A Mazak

MAINTENANCE MANUAL
for

Machine Relocation Detector

Battery Replacement Procedure Manual

MANUAL No. : HGENMA0016E

NC EquipmentiMAZATROL MATRIX,

MAINTENANCE
MANUAL
\
 Original Instructions

MAINTENANCE MANUAL
for

Machine Relocation Detector

Battery Replacement Procedure Manual

MANUAL No. : HGENMA0016E

NC Equipment:MAZATROL MATRIX,
MAZATROL MATRIX NEXUS,
MAZATROL SMART,
MAZATROL FUSION 640TX
Serial No. :

Before using this machine and equipment, fully understand the contents of this
manual to ensure proper operation. Should any questions arise, please ask the
nearest Technical Center or Technology Center.

IMPORTANT NOTICE
1. Be sure to observe the safety precautions described in this manual and the contents of the
safety plates on the machine and equipment. Failure may cause serious personal injury or
material damage. Please replace any missing safety plates as soon as possible.

2. No modifications are to be performed that will affect operation safety. If such modifications are
required, please contact the nearest Technical Center or Technology Center.

3. For the purpose of explaining the operation of the machine and equipment, some illustrations
may not include safety features such as covers, doors, etc. Before operation, make sure all
such items are in place.

4. This manual was considered complete and accurate at the time of publication, however, due to
our desire to constantly improve the quality and specification of all our products, it is subject to
change or modification. If you have any questions, please contact the nearest Technical Center
or Technology Center.

5. Always keep this manual near the machinery for immediate use.

6. If a new manual is required, please order from the nearest Technical Center or Technology
Center with the manual No. or the machine name, serial No. and manual name.

Issued by Manual Publication Section, Yamazaki Mazak Corporation, Japan

12. 2010
 CONTENTS
Page

1 INTRODUCTION 1-1

1-1 Background of the Installation of Machine Relocation Detectors 1-1

1-2 Procedure to Follow when Relocating the Machine 1-1

2 ALARM LIST 2-1

3 HOW TO REPLACE THE BATTERIES 3-1

3-1 Arrangement. 3-1

3-2 Preparation 3-2

3-3 Replacement Procedure .3-2

3-3-1 For relocation detector with covered battery connectors 3-2

3-3-2 For relocation detector with exposed battery connectors 3-9

 INTRODUCTION
a
1 INTRODUCTION
This manual explains what to do if the machine relocation detector raises an alarm, and also
important things you should keep in mind when replacing the batteries of the machine relocation
detector. If the alarm indicating drop in voltage of the battery is displayed, follow the instructions
given in this manual and replace the battery with new one specified by Mazak as soon as
possible. Otherwise, the automatic operation of the machine becomes impossible.
Do not start replacing the batteries until you fully understand the contents of this manual.

1-1 Background of the Installation of Machine Relocation Detectors

The machine relocation detector installed in the machine is designed to detect the replacement
of the machine and to restrict its operation if it is replaced.
The background of the installation of machine relocation detectors is that certain machines were
illegally exported by some Japanese manufacturers to third country as the proliferation of nuclear
weapons, weapons of mass destruction, and so on has been a global issue recently. In view of
this, the Japanese government requested each Japanese machine tool manufacturer to study
the feasibility of installing machine relocation detectors in order to prevent the illegal relocation
and export of machines.
In response to this request, we, Yamazaki Mazak, have decided to install machine relocation
detectors in our machines to prevent the machine from being illegally relocated to third country.
The current law enacted by the Japanese government in this control specifies that the reexport,
reselling and relocation of specified machines are subject to poor approval of the Japanese
government. If this is the case, please consult the Mazak Technical Center or Technology
Center.

1-2 Procedure to Follow when Relocating the Machine

If you are planning to relocate your machine, contact the Mazak Technical Center or Technology
Center without delay and let them know the scheduled date of relocation.
Note that relocating the machine without prior notice will make it incapable of operating
automatically. Also, it might make it impossible to reuse the machine, because particular
examinations are required to enable automatic operation.
Caution plate that indicates precautions to take when relocating the machine is attached in the
vicinity of the main power breaker for the machine.

This machine will not be operated automatically

when relocated. When this machine is transferred
please contact Yamazaki Mazak Coro, beforehand.
_3Aj I6QOC J_ 72 ENGLISH
 ALARM LIST
1
2 ALARM LIST
The machine relocation detector issues a total of 5 alarms, as listed below.

No. Alarm message Causes Operation condition Action

1393 R.D. Relocation Issued if the machine is replaced.
Detected Contact Mazak Technical
1394 R.D. Communication Issued if the machine relocation detector Center or Technology
Error is out of order or its wiring is faulty. The machine cannot Center.
1395 RD Battery Change Issued if power supply to the NC unit is be operated At that time, you may be
Time Exceeded cut off for 30 minutes or more during automatically. asked whether and how
replacement of the batteries. the machine was
1397 R.D. Battery Not relocated.
Issued if the batteries are exhausted or
Mounted the batteries are removed.
1396 R.D. Low battery Issued if the batteries are low. The machine can be Purchase replacement
operated normally. batteries from Mazak
Technical Center or
Technology Center and
replace the batteries with
new ones.

Notel: One month after the alarm 1396 R.D. Low battery is displayed on the NC unit, it
becomes impossible for the machine to be automatically operated. This period is given
as a guide, but not to guarantee a grace period of one month. So, if the alarm 1396 R.D.
Low battery is displayed, immediately replace the batteries with new ones.
Note 2: To prevent the battery from running out, leave the main power breaker ON as far as
possible during the period between when the alarm 1396 R.D. Low battery is
displayed on the NC unit and when the batteries are replaced with new ones, even
when the machine is not used.
Note 3: To change the batteries, follow the procedure in “3 HOW TO REPLACE THE
BATTERIES.” Before replacing the batteries, be sure to turn on the NC unit
temporarily.
 HOW TO REPLACE THE BATTERIES
i
3 HOW TO REPLACE THE BATTERIES

A| •Handling the batteries with wet hands may result in an electric shock.

Note 1: Never remove the machine relocation detector when replacing the batteries.
Note 2: If replacement steps (1) through (13) cannot be completed within 30 minutes, alarm
1395 RD Battery Change Time Exceeded will be given when the NC unit is turned on
in step (13) and it will become impossible to operate the machine automatically.
Note 3: Complete replacement of the batteries before the date measured by the clock in the
NC unit changes. If the date changes before the completion of replacement, alarm
1395 RD Battery Change Time Exceeded will also be issued, even if replacement of
the batteries is completed within 30 minutes.

3-1 Arrangement
The relocation detector is installed in the control panel of the machine. There are two types of
relocation detectors that differ in the method of connecting battery connectors, as shown below.
1. Relocation detector with covered battery connectors
2. Relocation detector with exposed battery connectors
Note that the procedures to follow when replacing the batteries differ depending on the detector
type, although there is no difference in functionality between the types.

1. With covered battery connectors 2. With exposed battery connectors

Unit: mm (in)
70 (2.76) 70 (2.76)

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CNl CN2 CN2

100
(3.94)
OPEN
m 100
(3.94)
V
=fT
<43 <43

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A 37.6
(1.48) (1.48)
Battery compartment cover Battery compartment cover
DHGENM0027

Fig. 3-1 Contour of the machine relocation detector

[3] HOW TO REPLACE THE BATTERIES f '

You will see two batteries installed side by side.

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Fig. 3-4 Opening of the battery compartment cover

(6) Remove the batteries from their compartment.

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Fig. 3-5 Removal of the batteries (1/2)

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HOW TO REPLACE THE BATTERIES

Note: Since the batteries are connected to a connector, do not pull them strongly to
avoid damage to the detector.

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DHGENM0019
Fig. 3-6 Removal of the batteries (2/2)

(7) Pull out the connector that connects the batteries to the detector.

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DHGENM0020
Fig. 3-7 Detachment of the connector

- Remove the batteries, holding the connector with hand. Detach the connector by pulling it
in the direction of the arrow indicated in Fig. 3-7. If your fingers cannot be put in the battery
compartment, hold the battery cable on the side closer to the connector and pull the
connector in the direction of the arrow.
Note 1: Do not pull the connector toward you, or the detector may be damaged. Some
force is required to detach the connector. [Pull-out force: Approx. 20 N (4.5 Ibf)]
Note 2: When detaching the connector, be careful not to hit your finger against the battery
compartment to avoid injury.
[3] HOW TO REPLACE THE BATTERIES
t

(8) Have a new set of batteries handy and attach the connector first.
f
- Insert the connector with the guide at an end facing downward.

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DHGENM0008
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Fig. 3-8 Shape of the battery connector (on the battery side)
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071J0001
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Fig. 3-9 Shape of the battery connector (on the battery compartment side)
DHGENM0021
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DHGENM0022
Fig. 3-10 Insertion of the connector
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 HOW TO REPLACE THE BATTERIES
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(9) Install the batteries in the detector.

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m
DHGENM0023
Fig. 3-11 Installation of the batteries

Note: When you put the battery cables in the battery compartment and close the battery
cover, be careful not to allow the cables to get caught between the battery
compartment and its cover.

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DHGENM0024
Fig. 3-12 Putting in the battery cables
[3] HOW TO REPLACE THE BATTERIES

(10) Attach the battery compartment cover. To do so, slide the battery cover diagonally upward
from this side.

[1] [2] [3]

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f
B

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DHGENM0025
Fig. 3-13 Attaching the battery compartment cover (1/2)

- Slide the battery compartment cover upward until the white line on the detector case is i
hidden behind it, push in the battery compartment cover with your fingers, and lastly check
to make sure the cover is securely attached.

[1] [2]
oma 3
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Fig. 3-14 Attaching the battery compartment cover (2/2)

Note: Failure to securely attach the battery cover could cause it to come off, thus
causing the batteries to fall down and their cables to break.
(11) Close the control panel door.
(12) Turn the main power breaker to the ON position.
(13) Turn on the NC unit.
- Make sure alarm 1397 R.D. Battery Not Mounted or 1396 R.D. Low battery has gone
out.
 HOW TO REPLACE THE BATTERIES
i
3-3-2 For relocation detector with exposed battery connectors
Note: When changing the batteries, always start out with turning on the NC unit, that is, with
the operation in step (1) below. If the operation is started in step (4), and steps (1) to (3)
are skipped, no matter whether the operation is completed within 30 minutes, an alarm
is raised and the machine is put in a state where it cannot be automatically operated.
(1) Turn on the main power breaker and the NC unit. (Turn on them without fail.)
(2) Turn off the NC unit.
(3) Turn the main power breaker to the OFF position.
(4) Open the control panel door.
- If the control panel door is opened before the main power breaker is turned to the OFF
position, the breaker will trip.
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II
i DHGENM0028
Fig. 3-15 Machine relocation detector
[s] HOW TO REPLACE THE BATTERIES

(5) Put your fingers on the projecting part of the battery cover and slide the cover downward to
remove it.

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DHGENM0029 1

Fig. 3-16 Removal of the battery compartment cover

Note: Be careful not to drop the battery compartment cover at that time.
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HOW TO REPLACE THE BATTERIES

4 You will see two batteries installed side by side.

1111
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DHGENM0030
Fig. 3-17 Opening of the battery compartment cover

(6) Remove the batteries from their compartment.

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DHGENM0031
Fig. 3-18 Removal of the batteries (1/2)
[3] HOW TO REPLACE THE BATTERIES

Note: Since the batteries are connected to a connector, do not pull them strongly to
avoid damage to the detector.

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DHGENM0032
Fig. 3-19 Removal of the batteries (2/2)

(7) Pull out the connector that connects the batteries to the detector.
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Hr
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.
DHGENM0033
Fig. 3-20 Detachment of the connector

- Remove the batteries, holding the connector with hand. Detach the connector by pulling it
in the direction of the arrow indicated in Fig. 3-20. If the connector cannot be removed
easily, hold the battery cable on the side closer to the connector and pull the connector in
the direction of the arrow.
Note: Do not pull the connector in other direction than that indicated by the arrow, or the
detector may be damaged. Some force is required to detach the connector. [Pull¬
out force: Approx. 20 N (4.5 Ibf)]
 i
HOW TO REPLACE THE BATTERIES

(8) Have a new set of batteries handy and attach the connector first.
- Insert the connector with the guide at an end facing upward.

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DHGENM0034
Fig. 3-21 Shape of the battery connector (on the battery side)

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DHGENM0035
Fig. 3-22 Shape of the battery connector (on the battery compartment side)

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DHGENM0036
Fig. 3-23 Insertion of the connector
[S] HOW TO REPLACE THE BATTERIES

(9) Install the batteries in the detector.

- Install the battery so that the battery cable comes on the right side as viewed toward the
detector.

UPS
IK

1111

II
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1;
n m
m
1/1 il DHGENM0037
Fig. 3-24 Installation of the batteries

Note: If the battery is installed so that the battery cable comes on the left side as viewed
toward the detector, the cable may get caught in the battery compartment cover
when the cover is closed.

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DHGENM0038
1
Fig. 3-25 Arrangement of the batteries and cables
 HOW TO REPLACE THE BATTERIES
i
(10) Attach the battery compartment cover. To do so, slide the battery cover diagonally upward
from this side.

[1] [2] [3]

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T
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CK

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m

DHGENM0039
Fig. 3-26 Attaching the battery compartment cover (1/3)

- Slide the battery compartment cover upward until the white line on the detector case is
hidden behind it, push in the battery compartment cover with your fingers, and lastly check
to make sure the cover is securely attached.

[1] [2]
Wff--

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ppjl!

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DHGENM0040
Fig. 3-27 Attaching the battery compartment cover (2/3)

Note: Failure to securely attach the battery cover could cause it to come off, thus
causing the batteries to fall down and their cables to break.

m
DHGENM0041
Fig. 3-28 Attaching the battery compartment cover (3/3)
[3] HOW TO REPLACE THE BATTERIES

(11) Close the control panel door.

(12) Turn the main power breaker to the ON position.
(13) Turn on the NC unit.
- Make sure alarm 1397 R.D. Battery Not Mounted or 1396 R.D. Low battery has gone
out.