2) Siemens axis default amplifier “Integral Gain Adjustment”.
a) Adjust X and Y-axis potentiometer labeled “TN” to approximately 35 % from
zero detent in a CW direction.
b) Adjust Z-axis potentiometer labeled “TN” to approximately 50 % from zero
3) Connect a digital voltmeter (DVM) to drive test point “W” (positive lead) and test point
4) Program the given axis to move back and forth at 50 IPM and observe the stability of
5) Fine adjust the “Integral Gain Adjustment” potentiometer labeled “TN” until the voltage
measured at drive test points becomes stable, typically +/-10mV fluctuation is adequate.
Rev. C 757-4002-109 Page

8
(Table 1, For Use with Version 1.6x Software)
Ultimax 3 Control Axis Tune Screen, <enter>,103,<enter>
MATRIX4 Axis Tune Diagnostics, BMC4020 X Axis Y Axis Z Axis Spindle

(Siemens)
Integral: 50 50 50 50
Proportional: 2500 2500 2500 2500
Feedforward: 1000 1000 1300 1800
Derivative: 150 150 150 200
Integral Limit: 12 12 12 14
Output Loop Gain: 1 1 1 1
Integral Bandwidth 200 200 200 1024
DAC Balance: 0 0 0 0
DAC Balance Limit: 0 0 0 0
Max. Rapid Accel: 140000 140000 140000 225000
Max. Contour Accel: 140000 140000 140000 NA
Max. Abort Accel: 300000 300000 300000 250000
Following Error Halt: 0.25 inch 0.25 inch 0.25 inch 3000 degr
Tap Deceleration NA NA NA 80000
Z/S Tap Gain NA NA NA 1
Ultimax 3 Control Machine Configuration Screen, <enter>,100,<enter>
Machine Config. Physical Parameters, BMC4020 X Axis Y Axis Z Axis

(Siemens)
Axis Pitch Metric Metric Metric
Counts per Revolution 6000 6000 6000
Limit Switch to Marker Distance 9 mm 9 mm 9 mm
Distance per Revolution 12 mm 12 mm 12 mm
In Position Tolerance 5 counts 5 counts 20 counts
Calib: To Lim Sw Velocity 5080 mmpm 5080 mmpm 5080 mmpm
Calib: To Marker Velocity 254 mm 254 mm 254 mm
Load Meter Bar One Value 0 0 0
Maximum Travel 1016 mm 508 mm 610 mm
Leadscrew Mapping Yes Yes Yes
Maximum Feedrate 20000 mmpm 20000 mmpm 15000 mmpm
Rev. C 757-4002-109 Page

9
(Table 2, For Use with Version 2.x Software) C3
AXES
Physical Parameters X Axis Y Axis Z Axis

Counts per Revolution 6,000 6,000 6,000
Distance per Revolution (mm.) 12.0000 12.0000 12.0000
In Position Tolerance 5 5 20
Maximum Feedrate (mmpm) 20000.0 20000.0 13462.0
Max DAC Volts 9.500 9.500 9.500
Vertical Parameters X Axis Y Axis Z Axis

Minus Direction Travel Limit (mm) 0.0000 0.0000 -610.0000
Plus Direction Travel Limit (mm) 1020.0000 510.0000 0.0000
Calibrate Home Position (mm) 0.0000 0.0000 0.0000
SPINDLE
Physical Parameters Spindle

Spindle Control Type Closed Loop Control
Number of Gears 1
Orient Mechanism Present Yes
Minimum Tap RPM 100
Maximum Tap RPM 2,000
Maximum DAC Volts 9.500
Counts per Revolution 1,024
In Position Tolerance 1,024

Maximum Spindle Motor Speed 6,500
Maximum Spindle Tool Speed 6,500
Rev. C 757-4002-109 Page

10
(Table 2, For Use with Version 2.x Software) C3
SPINDLE GEAR

Gear 0
Ratio 1.0000
Minimum RPM 1
Maximum RPM 6,500
Tap Acceleration 80,000
GENERAL
General Parameters
Configuration Parameter Units Metric
Max. Programmable Contour Feedrate (mmpm) 7620.0
Logic Control Sleep Time (msec) 50
Monitor Type (*) Monochrome
Text Screen Monitor Type (**) Monochrome
Graphics Screen Monitor Type (**) Monochrome
Pointing Device Mode Incremental
NOTE:
(*) Appears if SSM console.
(**) Appears if DSM console.
Rev. C 757-4002-109 Page

11
R
757-4002-110 CAD #: D8495
SUBJECT: Installation Procedure, Head Growth Compensation Kit

Rev. A

I. INTENT
To provide a standardized method of installation and configuration for Head Growth

Compensation Kits.
II. APPLICABILITY
Specific to all BMC30 (Frame A) and BMC4020 machining centers.

Machine Requirements: Head Cover Fans (Front Mounted)
8K Oil cooled Spindle
Oil Chiller
III. REFERENCE DOCUMENTS/DRAWINGS
A) Turmoil (OC-33-R) Operating Instruction Manual.

B) 003-1016-011 Assembly Head Growth Compensation
C) 003-1015-003 Assembly Spindle Temperature Controlled
D) 423-4401-126 Harness, Cooling Fan
E) 423-4401-127 Harness, Fan Power
F) 423-4401-128 Harness, Oil Cooler Power
IV. OIL COOLED SPINDLE INSTALLATION
A) Remove the head cover, loosen the bolts mounting the spindle motor to the head
casting.
B) Remove the spindle drive keys (mark their locations on the spindle shaft) and locate
the spindle stand underneath the spindle.
C) Remove the six M12 SHCS on the spindle flange, raise the head and remove the spindle.
D) Inspect the head casting spindle bore for any sharp corners that may cut the O-rings during
installation of the oil cooled spindle assembly.
Reference: 003-1016-011 Assembly Head Growth Compensation
SHT 2/3, VIEW D-D
E) Install Spindle Flange Oil Fittings & Air Purge Fitting.
SHT 1/3
Remove Air Purge Fitting from standard 8K spindle assembly and install on
oil cooled spindle assembly.
F) The head casting spindle bore and mating surface for the spindle flange should be clean
and free of burrs prior to installation of the oil cooled spindle.
G) Remove the spindle drive keys from the oil cooled spindle (mark their locations on the
spindle shaft).
H) Remove the spindle nose sleeve.
I) Set the spindle assembly on the spindle stand, run the head down onto the spindle, being
careful not to “bind” the spindle in the head casting bore. Install the six M12 SHCS
spindle mounting bolts, then the spindle drive and balance keys.
J) Tighten the spindle drive belt, the resulting belt tension should not deflect the spindle
shaft.
K) Check the spindle sweep.
L) Install the spindle nose sleeve.
M) Once the oil chiller has power, check for oil leaks at the spindle, verify the INLET &
OUTLET lines are per the drawing.
SHT 1/3
V. OIL CHILLER INSTALLATION
A) Modify the head cover mounting bracket.

SHT 2/3 VIEW B-B
B) Run the 1/2 inch oil line through the Z axis catrac.
C) Oil chiller turned ON/OFF with control power.
SHT 3/3
D) Oil Chiller Thermostat to be set at ambient temperature.
Reference: Turmoil OC-33-R, Operating Manual
E) Cycle Oil Chiller.
Check for Leaks
Verify INLET & OUTLET are per the drawing.
Cooling Oil: AW-32 MELTRAN or equivalent
ON/OFF with Control power.
VI. FAN INSTALLATION
A) Verify the distance between the Head cover and the right enclosure door
track to ensure there is room available for the fan enclosure, should be approx.
27mm.
SHT 1/3 DETAIL C
Note: If there is not enough room for the fan enclosure to clear the right
door track when the head is in the “up” position, the door track mounting
location will have to be moved forward (front of machine) to make room
available.
B) Modify the Head cover per the drawing.
SHT 2/3 DETAILS FOR BMC30 & BMC4020 MODIFICATIONS
C) Assemble the Fan Enclosure
SHT 1/3 DETAIL C
D) Center the assembled fan enclosure on the head cover cut out, transfer the mounting
hole locations then drill and tap.
E) Install the Fan Enclosure and seal with RTV.
F) Locate the CLAMP/UNCLAMP switch under the fan enclosure. Transfer the mounting
hole locations then drill and tap.
G) Install the CLAMP/UNCLAMP switch.
H) Fans turned ON/OFF with spindle.
SHT 3/3
I) Install Head Cover.
VII. ELECTRICAL INSTALLATION
A) Fan Hook-up
1) Connect the Cooling Fan Harness (423-4401-126) to each fan.

2) Install the Fan Power Harness (423-4401-127) from the spindle head assembly to the
machine control cabinet by pulling it through the spindle head cable trak. Note: the
two female Mate-N-Lock connectors are to be installed at the spindle head.
3) Connect the two Cooling Fan Harnesses to the Fan Power Harness. Reference sheet 3
of 3 on drawing 003-1016-011.
4) Control cabinet connections detailed in subsection C below.
B) Oil Cooler Power
1) Punch a 1/2” conduit knockout in the bottom of the control cabinet.

2) Install the Oil Cooler Power Harness (423-4401-128) from the oil cooler to the control
cabinet.
3) Connect the harness inside the oil cooler to the terminal strip located just inside the 1/2”
conduit entrance.
4) Control cabinet connections detailed in subsection C below.
C) Control and Power Connections
1) Reference sheet 3 of 3 on drawing 003-1016-011 for all steps outlined below.

2) Mount the terminal blocks, circuit breaker, fan relay, and oil cooler starter on the
existing DIN rail inside the control cabinet as illustrated.
3) Using #18 AWG wire, tap off existing 115VAC power and connect to the 2A fused
terminal block (115V-L) and the unfused terminal block (115V-N). From the terminal
blocks, route the 115V fan power to the fan reley contacts 6 and 7.
4) Connect the Fan Power Harness (423-4401-127) to the fan relay contacts 6 and 7.
Connect the ground wire to the grounding block provided.
5) Using #16 AWG wire, tap off existing 230VAC power and connect to the 2-pole, 10A
breaker. From the breaker, route the 230V oil cooler power to the Oil Cooler Starter
contacts 1 and 3.
6) Connect the Oil Cooler Power Harness (423-4401-128) to the Oil Cooler Starter
contacts 2 and 4. Connect the ground wire to the grounding block provided.
7) Using #18 AWG wire, connect OCS-A1 and FRLY-14 to CRP4/TB10-7 (+24V
switched). Connect OCS-A2 to CRP4/TB1-6 (MGND) and FRLY-13 to CRP4/TB1-3
(SER).
D) Test and Verification
When testing the Head Growth Compensation circuits, check for the following control: 1)
the oil cooler should run when control power is turned on, 2) the fans should run when
when the spindle is enabled.
CHIP CONVEYOR
AND
WASHDOWN OPTION
ENGINEERING DOCUMENT NO. 757-4002-119

C/N D8509
R
757-4002-119 CAD #D8509
SUBJECT: CHIP CONVEYOR AND WASHDOWN

INSTALLATION PROCEDURES.

Himat Patel _________________ ________
Jeff Bitant _________________ ________
Dan Ornelas _________________ ________ ____________________________ ________
Engineering Document 7574002-119 CAD #D8509

Rev. B

A 14003 Original Issue 3/31/97 JB/ HP
DO
B 15110 Revised procedures to include VMX40 series 11/06/00 ML
machines.
Page 2
1.0 INTRODUCTION
This document is intended as a guideline to install The Chip Conveyor and Washdown
option on BMC30, BMC4020 and VMX40 series machines. The option can
be ordered as one complete package (Chip Conveyor + Washdown) or individually as
either a Chip Conveyor or a Washdown. This procedure can be used for installing a
complete option package or for individual option of Chip Conveyor or Washdown.

COMPLETE OPTION CONSISTS OF WASHDOWN SYSTEM AND CHIP CONVEYOR
(ITEM #1 & #2). VMX40 DOES NOT REQUIRE ITEM #1, WASHDOWN OPTION.
BILL OF MATERIAL FOR ASS’Y, 003-1005-007, WASHDOWN OPTION (ITEM #1).
Page 3
BILL OF MATERIAL FOR ASS’Y #2, 003-1005-006, ASS’Y, CHIP CONVEYOR (ITEM #2).
3.0 INSTALL PROCEDURE.
3.1 MECHANICAL INSTALL PROCEDURE FOR ASS’Y, CHIP CONVEYOR,

DRAWING #003-1005-006.
BMC30, BMC4020 and VMX40 are designed to accept this option. Wash down System
is standard for VMX40. VMX40 requires just Chip Conveyor Option.
3.1.1. There is a plate located on the left side of the coolant tank (above fluid
levels) toward the front of the machine. To remove this plate, slide the coolant
tank forward to allow access to mounting screws. Remove this plate.
3.1.2. Remove the chip tray from the front of the machine. The chip tray could be
stored for use in the event the conveyor is removed for maintenance or service.
Install the front cover on coolant tank.
3.1.3. Adjust the height of the conveyor (by adjusting the height of the casters or
the casters mounting post) to align even with the opening in left side of the
coolant tank.
3.1.4. Slide the conveyor into the machine and be careful not to rip the rubber
flap.
*****IMPORTANT******TO PREVENT THE RUBBER FLAP (MOUNTED TO THE

FRONT OF THE BASE CASTING) FROM BEING TORN, THE RUBBER FLAP MUST
BE ROLLED INWARDS WHILE SLIDING THE CONVEYOR INTO THE MACHINE.
Page 4
Note: Balloon numbers
correspond to items in BOM
listing for this assembly
FIGURE 1.
¬ . Remove side plate in ® . Remove chip tray and Install front cover on
the coolant tank to slide machine coolant tank
the chip conveyor under
the machine base.
- . Adjust caster to align the height of the

conveyor to the opening in the coolant tank.
Page 5
3.1.5. The main conveyor wiring harness shall be routed as detailed in Figure 2.
¯. Harness routing.
FIGURE 2.
Page 6
3.1.6. There are (4) corelock hose clamps provided to secure the harness (Item 5) from
Chip Conveyor to the electric cabinet. NOTE: DO NOT drill any holes
into the machine enclosure!!! Mount the clips to the raised portion of the coolant
tank approximately 260mm from the tank bottom. Drill two 3mm holes (see
Figure 3 for location) and install clips.
Page 7
FIGURE 3.
° . Drill two 3.0mm holes 260mm from bottom of tank to area shown.
3.2 ELECTRICAL INSTALL PROCEDURE FOR ASS’Y, CHIP CONVEYOR.
*****IMPORTANT***** Ensure the chip conveyor motor voltage wiring is

configured for the proper machine type for which it is being installed. For example,
BMC4020’s and BMC30’s (Siemens) should be jumpered for 400VAC while the
BMC30SSM and VMX40 should be jumpered for 230VAC. Motor wiring
configuration is identified either on the motor ID plate or inside the terminal box
depending on chip conveyor model.
3.2.1. Connect Harness, Chip Conveyor (423-4400-017) to mating connector

located on underside of enclosure Assy, Chip Conveyor Control Panel
(003-1005-004).
3.2.2. Provide a 3/4” knockout in the bottom right hand corner of the control
cabinet to accommodate the Harness, Chip Conveyor (423-4400-017)
entrance.
3.3.3. Terminate motor power conductors to circuit breaker terminals CB6-2,4,

and 6, and frame ground wire to central ground point. Then terminate
control voltage, +24VDC SW, to TB2-53, machine ground and cable
shield to TB2-55 and TB2-56 respectively as indicated on harness drawing
(423-4400-017).
3.3 MECHANICAL INSTALL PROCEDURE FOR ASS’Y, WASHDOWN,

DRAWING #003-1005-007. VMX40 DOES NOT REQUIRE WASH DOWN
OPTION. WASH DOWN SYSTEM IS STANDARD FOR VMX40.
3.3.1. Remove (2) pump cover plates and (4) pipe plugs from the machine.
Page 8
¬ .Remove two cover plates and (4) pipe plugs located on back of enclosure wall.
¬ .Remove
(4) pipe
plugs, (2) from each side.
FIGURE 4.
3.3.2. Remove the two washdown pumps and pump mounting plates from box. Install
the two pump mounting plates in the same location as cover plates that were
removed from the coolant tank.
Install pump mounting plates to the top of the coolant tank as shown in Figure 5. Use (4)
M8 X 1.25PX25LG with M8 lockwasher to secure each mounting plate to coolant tank.
Page 9
Where a riser plate is used instead of the pump mounting plate, mount the riser plate to the top
of coolant tank (The flange of the riser plate with [4] 9.0mm through holes is on the top of the
coolant tank. The pump is mounted to the flange of the riser plate with (4) M8 threaded holes)
3.3.3. Pump Installation

Both pumps are pre-piped and ready for installation, refer to Figure 5 to ensure
correct orientation of plumbing and electrical utilities. Install both pumps to
pump mounting plates with (8) M8X1.25PX25LG SHCS with M8 lockwashers.
®. Install pumps as shown.
-. Install pump
mounting plate.
-. Install pump mounting plate.
FIGURE 5.
Page 10
3.3.4. Fitting and hose installation.
+ PLEASE REFER TO FIGURE 6 FOR RIGHT SIDE PUMP INSTALLATION AND

FIGURE 7 FOR LEFT SIDE PUMP INSTALLATION.
FIGURE 6 (Right Side Pump Installation)
¯. Install straight fitting, Item#1 on

Washdown Assembly.
°. Install 90 degree fitting as

shown.
±. Layout hose to and cut to length as

shown. Install one hose clamp to each
end of hose.
FIGURE 7 (Left Side Pump Installation)
². Install 90 degree fitting as shown.
³. Install straight fitting, Item#1 on

Washdown Assembly.
´. Layout hose to and cut to length

as shown. Install one hose clamp to
each end of hose.
Page 11
3.4 ELECTRICAL INSTALL PROCEDURE FOR ASS’Y, WASHDOWN.
*****IMPORTANT***** Ensure the washdown pumps motor voltage wiring is configured for
the proper machine type for which it is being installed. For example, BMC4020’s and
BMC30’s (Siemens) should be jumpered for 400VAC while the BMC30SSM should be
jumpered for 230VAC. Motor wiring configuration is identified either on the motor ID plate
or inside the terminal box depending on washdown pumps model.
3.4.1. Mount two contactors and overloads within the control cabinet on DIN rail assembly.
3.4.2. Connect Harnesses, Wash Down Right Pump (423-4405-048) and Wash Down Left Pump
(423-4405-049) from motor terminal box to control cabinet Washdown Pump #1 contact,
WDS1 at 2T1, 4T2, and 6T3 and Washdown Pump #2 contact WDS2 at 2T1, 4T2, and 6T3.
Cabinet knockouts are already provided in bottom left and right hand corners, simple remove
and discard plugs.
3.4.3. Using Wire, 16 AWG Black and Ferrules, 16 AWG Black connect 3 phase power conductors
from line side of Flood Coolant Pump contactor FCS at 1,3, and 5 to Washdown Pump #1
contactor at WDS1 at 1L1, 3L2, and 5L3.
3.4.4. Using Wire, 16 AWG Black and Ferrules, 16 AWG Black, jumper 3 phase power conductors
from Washdown Pump #1 contactor WDS1 at 1L1, 3L2, and 5L3 to Washdown Pump #2
contactor WDS2 at 1L1, 3L2, and 5L3.
3.4.5. Using Wire, 24 AWG Black and Ferrules, 24 AWG Black connect Washdown Pump #1
contactor WDS1-A1 to 24VDC control output terminal TB2-43. Then using same material
jumper 24VDC from Washdown Pump #1 contactor WDS1-A1 to Washdown Pump #2
contactor WDS2-A1.
3.4.6. Using Wire, 24 AWG Black and Ferrules, 24 AWG Black connect Washdown Pump #1
overload WDS1-96 (OL2) to machine ground terminal TB2-56. Then using same material
jumper machine ground from Washdown Pump #1 overload WDS1-96 (OL2) to Washdown
Pump #2 overload WDS2-96 (OL3).
Page 12
R
757-4002-120 CAD #D8510
SUBJECT: Heat Exchanger Retrofit Procedure

for Bedmill Machining Centers.
Heat Exchanger Retrofit Procedure, BMC 757-4002-120 Rev. A Page 1

RECORD OF CHANGES

I. INTENT

To provide a standardized method to retrofit and install a heat exchanger assembly on existing
bedmilling machining centers.
II. APPLICABILITY
As required on BMC4020’s and BMC30’s equipped with Siemens drive systems.
1) 420-0003-012, PPA, Heat Pipe Heat Exchanger, 110V, 35W/K.

2) 802-2601-007, Control Cabinet, Cutout Detail View “V” (Page 3, Attached).
3) 003-2007-001, Ass’y BMC4020HT Control Cabinet (Pages 2 & 3, Attached).
4) 003-2022-004, Interconnect Diagram, BMC4020HT (Page 17, Attached).
IV. INDEX
Page 3 Kit Definition (002-4315-003)

Page 4 Installation Procedure
Pages 5 - 8 Reference, Hurco Drawings
V. KIT DEFINITION
Heat exchanger assembly and associated hardware required to implement on bedmill machining
centers. The following table lists the necessary components required for this retrofit package.

Heat Pipe Heat Exchanger, 110V, 35W/K 420-0003-012 1
SHCS, M6 x 1.0 P x 12LG 101-5008-003 8
Lockwasher, M6 Helical Spring 110-0046-007 8
Hex Nut, M6 x 1.0 P 117-5013-001 8
Terminal Rail Mount Fuse Block 406-4005-049 1
Fuse, 1A 409-1001-001 1
1/C, 18 AWG, Black 406-2005-020 6”
3/C, 18 AWG Blk/Wht/Grn 406-1247-011 96”
Ferrule, 18 AWG Red 406-0965-004 10
Tie Wrap, Medium 406-5001-006 5

CAUTION: Ensure power to the machine has been turned off both at the machine and at the
customers panelboard (source) if possible prior to installation. Using a piece of material or paper
cover the drive system and ISA control to prevent metal shavings from falling into electronic
modules while drilling and punching cutout.
1) Refer to Control Cabinet drawing (802-2601-007), sheet 3, detail “V” for location of
cutout and holes required for mounting heat exchanger unit.
2) Install heat exchanger unit into cutout. Ensure that the fans and WAGO terminal block
is positioned on the right side of unit when viewed from the back door of control cabinet.
NOTE: Some earlier CE machines equipped with Siemens Filter Module may need to
have the Filter Module lowered approximately 1.0” for proper clearance between heat
exchanger and filter handle. This has been revised on later production units.
3) Reinforcement material and tapping of holes as shown on Control Cabinet drawing

(802-2601-007), sheet 3, detail “V” will not be used as part of this retrofit. Simply
drill M6 holes and use standard hardware provided with the kit - M6 SHCS,
lockwashers, and hex nuts.
4) Install 1 Amp Fuse (409-1001-001) in Terminal Rail Mount Fuse Block. (406-4005-049).
5) Attach Terminal Rail Mount Fuse Block (406-4005-049) on DIN rail as illustrated on
Ass’y BMC4020HT Control Cabinet drawing (003-2007-001), sheet 3, detail “B”.
6) Using 1/C, 18 AWG, Black wire (406-2005-020) and Ferrules, 18 AWG Red (406-0965-
004) connect wire from 115VAC gray WAGO terminal block, located right side on DIN
rail, to Terminal Rail Mount Fuse Block. (406-4005-049).
7) Using 3/C, 18 AWG Blk/Wht/Grn cable (406-1247-011) and Ferrules, 18 AWG Red
(406-0965-004) connect cable from heat exchanger terminal block to WAGO terminal
blocks, located right side on DIN rail. Route cable up around the top right of control
cabinet and secure using Tie Wraps, Medium (406-5001-006) provided. Ensure 115VAC
is connected to gray terminal block, neutral is connected to blue terminal block, chassis
ground is connected to green/yellow terminal block on DIN rail.
Reference Interconnect Diagram, BMC4020HT (003-2022-004), sheet 17.
8) Re-apply machine power. Observe that the both fans are operating properly in the correct
direction with no faults.

R
757-4002-144 CAD# D8543
Subject: Spindle Fan Retrofit Procedure

for Siemens Machines.

RECORD OF CHANGES

Spindle Fan Retrofit, Siemens 757-4002-144 Page 2

I. INTENT
To provide a standardized method to retrofit and install the Spindle Fan Contactor and
Overload.
II. APPLICABILITY
As required on all machines equipped with Siemens Spindle Drive Units.
III. INDEX

Page 4 Contactor Installation
IV. KIT DEFINITION
Spindle Fan Control Retrofit Hardware and Cabling.
BMC 30 SERIES Kit PN# 003-1016-013

Motor Contactor 402-0003-010 1
Manual Motor Starter Protector 402-0001-049 1
Control Wire 22AWG
Power Wire 18AWG
BMC 4020 Kit PN# 003-1016-014

Motor Contactor 402-0003-010 1
Manual Motor Starter Protector 402-0001-050 1
Control Wire 22AWG
Power Wire 18AWG

V. INSTALLATION PROCEDURE
(Refer to Figure1)
1. Locate the circuit breaker for the Siemens Drive System. It is on the upper of the two DIN
rails on the lower right side of the electrical panel.
2. The fan power is connected to the Circuit Breaker on the load side.
3. Remove the fan power wires, replace the Ferules on the remaining spindle power wires if
necessary.
4. Install the contactor(402-0003-010) and overload, (402-0001-049 BMC 30’s, 402-0001-050
BMC 4020) on the left side of the lower DIN rail, make sure to keep them together. Some
of the existing components will have to be moved to the right side of the rail.
5. Connect three individual wires from the load side of the new contactor (402-0003-010) to
the line side of the overload.
6. Connect the Fan Power wires that were removed in step 2 to the load side of the overload
(402-0001-049 or 402-0001-050).
7. Connect three individual wires to line side of the Siemens Drive System circuit breaker to
the line side of the new contactor (402-0003-010).
8. Connect a wire from+24vdc on TB2 to the positive side of the coil on the new contactor
(402-0003-010).
9. Connect a wire from the negative side of the coil to TB1-3 on the CRP4 PCB ASS’Y.

Figure 1

757-4002-205 CAD #D8617

BMC6434

Himat Patel _________________ ________
Mihai Leahu _________________ ________
Scott Wrobleski _________________ ________ ____________________________ ________

.
SW
B 14957 1) BOM item 16, was 418-5002-013 (NPN) 3 4/27/00 DEO DEO
10000 RPM Spindle Option 757-4002-205 Rev. B Page 2

1.0 INTRODUCTION
This document is intended as a guideline to install a new transmission on existing BMC6434 series
machines, in order to increase the Spindle speed from 8,000 RPM to 10000 RPM.

2 103-5008-001 SHSS, M6 X 1.0 P X 6 LG. 18
1 108-5004-001 BHCS, M6 X 1.0 P X 10 LG. 17
1 404-9300-003 SWITCH, PROXIMITY, M5 PNP 16 B1
4 110-0046-007 LOCKWASHER, HELICAL M6 14
2 101-5008-003 SHCS, M6 X 1.0 P X 12 LG. 13
REF 101-5007-008 SHCS, M5 X 0.8 P X 25 LG. 11
REF 803-1012-003 RETAINER, PULLEY 10
1 204-0008-034 BELT, POLY-CHAIN GT 9
REF 101-5012-007 SHCS, M12 X 1.75 P X 50 LG. 4
REF 105-5051-003 HHCS, M14 X 2.0 P X 35 LG. 2
PARTS LIST B

INSTALL PROCEDURE.

of Pulley, see Fig. 2, item #8.
3.1.12. Drill and tap new (4) holes M12 X 1.75 P, 80 mm to the back of machine from existing (4)

Harness. (blue prox. wire – brown wire) (black prox. wire – violet wire) (brown prox wire –
blue wire).
3.1.19. Reinstall new Belt, see Fig. 2, item #9, dwg. no. 204-0008-034.

document.

003-6003-005 sheet 1 and on Fig. 3.


Span Length
BMC6434 (10K) 30.86 0.48
Deflection
BMC6434 (10K) 15-17 0.45~0.50

GRAPHIC 1.
SPINDLE 8,000 RPM
26
24
22
20
18
16
14
12
10
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000
Motor R.P.M.


GRAPHIC 2.
SPINDLE 10000 RPM
26
24
22
20
18
16
MotorPower
( x) 14
Torque( x )
12
10
0
4
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 1 10
x
Motor R.P.M.
BMC 6434/40T-10K Torque / Horsepower Chart (Option)

1 Min Torque Rating 168 Ft*Lbs

SPINDLE

SPINDLE GEAR

Gear 0
Ratio 0.8000
Minimum RPM 1
Maximum RPM 10000




757-4002-245 CAD #D8660

BMC6434-50TAPER

Himat Patel _________________ ________
Mihai Leahu _________________ ________
____________________________ ________

.
A 14800 Original Issue 2/10/00 ML HP
B 14957 1) BOM item 17, was 418-5002-013 (NPN) 3 4/27/00 DEO DEO

1.0 INTRODUCTION
This document is intended as a guideline to install a new transmission on existing BMC6434-50Taper

series machines, in order to increase the Spindle speed from 6,000 RPM to 8000 RPM
(actual speed is 7875 RPM).

2 103-5008-001 SHSS, M6 X 1.0 P X 6 LG. 22
1 108-5004-001 BHCS, M6 X 1.0 P X 10 LG. 21
2 103-5008-001 SHSS, M6 X 1.0 P X 6 LG. 19
1 108-5004-001 BHCS, M6 X 1.0 P X 10 LG. 18
1 404-9300-003 SWITCH, PROXIMITY, M5 PNP 17 B1
2 110-0046-007 LOCKWASHER, HELICAL SPRING M6 15
2 101-5008-003 SHCS, M6 X 1.0 P X 12 LG. 14
13
REF 110-0046-013 LOCKWASHER, HELICAL SPRING M20 11
REF 105-5014-004 HHCS, M20 X 2.5 P X 45 LG. 10
REF 101-5014-007 SHCS, M16 X 2.0 P X 50 LG. 7
3 101-5008-010 SHCS, M6 X 1.0 P X 35 LG. 5
REF 803-6005-034 RETAINER, MOTOR PULLEY 4
REF 204-0008-028 BELT POLY CHAIN 3
1 803-6005-067 PULLEY, SPINDLE MOTOR (50 TAPER, 8K OPTION) 2
PARTS LIST B

INSTALL PROCEDURE.

BMC6434-50Taper, series machines are designed to accept this option.
of Pulley, see Fig. 2, item #11,12.
3.1.12. Drill and tap new (4) holes M12 X 1.75 P, 30 mm to the front of machine from existing (4)

Harness. (blue prox. wire – brown wire) (black prox. wire – violet wire) (brown prox wire –
blue wire).
3.1.19. Reinstall existing Belt, see Fig. 2, item #9, dwg. no. 204-0008-028.

3.1.24. Verify installed EPROM version. Please refer to page 11, item #4.2., of this document.
document.

003-6003-0 sheet 1 and on Fig. 3.


Span Length
BMC6434 (10K) 26.52 0.414
Deflection
BMC6434 (10K) 15-17 0.45~0.50

GRAPHIC 1.
SPINDLE 6,000 RPM
42
39
36
33
30
27
24
21
18
15
12
0
0 400 800 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800 5200 5600 6000
Motor R.P.M.


GRAPHIC 2.
SPINDLE 8000 RPM
34
32
30
28
26
24
22
20
18
16
14
12
10
0
0 400 800 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800 5200 5600 6000 6400 6800 7200 7600 8000
Motor R.P.M.
BMC 6434-50T Torque / Horsepower Chart(Option 8K)


SPINDLE

SPINDLE GEAR

Gear 0
Ratio 0.7619
Minimum RPM 1
Maximum RPM 7875




757-4002-281 CAD #D8698

VMX64 40Taper.

Mihai Leahu _________________ ________
Sam Thomas _________________ ________ ____________________________ ________


.
SJT

1.0 INTRODUCTION
This document is intended as a guideline to install a new transmission on existing VMX64 40Taper
series machines, in order to increase the Spindle speed from 8,000 RPM to 10,000 RPM.
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
4 406-0804-022 CONNECTOR PINS, FEMALE 3
-016 PARTS LIST A

INSTALL PROCEDURE.

3.1.3. Lower Z-axis at your convenience for easier access to the Motor; see Fig. 2.
from the Motor Mounting Plate, see Fig. 2, items #3, 4, 5.
3.1.8. Remove (6) SHCS, M6 X 1.0 P X 25 LG. screws and (6) washers from the bottom
of Pulley, see Fig. 2, items #11, 12.
3.1.9. Remove Flange, Spindle Motor Pulley, see Fig. 2, item #9.
3.1.10. Remove Locking Elements, see Fig. 2, item #10.
3.1.12. In reverse order, install a new Pulley on Motor, dwg. no. 803-6005-107, Locking Elements
and the Flnge.
3.1.13. Secure the Pulley on Spindle shaft using (6) M6 screws and washers. Use blue locktite on M6
screws.
3.1.14. If necessary, drill and tap new (4) holes M12, 15 mm to the front of machine from existing (4)
holes M12.
Please refer to Fig. 3, item #3.2 on page 6 of this document, for removing Proximity Switch.
3.1.15. Disconnect existing Encoder Harness (423-4401-507) with proximity sensor from Spindle
drive in Electrical Cabinet (2CN) and motor encoder connection.
3.1.16. Open 2CN backshell at spindle drive and un-solder wire at 2CN-14. Trim exposed wire and
fold back behind heatshrink to prevent a short.
3.1.17. Identify two spare conductors in cable assembly. Terminate and solder SPARE1 to 2CN-14
and SPARE2 to 2CN-15.

3.1.18. Using connector pins, female (406-0804-022) crimp pin on SPARE1 wire and insert into
spindle encoder connector position 7 and SPARE2 into position 8.
3.1.19. Reinstall the Belt, see Fig. 2, item #8.
3.1.24. Setup motor encoder orient. Please refer to page 11, item #4.2., of this document.

3.2. PROXIMITY SWITCH REMOVAL.
3.2.1. There are (2) M6 screws and (2) lockwashers for Bracket Proximity Switch, see Fig. 3,
items #13, 14. Remove those those items.
3.2.2. Remove item #15, Bracket Proximity Switch. See Fig. 3.
3.2.3. Remove item #16, Proximity Switch. See Fig. 3.


Span Length
VMX64 (10K) 27.85 0.43
Deflection
VMX64 (10K) 14-16 0.40~0.46

GRAPHIC 1.
SPINDLE 8,000 RPM
15 min, 30% cycle
30
28
26
24
22
20
18
16
14
12
10
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000
Motor R.P.M.
VMX64/40T-8K Torque / Horsepower Chart

Horse Power
Torque

GRAPHIC 2.
SPINDLE 10000 RPM
15 min, 30% cycle
26
24
22
20
18
16
14
12
10
0
4
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000 8500 9000 9500 1 10
Motor R.P.M.
VMX64/40T-10K (Option) Torque / Horsepower Chart


Horse Power
Torque

SPINDLE

SPINDLE GEAR

Gear 0
Ratio 1.0000
Minimum RPM 1
Maximum RPM 10000

4.2.12 Carefully and slowly jog Z-axis down (negative) until the spindle nose is approximately 1.0” from top of ATC
load arm.
4.2.13 Press the “Spindle OFF” button on console. Rotate the spindle by hand until the spindle balance key is
aligned with the ATC gripper key slot. If you have removed the keys because of clearance issues, remember
that you have made a mark for drive key location so the unmarked notch in the spindle is the balance key side
of the spindle.
4.2.14 Record spindle motor position (counts) from spindle drive display U2-03 ________ (V2-03). Depress DSPL
repeatedly on keypad until U1-XX is displayed, with the Up–Down arrow keys change display to U2-XX,

now with the “>, Reset” key, scroll to the far right changing the display to U2-03 and depress Data key to
view the counts.
4.2.15 Depress “Load Arm 0°key” – F3. and press Start.
NOTE: 6434-40 Station & 50 Taper 32 Station ATC’s load arm must cycle thru the sequence of
down & 180° ° , up and back to 60°
° by depressing (F5 & start) before load arm can be
returned to 0 ° .
4.2.16 Spindle Drive converter and inverter now display “-b”.
NOTE: Digital Keypad Sequence Of Operation.

A. Depress DSPL key to scroll through Control Constant’s parameters (C1-XX, C2-XX & U1-XX
Etc.).
B. Depress the Data key to view stored values.
C. Depress the “>, Reset” key to scroll to the column requiring change (the column scrolled to will be
blinking).
D. Use the Up/ Down arrow keys to change the value in the column that is blinking.
E. Depress the Enter key if you change any values you want to save.
F. Bit count is from the right column (Bit 0 far right hand column) to the left.
4.2.17 Set Spindle Drive parameter C1-37 to = 01000011 (change Bit 0 & 1 to 1). Once you have the Bit count
changed, Press and hold the Enter key until END is displayed.
4.2.18 Set Spindle Drive parameter C2-22 to = 11000000 (change Bit 4 to 0). Once you have the Bit count
4.2.19 Set Spindle Drive parameter d1-01 to = 0001000000 (change Bit 6 to 1). Once you have the Bit count
4.2.20 The Spindle Drive converter and inverter will display “–r” Alarm AL “60” will be displayed on the Keypad
(Orient Tune-up Incomplete).
4.2.21 Depress both “Reset” and “Stop” (of the Spindle Drive control panel) at the same time.
4.2.22 The Spindle Drive will execute automatic tuning and orient, then display “-r” on both converter and inverter.
4.2.23 When autotune is complete, the Spindle Drive Keypad display will show the data of C2-01.
4.2.24 Enter the number recorded in step #9 using the arrow keys, depress and hold the Enter key until “END” is
displayed.
4.2.25 Reset Spindle Drive parameter d1-01 = 0000000000 (change Bit 6 to back to 0). Once you have the Bit
count changed, Press and hold the Enter key until END is displayed.
4.2.26 Reset Spindle Drive parameter C2-22 = 11010000 (change Bit 4 back to 1). Once you have the Bit count
4.2.27 Reset Spindle Drive parameter C1-37 = 01000000 (Change Bits 0 and 1 to 0). Once you have the Bit count
changed, Press and hold the Enter key until END is displayed. Spindle Drive will toggle an internal contactor
and display “-b” on both converter and inverter.
4.2.28 Orient is now set, and may be commanded by Ultimax 4 control.
4.2.29 If you have removed the spindle drive keys, re-install them at this time. Remember to put the keys back per the
marks you made when the keys were removed.

4.2.30 Orient can be fine tuned by changing the parameter value in C2-01. Value can only be changed by 5 counts at
a time, press Enter key to store the change in counts.

757-4002-285 CAD #D8702

VMX64-50TAPER

Himat Patel _________________ ________
Mihai Leahu _________________ ________
Dan Ornelas ____________________________ ________

.
A 15120 Original Issue 11/16/00 ML HP
B 15218 Added control parameters N95:214, 240, 242 11 2/21/01 DEO

1.0 INTRODUCTION
This document is intended as a guideline to install a new transmission on existing VMX64-50Taper

series machines, in order to increase the Spindle speed from 6,000 RPM to 8000 RPM
(actual speed is 7875 RPM).

REF 803-4008-043 BRACKET, ADJUSTMENT 23
REF 101-5011-008 SHCS, M10 X 1.5 P X 30 LG. 22
REF 117-5016-001 HEX NUT, M10 X 1.5 P 21
2 103-5008-001 SHSS, M6 X 1.0 P X 6 LG. 19
1 108-5004-001 BHCS, M6 X 1.0 P X 10 LG. 18
1 404-9300-003 SWITCH, PROXIMITY, M5 PNP 17
2 110-0046-007 LOCKWASHER, HELICAL SPRING M6 15
2 101-5008-003 SHCS, M6 X 1.0 P X 12 LG. 14
REF 105-5049-008 HHCS, M10 X 1.5 P X 65 LG. 13
REF 105-5014-004 HHCS, M20 X 2.5 P X 45 LG. 10
REF 101-5014-007 SHCS, M16 X 2.0 P X 50 LG. 7
REF 101-5008-012 SHCS, M6 X 1.0 P X 45 LG. 5
REF 803-6005-034 RETAINER, MOTOR PULLEY 4
REF 803-6006-096 BELT TRANSMISSION SPINDLE 3
1 803-6005-067 PULLEY, SPINDLE MOTOR (50 TAPER, 8K OPTION) 2
PARTS LIST

INSTALL PROCEDURE.

VMX64-50Taper, series machines are designed to accept this option.
of Pulley, see Fig. 2, item #11,12.
3.1.12. Drill and tap new (4) holes M12 X 1.75 P, 30 mm to the front of machine from existing (4)
holes M12, if those holes are not there. See dwg. no. 003-6003-019 sheet 2.

3.1.18. Reinstall existing Belt, see Fig. 2, item #9, dwg. no. 803-6006-096.

document.

003-6003-012 sheet 1 and Fig. 3.

between item #3 and slot on item #4. This distance should be ~0.5 mm.

Span Length
VMX64 50Taper (8K) 26.52 0.414
Deflection
VMX64 50Taper (8K) 15-17 0.45~0.50

GRAPHIC 1.
SPINDLE 6,000 RPM
42
39
36
33
30
27
24
21
18
15
12
0
0 400 800 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800 5200 5600 6000
Motor R.P.M.
VMX64/50T-6K Torque / Horsepower Chart


GRAPHIC 2.
SPINDLE 8000 RPM
34
32
30
28
26
24
22
20
18
16
14
12
10
0
0 400 800 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800 5200 5600 6000 6400 6800 7200 7600 8000
Motor R.P.M.
VMX64-50T Torque / Horsepower Chart(Option 8K)



SPINDLE
SPINDLE GEAR
Gear 0
Ratio 0.7619
Minimum RPM 1
Maximum RPM 7875
B1
INTEGER
4.2 External Proximity Sensor Orient

4.2.12 Carefully and slowly jog Z-axis down (negative) until the spindle nose is approximately 1.0” from top
of ATC load arm.
4.2.13 Press the “Spindle OFF” button on console. Rotate the spindle by hand until the spindle balance key
is aligned with the ATC gripper key slot. If you have removed the keys because of clearance issues,
remember that you have made a mark for drive key location so the unmarked notch in the spindle is
the balance key side of the spindle.
Depress DSPL repeatedly on keypad until U1-XX is displayed, with the Up–Down arrow keys

change display to U2-XX, now with the “>, Reset” key, scroll to the far right changing the display to
U2-03 and depress Data key to view the counts.
4.2.18 Reset C2-24 bit 0 = 0.

Probe Options
D8297 757-4002-019 Part Probe Installation, Renishaw MP8 / M17

D8098 757-4002-020 Tool Probe Installation, Renishaw TS – 20
D8501 757-4002-112 Test Procedure, Precicsion Scan
D8503 757-4002-114 Installation Procedure, Precision Scan
D8610 757-4002-199 Installation Procedure, Renishaw Probe Systems, Siemens or Yaskawa
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
D0000
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D0000
D0000
757-4002-019 REV: C ECN #13098

R
04/26/93 CAD #D8097
SUBJECT: PART PROBE INSTALLATION, RENISHAW MP8/MI7

B 12559 Revised procedure to support sealtite conduit as a bulk 3/23/93
issue item.
C 13098 Inserted section K: Aligning the Stylus 4/26/93
I. INTENT. This document provides instruction on installation of either of these two

assemblies. Refer to their drawing(s) during the installation.
A. 002-3502-001 ASSY, PART PROBE, REN. MP8, CATV40
B. 002-3502-002 ASSY, PART PROBE, REN. MP8, CATV50
II. APPLICABILITY. Instructions apply to Renishaw MP8/MI7 Part Probe options to be

installed on Hurco machines that have a CRP3.
III. EQUIPMENT. The following tools are required to complete the installation:
A. 0.140 diameter drill.
B. 0.170 diameter drill.
C. Drill for M5 thru hole.
D. Drill for M4 thru hole.
E. 0.560 diameter punch or drill.
F. Metric hex wrenches.
G. Crimping tool for 24 AWG Wago ferrule #409-0965-014.
IV. PROCEDURE.
A. Familiarization of Terms. Before installing the part probe system for the first
time, become familiar with Renishaw’s terms. This will make the installation go much
faster. Relate the following terms to the illustrations on the print:
Term Illustrated Item (from print)
1. OMM (Optical Machine Module) 13
2. MP8 Part Probe 1&2
3. 50mm Ceramic Stylus 11
4. 100mm Ceramic Stylus 12
5. OMM Mounting Bracket 16
6. MI7 (m-i-7) Interface PCB 22
7. Sealtite Conduit Fitting 25
8. Sealtite Conduit 24
______________________ _______ ______________________ _______ ______________________ _______

757-4002-019 REV C
Note: Ilustrations on the print are designated with the letter P. For example, Figure
P1 is "print figure 1". Likewise, figures within this document are designated with the
letter D, i.e. Figure D1.
B. Mount MI7 Interface.

1. Drill four holes as shown in Figure P2a of print 002-3502-001/2. Note the
hole pattern per Figure P2c.
2. Mount the MI7 PCB (405-6001-001, item 22) per Figure P2a. Use four (4)
nylon PCB standoffs (110-0130-001, item 32), eight 4-40 X 1/4" BHCS (108-
0001-001, item 33), and four 4-40 nylon washers (110-0085-001, item 31).
C. Connect Harness, MI7 to CRP3.
1. Find MI7 TO CRP3 harness (423-6833-001, item 30).
2. Plug the 10 position Wago connector into the Control Relay Panel 3 as
indicated by the harness label.
3. Connect its nine (9) ferrules to the MI7 terminal strip per Figure P1b.
D. Mount OMM Bracket.
1. Jog the Z-axis to full negative travel (down). Per figure P2b, mark on the
inside of the chip enclosure a drill center that has a direct line of sight to the
spindle chuck. This is so that the MP8's infrared transmission will not be
obstructed. The actual location will vary with machine type.
2. Using bracket #418-0200-002 as a template, place the bracket's center
mounting hole over the chip enclosure's marked drill center. While ensuring that
the mounting bracket's mounting holes form a vertical line, mark the other two
drill centers through the bracket.
3. Drill three M5 thru holes as marked.
4. Mount bracket to inside of chip enclosure using three M5x10mm BHCS
(108-5003-003, item 29), three M5 external tooth washers (110-0066-009, item
20), and M5 hex nut (117-5012-001, item 21). Screw heads must face toward
the inside of the chip enclosure.
E. Make a Hole for OMM Conduit Fitting. Using a 0.560 diameter punch or drill,
make a hole as indicated in Figure P2a.
F. Fit the OMM conduit. Find the components that make up the conduit
assembly: items 24 and 25. You will probably not need all the conduit length called
out by the print. So, bring the entire bulk spool of sealtite to the machine in order to
customize the length. Extend the Sealtite from the OMM conduit hole to the top of the
OMM bracket. Leave enough slack such that the bend radius near the top of the CNC
power cabinet is no less than 2 inches. Saw off the excess conduit if necessary.
G. Assemble the OMM conduit and cable. Refer to the illustration in Figure P1c.
Assemble pieces in the following order:
Item Part Number Qty
13 418-0200-001 1
25 408-8002-038 1
24 408-0160-007 1
25 408-8002-038 1
2
757-4002-019 REV C
H. Mount OMM.
1. Using two M5x16mm mounting screws (101-5007-022, item 14) and two
M5 hex nuts (117-5012-001, item 15), mount the OMM (418-0200-001, item 13)
to the OMM bracket (418-0200-002, item 16). Make sure the OMM's conduit
fitting faces upward.
2. Temporarily unscrew the locking ring (408-8002-039, item 26) from the
OMM assembly. Route the OMM conduit and cable through the hole mentioned
in step E.
3. Replace the locking ring (408-8002-039, item 26) and tighten from within
the CNC power cabinet.
4. Adjust the OMM bracket such that the OMM faces toward the spindle.
J. Connect OMM Cable to MI7.
1. From within the CNC power cabinet, route the OMM cable (part of 418-
0200-001, item 13) to the MI7 interface PCB (405-6001-001, item 22) as if to
dress it along the inside surface of the cabinet.
2. Cut off excess cable length so as to allow connection to MI7 interface
terminals 1 thru 4.
3. Strip jacket 1.5 inches from the end.
4. Shrink wrap with 1/4 inch diameter heat shrink, 1 inch length (406-6481-
004, item 35).
5. Strip 1/4 inch of insulation from 5 conductors.
6. Using four 24 AWG ferrules (409-0965-014, item 29), terminate five
conductors plus a drain wire. Follow Figure P1c.
7. Connect the four ferrules to MI7 screw terminals as shown in Figure
P1a/P1c.
K. Align the Stylus. Align the stylus per the MP8 operator’s manual pages 19
and 20.
L. Install MP8 Battery.
1. Remove the battery cover of the MP8 probe (707-3001-001 or -002, item
1 or 2).
2. Install the 9 volt battery (413-8001-014, item 9) and replace battery cover.
M. Attach Retention Knob to MP8. Choose the retention knob that fits the
machine. Thread into the MP8 (707-3001-001 or 002, item 1 or 2). Note!! Before
shipment, remove retention knob. The customer will supply his own.
N. Electrically Test the Part Probe System.
1. Set a Volt meter to test 24 Volts DC.
2. Connect (+) test lead to CRP3/TB2-9.
3. Connect (-) test lead to CRP3/TB2-10.
4. Place Volt meter such that it can be seen from the console.
5. Power up the machine.
6. Make sure the Volt meter reads less than 0.5 Volts.
7. Jog the Z-axis to full positive travel (up).
8. Clamp the MP8 Probe (707-3001-001 or -002, item 1 or 2) with retention
knob into the spindle.
9. Thread the 50mm ceramic stylus (418-0100-001, item 11) into the MP8
probe head (707-3001-001 or -002, item 1 or 2). Save the plastic shipping tube
for the stylus.
3
757-4002-019 REV C
10. Gently deflect the stylus with a finger. The MI7 interface will beep
momentarily. Make sure the Volt meter reads greater than 20 Volts. Release
the stylus and watch the voltage return to less than 0.5 Volts.
11. If there is a problem, return to steps IV C and IV J to double check
connections and repeat electrical tests.
12. Dress OMM cable and MI7 to CRP3 harness to the inside of the CNC
power cabinet.
P. Clamp the Conduit.
1. Find nylon cable clamps (408-7501-044, item 27). Distribute clamps
along Sealtite conduit from the OMM to the top edge of the chip enclosure. See
Figure P2b for detail. Space clamps every eight (8) inches. You might not use
all four (4) clamps called out by the print.
2. Mark holes for each clamp. Drill thru holes for M4.
3. Fasten clamps with M4x10mm BHCS (108-5002-002, item 28), M4
external tooth washer (110-0066-006, item 37), and M4 hex nut (117-5011-001,
item 36). Screw heads must face toward the inside of the chip enclosure.
Q. Prepare Part Probe for Shipment.
1. Unscrew the 50mm ceramic stylus (418-0100-001, item 11) from the MP8
probe head (707-3001-001 or -002, item 1 or 2). Return the ceramic stylus to its
plastic shipping tube. Place the stylus in the MP8 shipping container.
2. Find the 100mm stylus (418-0100-002, item 12) and place in the MP8
shipping container.
3. Find the TK1 tool kit (item 8) and place in the MP8 shipping container.
4. Make sure the MP8 system guide (item 10) is in the MP8 shipping
container.
5. Remove the battery from the MP8 and place in the MP8 probe container.
Replace the MP8 battery cover.
6. Remove the retention knob from the MP8 probe and keep.
7. Return the MP8 probe to its molded styrofoam shipping container.
8. Secure the lid of the MP8 styrofoam box with tape. Secure the MP8 box
to the skid before shipment.
9. Cover the OMM (418-0200-001, item 13) and its conduit with sheets of
packing foam. Secure with shipping tape.
4
R
757-4002-020 REV: B ECN #12559

03/23/93 CAD #D8098
SUBJECT: TOOL PROBE INSTALLATION, RENISHAW TS-20
Rev. ECN Rev. Description Date

No.
B 12559 Revised procedure for TS-20 without MI8 3/23/93
interface.
I. INTENT. This document provides instruction on installation of Hurco

002-3502-003 (ASSY, TOOL PROBE, RENISHAW TS-20). Refer to its drawing
during the installation.
II. APPLICABILITY. Instructions apply to the Renishaw TS-20 Tool Probe

option to be installed on Hurco machines that have a CRP3.
III. EQUIPMENT. The following tools are required:

A. 0.170 diameter drill.
B. 0.560 diameter punch or drill.
C. Metric and English hex wrenches.
D. Crimping tool for 24 AWG Wago ferrule #409-0965-014.
IV. PROCEDURE.
A. Familiarization of Terms. Before installing the Renishaw tool
probe system for the first time, become familiar with Renishaws terms.
This will make the installation go much faster. Relate the following
terms to the illustrations on the print:
Term Illustrated Item (from print)
1. TS-20 Tool Set Probe 1
2. TS-20 Mounting Block 2
3. Sealtite Conduit Fitting 9
4. Sealtite Conduit 8
Note: Ilustrations on the print are designated with the letter P. For
example, Figure P1 is "print figure 1". Likewise, figures within this
document are designated with the letter D, i.e. Figure D1.
____________________________ ______ ___________________________ ______

B. Mount MI8 Interface PCB.
(Not applicable per revision B.)
C. Mount TS-20 Probe.
1. Find TS-20 Tool Set Probe (707-3001-014, item 1) and TS-
20 Mounting Block (707-3001-015, item 2).
2. Refer to Figure P1c of drawing 002-3502-003/4. Thread TS-
20 probe cable through the mounting block. Fasten the TS-20
probe with four M3x6mm SHCS (item 4).
D. Adjust Length of Sealtite Conduit.
1. Find the components of the Sealtite Conduit (items 8 and 9).
2. Find gasket seat (item 24) and slide over TS-20 cable per
Figure P1b/P1c.
3. Per Figure P1b, strip 2" of jacket from TS-20 probe cable.
From one of the conductors, cut off 1" of length. Strip 1/4" from
both wires. Terminate with two butt connectors (406-7001-072,
item 18).
4. Per item 17 on the bill of material, cut the appropriate length
of 2 conductor cable (406-1245-007). Strip 2" of jacket from the
end. Cut off shield and drain wire. Cut off 1" of length from one
conductor. Strip 1/4" from both wires. Insert wires into butt
connectors per Figure P1b and crimp.
5. Thread the newly lengthened TS-20 cable through the
Sealtite conduit. Screw the gasket seat (item 24) into the end of
the Sealtite.
6. Slide the gasket ring (item 25) over the Sealtite toward the
TS-20 Mounting Block. Fasten the Sealtite assembly to the TS-20
mounting block with the fitting collet (item 26).
E. Fasten TS-20 Mounting Block to Table.
1. Using 1/2-13x1.5" SHCS (110-0009-007, item 21) and T-slot
nut (117-0202-001, item 22), fasten the lower half of the TS-20
Mounting Block to the right rear corner of the machining table.
2. Fasten the upper and lower halves of the TS-20 Mounting
Block together by tightening three set screws (item 3). Make sure
the conduit fitting points to the right-hand side.
F. Make a Hole for TS-20 Conduit Fitting. Using a 0.560 diameter
punch or drill, make a hole as indicated in Figure P1e.
G. Connect TS-20 Cable.
1. Per Figure P1a, terminate the free end of the Sealtite
conduit and cable assembly with a conduit fitting and locknut (408-
8002-038, item 9).
2. Temporarily remove the locknut (408-8002-039, item 10).
Route the TS-20 cable and conduit through the hole mentioned in
step F.
3. Replace the locknut (408-8002-039, item 10) and tighten
from within the CNC power cabinet.
4. From within the CNC power cabinet, route the TS-20 cable
to CRP3/TB3, as if to dress it along the inside surface of the
cabinet.
5. Leave enough cable length to allow connection to
CRP3/TB3. Cut off excess cable length.
6. Strip jacket 1.5 inches from the end.
7. Shrink wrap with 1/4 inch diameter heat shrink, 1 inch length
(406-6481-004, item 19).
8. Strip 1/4 inch from 2 conductors.
9. Using three (3) 24 AWG ferrules (409-0965-014, item 16),
terminate two (2) conductors plus a drain wire. Follow Figure P1a.
10. Attach 6-position female Wago plug (item 20) per the
drawing.
H. Connect Harness, MI8 to CRP3.
(Not applicable per revision B.)
J. Electrically Test the Tool Probe System.
1. Set a Volt meter for testing 24 Volts DC.
2. Connect (+) test lead to CRP3/TB3-4.
3. Connect (-) test lead to CRP3/TB3-5.
4. Place Volt meter such that it can be seen from the console.
6. Make sure the Volt meter reads below 0.5 Volts.
7. Gently deflect the TS-20 stylus with a finger. Make sure the
Volt meter reads greater than 20 Volts. Release the stylus and
watch the voltage return to less than 0.5 Volts.
8. If there is a problem, return to step IV G and IV H to double
check connections and repeat electrical test.
K. Prepare Tool Probe for Shipment.
1. Detach the TS-20 tool probe and mounting block from the
table.
2. Place all of the following items in cardboard box (614-0002-
102, item 29).
a. One SHCS 1/2-13x1.5" (110-0009-007, item 21)
b. One T-slot nut (117-0202-001, item 22)
c. Six nylon clamps (408-7501-044, item 11)
d. Six BHCS M4x16mm (108-5002-002, item 12)
e. Six M4 hex nuts (117-5011-001, item 28)
f. Six M4 external tooth washer (110-006-006, item 27)
g. One drill bit, 3/6" (707-2001-003, item 30)
3. Cover the TS-20 with a sheet of packaging foam and wrap
with shipping tape.
4. Coil the TS-20 conduit and TS-20 probe and put in the
cardboard box. Leave enough slack in the conduit so that the box
may be placed in an unoccupied area in the chip enclosure.
5. Place this Tool Probe Installation Procedure in the
cardboard box.
6. Wrap the box with shipping tape and secure within the chip
enclosure.
7. Protect the Sealtite conduit with a sheet of packaging foam
and shipping tape.
FIELD INSTALLATION. The next group of instructions apply only to
Field Installations at the customer's site.
L. Mount TS-20 per the customer's request.
1. Left mount or right mount? At the customer's facility,
determine whether the customer and/or operator wants the tool
probe mounted on the right-hand side of the table, or the left hand
side. Choose either the Right-Hand Mounting Procedure or Left-
Hand Mounting Procedure.
2. Right-hand mounting procedure.

a. Fasten TS-20 Mounting Block to Table.
i. Using 1/2-13x1.5" SHCS (110-0009-007) and
T-slot nut (117-0202-001), fasten the lower half of
the TS-20 Mounting Block to the right rear corner of
the machining table. See Figure D1.
ii. Fasten the upper and lower halves of the TS-
20 Mounting Block together by tightening three set
screws. Make sure the conduit fitting points to the
right-hand side.
b. Route Conduit.
i. Jog the table to full +X and full +Y.
ii. Fasten the conduit to the chip enclosure using
nylon clamps, leaving just enough slack between the
machining table and chip enclosure, so as not to
stress the lowest nylon clamp. Push any excess
conduit length above the chip enclosure. See Figure
D1.
Figure D1. TS-20 Right-Hand Mounting
iii. Distribute clamps along Sealtite conduit from

the lowest clamp to the top edge of the chip
enclosure. Space four (4) clamps evenly. Mark holes
for each clamp.
iv. Drill thru holes for M4.
v. Fasten clamps with M4x10mm BHCS (108-
5002-002), M4 external tooth washer (110-0066-006),
and M4 hex nut (117-5011-001). Screw heads must
face toward the inside of the chip enclosure.
vi. Jog each axis to its maximum and minimum
travel and ensure that the TS-20 conduit does not
bind.
3. Left-hand mounting procedure.

a. Fasten TS-20 Mounting Block to Table.
i. Using 1/2-13x1.5" SHCS (110-0009-007) and
T-slot nut (117-0202-001), fasten the lower half of
the TS-20 Mounting Block to the left rear corner of
the machining table. See Figure D2.
ii. Fasten the upper and lower halves of the TS-
20 Mounting Block together by tightening three set
screws. Make sure the conduit fitting points to the
left-hand side.
b. Route Conduit.
i. Jog the table to full -X and full +Y.
ii. Fasten the conduit to the chip enclosure using
nylon clamps, leaving just enough slack between the
machining table and chip enclosure, so as not to
stress the lowest nylon clamp. Push any excess
length above the chip enclosure. See Figure D2.
iii. Distribute clamps along Sealtite conduit from
the lowest clamp to the top edge of the chip
enclosure. Space four (4) clamps evenly. Mark holes
for each clamp.
iv. Drill thru holes for M4.
v. Fasten clamps with M4x10mm BHCS (108-
5002-002), M4 external tooth washer (110-0066-006),
and M4 hex nut (117-5011-001). Screw heads must
face toward the inside of the chip enclosure.
vi. Jog each axis to its maximum and minimum
travel and ensure that the TS-20 conduit does not
bind.
Figure D2. TS-20 Left-Hand Mounting
757-4002-112 REV: B ECN # 13956

R
5/12/97 CAD # D8501B
SUBJECT: PRECISION SCAN TEST PROCEDURE
Wesley Shelton Mike Caron

REVISIONS:
Revision ECN # Revision Descrption Rev By Date Appd Date

By
A 13956 Release 1/17/97
B 14015 Revised format of this page. Also corrected the WRS 5/12/97
probe deflections in step 24 - 2 to match the
changes made on harness423-4401-140.
I. INTENT:
To provide a standardized test procedure for the Precision Scan option utilizing the test
fixture.
II. SCOPE:
Applies to the Precision Scan option.
III. PROCEDURE:
1. Set shunts on the interface board as follows.
E1 REG
E2, E4, E6, E8, E10, E12, E14, E16 CONNECT
E3, E5, E7, E9, E11, E13, E15, E17 NO CONNECT
2. Ensure that the delay cap. and diode are wired properly. The negative lead of the cap should be
connected to TB-1 pin 8 and the positive lead should be connected to TB-1 pin 7. The diode’s
cathode should be connected to TB-1 pin 7 and the anode should be connected to TB-1 pin 5.
3. Using an ohm meter check the DC wiring as follows:
FROM TO
+24V DC Wago Connector - 5 TB4-6
TB4-6 SC7-6
TB4-6 TB5-1
TB4-6 SC8-6
+5V DC Power Supply 2 & 3 TB4-3
Power Supply 2 SC9A-4
+15V DC Power Supply 1 TB4-1
Power Supply 1 SC9B-5
Power Supply 1 Pendent Connector - 9
-15V DC Power Supply 6 TB4-2
Power Supply 6 SC9B-7
+12V DC TB5-4 Probe Connector - 14
*Note: Use the diagram at the end of this document for the pin
out of the transputer.
4. Check that all other wiring is complete and the terminal block screws are tight.
5. Mount the P-Scan transputer enclosure to the side of the test fixture. Be sure to secure it with
the washers and nuts provided. Plug in the AC cord.
6. Ensure that the AC power cord is disconnected from the power supply. Turn power on and
check the voltage at the power supply connector.
7. Turn the power off and connect the AC power to the power supply.
8. Turn power back on. Using the test load check the DC voltages coming out of the power supply.
PIN VOLTAGE
1 +15V DC
2 +5V DC
3 +5V DC
4 GND
5 GND
6 -15V DC
1 AC
6 3 IN
DC Power
OUT Supply
1
9. Install the probe into the probe bracket with the power LED facing towards you and tighten bolt
to secure it.
10. Connect the probe harness to the probe and transputer. Also connect the pendent harness to
the transputer enclosure.
11. Install the RISC processor board into the PC on side of fixture.
12. Install the fiber optic cable to the PC and to the transputer.
13. Connect the encoder interface harnesses to the card rack and encoder harnesses.
14. Connect CN4 from the transputer box to fixture connector.
15. Power on the fixture and ensure the transputer is turned on.
16. Press “D” and “Enter” . This will start the P-Scan Software. If the software does not boot try
swapping the leads at one end of the fiber optic cable.
17. Once the control and the P-Scan software have booted up, verify that the key switch on the
pendant box is in the CNC MODE. Then power on the servos and calibrate the axises. This ensures
that the interface bd. works in the CNC mode. Also the red lamp on the fixture should be on at this
point. This lamp represents the spindle emergency signal being operable.
18. Now turn the key switch on the pendant box to the SCAN MODE. This will activate the
interface bd. and cause the encoder signal to be transferred to the transputer. The hardware E-Stop
will also be activated to ensure smooth transfer of control from the CNC to the P-Scan. Also the
Spindle Emg. Signal will be disconnected which is indicated when the red lamp on the fixture turns
off.
19. Find and press the P-Scan initialization icon. Identified with the Autocon emblem and the
words Precision Scan. (1,1,0) This Icon clears any faults or conditions that would not allow the
servos to power on.
*Note: (1,1,0) Stands for Level 1, Row 1, Icon 10 or F10
**Note: If the wrong icon is chosen just press the “ESC” key to return to level 1 icons.
20. Now press the Cycle Start button on the pendent box.
21. Next turn the power to the servos back on using the CNC control. The P-Scan now has
control of the axises.
22. Jog the axises using manual mode.

1. Press the icon which is identified by two blue squares each with an arrow in it pointing in
the opposite directions. (1,4,1)
2. Next press the axis you wish to check.

1. X axis (2,1,1)
2. Y axis (2,1,2)
3. Z axis (2,1,3)
3. Now choose the icon which has a solid arrow in it. (2,1,7) This is for continuous
movement.
4. Now using the + and - keys on the pendant box you should be able to jog the chosen axis.
The following chart shows the proper motor rotation for each axis.
X Axis Y Axis Z Axis

Positive Jog Button CW CCW CW
Negative Jog Button CCW CW CCW
5. To choose another axis just select it and jog. There is no need to repeat step 3.
23. Exit the manual jog mode by pressing the ESC key.
24. Jog the axises using stick mode.

1. Press the Icon identified by a picture of a probe and a hand pushing on the stylus of the
probe. (1,4,3)
2. Now the axis can be moved by deflection the probe stylus. The following chart describes
the direction both the probe and axes displays should be counting for each deflection.
Positive Negative
X Deflection Right Left
Y Deflection Backward Forward
Z Deflection Up Down
3. Check the rotation of the motors with the following chart.
X Axis Y Axis Z Axis

Positive Probe Deflection CCW CCW CW
Negative Probe Deflection CW CW CCW
25. Test the probe over travel signal by pressing the stylus in the positive direction firmly and the
servo power should drop out. Also the over travel icon should appear in the upper right hand
corner of the screen. This Icon identified by a probe, a triangle with an exclamation point, and an a
black/yellow stripped arrow. This signal is a switch inside the probe which is connected in the
hardware E- Stop string.
26. Ensure that the servos can be turned on again by clearing the fault, pressing the cycle start
button, and pressing the power on button as in steps 19, 20 and 21 above.
27. Switch the pendant box back to CNC MODE and exit the software. To exit the software find
the icon which is depicted by a brick wall, a yellow door, and a green arrow which points out the
door. (1,4,0) This Icon must be pressed twice to exit.
28. Now power off the transputer and the fixture.
29. Disconnect the harnesses, close the P-Scan box and repack the probe.
TRANSPUTER PIN OUT

757-4002-114 CAD # D8503

R
SUBJECT: PRECISION SCAN INSTALLATION PROCEDURE
Steve Potosnak 2/2/97 Mike Caron 5/9/97

Revisions:
757-4002-114
REV B

By
A 13956 Release SEP 2/2/97
B 14015 Added Schematic Diagrams WRS 5/12/97
Page 2
757-4002-114
REV B
I. INTENT:
This document is intended to describe the steps necessary to install a Precision Scan option kit.
II. SCOPE:
This document applies to the Precision Scan Three-Axis Digitizer Assembly, Hurco Part Number
007-0001-002.
III. TOOLS NEEDED:

1. Greenlee Punch Set
2. No. 9 Drill bit and M6 Tap
3. N0. 30 Drill bit and M4 Tap
4. 1/4” Drill bit and M8 Tap
IV. PROCEDURE:
1. Unpack all components.

2. Select a suitable location for the enclosure. For A Frame Bed Mills, the recommended location is
on the side of the Control Cabinet nearest to the Card Rack. For Knee Mills, the top or side of
the Control Cabinet is recommended. (Refer to Figure 1.)
3. Locate the proper location for the Harness Assy. to enter the cabinet. Be sure there are no
obstructions on either side of the Cabinet wall. Mask off the interior of the Control Cabinet to
prevent any chips from fouling the electrical equipment.
4. Make the cutout for the Harness Assy. Use either the Adapter Plate furnished with the kit or the
full-scale template provided in Figure 2 below. Drill and tap (6) M4 holes for the Harness Plate.
Using the Scanner Enclosure for a guide, mark the four holes for mounting the enclosure. Drill
and tap for M6. (NOTE: Corlok may be cut and shortened as necessary.)
5. Mount the enclosure using the shoulder screws provided. Also mount the Scanner to ISA harness
to the cabinet.
6. Find an appropriate location near the IEC module for entry of the AC cord into the mill cabinet .
Punch a hole for the sealing grip provided in the install kit.
7. Using the schematics on pages 7 - 10 wire in the AC line and the Scanner I/O harness.
8. Disconnect the Servo Amplifiers from the Card Rack at the Honda Breakout board. Connect the
Honda connectors from the Scanner to the Breakout board and to the Servo harnesses.
9. Connect the Pendant to the Scanner.
10. A Spindle Bracket is required on some machines if the spindle is free to rotate when powered off.
Install the Spindle Bracket as shown in Figure 3. Some machines will require a hole to be drilled
and tapped to M8 for mounting the bracket.
11. Assemble the Probe, Stylus, Tool Post and Probe harness. Install the Probe in the Spindle.
Connect the Probe to the Scanner.
12. Install the Transputer Interface board in the customer’s PC. Connect the Fiber Optic cable.
Page 3
757-4002-114
REV B
13. Install the software. Reboot the PC after the installation is complete. Power up the Scanner and
run the application. (NOTE: If the P-Scan software will not boot try swapping the fiber optic
leads at one end.)
14. Setup the configuration parameters from within the application. The encoder parameters will be
set according to machine type and setup. Use the Counts Per Revolution and Distance Per
Revolution parameters found in the Parameters Document 757-4002-048 for the correct encoder
pulses per rev and distance per rev parameters to load into the appropriate P-Scan parameters.
15. The Axises must be rebalanced now that the P-Scan is installed.
16. Once P-Scan is install the machine will only function properly if the P-Scan box is on and the
pendant box is attached.
Page 4
757-4002-114
REV B
19.75"
8.75" 3"
23"
7"
Left Side of Control Cabinet

7"
Figure 1
Page 5
757-4002-114
REV B
M4 THRU (6 PL)
0.250
1.500
2.125
CUT
3.750
OUT 2.125
0.250
2.000
Figure 2
Page 6
757-4002-114
REV B
Spindle
M8 x 16 SHCS
M4 x 10 Set Screw (2)
M5 x 12 BHCS (2)
Figure 3
Page 7
757-4002-114
REV B
Page 8
757-4002-114
REV B
Page 9
757-4002-114
REV B
Page 10
757-4002-114
REV B
Page 11
R
757-4002-199 CAD #D8610
SUBJECT:
INSTALLATION PROCEDURE, RENISHAW PROBE SYSTEMS.
(Applicable to either Yaskawa or Siemens spindled Machining Centers.)
M. J. Whittemore, Jr. 12/3/98

RECORD OF CHANGES

By
I. INTENT
To provide a procedure for the installation of the Renishaw MP8 Part Probe (with the
MI-12 Interface Unit) and the Renishaw TS27R Tool Setting Probe.
II. APPLICABILITY
Applies to Yaskawa (YSM) spindle-equipped MC’s (BMC2416, 30, 4020 & 6434) and
Siemens spindle-equipped MC’s (BMC30 series, BMC4020 series).
Installation Procedure – Renishaw probe systems. 757-4002-199 Rev. A Page 2

III. Installation Procedure for the Renishaw MP8 Part Probe w/MI 12 I’face
A. General (All Machining Centers):

1. With reference to the rear of the machine, face the left side of the Power Cabinet. At a
point 3” in from the right (outside), and 18” up from the bottom of the Power Cabinet,
punch or drill a 0.560” diameter hole to accept the Renishaw-furnished conduit fitting (for
entry of the Optical Machine Module Harness).
2. Power up the machine and jog the Z axis to full negative travel (down).
3. The OMM is equipped with a magnetic mount. Place the OMM on the inside of the
chip enclosure such that it has a direct line of sight to the spindle chuck. (This is to insure
that the MP8’s infrared transmission will not be obstructed.) The actual location will vary
with machine type.
Note: Renishaw furnishes the armored sheath used to protect the OMM shielded cable.
4. Extend this sheath from the OMM entrance hole in the side of the Power Cabinet to
the connector on the side of the OMM unit. (Leave enough slack such that the bend
radius near the top of the Power Cabinet is not less than 2 inches.) Saw off the excess
sheath.
5. If not already assembled, slide the OMM cable through the armored sheath.
6. Finish installing the OMM sheath/cable set by using Renishaw-furnished conduit
fittings at both ends of the sheath.
7. On the inside of the Power Cabinet, cut the OMM cable to a length of 36”. Strip
jacket 4” from the end, then strip ¼” of insulation from the 5 conductors. Keep the
drain/shield wire.
8. Insulate the drain wire with a 3 ¾” length of 1/16” shrink tubing (406-6481-001), and
shrink wrap the end of the jacket with a 1” length of ¼” shrink tubing (406-6481-004).
9. Using six 24 AWG ferrules (409-0965-014) terminate all conductors.
10. Locate the Renishaw MI 12 Interface Module. Remove the upper cover to expose the
wiring access terminal blocks.
11. Slide the prepared OMM cable through either the mid-left or mid-right cable clamp
and wire to the terminal block per schematic 007-3022-007 or –008. Use the pictorial
inside the MI 12 Module cover as a guide to connector location.
B. For MCs with Yaskawa (YSM) Spindle Systems (BMC 2416, 30, 4020 & 6434):
1. Locate the 423-4401-319 Harness Ass’y. Wire the Block 1, Block 2 and TB-1
branches into the corresponding machine terminal blocks on the Power Cabinet rear wall
per schematic 007-3022-007.
2. Route the harness through the wiring bays such that the free end emerges at the lower
left rear of the power cabinet.
3. Slip the free end (the MI 12 branch) of the harness through the extreme right cable
clamp of the MI 12 module and wire to the terminal block per schematic 007-3022-007.
Again, the pictorial inside the MI 12 cover is useful as a wiring guide.
4. This completes the wiring of the Part Probe system. Tighten the cable clamps on the
MI 12 module and replace the top cover.
5. There is sufficient space in the lower left corner of the Power Cabinet to mount the MI
12 module. Since the module is quite well-protected physically, the mounting method (if
any) is left to the discretion of the installer.
C. For Machining Centers with Siemens Spindle Systems (BMC 30 Series & 4020 Series):
1. If the machine is not already so equipped, install the 415-0601-002T Canbus DC I/O
card in the 3rd (last available) open slot in the controller card rack.
2. Locate the 423-4401-320 Harness Ass’y. Connect the DC I/O J1 & J2 connectors to
their corresponding mates on the DC I/O #2 card, then wire the TB-1 branch into the
machine terminal block on the Power Cabinet rear wall per the 007-3022-008 schematic.
3. Route the harness through the wiring bays such that the free end emerges at the lower
left rear of the power cabinet.
4. Slip the free end (the MI 12 branch) of the harness through the extreme right cable
clamp of the MI 12 module and wire to the terminal block per schematic 007-3022-007.
Again, the pictorial inside the MI 12 cover is useful as a wiring guide.
5. This completes the wiring of the Part Probe system. Tighten the cable clamps on the
MI 12 module and replace the top cover.
6. There is sufficient space in the lower left corner of the Power Cabinet to mount the MI
12 module. Since the module is quite well-protected physically, the mounting method (if
any) is left to the discretion of the installer.
Note: The remaining instructions for Part Probe installation apply to all machines.
D. Align the Stylus:

1. The procedure for the Stylus-On-Center Adjustment.of the MP8 Probe may be found
on page 1-14 of the operator’s manual.
E. Install MP8 Battery:

1. Remove the battery cover of the MP8 Probe. Install the 9v battery (413-8001-014).
F. Attach Retention Knob to MP8:

1. Choose the retention knob that fits the drawbar system being used. Thread into the
MP8.
G. Electrically Test the Part Probe System:

1. Set a voltmeter to test 24 volts DC.
2. For Yaskawa-spindled systems connect the (+) test lead to TB-1, pin 17 and the (-)
lead to TB-1, pin 3. For Siemens-spindled systems connect the (+) test lead to TB-1, pin
35 and the (-) lead to TB-1, pin 4 or 5.
3. Place voltmeter where it can be seen from the operator console. Power up the
machine.
4. Make sure the voltmeter reads less than 0.5 volts.
5. Jog the Z-axis to full positive travel (up).
6. Clamp the MP8 probe (with retention knob) into the spindle.
7. Thread a 50mm ceramic stylus into the MP8 probe head.
8. Gently deflect the stylus with a finger. The MI 12 interface module will beep briefly.
Make sure the voltmeter reads greater than 20 volts. Release the stylus and verify that the
voltage returns to less than 0.5 volts.
9. If there is a problem, double check connections by returning to steps A11, B1 and B3
for Yaskawa machines, and steps A11, C2 & C4 for Siemens machines.

H. Clamp the Sheath:
1. Find nylon cable clamps (408-7501-044). Distribute the clamps along the sheath from
the OMM to the top edge of the chip enclosure. Space the clamps approximately every 8
inches. (All four furnished clamps may not be used in every installation.)
2. Mark holes for each clamp. Drill thru holes for M4 screws.
3. Fasten clamps with M4X10mm BHCS (108-0100-001), M4 external tooth
lockwashers (110-0066-006), and M4 hex nut (117-5011-001). Screw heads must face
toward the inside of the chip enclosure.
This completes the installation and functional test of the Renishaw MP8/MI-12 Part Probe system.
IV. Installation Procedure for the Renishaw TS27R Tool Setting Probe.
A. General (All Machining Centers):

1. With reference to the rear of the machine, face the left side of the Power Cabinet. At a
point 3” in from the right side, and 21” up from the bottom of the Power Cabinet, punch
or drill a 0.560” diameter hole to accept the Renishaw-furnished conduit fitting.
2. Select a position for the probe on the machine table.
3. Detatch the probe base from the probe holder by removing the two capscrews, using a
3mm hex key.
4. After fitting a T bolt, tighten it to secure the probe base to the machine table.
5. Refit probe holder to base, orienting the conduit fitting to the right hand side of the
table. Now tighten and adjust the capscrews to obtain stylus vertical alignment.
Note: Renishaw furnishes the armored sheath used to protect the TS27R’s shielded cable.
6. Dress the conduit/cable ass’y. from the tool probe up the rear wall of the chip
enclosure, then to the entrance hole in the side of the Power Cabinet.
7. Leave enough slack in this ass’y. to prevent binding when each axis is jogged to its
maximum and minimum travel points. Leave additional slack such that the bend radius
near the top of the Power Cabinet is not less than 2 inches.
8. Saw off the excess sheath.
9. If not already assembled, slide the probe cable through the armored sheath.
Finish installing the probe sheath/cable set by using Renishaw-furnished conduit fittings at
both ends of the sheath.
B. For MCs with Yaskawa (YSM) Spindle Systems (BMC 2416, 30 4020 & 6434):
1. On the inside of the Power Cabinet, cut the probe cable to a length of 37”. Strip
jacket 15” from the end.
2. Cut one of the conductors to a length of 5” from the jacket end, then strip1/4” of
insulation from the 2 conductors. Remove the drain/shield wire.
3. Shrink wrap the jacket end with a 1” length of ¼” shrink tubing (406-6481-004).
4. Using two 24 AWG ferrules (409-0965-014) terminate both conductors.
5. After routing the cable throught the wiring bays, connect the 5” lead to Block1,
terminal 4 (Tool Probe Deflect) and the 15” lead to TB1, terminal 2 (+24V).

C. For Machining Centers with Siemens Spindle Systems (BMC 30 Series & 4020 Series):
1. On the inside of the Power Cabinet, cut the probe cable to a length of 30”. Strip
jacket 2” from the end.
2. Strip ¼” of insulation from the 2 conductors. Leave the shield/drain wire intact.
3. Insulate the drain wire with a 1 ¾” length of 1/16” shrink tubing (406-6481-001), then
shrink wrap the jacket end with a 1” length of ¼” shrink tubing (406-6481-004).
4. Using three 24 AWG ferrules (409-0965-014), terminate all conductors.
5. There is furnished a male, 3-pin Wago mini-connector (406-4005-324). It is located
on the “dongle” of the DC I/O2 J1 connector (harness # 423-4401-320). Disconnect it
from the female connector, and install the 3 aforementioned wires, making sure the shield
is installed in location #3.
6. Reconnect the male/female Wago connectors.
D. Electrically Test the TS27R Tool Setting Probe System:

1. Set a voltmeter for testing 24 Volts DC.
2. For Yaskawa-spindled systems, connect the (+) test lead to Block1 TB4 and the (-)
lead to Block1 TB33. For Siemens-spindled systems, connect the (+) test lead to J-TP pin
1 and the (-) lead to TB1 pin 4 or 5.
3. Place voltmeter such that it can be seen from the console.
5. Make sure the meter reads less than 0.5 volts.
6. Gently deflect the TS27R stylus with a finger. Make sure that the meter now reads
greater than 20 volts. Now release the stylus and verify that the voltage returns to less
than 0.5 volt.
7. If there is a problem, double check connections by returning to step B5 for Yaskawa
machines and steps C5 & C6 for Siemens machines. Repeat the electical test.
E. Clamp the Conduit:

1. Find the nylon cable clamps (408-7501-044). Distribute the clamps along the sheath
from where it meets the chip enclosure to the top edge of the enclosure, leaving just
enough slack between the machining table and chip enclosure so as to not stress the
lowest nylon clamp. Jog to full +X and full +Y to verify its placement.
2. Space the clamps approximately every 8 inches.
3. Mark holes for each clamp. Drill thru holes for M4 screws.
4. Fasten clamps with M4X10mm BHCS (108-0100-001), M4 external tooth
lockwashers (110-0066-006), and M4 hex nut (117-5011-001). Screw heads must face
toward the inside of the chip enclosure.
This completes the installation and functional test of the Renishaw TS27R Tool Setting Probe
system.

Rotary Tables
D8434 757-4001-129 Rotary Table Electrical Specifications

D8439 757-4002-063 Install Guide, 4th Axis ISA and Delta Platforms
D8492 757-4002-106 Installation Procedures and Parameter Settings for
Rotary Table, TB200 and TB250 With Sigma Motors
D8492B 757-4002-106 Installation Procedures, Revised
D8572 757-4002-165 Installation and Parameters of Rotary Table on Hawk 30 / Hawk 40
DP0016 757-4005-016 Installation Procedures and Parameters for Rotary / Tilt, Sigma Motors
D0000
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R
757-4001-129 REV:B ECN #13611
1/29/96 CAD #D8434
SUBJECT: ROTARY TABLE ELECTRICAL SPECIFICATIONS
I. INTENT:
Aid Marketing and Distributors during selection of Rotary Tables that are not supported
by Hurco Manufacturing, but that a customer has specifically requested to work on a
machine that has been purchased.
II. SCOPE:
Covers the general Rotary Table Electrical Specifications that must be adhered to in order for the
unsupported Rotary Table to function properly with a Hurco manufactured Machine Tool or
Kneemill. This document does not cover any UltiMax Control related issues such as
parameters or Servo System tuning nor does it cover any Machine built prior to
September 01, 1994.
(Rev. B)
III. PROCEDURE:
First and foremost, it is the Customer Distributors responsibility to contact the Rotary Table
Manufacturer with the specifications and components that must be included with the Table
Model selected. These Specifications are listed as follows:
1.) Motor Type

a.)For AC Tables....Yaskawa model USAGED-09A21 tapered shaft
b.)For DC Tables.... Baldor CONTACT HURCO ENGINEERING
2.) Clamping /Unclamping

a.) Pneumatic or Hydrualic*
b.) Solenoid 24vdc 100mA load.
c.) The following chart illustrates the relationship of the solenoid, sensors, and the
physical state of the table.
Solenoid Clamp sensor Unclamp sensor Table
Off On Off Clamped
On Off On Unclamped
3.) Reference/Home switch

a.) 24 VDC, PNP (sourcing), N.C., TTL compatible ,Inductive Proximity Switch
(rev B)
cont. on next page
______________________ _______ ______________________ _______ ______________________ _______

757-4001-129 REV B
IV. TESTING:
All testing of the non-standard Rotary Table shall be done by the Rotary Table manufacturer.
However, Hurco Manufacturing will, at an added cost, provide testing of any Rotary Table. (Contact the
Hurco Technical Sales Department for details).**
There are some basic tests that Hurco manufacturing expects the Rotary Table manufacturer will
perform as part of agreement to accept shipment. They are comprised of the following:
1.) PHYSICAL - MECHANICAL WELL BEING
a.) No physical defects before shipment.
b.) Table Mechanics have no defects.
2.) ELECTRICAL SYSTEMS
a.) Servo Motor positions correctly.
b.) Reference Switch operates correctly.
c.) Clamping sensors operate correctly and in the proper state.

(See previous chart).
d.) Solenoid operates correctly and with the proper voltage and load.
3.) PNEUMATIC OR HYDRAULIC SYSTEMS
a.) Pneumatic clamping systems only:
1.) Clamping takes place under 90lb of air supplied.
b.) Hydraulic clamping systems only:
1.) Clamping takes place under Table manufacturers Specified Hydraulic

pressure.
2.) No unusual fluid leakage.
V. ELECTRICAL WIRING
Cable hookup and the connectors needed are shown on the following diagrams. The cable and
connectors should be used with no substitutions unless written authorization is obtained from the Hurco
Manufacturing Engineering Department. Refer to Hurco Drawing no. 002-4122-039 page 5 for Ref.
switch
connections.(Rev. B)
**Hurco Manufacturing does not in any way, guarantee any non-supported Rotary Table Manufacturer’s
claims as to any specification written or implied by said manufacturer.
2
757-4001-129 REV B
V. ELECTRICAL WIRING:
YASKAWA A.C. MOTOR
RECP1-------MS3102R28-11P
RECP2-------MS3102R20-29P
PLG11--------97-3106E18-10S AMPHENOL ENVIRONMENTAL
PLG12--------97-3106E20-29S AMPHENOL ENVIRONMENTAL
CABLE--------8 CONDUCTOR UNSHIELDED 24 AWG--ALPHA OR BELDEN
-------4 CONDUCTOR SJO 14 AWG RWBG--ALPHA OR BELDEN
-------9 PR SHIELDED 24 AWG--ALPHA OR BELDEN
3
757-4001-129 REV B
V. ELECTRICAL WIRING: (cont.)
BALDOR D.C. MOTOR
RECP1--------MS3102R28-11P
RECP2--------MS3102R20-29P
PLG11---------97-3106E24-7S AMPHENOL ENVIRONMENTAL
CABLE--------8 CONDUCTOR UNSHIELDED 24 AWG--ALPHA OR BELDEN
-------4 CONDUCTOR SJO 14 AWG RWBG--ALPHA OR BELDEN
-------9 PR SHIELDED 24 AWG--ALPHA OR BELDEN
4
757-4002-063 REV: B ECN #

04/11/95 CAD #D8439b
SUBJECT: 4th Axis Installation Guide for MAX/ISA and DELTA Control
Machines

A 13394 Original release 08/01/95
B Update Matrix 4 Axis Tune Parameters 10/31/95
I. INTENT
To provide a standardized procedure for proper installation, and set-up of Rotary Tables.
II. APPLICABILITY
This Document is specifically designed for use to facilitate the Installation and Setup of 4th Axis Rotary
Tables that are supported by Hurco Manufacturing. This consists of the Technara and Hurco Rotary Tables in
conjunction with Yaskawa AC Digital Servo Drives and Servo Dynamics D.C. Servo Drives. NOTE: All AC
Drive instructions are for the Digital version only. Do not try to use a Digital
Drive with an Analog Table. There are two (2) types of Controls that are covered by this document; they are the
MAX/ ISA and the DELTA (mfg. by AutoCon). This is the only procedure to be used within HURCO facilities,
contract manufacturing sites, and Customer-site installations to help achieve factory proven performance.
III. INDEX
1.1 TECHNARA ROTARY TABLE DESCRIPTION............................pg. 2

2.1 HURCO ROTARY TABLE DESCRIPTION....................................pg. 2
3.1 PRELIMINARY GUIDE TO INSTALLATION ...............................pg. 3
4.1 MAX ISA SPECIFIC INFORMATION.............................................pg. 4
5.1 DELTA CONTROL SPECIFIC INFORMATION.............................pg. 6

1.1 TECHNARA ROTARY TABLE DESCRIPTION
1.1.1 There are three (3) models of Technara Rotary Tables that will be of concern.
Model TB-200, TB-250, & TB-320.
The following explanation illustrates the configuration of each model and each Hurco
machine and control that these models apply to.
1.1.2 Model TB-200 Baldor MTE-4345 DC Motor

Clamping Circuit 24VDC, 100mA solenoid, pneumatic
Reference Circuit 24VDC, N.C. 2 wire proximity Switch
Applicable machines BMC30D, Hawk 5D, Hawk 5M
1.1.3 Model TB-250 Baldor MTE-4345 DC Motor

Yaskawa USAGED-09A21 AC Motor
Applicable machines (AC motor vers. only)
BMC30M, BMC30M/HT, BMC40M
BMC40M/HT, BMC40/50M, BMC50M
BMC50/50M
(DC motor vers. only)
BMC30D, Hawk 5D, Hawk 5M
1.1.4 Model TB-320 Yaskawa USAGED-09A21 AC Motor

Applicable machines BMC30M, BMC30M/HT, BMC40M,
BMC40M/HT, BMC40/50M, BMC50M,
& BMC50/50M
2.1 HURCO ROTARY TABLE DESCRIPTION
2.1.1 There is at present only one (1) model of Hurco Rotary Table
2.1.2 Baldor MTE-4345 DC Motor

Yaskawa USAGED-09A21 AC Motor
Clamping Circuit None
Applicable machines (AC motor vers. only)
BMC30M, BMC30M/HT, BMC40M,
BMC40M/HT, BMC40/50M, BMC50M,
BMC50/50M
(DC motor vers. only)
BMC30D, Hawk 5D, Hawk 5M
2
3.1 PRELIMINARY GUIDE TO INSTALLATION (applicable to all machine configurations)
3.1.1 Specific Equipment Needed
HONDA Pin Crimpers

HONDA Pin Extractors
AMP “Mini Mate-N-Lok” Pin Crimpers
AMP “Mini Mate-N-Lok” Pin Extractors
3.1.2 Schematics/Diagrams
The installer should become familiar with the following manuals and drawings before proceeding
with the installation:
Wiring Schematics 002-4122-039

ISA Control Package
Service Manual 704-0001-717
Autocon D10/20
Installation Manual (Sent with Machine)
Yaskawa Servo Drive
Maintenance Manual (Sent with Machine)
Servo Dynamics Servo
Maintenance Manual (Sent with Machine)
3.1.3 Preliminary Instructions
Insure that all machine power is completely “OFF”.

All the necessary parts were included in the Power Cabinet Additions, but of particular
importance is the Universal Rotary Table Connection Kit. This Kit contains essential parts
such as pins and wire that is needed to complete the wiring. Locate this Kit first. The part
number for this Kit is 002-4311-005. This Kit was designed for use on all Rotary Table
installations and contains all necessary parts for use with any machine built after 09-31-94.
Locate the two (2) Rotary Table External Harnesses. Part number 423-6812-021 and
423-6812-022.
To properly install the Rotary Table Harnesses, the Installation Technician will have to
decide were to place the entry holes at the Electrical Cabinet. (see figure 4,5, or 6).
Feed the free ends of the cables through the holes and secure .
Using the proper schematic, route the wire, strip and cut to length as needed. No one
machine is the same, however, try to insure that there are no hidden connectors (i.e., MiniMate-
N-Lok connectors stuffed in the wire/cable track).
After wiring is complete, with an OHMMETER, check all connections, being sure that there
is no improper wire crossing and that all connections are secure.
3
4.1 MAX ISA SPECIFIC INFORMATION
4.1.1 Bedmills
B.O.M.
Harness, Rotary External Armature 423-6812-022
Harness, Rotary External Encoder 423-6812-022
Harness, ISA/DSP Servo I/O 423-4400-006
Harness, MX4 to Axis 1CN 423-4406-003
Harness, ISA/DSP Sync 423-4400-011
Harness, ISA/DSP TTL I/O 423-4400-002
Universal Rotary Tbl Conn. Kit 002-4311-005
PCB Assy,CANBUS DC I/O 415-0601-002
PSB Assy, ISA/DSP Motion 415-0247-006
PCB Assy, ISA/DSP Honda 415-0609-901
Drive, Servo Digital Yaskawa 402-6009-089
Labels 703-1005-341,342,348
4.1.2 Kneemill (H5M)

B.O.M.

Harness, ISA/DSP Servo I/O 423-4400-006
Harness, ISA/DSP Sync 423-4400-011
Harness, ISA/DSP TTL I/O 423-4400-002
Universal Rotary Tbl Conn. Kit 002-4311-005
PCB Assy,CANBUS DC I/O 415-0601-002
PSB Assy, ISA/DSP Motion 415-0247-006
PCB Assy, ISA/DSP Honda 415-0609-901
FET Module,Single Axis 415-0055-010
Servo Dynamics Inductors 330-314
Labels 703-1005-341,342,348
Harness, ISA CANBUS DC 423-4400-008
4.1.3 Parameters
At this point, if the Machine is an ISA platform insure that the software is version 1.54.
After wiring is completed and checked, power up machine and using figure 1, 2, or 3 set
parameters for the Control and Servo Drive (if applicable).
4
Figure 1:Yaskawa Digital Servo Drive Parameters
Servo Digital Drive Constants Factory Default Hurco Setting
Cn-01 User Constant (*) 0 * (see Yaskawa manual)
Cn-02 Reserved 0 0
Cn-03 Speed Ref. (rpm/volt) 150 263
Cn-04 Loop Gain (hz) 00040 00040
Cn-05 Intregal Time Const. (ms) 00020 00020
Cn-06 Emerg. Stop Torque (%) 00221(?) 00200
Cn-07 Soft Start Time (ms) 00000 00000
Cn-08 Fwd. Torque Limit (%) 00221(?) 00217
Cn-09 Rev. Torque Limit (%) 00221(?) 00217
Cn-0A PG Divide Ratio (p/rev) 2500 4000
Cn-0B Zero Speed Level (rpm) 00020 00020
Cn-0C Mode Switch (Torque ref. - %) 00200 00200
Cn-0D Mode Switch (Speed ref. - rpm) 00000 00000
Cn-0E Mode Switch (Accel. - 10 X rpms/s) 00000 00000
Cn-0F Zero Clamp Level (rpm) 00010 00010
Cn-10 Jog Speed (rpm) 00100 00100
Cn-11 PG Resolution (p/rev) 8192 8192
Cn-12 Brake Delay Time (rms) 00020 00020
Cn-13 torque Ref. Gain 00030 00030
Cn-14 Max Speed in Torq. Cont. (rpm) 03000 03000
Cn-15 Brake Timing Speed Level (rpm) 00100 00100
Cn-16 Brake Timing (10ms) 00050 00050
Cn-17 Torque Ref. Filter Time (100us) 00004 00020
Figure 2:MAX ISA Control Parameters

** ROTARY PARAMETERS TB-200 TB-250 TB-320 HURCO
**
Rotary Resolution (counts / degree) 2049 2049 4098 2049
Maximum RPM 22 22 11 33
Clamp Mechanism Present Yes Yes Yes No
Clamp Signal Present Yes Yes Yes No
Clamp Signal Logic 0 0 0 0
Unclamp Signal Present Yes Yes Yes No
Unclamp Signal Logic 0 0 0 0
Fault Signal Present Yes Yes Yes Yes
Fault Signal Logic 1 1 1 1
Machine Wiring Logic Normal Normal Normal Normal
Limit Switch Present Yes Yes Yes Yes
Limit Switch to Marker Distance 6 Degrees 6 Degrees 6 Degrees 6 Degrees
Limit Switch Signal Logic 1 1 1 1
Backlash Compensation Table Specific Table Specific Table Specific Table Specific
In Position Tolerance 4 Counts 4 Counts 4 Counts 4 Counts
Calib: To Lim Sw Velocity 200 200 200 200
Calib: To Marker Velocity 100 100 100 100
Table Ratio (Driver : Driven) 90 : 1 90 : 1 180 : 1 90 : 1
5
Figure 2: MAX ISA Control Parameters cont.
Matrix 4 Axis Tune Parameters

TB-200(DC) TB-250(DC) TB-250(AC) TB-320(AC) Hurco(DC) Hurco (AC)
Integral: 10 10 100 10 10 10
Proportional 5000 3800 2800 4000 4000 4000
Feedforward 250 250 1315 1000 250 250
Derivative 30 30 50 300 300 300
Int. Limit 11 5 5 5 5 5
Out Loop Gain 1 1 1 4 4 4
Int. Bandwdth 200 200 200 100 200 200
DAC Bal. 0 0 0 0 0 0
DAC Bal. lim. 0 0 0 0 0 0
Max. Acc. 750000 750000 750000 250000 750000 750000
Max Abort Acc. 750000 750000 750000 250000 750000 750000
Follow error 2 deg. 2 deg. 2 deg. 2 deg. 2 deg. 2 deg.
5.1 DELTA CONTROL SPECIFIC INFORMATION
5.1.1 Bedmills
B.O.M.
Kit, Univ. Rot.Tab. Connection 002-4311-005
Board, DC I/O Dyna #420175 330-366
Board,4TH Axis Dynapath 330-268
FET Module, Single Axis 415-0055-010
Labels 703-1005-341,342,348
5.1.2 Kneemill (H5D)

B.O.M.
Kit, Univ. Rot.Tab. Connection 002-4311-005
Board, DC I/O Dyna #420175 330-366
Board,4TH Axis Dynapath 330-268
FET Module, Single Axis 415-0055-010
Labels 703-1005-341,342,348
6
Figure 3 is a list of Delta parameters, and the proper settings for each model of Rotary
Table. For a detailed explanation of each parameter, see the Autocon D10,20 Installation
Guide. The remaining 4th axis parameters have already been loaded with BMC30D15.PAR.
There are no parameters for the Servo Dynamics Drive Package.
Figure 3: Delta 10/20 4th Axis Parameters

Rotary Parameter Address TB-180 TB-250 TB-320 HURCO
000 (no. of Axis present?) 04 04 04 04
090 (Axis hardware installed?) 01 01 01 01
091(Aux. axis type?) 00 00 00 00
Figure 4: Rotary Table Placement (Bedmill)
Figure 5: Cable Placement (Bedmill)
7
Figure 6: Rotary Table and Cable Placement (Kneemill)
8
R
757-4002-106 CAD #D8492
SUBJECT: Installation Procedures and Parameter Settings for

Rotary Table, TB200 and TB250 with Sigma Motors.
RECORD OF CHANGES
Dan Ornelas 11/11/96 Mike Caron 11/11/96


B 13985 1) Page 10, TB200 & TB250, Ki was 850, Kp DEO 3/3/97 MFC 3/8/97
was 6000, Kf was 1300 & Kd was 550.
C 14090 1) Latest production units will include Rotary DEO 9/5/97
Table harness and terminal block as standard
I. INTENT
Page 2
To provide a standardized method of installation and configuration for TB200 and TB250 rotary
tables with Yaskawa Sigma series drives/motors on Ultimax 3 ISA type machining centers.
II. APPLICABILITY
Specific to all BMC4020HT, BMC4020SSM, and BMC30SSM Ultimax 3 type machining centers
using software version 1.62 or later. This is the only procedure to be used within Hurco facilities
1) Yaskawa Sigma Series Users Manual (TSE-S800-16) Reference

2) Yaskawa Digital Operator Instruction (TOE-S800-15.4)
3) Assy, BMC30/SSM Control Cabinet (003-1007-009)
4) Assy, BMC4020HT/M Control Cabinet (003-2007-001)
5) Assy, BMC4020SSM Control Cabinet (003-2007-003)
6) Assy, Rotary Table Option (003-1016-010)
7) Schematics Electrical, Rotary Cable (003-2022-005)
8) Assy, Rotary Table Harnesses (002-4321-012)
9) Harness Rotary Motor (423-4401-117)
10) Harness Rotary Encoder (423-4401-118)
11) Harness, Axis 1CN to MX4/TB1 (423-4401-119)
12) Harness, Rotary Table Motor (423-4401-120)
13) Harness, Rotary Table Encoder (423-4401-121)
14) Harness, TB1 to IOIF/DCIO (423-4401-122)
15) Assy, ISA/P Card Cage M/C SVGA (007-3002-001)
16) Assy, ISA/P Card Cage M/C Dual VGA (007-3002-002)
17) Plate, Rotary Table Connect (802-2700-019)
18) NC Rotary Table Manual (1994.07. 200)
19) TB200 Source Control Document (TB200A4Y04)
IV. INDEX
Page 4 Installation Procedure, Hardware Mounting

Page 5 Installation Procedure, Discrete Wiring
Page 5 Installation Procedure, Harness Assemblies
Page 6 Installation Procedure, Pneumatics
Page 6 Installation Procedure, Rotary Table Kit
Page 7 Drive and Control Parameters, Rotary Table
Page 8 Sigma Series Parameters, Yaskawa Drive
Page 10 MAX Controller Parameters, 103 and 100 Screen
V. KIT DEFINITION
Page 3
The rotary table option can be configured as a complete system, which incorporates the “Rotary
Table Kit” and the “Rotary Table Interface Kit”. It may also be configured separately, as the
“Rotary Table Interface Kit” only, with the possibility to add the “Rotary Table Kit” at a later
date. The various configuration categories are listed below:
Description, Configuration Items Part Numbers

Option, Rotary Table Complete, TB200 002-4321-010
Option, Rotary Table Kit, TB200 002-4321-014
Option, Rotary Table Interface Kit 002-4321-013
NOTE: Prior to rotary table installation verify machine is functioning properly.
CAUTION: During this procedure high voltage is present at the line side of main circuit breaker,
MCCB. Be sure the main circuit breaker is in the OFF position prior to starting this installation
procedure.
A. Hardware Mounting and Installation

(Reference Documents 3,4,5, and 6, Control Cabinet and Installation Assy’s.)
1. Install the 8A control circuit breaker (403-5502-037) and the 25A contactor
(404-9081-060) onto the DIN rail.
2. Strap diode across the contactor coil terminals labeled V DC 24. Ensure cathode
is referenced to 24VDC and the anode is referenced to ground.
3. Install the Servopack amplifier (402-6009-106) to the control panel using the M5
screws, flat washers, and lockwashers provided. On a BMC4020 machine the
location reserved is the upper left corner while on a BMC30SSM machine this
location is the upper center when viewed from the back of the machine.
4.C1 Terminal block standard on newer machines, otherwise, install 20 position terminal
block assembly (406-4005-323) to the control panel using the M3 screws and flat
washers provided. On a BMC4020 machine this location is the upper left corner
while on a BMC30SSM machine this location is the upper center when viewed
from the back of the machine.
5. Verify configuration of fourth axis MX4 PCB assembly (415-0247-008T) as

follows:
JU3 Interrupt Set jumper for interrupt = 7

SW1 Address Set switches for address = D0800h
(SW 1,2,4,9 OFF; SW 3,5-8,10 ON)
Page 4
6. Install and configure the fourth axis PCB assemblies per Assy,
ISA/P Card Cage 007-3002-001, -002.
415-0601-002T Assy PCB, Canbus DC I/O
415-0609-901 PCB Assy, ISA/DSP Honda
415-0247-008T Assy PCB, MX4 CNC++, a,b,c,d
7. Install the following ISA harnesses for the fourth axis:

423-4400-011 Harness, ISA/DSP Sync
423-4400-002 Harness, ISA/DSP TTL I/O
423-4400-006 Harness, ISA/DSP Servo I/O
B. Discrete Wiring (Reference Document 7, Schematic page 4)
NOTE: When connecting three phase power take care when wiring the system to keep
the phasing the same throughout the circuit.
1. Install 16AWG black wire with terminal lugs from load side of main circuit
breaker to line side of 8A control breaker with ferrules, refer to the schematic
diagram for circuit wiring.
2. Install 16AWG black wire with ferrules from load side of 8A control breaker to
25A contactor input terminals with ferrules, refer to the schematic diagram for
circuit wiring.
3. Install 16AWG black wire with ferrules from 25A contactor output terminals to
Servopack power terminals R,S ,and T with terminal lugs, refer to the schematic
4. Install 16AWG black wire with ferrules from 25A contactor input terminals to
Servopack power terminals r and t with terminal lugs, refer to the schematic
5. Install 16AWG green wire with terminal lug from Servopack power terminal G
to single point ground plate with terminal lug, refer to the schematic diagram for
circuit wiring.
C. Harness Assemblies (Reference Documents 8,11,12,13, and 14, Harness Assy’s)
NOTE: If machine does not have production knockouts or panel cutout for mounting
“Assy, Rotary Table Harness”, (002-4321-012), holes in machine enclosure and control
cabinet will be required. Make holes in machine enclosure using dimensions shown in
“Plate, Rotary Table Connect”, (802-2700-019) drawing. Also, make two 3/4” holes in
left side of control cabinet using “Assy, Rotary Table Option”, (003-1016-010).
1.C1 Cable harness standard on newer machines, otherwise, prior to installing the cable
harness assemblies between the control cabinet and enclosure remove the two
Page 5
caps on the left side of the control cabinet. Remove the blank panel assembly from
the enclosure located in the rear upper left corner. Retain mounting hardware and
gasket since it will be required to resecure the new panel and harness assembly.
At this point install cable assembly 002-4321-012. Feed connector, terminal lugs,
and ferrules through the control cabinet openings. Route cable harnesses to there
appropriate reference destinations within the control cabinet (Note: Remove
backshell on 423-4401-121, then replace).
2. Install the remaining harnesses to their appropriate reference destinations within

the control cabinet. Route harnesses in wire ducts along the left side of control
cabinet, keeping the control signals away from power signals as much as possible.
423-4401-119 Harness, Axis 1CN to MX4/TB1
423-4401-120 Harness, Rotary Table Motor
423-4401-121 Harness, Rotary Table Encoder
423-4401-122 Harness, TB1 to IOIF/DCIO
D. Pneumatics Installation (Reference Document 6, Assy, Rotary Table Option)
1. With main air supply disconnected to the machine remove the plug fitting from
the oil/air panel. Install adapter, 3/8” PT to 1/4” tube straight.
2. Route 1/4” nylon tubing from adapter to the bulkhead mounted fitting. The air
supply system will be equiped with a quick disconnect fitting and a recoil hose for
attaching main supply to rotary table at air input.
E. Rotary Table Kit Install (Reference Document 6, Assy, Rotary Table Option)
1. Remove rotary table from crate and place on the machine table surface and secure.
Inspect the rotary table for damage.
2. Connect rotary table motor harness (423-4401-117) and encoder harness

(423-4401-118) from enclosure bulkhead to the rotary table.
3. Connect 1/4” recoil hose with integral fittings from enclosure bulkhead to the
rotary table.
4. Install mounting bracket hanger assembly within enclosure area as shown on

assembly drawing.
5. Secure two cable harnesses and air hose to mounting bracket hanger for proper
support and strain relief.
VII. DRIVE AND CONTROL PARAMETERS
Page 6
A. At this point the machine may be powered ON. Verify that the drive system
comes up with no errors, indicated by a green LED only. Should a red LED be
present with error code, refer to Reference Document 1, Yaskawa Sigma Series
Users Manual, for diagnostics.
1. Measure three phase line voltage across control circuit breaker, CB6,
voltage readings should be 230VAC +/- 10%.
2. Select controller “Power ON” and then “Start Cycle”. From the “Axis Jog
Control” select Axis-A. Control contactor RBS will be enabled, power
present at drive assembly. You will also hear the unclamp solenoid
activate to release the rotary table mechanical brake.
B. Enter the Yaskawa Sigma Series parameters into the drive system from the data
contained in the following table. If necessary use Reference Document 2,
Yaskawa Digital Operator Instruction, to explain how to enter or observe data
values. After drive parameters have been entered into the amp proceed by
entering the system control parameters for screen 100 and 103 from the data listed
in the table at the end of this document. Once completed the rotary table should
be exercised to verify proper operation.
1. Perform machine calibration to verify that Axis-A calibrates properly.
2. Jog rotary table in CW and then in CCW directions at various feedrates to

verify proper operation.
3. Finally run an automatic program that exercises the rotary table to verify
proper operation with the overall system.
Page 7
System Parameters, TB200 and TB250
P No. YASKAWA SIGMA SERIES PARAMETER DESCRIPTIONS DIMENSION SETTING

Cn-00 Special Mode Selector - N/A
Cn-01 Memory Switch Settings, 1 - N/A
Bit 0 Input signal enable disable Binary 0
Bit 4 Reserved Binary 0
Bit 5 Operation performed at recovery from power loss Binary 0
Bit 6 Sequence selection at alarm condition Binary 0
Bit A Process selection for Servo OFF Binary 0
Bit B Mode switch selection Binary 0
Bit C Mode switch selection Binary 1
Bit D Mode switch selection Binary 0
Bit E Encoder selection Binary 0
Bit F Reserved Binary 0
Cn-02 Memory switch Settings, 2 - N/A
Bit 0 Rotation direction Binary 0
Bit 1 Home position error processing selection Binary 0
Bit 2 Analog speed limit function Binary 0
Bit 3 Reference pulse form Binary 0
Bit 6 Analog monitor selection Binary 0
Bit 7 Analog monitor selection Binary 0
Bit 8 Analog current limit function Binary 0
Bit 9 Torque feedforward function Binary 0
Bit A Clear signal Binary 0
Bit B Reserved Binary 0
Bit C Torque Filter Binary 0
Bit D Reference pulse form Binary 0
Bit E Position error monitor Binary 0
Bit F Reference pulse filter Binary 0
Cn-03 Speed reference adjustment gain RPM/V 158
Cn-04 Speed loop gain Hz 51
Cn-05 Speed loop integration time constant 0.01 ms 3000
Cn-06 Emergency stop torque % 800
Cn-07 Soft start acceleration ms 0
Page 8

Cn-08 Forward rotation torque limit % 800
Cn-09 Reverse rotation torque limit % 800
Cn-0A PG dividing ratio P/R 4800
Cn-0B Zero-speed level RPM 20
Cn-0C Mode switch torque reference % 200
Cn-0D Mode switch speed reference RPM 0
Cn-0E Mode switch acceleration 10 RPM/s 0
Cn-0F Mode switch error pulse Ref. unit 0
Cn-10 Jog speed RPM 500
Cn-11 Number of encoder pulses P/R 8192
Cn-12 Time delay from brake reference until servo OFF 10 ms 0
Cn-13 Torque reference gain 0.1V 30
Cn-14 Speed limit for torque control RPM 10000
Cn-15 Speed level for brake ref output during motor operation RPM 100
Cn-16 Output timing of brake ref during motor operation 10 ms 50
Cn-17 Torque reference filter time constant 0.1 ms 4
Cn-18 Forward external current limit % 100
Cn-19 Reverse external current limit % 100
Cn-1A Position loop gain 1/s 40
Cn-1B Positioning completion range Ref. unit 7
Cn-1C Bias RPM 0
Cn-1D Feed-forward % 0
Cn-1E Overflow 256 Ref. unit 1024
Cn-1F 1st speed (contact input speed control) RPM 100
Cn-20 2nd speed (contact input speed control) RPM 200
Cn-21 3rd speed (contact input speed control) RPM 300
Cn-22 Speed coincidence signal output range RPM 10
Cn-23 Soft start deceleration range ms 0
Cn-24 Electronic gear ratio (numerator) - 4
Cn-25 Electronic gear ratio (denominator) - 1
Cn-26 Position reference acceleration/deceleration 0.1 ms 0
Cn-27 Feed-forward filter 0.1 ms 0
Cn-28 Speed loop compensation constant - 0
Cn-29 Zero clamp level RPM 10
Cn-2A Motor selection - 143
Cn-2B Control method selection - 0
Cn-2C PG power supply voltage change - 52500
Cn-2D Output signal selection - 210
Page 9
Ultimax 3 Control Axis Tune Screen, <enter>,103,<enter>
MATRIX4 Axis Tune Diagnostics A Axis (TB200) A Axis (TB250)

Integral: 1050 B1 2000 B1
Proportional: 3000 B1 3500 B1
Feedforward: 1000 B1 900 B1
Derivative: 250 B1 250 B1
Integral Limit: 5 5
Output Loop Gain: 1 1
Integral Bandwidth 200 200
DAC Balance: 0 0
DAC Balance Limit: 0 0
Max. Rapid Accel: 750,000 750,000
Max. Contour Accel: 750,000 750,000
Max. Abort Accel: 750,000 750,000
Following Error Halt: 2.0 2.0
Ultimax 3 Control Machine Configuration Screen, <enter>,100,<enter>
Machine Configuration Physical Parameters A Axis (TB200) A Axis (TB250)

Rotary Resolution 4800 4800
Maximum RPM 16 16
Clamp Mechanism Present Yes Yes
Clamp Signal Present Yes Yes
Clamp Signal Logic 0 0
Unclamp Mechanism Present Yes Yes
Unclamp Signal Present 0 0
Fault Signal Present Yes Yes
Limit Switch Present Yes Yes
Limit Switch to Marker Distance 4 4
Limit Switch Signal Logic 1 1
Backlash Compensation Table Specific Table Specific

In Position Tolerance 4 4
Calibrate to Limit Switch Velocity 200 200
Calibrate to Marker Velocity 10 10
-MORE-
Calibrate Home Position 0.0 0.0
Page 10
R
757-4002-106 CAD #D8492
SUBJECT: Installation Procedures and Parameter Settings for

Rotary Table, TB200 and TB250 with Sigma Motors.
RECORD OF CHANGES
Dan Ornelas 11/11/96 Mike Caron 11/11/96


B 13985 1) Page 10, TB200 & TB250, Ki was 850, Kp DEO 3/3/97
was 6000, Kf was 1300 & Kd was 550.
I. INTENT
Page 2
To provide a standardized method of installation and configuration for TB200 and TB250 rotary
tables with Yaskawa Sigma series drives/motors on Ultimax 3 ISA type machining centers.
II. APPLICABILITY
Specific to all BMC4020HT, BMC4020SSM, and BMC30SSM Ultimax 3 type machining centers
using software version 1.62 or later. This is the only procedure to be used within Hurco facilities
1) Yaskawa Sigma Series Users Manual (TSE-S800-16) Reference

2) Yaskawa Digital Operator Instruction (TOE-S800-15.4)
3) Assy, BMC30/SSM Control Cabinet (003-1007-009)
4) Assy, BMC4020HT/M Control Cabinet (003-2007-001)
5) Assy, BMC4020SSM Control Cabinet (003-2007-003)
6) Assy, Rotary Table Option (003-1016-010)
7) Schematics Electrical, Rotary Cable (003-2022-005)
8) Assy, Rotary Table Harnesses (002-4321-012)
9) Harness Rotary Motor (423-4401-117)
10) Harness Rotary Encoder (423-4401-118)
11) Harness, Axis 1CN to MX4/TB1 (423-4401-119)
12) Harness, Rotary Table Motor (423-4401-120)
13) Harness, Rotary Table Encoder (423-4401-121)
14) Harness, TB1 to IOIF/DCIO (423-4401-122)
15) Assy, ISA/P Card Cage M/C SVGA (007-3002-001)
16) Assy, ISA/P Card Cage M/C Dual VGA (007-3002-002)
17) Plate, Rotary Table Connect (802-2700-019)
18) NC Rotary Table Manual (1994.07. 200)
IV. INDEX
Page 4 Installation Procedure, Hardware Mounting

Page 5 Installation Procedure, Discrete Wiring
Page 5 Installation Procedure, Harness Assemblies
Page 6 Installation Procedure, Pneumatics
Page 6 Installation Procedure, Rotary Table Kit
Page 7 Drive and Control Parameters, Rotary Table
Page 8 Sigma Series Parameters, Yaskawa Drive
Page 10 MAX Controller Parameters, 103 and 100 Screen
V. KIT DEFINITION
Page 3
The rotary table option can be configured as a complete system, which incorporates the “Rotary
Table Kit” and the “Rotary Table Interface Kit”. It may also be configured separately, as the
“Rotary Table Interface Kit” only, with the possibility to add the “Rotary Table Kit” at a later
date. The various configuration categories are listed below:
Description, Configuration Items Part Numbers

Option, Rotary Table Interface Kit 002-4321-013
NOTE: Prior to rotary table installation verify machine is functioning properly.
CAUTION: During this procedure high voltage is present at the line side of main circuit breaker,
MCCB. Be sure the main circuit breaker is in the OFF position prior to starting this installation
procedure.
A. Hardware Mounting and Installation

(Reference Documents 3,4,5, and 6, Control Cabinet and Installation Assy’s.)
1. Install the 8A control circuit breaker (403-5502-037) and the 25A contactor
(404-9081-060) onto the DIN rail.
2. Strap diode across the contactor coil terminals labeled V DC 24. Ensure cathode
is referenced to 24VDC and the anode is referenced to ground.
3. Install the Servopack amplifier (402-6009-106) to the control panel using the M5
screws, flat washers, and lockwashers provided. On a BMC4020 machine the
location reserved is the upper left corner while on a BMC30SSM machine this
location is the upper center when viewed from the back of the machine.
4. Install 20 position terminal block assembly (406-4005-323) to the control panel

using the M3 screws and flat washers provided. On a BMC4020 machine this
location is the upper left corner while on a BMC30SSM machine this location is
the upper center when viewed from the back of the machine.
5. Verify configuration of fourth axis MX4 PCB assembly (415-0247-008T) as

follows: JU3 Interrupt Set jumper for interrupt = 7
SW1 Address Set switches for address = D0800h
(SW 1,2,4,9 OFF; SW 3,5-8,10 ON)
6. Install and configure the fourth axis PCB assemblies per Assy,
ISA/P Card Cage 007-3002-001, -002.
Page 4
415-0601-002T Assy PCB, Canbus DC I/O
415-0609-901 PCB Assy, ISA/DSP Honda
415-0247-008T Assy PCB, MX4 CNC++, a,b,c,d
7. Install the following ISA harnesses for the fourth axis:

423-4400-011 Harness, ISA/DSP Sync
423-4400-002 Harness, ISA/DSP TTL I/O
423-4400-006 Harness, ISA/DSP Servo I/O
B. Discrete Wiring (Reference Document 7, Schematic page 4)
NOTE: When connecting three phase power take care when wiring the system to keep
the phasing the same throughout the circuit.
1. Install 16AWG black wire with terminal lugs from load side of main circuit
breaker to line side of 8A control breaker with ferrules, refer to the schematic
2. Install 16AWG black wire with ferrules from load side of 8A control breaker to
25A contactor input terminals with ferrules, refer to the schematic diagram for
circuit wiring.
3. Install 16AWG black wire with ferrules from 25A contactor output terminals to
Servopack power terminals R,S ,and T with terminal lugs, refer to the schematic
4. Install 16AWG black wire with ferrules from 25A contactor input terminals to
Servopack power terminals r and t with terminal lugs, refer to the schematic
5. Install 16AWG green wire with terminal lug from Servopack power terminal G
to single point ground plate with terminal lug, refer to the schematic diagram for
circuit wiring.
C. Harness Assemblies (Reference Documents 8,11,12,13, and 14, Harness Assy’s)
NOTE: If machine does not have production knockouts or panel cutout for mounting
“Assy, Rotary Table Harness”, (002-4321-012), holes in machine enclosure and control
cabinet will be required. Make holes in machine enclosure using dimensions shown in
“Plate, Rotary Table Connect”, (802-2700-019) drawing. Also, make two 3/4” holes in
left side of control cabinet using “Assy, Rotary Table Option”, (003-1016-010).
1. Prior to installing the cable harness assemblies between the control cabinet and
enclosure remove the two caps on the left side of the control cabinet. Remove the
blank panel assembly from the enclosure located in the rear upper left corner.
Page 5
Retain mounting hardware and gasket since it will be required to resecure the new
panel and harness assembly.
At this point install cable assembly 002-4321-012. Feed connector, terminal lugs,
and ferrules through the control cabinet openings. Route cable harnesses to there
appropriate reference destinations within the control cabinet (Note: Remove
backshell on 423-4401-121, then replace).
2. Install the remaining harnesses to their appropriate reference destinations within

the control cabinet. Route harnesses in wire ducts along the left side of control
cabinet, keeping the control signals away from power signals as much as possible.
423-4401-119 Harness, Axis 1CN to MX4/TB1
423-4401-120 Harness, Rotary Table Motor
423-4401-121 Harness, Rotary Table Encoder
423-4401-122 Harness, TB1 to IOIF/DCIO
D. Pneumatics Installation (Reference Document 6, Assy, Rotary Table Option)
1. With main air supply disconnected to the machine remove the plug fitting from
the oil/air panel. Install adapter, 3/8” PT to 1/4” tube straight.
2. Route 1/4” nylon tubing from adapter to the bulkhead mounted fitting. The air
supply system will be equiped with a quick disconnect fitting and a recoil hose for
attaching main supply to rotary table at air input.
E. Rotary Table Kit Install (Reference Document 6, Assy, Rotary Table Option)
1. Remove rotary table from crate and place on the machine table surface and secure.
Inspect the rotary table for damage.
2. Connect rotary table motor harness (423-4401-117) and encoder harness

(423-4401-118) from enclosure bulkhead to the rotary table.
3. Connect 1/4” recoil hose with integral fittings from enclosure bulkhead to the
rotary table.
4. Install mounting bracket hanger assembly within enclosure area as shown on

assembly drawing.
5. Secure two cable harnesses and air hose to mounting bracket hanger for proper
support and strain relief.
Page 6

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Machine Options Machine Config Miscellaneous Parameters

Spindles Hurco Field Software Technical

Customer Name ________________________________ Sales Order Number _________________________

VERIFICATION Comments: _______________________________

BASE PART NUMBER: HAWK5MASIADSP CHANGE OPTIONS: A = Add D = Delete

1. REQUIRED BASIC CONFIGURATION (select one)

3. OPTIONAL SOFTWARE (OPTIKEY)

*To Be Used With 002-4311-007 Only.

Serial Number:__________________ Page 1 of 1

Customer Name ________________________________ Sales Order Number _________________________

VERIFICATION Comments: _______________________________

BASE PART NUMBER: HAWK5MEUROPEDSP CHANGE OPTIONS: A = Add D = Delete

1. REQUIRED BASIC CONFIGURATION (select one)

3. OPTIONAL SOFTWARE (OPTIKEY)

*To Be Used With 002-4311-007 Only .

Serial Number:__________________ Page 1 of 1

Customer Name ________________________________ Sales Order Number _________________________

VERIFICATION Comments: _______________________________

BASE PART NUMBER: HAWK5MUSADSP CHANGE OPTIONS: A = Add D = Delete

1. REQUIRED BASIC CONFIGURATION (select one)

3. OPTIONAL SOFTWARE (OPTIKEY)

*To Be Used With 002-4311-007 Only.

Serial Number:__________________ Page 1 of 1

Customer Name ________________________________ Sales Order Number _________________________

VERIFICATION Comments: _______________________________

BASE PART NUMBER: HAWK5SSMASIADSP CHANGE OPTIONS: A = Add D = Delete

1. REQUIRED BASIC CONFIGURATION 3. OPTIONAL SOFTWARE (OPTIKEY)

* To Be Used With 002-4311-007 Only.

Serial Number:__________________ Page 1 of 1

Customer Name ________________________________ Sales Order Number _________________________

VERIFICATION Comments: _______________________________

BASE PART NUMBER: HAWK5SSMEURDSP CHANGE OPTIONS: A = Add D = Delete

1. REQUIRED BASIC CONFIGURATION 3. OPTIONAL SOFTWARE (OPTIKEY)

* To Be Used With 002-4311-007 Only.

Serial Number:__________________ Page 1 of 1

Customer Name ________________________________ Sales Order Number _________________________

VERIFICATION Comments: _______________________________

BASE PART NUMBER: HAWK5SSMUSADSP CHANGE OPTIONS: A = Add D = Delete

1. REQUIRED BASIC CONFIGURATION 3. OPTIONAL SOFTWARE (OPTIKEY)

* To Be Used With 002-4311-007 Only.

Serial Number:__________________ Page 1 of 1

Customer Name ________________________________ Sales Order Number _________________________

VERIFICATION Comments: _______________________________

BASE PART NUMBER: H30 CHANGE OPTIONS: A = Add D = Delete

1. REQUIRED BASIC CONFIGURATION (SELECT ONE) 3. OPTIONAL SOFTWARE

_____H30-0102-001H HAWK 30/SSM USA ------007-4124-001 3D Mold

Serial Number:______________ Page 1 of 1

Customer Name ________________________________ Sales Order Number _________________________

VERIFICATION Comments: _______________________________

BASE PART NUMBER: H40 CHANGE OPTIONS: A = Add D = Delete

1. REQUIRED BASIC CONFIGURATION (SELECT ONE) 3. OPTIONAL SOFTWARE

_____H40-0102-001H HAWK 40/SSM USA -----007-4124-001 3D Mold

Serial Number:______________ Page 1 of 1

Customer Name ________________________________ Sales Order Number _________________________

VERIFICATION Comments: _______________________________

BASE PART NUMBER: B24M CHANGE OPTIONS: A = Add D = Delete

___ _ B24-0809-001 H BMC2416/DSM USA 3.OPTIONAL SOFTWARE

Serial Number:______________ Page 1 of 1

Customer Name ________________________________ Sales Order Number _________________________

Customer Name ________ Sales Order Number _

Customer Name ________ Sales Order Number _

Customer Name ________ Sales Order Number _

Customer Name ________ Sales Order Number _

Customer Name ________ Sales Order Number _

Customer Name ________ Sales Order Number _

Customer Name ________ Sales Order Number _

Customer Name ________ Sales Order Number _

Customer Name ________ Sales Order Number _

Customer Name ________ Sales Order Number _

Customer Name ________ Sales Order Number _

Customer Name ________ Sales Order Number _

Customer Name ________ Sales Order Number _

Customer Name ________ Sales Order Number _

_B30-0804-001H USA(COLOR)MAX4(SIEMENS) _003-1018-003 Ass'y, Scale Option (Yaskawa)

Customer Name ________ Sales Order Number _

Customer Name ________ Sales Order Number _

Customer Name ________ Sales Order Number _

Customer Name ________ Sales Order Number _

Customer Name ________ Sales Order Number _

Customer Name ________ Sales Order Number _