Mazatrol Fusion 640MT-Pro_Integrex-100~400MkIII Series

Applications Training for Integrex-100~400MkIII Series Mazatrol Fusion 640MT-Pro Publication # C373AT1000E 3/2005

CAUTION

This Manual is published to assist experienced personnel on the operation, maintenance and/or programming of Mazak machine tools. All Mazak machine tools are engineered with a number of safety devices to protect personnel and equipment from injury or damage. Operators should not, however, rely solely upon these safety devices, but should operate the machine only after fully understanding what special precautions to take by reading the following documentation thoroughly. Do not attempt to operate or perform maintenance / repair on the machine without a thorough understanding of the actions about to be taken. If any question exists, contact the nearest Mazak service center for assistance. Certain covers, doors or safety guards may be open or removed to more clearly show machine components. These items must be in place before operating the machine. Failure to comply with this instruction may result in serious personal injury or damage to the machine tool. 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 Mazak products, it is subject to change or modification.

Notes:

INTEGREX-100~400MkIII APPLICATIONS TRAINING CONTENTS SAFETY PRECAUTIONS .................................................................................................................. S1 LOCKOUT PROCEDURE .................................................................................................................. S1 INSTALLATION PRECAUTIONS.......................................................................................................S4 WARNINGS........................................................................................................................................ S5 DOOR INTERLOCK SAFETY SPECIFICATION ............................................................................... S11 SWITCH PANEL DIAGRAM............................................................................................................... S12 1 INTEGREX-100~400MkIII MANUAL ATC OPERATION .............................................................. 1-1 Updating the Current Tool in the Turret Pocket........................................................... 1-8 2 UPPER TURRET ALIGNMENT..................................................................................................... 2-1 3 LOWER TURRET ALIGNMENT.................................................................................................... 3-1 4 FIRST & SECOND SPINDLE ALIGNMENT.................................................................................. 4-1 4-1 Outline of the 1st Spindle & 2nd Spindle.......................................................................... 4-1 4-2 Alignment of the First Spindle........................................................................................ 4-1 4-3 Concentricity Adjustment Between the First and Second Spindle ................................ 4-5 5 RENISHAW TOUCH PROBE ADJUSTMENT PROCEDURE ...................................................... 5-1 5-1 Touch Probe Adjustment Procedure............................................................................... 5-1 6 TURRET CENTER OF ROTATION ADJUSTMENT PROCEDURE (Parameter B234) .............. 6-1 7 TOOL EYE CALIBRATION PROCEDURE ................................................................................... 7-1 7-1 Integrex-100~400ST Tool Eye Parallelism Adjustment................................................. 7-1 7-2 Tool Eye Parameters ..................................................................................................... 7-3 7-3 Parameter Screen Selection .......................................................................................... 7-4 7-4 Tool Eye Calibration Procedure.....................................................................................7-5 8 TURRET SIDE ATC POSITION ADJUSTMENT ........................................................................... 8-1 9 TOOL FUNCTIONS ....................................................................................................................... 9-1 9-1 Tool Function (4 Digit T-Code) ......................................................................................9-1 9-2 Tool Function (6 Digit T-Code_......................................................................................9-2 9-3 Next Tool Automatic Selection....................................................................................... 9-2 10 EIA/ISO PROGRAMMING EXAMPLE ........................................................................................ 10-1 11 COORDINATE SYSTEM SETTING.............................................................................................11-1 11-1 G125 Coordinate System Setting Macro .....................................................................11-1 11-2 G128.8 Coordinate System Setting Macro ..................................................................11-4 APPENDIX PLC ALARMS .............................................................................................................. APP-1 ADDITIONAL PLC ALARMS........................................................................................ APP-1 M CODE TABLE ..........................................................................................................APP-15 LOWER TURRET M-CODES .................................................................................. APP-26 INTEGREX-MkIII STROKE DIAGRAMS ..................................................................... APP-29 INTEGREX-100MkIII............................................................................................... APP-29 INTEGREX-200MkIII............................................................................................... APP-35 INTEGREX-300/400MkIII........................................................................................ APP-43

Notes:

SAFETY PRECAUTIONS 6) Do not deface, scratch or remove any caution plate. Should it become illegible or missing, order another caution plate from the supplier, specifying the part number shown at the lower right corner of the plate. • BEFORE POWERING UP DANGER: Cables, cords or electric wires whose insulation is damaged can produce current leaks and electric shocks. Before using, check their condition. WARNING: 1) Be sure the instruction manual and the programming manual are fully understood before operating the machine. Every function and operating procedure should be completely clear. 2) Use approved oil resistant safety shoes, safety goggles with side covers, safe clothes, and other safety protection required. 3) Close all NC unit, operating panel, electric control panel doors and covers. CAUTION: 1) The power cable from the factory feeder switch to the machine main circuit breaker should have a sufficient sectional area to handle the electric power used. 2) Cables which must be laid on the floor must be protected from hot chips, by using rigid or other approved conduit, so that short-circuits will not occur. 3) Before first time operation of the machine after unpacking it or from being idle for a long period of time (several days or more), each sliding part must be sufficiently lubricated. To do so, push and release the pump button several times until the oil seeps out on the sliding parts. The pump button has a return spring, so do not force it to return. 4) Oil reservoirs should be filled to indicated levels. Check and add oil, if needed. 5) For lubrication points, oil specification and appropriate levels, see the various instruction plates. 6) Switches and levers should operate smoothly. Check that they do. 7) When powering the machine on, turn on the switches in the following order: first the factory feeder switch, then the machine main circuit breaker, and then the control power on switch located on the operating panel. 8) Check the coolant level, and add coolant, if needed.

The machine is provided with a number of safety devices to protect personnel and equipment from injury and damage. Operators should not, however, rely solely upon these safety devices, but should operate the machine only after fully understanding what special precautions to take by reading the following documentation thoroughly. • BASIC OPERATING PRACTICES DANGER: 1) Some control panels, transformers, motors, junction boxes and other parts have high voltage terminals. These should not be touched or a severe electric shock may be sustained. 2) Do not touch any switches with wet hands. This too, can produce an electric shock. WARNING: 1) The emergency stop pushbutton switch location should be well known, so that it can be operated at any time without having to look for it. 2) Before replacing a fuse, turn off the main incoming power switch to the machine. 3) Provide sufficient working space to avoid hazardous falls. 4) Water or oil can make floors slippery and hazardous. All floors should be clean and dry to prevent accidents 5) Do not operated any switch without a thorough understanding of the actions about to be taken. 6) Avoid accidental operation of switches. 7) Work benches near the machine must be strong enough to hold materials placed on them to prevent accidents. Articles should be prevented from slipping off the bench surface. 8) If a job is to be done by two or more persons, coordinating signals should be given at each step of the operation. The next step should not be taken unless a signal is given and acknowledged. CAUTION: 1) In the event of power failure, turn off the main circuit breaker immediately. 2) Use the recommended hydraulic oils, lubricants and grease or acceptable equivalents. 3) Replacement fuses should have the proper current ratings. 4) Protect the NC unit, operating panel, electric control panel, etc. from shocks, since this could cause a failure or malfunction. 5) Do not change parameters or electrical settings. If changes are unavoidable, record the values prior to the change so that they can be returned to their original settings, if necessary.

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• AFTER CONTROL POWER IS TURNED ON CAUTION: When the control power “ON” switch on the operating panel is on, the "READY" lamp on the operating panel should also be on (check to see that it is). • ROUTINE INSPECTIONS WARNING: When checking belt tensions, do not get your fingers caught between the belt and pulley. CAUTION:

4) Tools and other items around the machine or equipment should be stored to ensure good footing and clear aisles. 5) Do not place tools or any other items on the headstock, turret, covers and similar places (For T/M). CAUTION: 1) Tool lengths should be within specified tolerances to prevent interference. 2) After installing a tool, make a trial run.

1) Check pressure gages for proper readings. 2) Check motors, gear boxes and other parts for abnormal noises. 3) Check the motor lubrication, and sliding parts for evidence of proper lubrication. 4) Check safety covers and safety devices for proper operation. 5) Check belt tensions. Replace any set of belts that have become stretched with a fresh matching set.

• OPERATION WARNING: 1) Do not work with long hair that can be caught by the machine. Tie it back, out of the way. 2) Do not operate switches with gloves on. This could cause mis-operation. 3) Whenever a heavy workpiece must be moved, if there is any risk involved, two or more people should work together. 4) Only trained, qualified workers should operate forklift trucks, cranes or similar equipment and apply slings. 5) Whenever operating a forklift truck, crane or similar equipment, special care should be taken to prevent collisions and damage to the surroundings. 6) Wire ropes or slings should be strong enough to handle the loads to be lifted and should conform to the mandatory provisions. 7) Grip workpieces securely. 8) Stop the machine before adjusting the coolant nozzle at the tip. 9) Never touch a turning workpiece in the spindle with bare hands, or in any other way. 10) To remove a workpiece from the machine other than by a pallet changer, stop the tool and provide plenty of distance between the workpiece and the tool (for M/C). 11) While a workpiece or tool is turning, do not wipe it off or remove chips with a cloth or by hand. Always stop the machine first and then use a brush and a sweeper. 12) Do not operate the machine with the chuck and front safety covers removed (For T/M). 13) Use a brush to remove chips from the tool tip, do not use bare hands . 14) Stop the machine whenever installing or removing a tool. 15) Whenever machining magnesium alloy parts, wear a protective mask.

• WARM UP CAUTION: 1) Warm up the machine, especially the spindle and feed shaft, by running the machine for 10 to 20 minutes at about one-half or one-third the maximum speed in the automatic operation mode. 2) The automatic operation program should cause each machine component to operate. At the same time, check their operations. 3) Be particularly careful to warm up the spindle which can turn above 4000 rpm. If the machine is used for actual machining immediately after being started up following a long idle period, the sliding parts may be worn due to the lack of oil. Also, thermal expansion of the machine components can jeopardize machining accuracy. To prevent this condition, always make sure that the machine is warmed up. • PREPARATIONS WARNING: 1) Tooling should conform to the machine specifications, dimensions and types. 2) Replace all seriously worn tools with new ones to prevent injuries. 3) The work area should be adequately lighted to facilitate safety checks.

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CAUTION: 1) Thoroughly read and understand the safety precautions in the instruction manual. 2) Thoroughly read the whole maintenance manual and fully understand the principles, construction and precautions involved. • MAINTENANCE OPERATION DANGER: 1) Those not engaged in the maintenance work should not operate the main circuit breaker or the control power "ON" switch on the operating panel. For this purpose, "Do not Touch the Switch, Maintenance Operation in Progress!" or similar warning should be indicated on such switches and at any other appropriate locations. Such indication should be secured by a semi-permanent means in the reading direction. 2) With the machine turned on, any maintenance operation can be dangerous. In principle, the main circuit breaker should be turned off throughout the maintenance operation. WARNING: 1) The electrical maintenance should be done by a qualified person or by others competent to do the job. Keep close contact with the responsible person. Do not proceed alone. 2) Overtravel limit and proximity switches and interlock mechanisms including functional parts should not be removed or modified. 3) When working at a height, use steps or ladders which are maintained and controlled daily for safety. 4) Fuses, cables, etc. made by qualified manufacturers should be employed. • BEFORE OPERATION & MAINTENANCE BEGINS WARNING: 1) Arrange things in order around the section to receive the maintenance, including working environments. Wipe water and oil off parts and provide safe working environments. 2) All parts and waste oils should be removed by the operator and placed far enough away from the machine to be safe. CAUTION: 1) The maintenance person should check that the machine operates safely. 2) Maintenance and inspection data should be recorded and kept for reference.

CAUTION: 1) During automatic operation, never open the machine door. Machines equipped with the door interlock will set the program to single step. 2) When performing heavy-duty machining, carefully prevent chips from being accumulated since hot chips from certain materials can cause a fire. • TO INTERRUPT MACHINING WARNING: When leaving the machine temporarily after completing a job, turn off the power switch on the operation panel, and also the main circuit breaker. • COMPLETING A JOB CAUTION: 1) Always clean the machine or equipment. Remove and dispose of chips and clean cover windows, etc. 2) Make sure the machine has stopped running, before cleaning. 3) Return each machine component to its initial condition. 4) Check the wipers for breakage. Replace broken wipers. 5) Check the coolant, hydraulic oils and lubricants for contamination. Change them if they are seriously contaminated. 6) Check the coolant, hydraulic oil and lubricant levels. Add if necessary. 7) Clean the oil pan filter. 8) Before leaving the machine at the end of the shift, turn off the power switch on the operating panel, machine main circuit breaker and factory feeder switch in that order. • SAFETY DEVICES 1) Front cover, rear cover and coolant cover. 2) Chuck barrier, tail barrier and tool barrier (NC software). 3) Stored stroke limit (NC software). 4) Emergency stop pushbutton switch. • MAINTENANCE OPERATION PREPARATIONS 1) Do not proceed to do any maintenance operation unless instructed to do so by the foreman. 2) Replacement parts, consumables (packing, oil seals, O rings, bearing, oil and grease, etc.) Should be arranged in advance. 3) Prepare preventive maintenance and record maintenance programs.

000X717-KY 11/98

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WARNING

ALWAYS TURN THE MAIN CIRCUIT BREAKER TO THE “OFF” POSITION & USE AN APPROVED LOCKOUT DEVICE WHEN COMPLETING MAINTENANCE OR REPAIRS. THE LOCKOUT PROCEDURE THAT FOLLOWS IS INTENDED TO SAFEGUARD PERSONNEL & EQUIPMENT DURING MAINTENANCE OPERATIONS, AND, REPRESENTS THE MINIMUM REQUIREMENTS. ANY ACTION SHOULD BE PRECEDED BY A “HAZARD ANALYSIS” TO DETERMINE ANY ADDITIONAL SAFETY PRECAUTIONS THAT MAY BE NECESSARY TO ENSURE THE SAFETY OF PERSONNEL AND EQUIPMENT.

NOTE: USE OF THE FOLLOWING LOCKOUT PROCEDURE IS MANDATORY WHEN COMPLETING MAINTENANCE OR REPAIRS.

LOCKOUT PROCEDURE 1)

THE LOCKOUT PROCESS MUST BE PERFORMED BY AUTHORIZED PERSONNEL ONLY.

2)

INFORM ALL EFFECTED PERSONNEL OF YOUR INTENT TO LOCKOUT AND SERVICE THE SPECIFIED MACHINE.

3)

SHUT OFF MACHINE POWER USING NORMAL SHUT DOWN PROCEDURES.

4)

TURN OFF THE MACHINE AND INDIVIDUAL BUILDING CIRCUIT BREAKERS. MAKE SURE ALL STORED ELECTRICAL ENERGY IS RELIEVED. (EG: SPINDLE & AXIS SERVO CONTROLLERS)

5)

CONNECT THE LOCKOUT DEVICE AS SHOWN IN FIGURE 1, AND ATTACH THE APPROPRIATE TAG AT THE MACHINE CIRCUIT BREAKER. THE TAG MUST IDENTIFY THE PERSON RESPONSIBLE FOR THE LOCKOUT. THIS WILL ENSURE THAT POWER CANNOT BE RESTORED BY ANYONE ELSE.

6)

TEST THE MACHINE TO VERIFY THAT MACHINE SYSTEMS DO NOT OPERATE IN ANY WAY. ONCE TESTING IS COMPLETE, MAKE SURE ALL SWITCHES ARE IN THE “OFF” POSITION. CONFIRM THAT THE LOCKOUT DEVICES REMAIN PROPERLY INSTALLED.

7)

COMPLETE THE REQUIRED MAINTENANCE OPERATIONS.

8)

MAKE SURE ALL PERSONNEL ARE CLEAR OF THE MACHINE.

9)

REMOVE THE LOCKOUT DEVICE. MAKE SURE ALL PERSONNEL ARE AT A SAFE LOCATION BEFORE RESTORING MACHINE POWER.

PADLOCK FIGURE

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INSTALLATION PRECAUTIONS The following subjects outline the items that directly affect the machine installation and startup. To ensure an efficient and timely installation, please follow these recommendations before calling to schedule a service engineer.

6)

• ENVIRONMENTAL REQUIREMENTS Avoid the following places for installing the machine: 1) Avoid exposure to direct sunlight and/or near a heat source, etc. Ambient temperature during operation: 0° thru 45°C (32°F to 113°F). 2) Avoid areas where the humidity fluctuates greatly and/or if high humidity is present; normally 75% and below in relative humidity. A higher humidity deteriorates insulation and might accelerate the deterioration of parts. 3) Avoid areas that are especially dusty and/or where acid fumes, corrosive gases and salt are present. 4) Avoid areas of high vibration. 5) Avoid soft or weak ground (minimum load bearing capacity of 1025 lbs./ft2)

In pouring grout, fasten the leveling block base plates with the collar retaining screws to prevent the base plates from dropping. When the grout has completely hardened, level the machine properly, and tighten M24 nuts to secure the machine to the foundation.

Note: The machine must be anchored to the foundation with J-bolts, expansion bolts or other suitable method. The machine accuracy and alignment specifications quoted by Mazak can usually be obtained when the minimum foundation requirements are met. However, production of close tolerance parts requires the use of an appropriate certified foundation. Foundations that do not meet certified specifications may require more frequent machine re-leveling and re-alignment, which can not be provided under terms of warranty. If any of these conditions cannot be met, contact the nearest Mazak service office immediately.

• FOUNDATION REQUIREMENTS For high machining accuracy, the foundation must be firm and rigid. This is typically accomplished by securely fastening the machine to the foundation with anchor bolts. In addition, the depth of concrete should be as deep as possible (minimum 6 - 8 inches). Note the following: 1) There can be no cracks in the foundation concrete or surrounding area. 2) Vibration proofing material (such as asphalt) should be put all around the concrete pad. 3) Form a “cone” in the foundation for J-bolt anchors, or use expansion anchors. 4) With the foundation anchor bolt holes open pour the primary concrete at a minimum thickness of 6 - 8 inches. Typically, the concrete must have a minimum compression rating of 2500 lbs. @ 250 lbs. compression and strengthened with reinforcing rods. When the concrete has cured, rough level the machine, and install the J-bolts, leveling blocks, etc., and pour grout into foundation bolt holes. 5) Mix an anti-shrinkage agent such as Denka CSA with concrete, or use Embeco grout to fill the foundation bolt holes.

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• WIRING 1) Use only electrical conductors with performance ratings equivalent or superior. 2) Do not connect any power cables for devices which can cause line noise to the power distribution panel, such as arc welders and high frequency machinery. 3) Arrange for a qualified electrician to connect the power lines. 4) Incoming supply voltage should not deviate more than ±10% of specified supply voltage. 5) Source frequency should be±2 Hz of nominal frequency.

Desirable Independent Grounding:

NC Machine

Earth resistance: Less than 100 ohms

Common Grounds:

Resistance to ground = 100 ÷ the number of devices connected to the grounding (ohms)

[ CAUTION ]

VERIFY THE ACTUAL MACHINE ELECTRICAL Note: Never ground equipment as shown below:

POWER REQUIREMENT AND THE MAIN TRANSFORMER RATING (IF APPLICABLE), AS WELL AS THE LOCAL ELECTRICAL CODE BEFORE SIZING AND INSTALLING THE INCOMING POWER WIRING. PLEASE SEE THE ADDITIONAL CAUTIONS ON THE FOLLOWING PAGE.

• GROUNDING 1) An isolated earth ground with a resistance to ground of less than 100 ohms is required. Typically, a 5/8” copper rod, 8 feet long, and no more than 5 feet from the machine, is sufficient. Building grounds or multiple machines grounded to the same ground rod, are not acceptable. 2) The wire size should be greater than AWG (American Wire Gauge) No. 5 and SWG (British Legal Standard Wire Gauge) No. 6.

000X713-KY 11/98

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CAUTION

A step-down transformer is optional on some machine models. Be certain to verify the transformer Kva rating (where applicable), as well as local electrical code requirements before sizing and installing the incoming power wiring. Machines not equipped with a main transformer are wired for 230 VAC, 3 phase. The end user must supply a step-down transformer where factory electrical power varies more than ± 10% of the 230 VAC rating.

NOTE: Step-down or voltage regulating transformers are external (peripheral) to the machine tool and are considered the primary input line (source) for the machine. Local electrical code or practice may require a circuit breaker or other switching device for the isolation of electrical power when this type of transformer is used. In such cases, the machine tool end user is required to supply the necessary circuit breaker or switching device.

FAILURE TO COMPLY CAN RESULT IN PERSONAL INJURY AND DAMAGE TO THE MACHINE. IF ANY QUESTION EXISTS, CONTACT THE NEAREST MAZAK SERVICE CENTER FOR ASSISTANCE.

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WARNING

MAZATROL CNC CONTROLLERS PROVIDE PARAMETER SETTINGS TO LIMIT SPINDLE RPM. THESE SETTINGS ARE BASED ON THE MAXIMUM SPEED SPECIFIED BY THE CHUCK/ACTUATOR MANUFACTURER. MAKE SURE TO SET THESE PARAMETERS ACCORDING TO CHUCK SPECIFICATION WHEN INSTALLING A CHUCKING PACKAGE. ALSO, STAMP THE MAXIMUM SPINDLE RPM ON THE CHUCK IDENTIFICATION PLATE LOCATED ON THE MACHINE TOOL COVERS. REFERENCE THE CNC PARAMETER MANUAL SUPPLIED WITH THE SPECIFIC MACHINE TOOL TO IDENTIFY THE REQUIRED PARAMETERS TO CHANGE. FAILURE TO COMPLY WITH THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE MACHINE, SERIOUS INJURY OR DEATH. IF ANY QUESTIONS EXIST, CONTACT THE NEAREST MAZAK SERVICE CENTER FOR ASSISTANCE.

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WARNING

MAZAK MACHINES ARE ENGINEERED WITH A NUMBER OF SAFETY DEVICES TO PROTECT PERSONNEL AND EQUIPMENT FROM INJURY AND DAMAGE. DO NOT REMOVE, DISCONNECT, BYPASS OR MODIFY ANY LIMIT SWITCH, INTERLOCK, COVER, OR OTHER SAFETY FEATURE IN ANY WAY, EITHER MECHANICALLY OR ELECTRICALLY. FAILURE TO COMPLY WITH THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE MACHINE, SERIOUS INJURY OR DEATH. IF ANY QUESTIONS EXIST, CONTACT THE NEAREST MAZAK SERVICE CENTER FOR ASSISTANCE.

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WARNING

MAZAK MACHINES ARE ENGINEERED WITH A NUMBER OF SAFETY DEVICES TO PROTECT PERSONNEL AND EQUIPMENT FROM INJURY AND DAMAGE. MACHINE OPERATOR DOORS AND COVERS ARE DESIGNED TO WITHSTAND ACCIDENTAL IMPACT OF A BROKEN INSERT WHERE A MAXIMUM WEIGHT INSERT AT MAXIMUM TOOL DIAMETER IS RUNNING AT MAXIMUM SPINDLE RPM NEVER USE A CUTTING TOOL OR TOOL INSERT THAT EXCEEDS MACHINE SPECIFICATIONS OR THAT OF A SPECIFIC TOOL HOLDER ITSELF, WHICHEVER IS LESS. THIS RESTRICTION APPLIES TO DIAMETER, WEIGHT, MAXIMUM SPINDLE RPM, MAXIMUM CUTTING TOOL ROTATION SPEED, ETC. FOR COMPLETE SPECIFICATIONS, MAKE SURE TO REFERENCE OPERATION, MAINTENANCE AND DETAIL SPECIFICATION DOCUMENTATION SUPPLIED WITH THE MACHINE AND BY THE TOOLING MANUFACTURER. NOTE: THE MAXIMUM INSERT WEIGHT FOR MAZAK MACHINES IS 20 gf. (0.04 lbs.). FAILURE TO COMPLY WITH THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE MACHINE, SERIOUS INJURY OR DEATH. IF ANY QUESTIONS EXIST, CONTACT THE NEAREST MAZAK SERVICE CENTER FOR ASSISTANCE.

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WARNING

BEFORE STARTING OPERATION, CHECK THAT THE WORKPIECE IS SECURELY MOUNTED IN A VISE OR A SUITABLE FIXTURE. BE CERTAIN THAT THE MOUNTING IS SUFFICIENT TO WITHSTAND CUTTING FORCES DURING WORKPIECE MACHINING. FAILURE TO COMPLY WITH THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE MACHINE, SERIOUS INJURY OR DEATH. IF ANY QUESTIONS EXIST, CONTACT THE NEAREST MAZAK SERVICE CENTER FOR ASSISTANCE.

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WARNING

CONFIRM PROPER WORKPIECE FIXTURING/CLAMPING, TOOL SETUP AND THAT THE MACHINE DOOR IS SECURELY CLOSED BEFORE THE START OF MACHINING. VERIFY ALL SAFETY PRECAUTIONS OUTLINED IN THIS MANUAL BEFORE USING THE FOLLOWING CUTTING CONDITIONS: -

CUTTING CONDITIONS THAT ARE THE RESULT OF THE MAZATROL FUSION 640 AUTOMATIC CUTTING DETERMINATION FUNCTION

-

CUTTING CONDITIONS SUGGESTED BY THE MACHINING NAVAGATION FUNCTION

-

CUTTING CONDITIONS FOR TOOLS THAT ARE SUGGESTED TO BE USED BY THE MACHINING NAVAGATION FUNCTION

FAILURE TO COMPLY WITH THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE MACHINE, SERIOUS INJURY OR DEATH. IF ANY QUESTIONS EXIST, CONTACT THE NEAREST MAZAK SERVICE CENTER FOR ASSISTANCE.

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CENGDB0551E DOOR INTERLOCK SAFTY SPEC.

Determined by YMW Eng. H.Q. ‘99/9/1 Revised by YMC Prod. Eng. ’99.10.28

MACHINING CENTER DOOR

MODE

OPEN

MANUAL

AUTO

CLOSE I V OPEN

MANUAL

Prohibit Prohibit Prohibit Prohibit Prohibit

I (ON) Limit the rapid override. Max is 12%. Prohibit to run chip spiral conveyor. Can run spindle JOG. Can run spindle Orient. Can operate manual ATC.

to move axis. to start spindle running. to operate manual ATC. to operate manual Pallet Changer. to run chip spiral conveyor.

Prohibit cycle start. Prohibit to run chip spiral conveyor.

Prohibit cycle start. Prohibit to run chip spiral conveyor.

Door is always locked. Door lock can be released by pushing “DOOR UNLOCK SW” on operator panel. But, it can not release in operating ATC/Pallet changer/Axis/Spindle. Prohibit Prohibit Prohibit Prohibit Prohibit

AUTO

CLOSE

SET UP SWITCH O (OFF)

Limit the rapid override. Max is 12%. Chip spiral conveyor would stop. Can run spindle JOG. Can run spindle Orient. Can operate manual ATC.

to move axis. to start spindle running. to operate manual ATC. to operate manual Pallet Changer. to run chip spiral conveyor.

Door is always locked. Door lock can be released by pushing “DOOR UNLOCK SW” on operator panel. But, it can not release in auto operation running except single block stop or feed hold stop or M00 program stop or M01 optional stop and spindle stop. If not, Alarm displayed “Door open invalid”. If release the lock by note(*1), Alarm will occur then stop the all motion. Chip spiral conveyor would stop.

Prohibit cycle start. Chip spiral conveyor would stop.

MANUAL

No Limitation.

No Limitation.

AUTO

No Limitation.

Can not run auto operation.

TURNING CENTER SET UP SWITCH DOOR

MODE

O (OFF)

I (ON)

Can operate CHUCK, TAILSLEEVE , STEADY REST for Loading workpiece.

Can operate CHUCK, TAILSLEEVE , STEADY REST for Loading workpiece.

Can NOT operate Spindle, Axis, Turret, MANUAL Coolant, ToolEye, Partscatcher, Chip Conveyor.

Can not operate Spindle running, but Can operate Spindle JOG and Spindle Orient. Limitation of speed for axis movement . (Override is 10% max.) 1 step index only for turret.

OPEN AUTO CLOSE -> OPEN

Can operate CHUCK, TAILSLEEVE , STEADY REST for Loading workpiece. Can not run Auto-operation.

Can operate CHUCK, TAILSLEEVE , STEADY REST for Loading workpiece. Can not run Auto-operation.

MANUAL Can not open the front door in Spindle running, Axis moving, Auto-running( Cycle start, Feed hold ) due to & Mechanical locking system. (Except Single Block Stop or M00 program stop or M01 optional stop) AUTO But, if release the lock by note(*1), Alarm will occur then stop the all motion. MANUAL No Limitation.

CLOSE

AUTO

No Limitation.

No Limitation.

Can not run Auto-operation.

*1 : Door lock mechanism can not be released in machine stop by NC power OFF. If it is necessary to release the lock such as emergencies, the lock can be released by operating the supplementary lock release mechanism of the main body of the safety door lock switch. *2 : Override Limitation of Rapid speed of AXIS Machining Center : 12%. Turning Center : 10%. *3 : Chip Conveyor and Coolant should stop in the door open.

PED-EDS-001

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CENGDB0551E APPENDIX SWITCH PANEL for M640M (Machining Center)

MACHINE SET UP SWITCH SWITCH PANEL for M640MT/T (Turning Center)

PED-EDS-001

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DOOR UNLOCK SWITCH

1 INTEGREX-100~400MkIII MANUAL ATC OPERATION

Set the B-axis at zero degrees. Press the “POSITION” menu key. Press the “C-AX Connect” menu key with the “MFI” auxiliary key. Place the “TOOL SELECT” switch to “F/H/0” and press. Note: If a “256 TOOL ROTATION INHIBIT” alarm occurs, place the TOOL SELECT switch to

R/V/2 and press.

Press the “HOME” key and move the axes to home position as shown below: Move X-axis to home position. Move Y-axis to home position. Move Z-axis to home position.

1-1

Press the MDI key. The MDI window will open:

Key in: M601S__ (where S__ is the desired tool number) to index the tool magazine to the

desired tool number. Press the “MACHINE” key to display the ATC menu screen.

Turn MDI off by pressing any manual operation key. Press the “ATC MAINTE.” menu key.

Press the “TOOL LOAD” menu key.

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Verify that that the “MILL 0 ORIENT” key is highlighted.

If it is not, press the “MILLAXIS UNCLAMP” key, then the “MILL 0 ORIENT” key to orient the mill spindle. Next press the “MILLAXIS CLAMP” key to re-clamp the mill spindle.

Press the “AXIS ATC POS” key to position the Y axis to the ATC position.

Press the “Display Select” Menu soft key (Left end of menu keys).

Press the “ATC MENU” key.

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Verify that the shifter is at the ATC side. Move to the ATC side if currently at the Magazine side.

Press the “Menu Select” soft key (Right end of menu keys.)

Press the “ATC ARM SWING” menu key.

Turn the TOOL CLAMP/UNCLAMP key switch to the UNCLAMP position

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Press the “ATC ARM CHG POS” key.

Turn the TOOL CLAMP/UNCLAMP key switch to CLAMP.

Press the “ATC ARM HOME POS” key.

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Press the HOME key.

Move the Y-axis to the home position.

Press MDI menu key.

The MDI window will open:

Key in M602 S___ (Where “S___” is the proper next tool number.) Key in M601 S___ (Where “S___” is the proper magazine position.)

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Press the “Menu Select” menu soft key (Left end of menu keys).

Press the “ATC MAINTE” menu key.

Press the “TOOL UNLOAD” menu key.

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Updating The Current Tool In the Turret Pocket When the tool has been replaced by the ATC unit manually, set the number of the tool being mounted on the turret on the TURRET TOOL window of the DIAGNOSTIC display.

When TNo 5 is mounted as shown above, perform operation following the procedure described below: (1) Open the TURRET TOOL window and move the cursor to the first line of Tno. using the cursor keys

1-8

Press the MDI key.

-The MDI window will open on the monitor.

Input MDI data: M65 (ATC TOOL No. MEMORY CLEAR) Do a tool change. (Eg: T01000.0001) If you get an alarm, “Tool Number Mismatch” you forgot the M65. NOTE: If you get a “Not in ATC Position” alarm, make sure the shifter is at the magazine side and issue a M602S0, this will set the “Next Tool” display to zero.

1-9

Notes:

1-10

2 UPPER TURRET ALIGNMENT

1.Turret adjustment Mount a test bar to the mill spindle.

2. Measure parallelism between X-axis and the turret. Tolerance: 0.01mm (0.0004 in.) or less per L=100mm (4 in.)

3. If the turret is off center, mount a test bar as shown in the photo and loosen all six turret mounting bolts. (The photo shows the turret in H direction, but it will be easier to do this with the turret in V direction.)

2-1

4. Place the turret in V direction, loosen all six mounting bolts, and fit an indicator to a side face of a test bar. While tapping a turret box (arrow) with a soft hammer, adjust parallelism between the X-axis and the turret so that it will be within tolerance. Some old machines used a taper pin, but current machines do not (as of November 2000).

5. Tolerance: 0.01mm (0.0004 in.) or less per L=100mm (4 in.) After the turret mounting bolts are tightened, measure parallelism between X-axis and the turret again.

2-2

Note: The INTEGREX-100MKIII series only uses a set screw for adjustment. It will not move even if it is tapped with a soft hammer.

Adjust by pushing or pulling a set screw (2 places, arrow) in the two photos.

2-3

Notes:

2-4

3 LOWER TURRET ALIGNMENT Note: The concentric adjustment between the main & 2nd spindles must be completed before starting this adjustment.

1. Rotational Alignment Select the turret No. 2 and place it toward the secondary spindle. Then mount a magnet stand to the upper turret. Mount a dial indicator as shown to measure parallelism of the grooves for installing a boring bar holder.

Loosen the eight bolts for mounting a turret coupling.

Using a plastic hammer, tap the turret in a rotational direction for parallel adjustment of the grooves for a boring bar holder. L = 5/1000 mm or less per 40 mm (L = 0.0002 inch or less per 1.575 inch) When the adjustment is completed, tighten the eight turret coupling mounting bolts that have been loosened before, and check the parallelism again.

3-1

2. Lower Turret Alignment

Mount a boring bar holder to the turret No. 2 and measure the center of the main spindle and that of the lower turret. Align the centers so that a runout (up/down) becomes "0" in the X direction. Also, find a place where a runout (right/left) is the minimum in the Y direction.

Measure a difference between the center of the main spindle and that of the secondary spindle. With the X2-axis stationary, move the boring bar holder toward the secondary spindle side and measure a difference between the center of the secondary spindle and that of the lower turret.

Take out a shim (indicated by a red arrow) from the carriage base of the lower turret. Grind the shim so that the turrets of the main and secondary spindles will be in a range of tolerance in the X and Y directions.



Measure at the main spindle and at the secondary spindle. Tolerance must be 2/100 mm (0.0008inch) or less.

3-2

3. Parallel adjustment of the lower turret

Mount a millimess indicator to the upper surface of the turret and measure parallelism by moving the Z2-axis.

Loosen the lower turret & linear guide mounting bolts (M8 x 30) and check parallelism on the upper surface of the turret using the adjusting bolts (M6 x 20) indicated by a red arrow.

Tolerance: 5/1000 mm (0.0002inch) or less Refer to the illustration below (the right photo is not good for viewing).

3-3

4. Final alignment & checking There are four adjusting bolts only at the main spindle side.

3-4

4 FIRST & SECOND SPINDLE ALIGNMENT 4.1

Outline of the 1st Spindle & 2nd Spindle

1st spindle (standard specifications): 22kw/350N.m and dia. 76 bore in 0.0001-deg. C-axis encoder 2nd spindle (standard specifications): 18.5kw/326N.m and dia. 76 bore in 0.001-deg. PLG encoder Secondary spindle (optional specifications): 18.5kw/326N.m and dia. 76 bore in 0.0001-deg. C-axis encoder.

4.2

Alignment of the First Spindle

1. Check the current vertical alignment (spindle centerline parallelism to Z1 axis movement) Mount a test bar to the 1st spindle and mount a millimess indicator on the test bar as shown below. Note: The indicator is mounted on the top of test bar for this measurement.

4-1

2. Center height adjustment of the first spindle.

Lift the 1st. spindle using a crane, and remove the shims (4 places) to grind.

Note: Viewed from the chuck cylinder side and at the left side of the 1st spindle. The positioning pin (indicated by a red arrow) is located between the spindle mounting bolts. Remove the pin using an M6 pin puller and lift the spindle. After the shims are ground, remember to put the positioning pin back.

Re-install the shims and hand-tighten the 1st spindle mounting bolts. Re-check the spindle centerline parallelism to Z axis movement.

L = 300 mm (11.811 inch) A = 1/100 mm (0.0004 inch) or less B = 5/1000 mm (0.0002 inch) or less.

4-2

3. Check the current horizontal alignment (spindle centerline parallelism to Z1 axis movement) Mount a test bar in the 1st spindle and a millimess dial indicator to the side of the test bar as shown. Note: The indicator is on the back of test bar for this measurement.

4-3

4. Center horizontal adjustment of 1st spindle.

Adjust the parallelism in the horizontal direction using the adjusting bolts on the block indicated by the red arrow.

The adjusting bolt A is a pull bolt while adjusting bolt B is a push bolt.



L = 300 mm (11.811 inch) A = 1/100 mm (0.0004 inch) or less B = 5/1000 mm (0.0002 inch) or less Tighten the 1st. spindle mounting bolts firmly and check parallelism both in the height direction and in the horizontal direction again. 5. Center horizontal adjustment of the 1st spindle Put a workpiece in the chuck for a test cut. Using a micrometer, measure the outer diameter at each end to check for taper. Re-adjust as shown above to remove any taper. 0.0003 inch or less Note: Adjust in the following order: X & Yt axis home position X & Yt ATC position Tool Eye parameter adjustment Tailstock alignment or concentricity adjustment between the first & second spindle

4-4

4.3

Concentricity Adjustment Between the First and Second Spindle

NOTE: Make this adjustment after the 1st. spindle alignment is completed.

1. Check the current alignments

Mount a jig with reference to the 1st spindle, and measure the outer diameter of the 2nd spindle to check whether any variance exists.

Mount a test bar to the 2nd spindle and a millimess dial indicator to the test bar to check the parallelism in the height direction.

4-5

2. Center height adjustment of 2nd spindle

Based on the data obtained in step 1, remove the shims for grinding. Loosen the mounting bolts (6 places) on the 2nd spindle.

Lift the 2nd spindle using a crane, and remove the shims (4 places) to grind.

Re-install the shims that have been ground and hand-tighten the mounting bolts on the 2nd spindle. Re-check the parallelism in the height direction.



L = 300 mm (11.811 inch) A = 1/100 mm (0.0004 inch) or less B = 5/1000 mm (0.0002 inch) or less concentricity adjustment between the 1st & 2nd spindle Make this adjustment after the 1st. spindle alignment is completed.

4-6

3. Concentricity adjustment between the 1st & 2nd spindle Note: Make this adjustment after the1st spindle alignment has been completed.

Touch the dial indicator (A) attached to the 1st spindle to the side of the test bar mounted to the 2nd spindle. Touch the millimess dial indicator (B) attached to the upper turret to the other side of the test bar. Unlike the 1st spindle, the 2nd spindle does not have a positioning pin. Therefore, adjust both spindles by using the two measuring instruments as described above.

To fit the1st spindle, adjust the 2nd spindle in the right/left direction using the adjusting bolts on the adjusting blocks (2 places) indicated by a red arrow.

Tolerance = 1/100 mm (0.0004 inch) or less

4-7

3. Concentricity Adjustment Between the 1st. & 2nd. Spindle (Cont’d) Note: Make this adjustment after the 1st spindle alignment has been completed.

Touch the dial indicator (A) attached to the 1st spindle to the upper surface of the test bar mounted to the 2nd spindle. Touch the millimess dial indicator (B) attached to the upper turret to the side face of the test bar, then tighten the mounting bolts on the 2nd spindle. Tighten the bolts little by little while checking the dial indicator (A) and the millimess dial indicator (B).

4. Checking concentricity after adjustment. Remove the test bar from the 2nd spindle and measure the outer diameter as shown.



Tolerance = 1/100 mm (0.0004 inch) or less

4-8

5 RENISHAW TOUCH PROBE ADJUSTMENT PROCEDURE Mount a touch probe to the milling spindle and apply a lever type dial indicator to the tool edge. While turning the tool, adjust runout at the edge of the tool while rotating the spindle manually.

5-1

Descriptions of touch probe

5-2

5.1

Touch Probe Adjustment Procedure

As shown in the illustration below, the tool shank has four adjusting screws. Unscrew all the lock screws and make an adjustment with the adjusting screws.

As shown in the picture below, set a lever indicator to the edge of the stylus and tighten or loosen the four adjusting screws while turning the tool. With the four adjusting screws tightened, the runout of the lever indicator must be within 0.02 mm (0.0008 in.) or less. After the adjustment is completed, tighten all the lock screws firmly.

5-3

Notes:

5-4

Turret Center of Rotation Adjustment Procedure (Parameter B234) A W- Axis Stroke

Reference workpiece origin Turret center of rotation 100mm

R

A8 B234

A = The full W-axis stroke between head 1 & head 2. To Determine the A value: a) Move head 2 to head 1. b) Touch the head 2 chuck face to the head 1 chuck face using a gauge block or feeler gauge c) Make note of the W axis on the POSITION screen (absolute value). d) Add this value to the gauge block or feeler gauge dimension to determine variable A.

R = The distance from the turret face to the center of rotation. (See the adjustment procedure on the following page.)

Parameters: A8 = The distance from the turret face to the reference workpiece origin. B234 = The distance from the turret center of rotation to the reference workpiece origin. Reference workpiece origin = 100mm from the chuck face.

6-1

Turret Center of Rotation Adjustment Procedure (Parameter B234) 1) Determine the turret center of rotation value ( R ). a) Move the Z1 axis to head 1. b) Touch the turret face to the chuck face using a gauge block or feeler gauge as shown below.

B

c) Make note of the Z1 axis on the POSITION screen (absolute value). d) Add this value to the gauge block or feeler gauge dimension to determine variable B. e) Repeat steps a ~ d for head 2 as shown below to determine variable C.

C

f) Add B to C and subtract from the Z1 axis stroke value A to determine the turret rotation diameter. g) Divide by 2 for value R. 2) Add value R to the value of parameter A8. 3) Enter this value into parameter B234.

Formula:

B234 = A8 + R R = [ A - (B +C) ] / 2

6-2

7 TOOL EYE CALIBRATION PROCEDURE 7.1

Integrex-100~400ST MkIII Tool Eye Parallelism Adjustment

Parallelism measurement between the tool eye sensors is taken with respect to points A and B as indicated by the red arrows in the photo below. It is unnecessary to check parallelism between the sensors between the upper turret and the lower turret.

7-1

1) Upper turret tool eye parallelism adjustment Attach a magnetic stand with a millimess dial indicator to the upper turret as shown. Set the indicator to the outer point A and take a reading to the lower point A. Adjust as described in step (3).

2) Lower turret tool eye parallelism adjustment Attach a magnetic stand with a millimess dial indicator to the upper turret as shown. Set the indicator to the outer point B and take a reading to the lower point B. Adjust as described in step (3).

3) Loosen the 4 tool eye mounting bolts and adjust with a wrench as shown. Parallelism must be 1/100mm (0.0004 inch) or less.

7-2

7.2

Tool Eye Parameters

The upper turret parameters are shown in blue and the lower turret are in red. Note: Tool eye parameters must be adjusted whenever a home position confirmation sensor is replaced or accuracy needs to be assured after a collision. The address names and adjusting procedure are the same as for earlier Integrex machines. For parameters B61 & B62, the measured value is entered. For parameter B63, one half of the measured value is entered. The input unit is 0.001mm (metric only). These parameters become valid immediately after the setting change.

7-3

7.3

Parameter screen selection

The parameter drawing on the previous page shows the same parameter address names for the upper and lower turrets. Use the [TURRET SELECT] switch as shown below to select the parameter page for the desired turret.

7-4

8 TURRET SIDE ATC POSITION ADJUSTMENT Using the ATC alignment tools shown below, adjust the tool change position at the turret side and the X-axis and Yt-axis positions.

Note: Make sure no tools are in the turret or ATC arm. From the ATC menu, select the “INTERLOCK NEG.” menu key. CAUTION: Interlocks will be ignored, perform the following operation with extreme care.

Note: Make sure the X-axis and Yt-axis are in a position where no interference occurs before performing the ATC arm swing-in operation. Press the “ATC ARM SWING” menu key to swing in the ATC arm as shown.

Mount the alignment tool B to the arm No. 1 and the alignment tool C to the mill spindle respectively.

Move the X-axis and Yt-axis close to the ATC arm with the manual hand wheel, and find a position where alignment tool A passes through the alignment tools B and C smoothly. Make note of the machine position value for input into parameter data. Remove the alignment tool A, and press the “ATC ARM HOME POS” menu key to return the arm. Remove the alignment tools B and C. From the ATC menu, select the “INTERLOCK NEG.” menu key to cancel the interlock neglect function.

8-1

Parameter Change Input the values of the machine position noted above for X-axis and Yt-axis to the following parameters: RL-16 (tool change position for Yt-axis) RL-17 (tool change position for X-axis) Note: Unlike previous M640, the parameter input unit of M640 MT-Pro is changed from 1/1000 to 1/10000.

8-2

9 TOOL FUNCTIONS 9-1 Tool Function (4-Digit T-Code) Tool function, also referred to as T-code function, is used to designate the tool number and offset number. Of a four-digit integer at address T, upper and lower two digits are respectively used to specify the tool number and offset number. T !!"".△△◇◇ ; Tool ID code Application direction Tool offset number Tool number Use two digits after the decimal point to specify the application direction of the tool in accordance with the registration on the TOOL DATA display. △△

0, 2, 4, 6, 8

1, 3, 5, 7, 9

11

13

14

15

DIRECTION

←

↓

→

←

↓

→

Note 1: The directions shown above may not all apply to some machine models. Note 2: The reverse-display directions refer to a milling spindle orientation of 180 degrees, and can be used for the application of a turning tool with the tip reversely directed. In addition to the application direction, the ID code (A to Z) of the tool can also be designated in accordance with the registration on the TOOL DATA display on condition that the bit 6 of the parameter P111 is set to 1. ◇◇

1

2

3

4

5

6

7

8

9

11

12

13

ID code

A

B

C

D

E

F

G

H

J

K

L

M

◇◇

14

15

16

17

18

19

21

22

23

24

25

26

ID code

N

P

Q

R

S

T

U

V

W

X

Y

Z

Note 3: An alarm will result if no corresponding tool for the specified direction and ID code is registered on the TOOL DATA display. Note 4: Depending on the number of the decimal places, the T-code is processed as follows: 1) A designation of a single or two decimal places is always processed as that of the application direction. It is not possible, therefore, to merely designate the ID code. 2) The T-code with three or five and more decimal places causes an alarm. 3) The default attribute of the T-code is of “← ← direction without ID code”. Only one T-code can be included in a block, and the available range of T-codes depends on the machine specifications. For further details, especially on how to number the actual tools to be used, refer to the operating manual of the relevant machine. The T-code can be given with any other commands in one block, and the T-code given together with an axis motion command is executed, depending upon the machine specifications, in one of the following two timings: - The T-code is not executed till completion of the motion command, or - The T-code is executed simultaneously with the motion command.

9-1

9-2 Tool Function (6-Digit T-Code) This function is also used to designate the tool number and offset number. Of a six-digit integer at address T, upper and lower three digits are respectively used to specify the tool number and offset number. See the above description of the 4-digit T-code for the meaning of the decimal fractions. The available range of T-codes depends on the machine specifications. For further details, refer to the operating manual of the relevant machine. Only one T-code can be included in a block. T !!!""".△△◇◇ ; Tool ID code Application direction Tool offset number Tool number Set bit 4 of parameter P10 to “0” or “1” respectively to use 4-digit or 6-digit T-codes.

9-3 Next Tool Automatic Selection You can designate return tool and a next tool for the machine provided with ATC function by commanding T-code in the format shown below. The return tool refers to an unnecessary tool returned to load another tool to be used. The assigned return tool is accomodated in the magazine. The next tool refers to a tool used for the next machining, which can be assigned when it is now accomodated in the magazine. The next tool in the magazine can be indexed at ATC position beforehand by commanding the next tool, thus permitting reduced ATC time. See Section 11-1 for the details of the application direction and ID code. T !!!""".△△◇◇ A∗∗∗ B∗∗∗ ; Next tool Return tool Tool ID code Application direction

9-2

10 EIA/ISO PROGRAMMING EXAMPLE

10-1

O00000001 (Integrex-200S

Programming Example)

#500=30. (SUB SHIFT ) N1(Edge Face) G53 (T32 MODE) M202 G28 U0 Y0 T0101.9 B2 G96 S250 M03 M08 G00 Z.1 G00 X10. G00 X3.1 Z0 G99 G01 X-.0625 F.005 G00 Z.08 X2.6 Z.05 G01 Z-.995 X3.1 G00 X3.2 Z.05 X2.2 G01 Z-.995 X2.6 G00 Z.05 X1.8575 G01 X1.9017 Z-.0092 X2.04 Z-.0783 Z-.995 X2.2 G00 Z.0474 X1.7486 G01 X1.8617 Z-.0092 X2. Z-.0783 Z-1. X2.9375 X3.0975 G28 U0 Y0 M05

N2(Mill Hex on Face HD1) G53 M302 M201 T0202.8 B3 G97 S2000 M203 G28 U0 Y0 M212 G0 C0 M211 G98 G00 Z1. G17 UV G12.1 G00 X1.6495 Y-.375 M08 Z.1 Z-1. F20. G41 G01 X1. Y0 X.5 Y-.866 X-.5 X-1. Y0 X-.5 Y.866 X.5 X1. Y0 Z1. F100. G40 X1.6495 Y.375 G13.1 M212 G28 U0 M302 M201 T0202.8 B3 G97 S2000 M203 G28 U0 Y0 M212 G0 C0

10-2

M211 M153 M250 B45. M251 G125 X1. Y0 Z-1. R1 G17 UV G00 Z.5 X0 Y1.616 G01 Z0 F20. G41 G01 X1. Y.866 F10. Y-.866 G40 Y-1.616 F10. G0 Z.5 M212 M205 G69.5

N3(Drill 1/8" hole 45 degree Face) G53 M302 M201 T0303.8 B11 G97 S2000 M203 G28 U0 Y0 M212 G0 C0 M211 M153 M250 B45. M251 G125 X1. Y0 Z-1. R1 S#500 G17 UV G98 G00 X.25 Y.3 M08 Z.1 G83 Z-.25 F2. Y0 Y-.3 Z1. M09 G80 G69.5 M212 M154 G28 U0 T0303.8

10-3

N4 ( TRANSFER ) G28 U0 Y0 M202 M05 M305 G110 Z2 M306 G00 Z-#500 ( TRANSFER POSITION ) M544 M508 G98 G31 W-.1 F20. M307 M06 G28 W0 G111 M545 M509 G50 W-#500 ( SUB SHIFT ) M300

N5(Edge Face HD2) G53 G28 U0 Y0 G50 S3000 T1111.9 B12 G96 S250 M03 M08 G50 W-#500 (SUB SHIFT ) G00 Z.1 G00 X10. G00 X3.1 Z-.9325 G99 Z-4. G01 X-.0625 F.005 G00 Z-4.08 (Rough OD turn HD2) X2.6 Z-4.05 G01 Z-3.005 X3.1 G00 X3.2 Z-4.05 X2.2 G01 Z-3.005 X2.6 G00 Z-4.05 X1.8575 G01 X1.9017 Z-3.9908 X2.0017 Z-3.9408 X2.04 Z-3.9217 Z-3.005 X2.2 (Finish OD Turn HD2) G00 X3.1 Z-4.0474 X1.7486 G01 X1.8617 Z-3.9908 X2. Z-3.9217 Z-3. X2.9375 X3.0975 G69.5 G28 U0 Y0 M05

10-4

N6(Mill 45 degree Face) G53 M300 M201 G112 M19 S0 T1212.8 B13 G97 G112 S2000 M203 M212 G0 C0 M211 G28 U0 Y0 M153 M250 G00 B135. M251 G125 X1. Y0 Z-3. R1 S#500 G98 G00 Z1. G17 UV G00 X0 Y-1.616 M08 Z.5 Z0 F20. G01 G41 Y-.866 F10. Y.866 Y1.616 F10. G40 G00 Z.5 M205 M212 G69.5 M154

N7(Drill 1/8" hole 45 degree Face HD2) G53 M302 M201 T1313.8 B1 G97 S2000 M203 G28 U0 Y0 M212 G0 C0 M211 M250 B135. M251 G125 X1. Y0 Z0 R1 S#500 G17 UV G00 Z.1 G98 G00 X-.25 Y.3 M08 G83 Z-1. F2. Y0 T-.3 G0 Z5. M09 M205 M212 G80 G69.5 G28 U0 Y0 M30

10-5

Notes:

10-6

11 COORDINATE SYSTEM SETTING 11.1 G125 Coordinate System Setting Macro Program position coordinate system rotation 1. Outline This command is used to determine a new coordinate system through the translation of the origin of the currently active workpiece coordinate system and the rotation on an axis of coordinate. Use this command to specify freely a plane in space which is convenient for programming. 2. Programming format G125 Xx 0 Zz0 Yy0 Rr Ss ;

Program coordinate system rotation ON

G69.5 ;

Program coordinate system rotation OFF Xx0 Zz0 Yy0 :

Coordinates of the center of rotation Specify in absolute dimensions the translation of the workpiece origin.

Rr : Designation of plane rotation (1: valid, 0: invalid)

After the selection of the G17 (X-Y) plane, the workpiece origin is shifted to the point (X, Z, Y) = (1, –2, 0) and the plane is rotated by 30 degrees on the Y’-axis. The new coordinate system (X’, Y’, Z’) has thus been established. The sub spindle shift is zero. -The cancel command G69.5 will set again the coordinate system subjected to the translation and rotation by the preceding G125 command. -In the G125 mode all the dimensions must be entered in radius values.

11-1

3. G125 Macro Program Example

O00000001 (sample 1) N1(Mill Slot) G53 ( T32 MODE ) M201 T0101.8 B2 G97 S2000 M203 G28 U0 M250 G00 B30. M251 G17 G125 X2.5 Y0 Z-2. R1 S0. G98 G00 C0 Z1. G0 X4. Y0M08 Z.1 M211 G01 Z-.25 F20. X-4. F10. M212 G00 Z1.0 M205 G69.5 G28 U0Y0

11-2

G125 Macro Program Example (Cont’d)

N2(Drill .5" hole Solid Carbide) G53 ( T32 MODE ) M201 T0202.8 B1 G97 S2000 M203 G28 U0 Y0 M250 B30. M251 G17 G125 X2.5 Y0 Z-2. R1 S0. G98 G00 X2. C0 M08 M211 Z1.0 Y-1.0 G01 Z.1 F20. G01 Z-1. F7.5 G01 Z.1 F400. G00 Y1.0 G01 Z-1. F7.5 G01 Z.1 F400. M212 M09 M205 G69.5 G28 U0 Y0 M30

11-3

11.2 G128.8 Coordinate System Setting Macro G128.8 Program position coordinate system rotation (G43.4 Supported) 1. Outline This command is used to determine a new coordinate system through the translation of the origin of the currently active workpiece coordinate system and the rotation on an axis of coordinate. Use this command to specify freely a plane in space which is convenient for programming. 2. Programming format G128 Ee Xx 0 Zz0 Yy0 Rr Ss Qq;

Program coordinate system rotation ON (If Xx. Yy or Zz omitted “0” is the default)

Xx0 Zz0 Yy0 :

Coordinates of the center of rotation Designation of plane rotation (1; valid, 0: invalid)

Rr :

Designation of plane rotation (1: valid, 0: invalid)

Ss;

Designation of Z2 axis shifter for transfer of HD2 (amount Z2 moved)

Q**

Calculating point 0: Tip of tool 1.0: Center of ball nose (for mold machining) 2.0: Center of turret (for B axis contouring) (Data Q is not necessary to command if choosing tip of tool for calculating point)

11-4

G128.8 Program position coordinate system rotation (Cont’d) 1) 2) 3) 4) 5)

Y axis must be at home position before commanding the macro program. B axis must be positioned to programming point before commanding the macro program. X and Z axis do not require home position return before commanding the macro program. Workpiece coordinate created by this macro program will be canceled by G53.5 or next tool change. The following data is required in the TOOL DATA and SET UP SCREEN: (TOOL DATA SCREEN) Tool Name Actual Tool Diameter Tool Set X Tool Set Z

6)

(SET UP SCREEN) Z Offset

Make sure parameters B234 and B263 are set properly.

11-5

Notes:

11-6

INTEGREX-100~400MkIII

PLC

ALARM

LISTS

! As shown below, the alarm message in the DIAGNOSIS display varies between models INTEGREX 300/400-III/IIIT and INTEGREX 300/400-IIIS/IIIST. CAUTION

D135W0049E’

1.

INTEGREX 300/400-III Neither SP1 nor SP2 is displayed on the display.

2.

INTEGREX 300/400-IIIS/IIIST SP1 or SP2 is displayed on the display. The alarm message related to the secondary spindle or W-axis is displayed with SP2. Example:

3.

250 SPINDLE START MISOPERATION ( , , )SP1 An alarm message related to the main spindle. SP1 is replaced with SP2 for an alarm of the same message but related to the secondary spindle.

INTEGREX 300/400-IIIT TR1 or TR2 is displayed on the display. The alarm message related to the lower turret is displayed with TR2. (Only SP1/SP2 is used for IIIST.) Example:

256 TURRET ROTATION PROHIBITED ( , , )TR1 An alarm message related to the upper turret (milling head). TR1 is replaced with TR2 for an alarm of the same message but related to the lower turret.

Remark: Alarms shown in Section 2-1 “Alarm List for the INTEGREX 300/400III/IIIT/IIIS/IIIST” are all displayed with “SP1” in the INTEGREX 300/400-IIIS.

H374S5B012E

APP-1

Alarm List for the INTEGREX 300/400-II II Alarm No. and message

Description

Check and remedy

Address

200: THERMAL TRIP Thermal relay for the hydraulic unit has (EMERGENCY STOP) tripped.

Check that the hydraulic unit motor is normal, and then turn the power off and on.

X2

201: BREAKER TRIP

Power line on/off circuit breaker QF2, QP3, QF4, QF81, or QF82 has tripped.

Check the circuit breakers within the control panel and then reset the circuit breaker that has tripped.

X3 X4

202: HYDRAULIC PRESSURE DOWN

An oil pressure decrease below the required level has activated the pressure switch.

Check the hydraulic unit and piping for abnormalities.

X447

203: AIR PRESSURE DOWN

An air pressure decrease below the required level has activated the pressure switch SP30.

Check the air supply port and piping for abnormalities.

X446

204: SPINDLE CONTROLLER MALFUNCTION

An alarm occurred at spindle controller.

Turn off the main circuit breaker and then turn it back on. If the alarm is not released, please contact your MAZAK service representative.

―

205: MILLING CONTROLLER MALFUNCTION

An alarm occurred at milling spindle controller.

Turn off the main circuit breaker and then turn it back on. If the alarm is not released, please contact your MAZAK service representative.

―

206: OPEN FRONT DOOR (EMERGENCY STOP)

Coolant cover (front door) is opened during automatic operation.

Close the coolant cover (front door) and start the machine in automatic operation mode.

211: NOT OPERATED MCODE SIMULTA.

M-codes which must not be used in combination were selected at the same time.

Correct the program.

212: CHUCK OPEN/CLOSE SWITCH MALF.

The signal from the chuck open/close foot switch has been input during chuck open/close command (M6, M7) in the automatic operation.

Fault in the chuck open/close foot switch circuit

213: ILLEGAL DESIGNATED TOOL No.

T code that does not exist in the specification is assigned.

Correct the program.

215: CHUCK SYSTEM MALFUNCTION

An erroneous chucking action was detected during chucking operation.

The chuck unit has failed to grip the material.

XA

― X44E (X44F)

―

The chuck open/close end sensor (SQ2/SQ3) is abnormal or faulty. 218: CHUCKING TYPE NOT SELECTED

Type of chucking (inner/outer) of spindle chuck is not selected.

Select the type of chucking.

220: TURRET POSITION SENSOR MALF.

The milling head positioning /B-axis sensor (encoder) signal has become invalid.

The milling head positioning /B-axis sensor (encoder) is in trouble.

The milling head index /B-axis motor is malfunctioning.

Turn off the main circuit breaker and then turn it back on. If the alarm is not released, please contact your MAZAK service representative.

― X440/ X441 ―

―

221: TURRET CLAMP SENSOR MALFUNCTION

In spite of the fact that the milling head is The clamping confirmation sensor is actually clamped, the clamping confirmation abnormal or faulty. sensor (SQ18) does not turn on. In spite of the fact that the milling head is actually unclamped, the clamping confirmation sensor (SQ18) does not turn off.

X460

224: CHUCK SENSOR MALFUNCTION

The chuck open or close confirmation sensor fails in function, or both of the sensors are ON simultaneously.

X440/ X441

APP-2

The chuck open or close confirmation sensor (SQ2/SQ3) is abnormal or faulty.

Alarm No. and message

Description

Check and remedy

Address

225: FRONT DOOR SENSOR MALFUNCTION

For the machine with an optional automatic door, the front door open or close confirmation sensor fails in function, or both of the sensors are ON simultaneously.

The front door open or close confirmation sensor (SQ2/SQ3) is abnormal or faulty.

231: TOOL EYE POSITION SENSOR MALF.

The TOOL EYE extension or retraction confirmation sensor (SQ7/SQ8) does not turn on, or both of the sensors are ON simultaneously.

The TOOL EYE arm is likely to be obstructed in the middle of its operation.

234: TOOL CLAMP SENSOR MALFUNCTION

The tool clamp check sensor fails to function.

Adjust the setting of the TIM12 timer.

236: PARTS-CATCHER SENSOR MALF.

For the machine with an optional automatic parts catcher, the advance end confirmation sensor or retract end confirmation sensor does not turn on, or both of the sensors are ON simultaneously.

The parts catcher advance/retract end confirmation sensors are faulty or malfunctioning.

―

243: MEASURING CONTROLLER MALF.

An error occurred at the workpiece measurement controller (option).

Check the cause of error at the workpiece measurement controller.

―

245: BAR-FEEDER CONTROLLER MALF.

An error occurred at the bar feeder controller.

Check the cause of error at the bar feeder controller.

―

248: EXTERNAL CONTROLLER (No.1) MALF.

Failure of controller of a peripheral unit (option)

Check the cause of error at the controller of a peripheral unit (option).

―

250: SPINDLE START MISOPERATION

1. A spindle rotation command was given during mis-chucking. (Chuck sensor provided.)

1. Close the chuck and start operation with the workpiece gripped. Alternatively, the chuck open/close check sensor may be improperly adjusted. → Check the sensor.

2. A spindle rotation command was given even though the chuck was not closed.

2. After closing the chuck using the chuck clamp command, designate the spindle rotation command.

3. A spindle rotation command was given together with an orient command.

3. Take steps so that the commands are not given together.

4. The M3, M4, M16, M17, M18 or M19 command was given in the milling mode.

4. 1) Program error → Correct the program.

Or the corresponding sensor is faulty.

X14/ XA

― X444/ X445 ―

X440/ X441

―

2) Switch to the turning mode and then designate the command. 5. A spindle rotation command was given without the TOOL EYE at the backward end.

5. Retract the TOOL EYE. Also, check the backward end sensor.

X445

6. A spindle rotation command was given with the door not closed when the door interlock switch was set to AUTO.

6. Close the door and start the spindle rotation.

X15

7. Alarm 297 CHUCK PRESSURE DOWN or 296 TAIL SLEEVE PRESSURE DOWN is displayed.

7. Clear the alarm 297 or 296.

X442 X443 X480

APP-3

XA

Alarm No. and message

Description

Check and remedy

251: MILLING MOTOR ROTATION PROHIB.

1. A milling spindle rotation command was given even though the chuck was not closed.

1. After closing the chuck using the chuck clamp command, designate the milling spindle rotation command.

2. A milling spindle rotation command was given even though the milling tool was not clamped.

2. After clamping the milling tool, designate the milling spindle rotation command.

3. A milling spindle rotation command was given even though the milling head (Baxis) was not clamped.

3. After clamping the milling head (Baxis), designate the milling spindle rotation command and check the milling head clamp sensor.

4. The M203, M204 or M219 command was given in the turning mode.

4. 1) Program error → Correct the program.

Address

―

X460

―

2) Switch to the milling mode and then designate the command.

252: AXIS MOVE MISOPERATION

5. A milling spindle rotation command was given with the door not closed when the door interlock switch was set to AUTO. [When the door interlock option is provided.]

5. Close the door and start the milling spindle rotation.

X15 XA

6. Alarm 297 CHUCK PRESSURE DOWN or 296 TAIL SLEEVE PRESSURE DOWN is displayed.

6. Clear the alarm 297 or 296.

X442 X443 X480

7. The touch sensor for workpiece measurement is mounted on the milling head.

7. Change the touch sensor for a rotating tool in the MDI or automatic mode.

8. The milling tool rotation command is given though the TOOL EYE is not placed at the backward end.

8. Retract the TOOL EYE. Also check the backward end sensor.

X445

An attempt was made to execute an axis movement under the axis movement interdiction.

1. First close the magazine cover and then execute the axis movement.

XD

―

1. An attempt was made to execute an axis movement with the magazine cover opened. 2. An attempt was made to execute a movement along the X-axis with the Xaxis interlock activated.

2. X-axis interlock is activated in the following states: 1) When the milling head is not clamped. 2) When the tool is not clamped. 3) When the milling head is not positioned at the indexing position. 4) When the arm is positioned somewhere between the stand-by position and the swinging-in position. 5) When the magazine cover is opened. Note: When states 1) to 5) occur, an axis movement can be executed by the manual pulse handle and the [ATC MENU] → [INTERLOCK NEG.] menu key operation. (Refer to PART 2.) 6) When the steady rest is connected. 7) When the tailstock body is connected.

APP-4

X460

XD

Alarm No. and message 252: AXIS MOVE MISOPERATION

Description

Check and remedy

3. An attempt was made to execute a movement along the Z-axis with the Zaxis interlock activated.

Address

3. Z-axis interlock is activated in the following states: 1) Same as states 1) to 7) for the X-axis interlock. ―

Note: An axis movement can be executed by the manual pulse handle and the [ATC MENU] → [INTERLOCK NEG.] menu key operation. (Refer to PART 2.) 4. An attempt was made to execute a Caxis movement with the C-axis interlock activated.

4. C-axis interlock is activated in the following states: When the C-axis is clamped.

253: OVERLOAD DETECTION

An overload has been detected in a machine having an overload detection option.

Check the overload detection level.

256: TURRET ROTATION PROHIBITED

This alarm display lights when an attempt has been made to turn the milling head or when the conditions were unstable.

―

―

Reduce the cutting load.

―

―

1. Set the arm to the stand-by position by using the ATC menu. (Refer to PART 2.)

―

2. The turning tool or milling tool has been unclamped.

2. Clamp the tool using the clamp switch.

―

257: ILLEGAL M-CODE

An illegal M code has been specified.

Correct the program.

―

258: TNo. MISMATCH

Since ATC has been aborted by pressing the emergency stop button in the middle of the ATC process, the number of the tool mounted on the milling head is different from that displayed on the NC display.

Change the “TURRET TOOL” number displayed in the DIAGNOSIS display to the number of the current tool (that is, the parenthesized numerals in alarm messages).

―

259: MODE CHANGE IMPOSSIBLE

The rapid feed mode or zero point return mode switch on the operating panel has been pressed during tool nose measurement with the TOOL EYE.

The rapid feed or zero point return mode cannot be selected during tool nose measurement.

260: SLIDEWAY LUBRICATION ALARM

The pressure switch for slideway lubrication (SP67) does not turn on within a fixed time.

Check the lubricating grease amount, and replenish grease if required.

X465

261: HEAD LUBRICATION ALARM

The pressure switch (SP25, SP26, SP27) in the spindle cooling unit has worked.

Check the coolant level.

X485

264: THERMAL TRIP (SINGLE BLOCK)

Thermal relay F13 for the coolant motor has tripped.

Check the regarding unit (e.g. chip conveyor for clogging with chips) and then reset the thermal relay.

X5

1. When the arm is at the milling head side or at a swinging-in position between stand-by and the milling head side. In the automatic/manual mode:

Thermal relay F14 for the chip conveyor has tripped. 267: BALL SCREW LUBRICATION ALARM

The pressure switch (SP7) for ball screw and C-axis gear lubrication does not turn on or off within a fixed time.

Check the lubrication oil level, and replenish lubricating oil if required.

The float switch (SL1) has turned off.

―

X6 X44C

X44D

270: SPINDLE ORIENT EXCEED TIME

Although a spindle orientation command is given, the orientation confirmation signal does not turn on within a predetermined time.

The spindle motor detector/controller is abnormal.

―

272: TURRET INDEX EXCEED TIME

Although a milling head indexing command is given, the index confirmation signal does not turn on within a predetermined time.

The milling head index motor detector/controller is abnormal.

―

APP-5

Alarm No. and message

Description

Check and remedy

275: ROBOT SERVICE EXCEED TIME

For machines with an optional robot, although a robot service command is given, the confirmation signal does not turn on within a predetermined time.

The robot is malfunctioning (check the robot controller to examine the cause).

276: ATC CYCLE EXCEED TIME

Although 120 seconds have passed since the issuance of the ATC command, the operation complete signal does not turn on.

Reset the ATC unit using either of the following methods:

Address

―

(1) Cancel the ATC command by pressing the emergency stop button. (2) Release the emergency stop status by pressing the RESET key.

―

(3) Execute the ATC reset function of the machine menu. If the ATC unit cannot be reset, please contact your MAZAK service representative. 279: PARTS CATCHER CYCLE EXCEED TIME

For the machine with an optional automatic parts catcher, although a parts catcher advance/retract command is given, the advance end confirmation sensor or retract end confirmation sensor does not turn on within a predetermined time.

The parts catcher advance/retract end confirmation sensor are faulty or malfunctioning.

282: CHUCK CLAMP EXCEED TIME

Although a chuck open/close command is given, the confirmation signal does not turn on within a predetermined time.

Adjust the chuck open/close end sensor. Or the sensor is in trouble.

286: FRONT DOOR EXCEED TIME

For machines with an optional automatic door, although a door open/close command is given, the confirmation signal does not turn on within a predetermined time.

―

X440/ X441

The hydraulic system is abnormal.

―

Adjust the front door open/close end sensor. Or the sensor is in trouble.

―

The pneumatic system is abnormal.

―

292: SENSOR MALFUNCTION No. 3

The correction value has exceeded the limit set in the thermal displacement compensation.

Check that the thermal sensor is correctly wiring.

R1, R2, R3

293: SENSOR MALFUNCTION No. 4

The correction value has changed largely than the previous one in the thermal displacement compensation.

Check that the thermal sensor is correctly wiring.

R1, R2, R3

297: CHUCK PRESSURE DOWN

The spindle chuck pressure remains reduced in a machine having a spindle chuck pressure guarantee option.

Check the spindle chuck pressure.

X442/ X443

300: START COND. ERR. (DOOR OPEN)

The cycle start button was pressed while the front cover (front door) was opened.

Close the front cover.

XA

301: START COND. ERR. (TUR UNCLAMP)

The cycle start button was pressed while the milling head was unclamped.

Clamp the milling head.

X460

302: START COND. ERR. (EXT RESET)

The cycle start button was pressed while the external reset signal was ON.

Check the controller of the external unit.

―

303: START COND. ERR. (EXT FEED HOLD)

The start button was pressed while the external feed hold signal was ON.

Check the controller of the external unit.

―

308: C/S ERROR (TOOL EYE EXTEND)

The cycle start button has been pressed with the TOOL EYE arm placed in a measurement position.

Retract (restore) the TOOL EYE arm into position.

310: C/S ERROR (TNo.MISMATCH)

During the restart of operation after manual interruption, a tool number different from that which was valid before interruption has been specified.

Specify the same tool number as that which was valid before interruption.

―

311: C/S ERROR (TAIL STOCK QUILL)

The cycle start button has been pressed with the tail spindle not placed at its zero point or advance end.

Place the tail spindle at its zero point or advance end.

―

APP-6

X445

Alarm No. and message

Description

Check and remedy

Address

312: C/S ERROR (PTCATCHER EXTEND)

The cycle start button has been pressed with the parts catcher (workpiece unloader) extended.

Retract (restore) the parts catcher into the position.

―

313: C/S ERROR (C/S QUILL COMMAND)

A tailstock advance/retract command was given with the tail spindle advance/retract switch (SA2) not placed at the neutral position.

Place the tail spindle advance/retract switch at the neutral position.

―

320: TOOL UNCLAMP IMP. (M-SP ROT.)

A milling head unclamping command has been given during rotation of the milling spindle motor.

After the milling spindle motor has stopped, perform the operations described at left.

―

321: MODE CHANGE IMPOSSIBLE (DURING ATC CYCLE)

Mode changing has been attempted during the ATC cycle.

The operation mode cannot be changed during ATC. To change the mode, wait until ATC has been completed.

322: RAPID MODE IMP. (ORIGIN RET UNF)

The rapid feed mode was selected without carrying out the zero point return operation after the power supply had been turned on.

Carry out the zero-point return operation.

324: DIFF. MODE (ORIGIN RET UNFIN.)

The automatic operation mode was selected without carrying out the zero-point return operation after the power supply had been turned on.

Carry out the zero-point return operation.

325: TL. EYE EXT. IMP.

A TOOL EYE extend/retract command has been given with the SET UP switch remaining set to “O” and the front door remaining open.

Change the setting of the SET UP switch to “I”. Or close the front door.

X11C/ XA

326: T/S QUILL EXT. IMP.

The tail spindle has advanced with the TOOL EYE arm extended.

Retract the TOOL EYE arm.

X444

The tail spindle has advanced/retracted during the spindle rotation.

Stop the spindle.

The tail spindle has advanced/retracted during the milling spindle rotation.

Stop the milling spindle.

The condition to perform ATC is not appropriate. The details are described at the left. See D200/D201.

90 (D201)

The machine is under locking state. After releasing the machine lock, press the cycle start button. The ATC will be executed.

91 (D201)

The tailstock is in the connection state. After releasing the connection of the tailstock, perform the ATC.

97 (D201)

When the loading tool is specified in the ATC, the shifter is not placed at the ATC side. Move the shifter manually on the ATC side.

98 (D201)

The magazine cannot be rotated because the specified tool is different from the loading tool and the shifter is not placed on the ATC side. Move the shifter to the ATC side manually.

327: NOT IN ATC START POSITION

APP-7

―

―

―

―

Alarm No. and message 327: NOT IN ATC START POSITION

329: CHUCKING SELECTION PROHIBITED

340: CONDITION No.1 MISSING

Description

Check and remedy

The condition to perform ATC is not appropriate. The details are described at the left. See D200/D201.

99 (D201)

The shifter is not placed in the magazine side without the loading tool when commanding the ATC. Move the shifter to the magazine side/retract position manually.

9800 (D200)

The tool command is given incorrectly. Perform again.

9900 (D200)

The ATC arm is not at the reference point position. Move the ATC arm to the reference point position manually. Then perform again the ATC.

The inside/outside chucking selection is performed with the chuck not opened.

Open the chuck (and remove the workpiece.)

The inside/outside chucking selection is performed when the spindle or milling spindle is not stopped.

Stop the spindle or milling spindle.

Address

―

―

In a machine having a warming-up option - the warming-up program number is not registered.

Register the warming-up program number (1 – 9999) in the MACHINE PARAMETER display.

R18

- the front cover (front door) is open.

Close the front cover (front door).

XA

- The axis had not yet been initialized when the NC unit was turned off.

To warm up the machine, return all axes to their zero points before turning off the NC unit.

341: CONDITION No.2 MISSING

The M-code command for milling spindle through air blowout has been issued during coolant injection.

Correct the program.

361: TAIL ALARM

The tailstock amplifier has detected an overload or too great an error.

If the alarm is not cleared, please contact your MAZAK service representative.

―

The tailstock has moved during spindle rotation. 365 CARRIER CONTROLER MALFUNCTION

An alarm signal has been sent from the carrier-use amplifier to the NC unit.

After turning NC power off, turn the main circuit breaker off and then turn it back on.

366: SHIFTER CONTROLER MALFUNCTION

An alarm signal has been sent from the shifter-use amplifier to the NC unit.

374: OPERATING SWITCH FAULT

A control (switch) on the operation panel was ON upon turning-on.

The control is faulty unless it has been inadvertently turned on.

375: MOTOR & SERVO TURNING OFF ERR.

Since the electromagnetic switch OFF command for the motor and servo system has been issued by activation of the emergency stop or door interlock function under CE machine specifications, the electromagnetic switches did not turn off within the required time.

After turning NC power off, turn the main circuit breaker off and then turn it back on.

376: MAIN POWER TURNING OFF MALFUNCTION

When the front door of a CE specifications machine was opened with the setup key switch set to “O”, the electromagnetic switch for spindle power did not turn off within the required time.

After turning NC power off, turn the main circuit breaker off and then turn it back on.

377: COOLANT LEVEL LOW

The coolant level in the coolant unit of a machine of the high-pressure coolant specifications has decreased.

Check the coolant level in the coolant unit and add coolant.

If the alarm is not cleared, please contact your MAZAK service representative. After turning NC power off, turn the main circuit breaker off and then turn it back on. If the alarm is not cleared, please contact your MAZAK service representative.

APP-8

―

―

―

―

― X10

If the alarm is not cleared, please contact your MAZAK service representative.

X11

If the alarm is not cleared, please contact your MAZAK service representative. X492

Alarm No. and message

Description

Check and remedy

Address

378: HIGH PRESSURE PUMP THERMAL TRIP

The thermal relays in the coolant unit of a machine of the high-pressure coolant specifications have become tripped.

Check the thermal relays of the coolant unit.

X490

379: TANK PRESSURE LOW

The pressure in the coolant unit tank of a machine of the high-pressure coolant specifications has decreased.

Check and adjust the coolant unit tank pressure.

X491

381: CONDITION MISSING (SET UP SWITCH)

The cycle start button has been pressed in automatic operation mode with the front door open and the setup key switch set to “O”.

Change the setting of the setup key switch to “I” and then press the cycle start button. Single-block automatic operation will be activated.

For a machine of the front door lock pin specifications, a manual-starting button has been pressed with the front door open and the setup key switch set to “O”.

Change the setting of the setup key switch to “I” and then press the desired manualstarting button. The override rate will be reduced to 25%.

382: COOLANT SYSTEM MALF.

An error signal has been sent from the coolant unit of a machine of the highpressure coolant specifications.

Check the coolant unit for alarms.

383: ATC ALM: CARRIER&SHIFT. POS. MALF.

In a machine of the 80/120-tool magazine specifications, the cycle start command or the tool change command was issued when the carrier and the shifter were not present at their stand-by positions.

Before issuing the cycle start command or the tool change command, move the carrier and the shifter to their stand-by positions using the required switch of the magazine manual operations box.

385: START COND. ERR. (Z-AXIS POS.)

Under 20- or 40-tool magazine specifications, executing the machine menu function for opening the ATC cover has been attempted with the Z-axis existing in the minus direction relative to its zero point.

Move the Z-axis in the plus direction relative to its zero point before opening the ATC cover.

―

When the [ATC STOP] menu key in the machine menu was pressed (that is, when the menu was displayed in reverse mode), the axis was moved to the ATC position by the ATC command.

Cancel the ATC stop mode by pressing the [ATC STOP] menu key in the machine menu.

―

390: TOOL ON INTERFER ALARM

An attempt has been made to return the tool to a magazine pocket containing another tool.

Check the tool number of the tool to be returned and that of the tool stored within the magazine pocket.

391: LD/ULD/ACHG CONDITION ALARM

During ATC, although returning the tool was attempted, the magazine pocket tool confirmation sensor did not detect that tool probably because of dropping. Valid when bit 6 in parameter R59 is set to “1”. (Standard setting: 1)

Confirm whether the tool is mounted in the ATC arm. Check the magazine pocket tool confirmation sensor for normal operation.

X475

392: MAGAZINE MANUAL INTERR.

Under 20- or 40-tool magazine specifications, the tool change command has been entered or the cycle start button pressed with the magazine manual interruption switch set to ON.

Change the setting of the magazine manual interruption switch to OFF.

X1C

394: ATC CONTROLLER MALF.

An alarm signal has been received from the ATC amplifier.

After turning NC power off, turn off the main circuit breaker and then turn if back on. If the alarm is not cleared, please contact your MAZAK service representative.

386: ATC STOP

APP-9

―

X493

―

―

―

Alarm No. and message 395: CHECK SENSOR MALF. (SEE D199)

Description

Check and remedy

The operational check sensors at both ends of the stroke have turned on.

The positions of the operational check sensors or watchdogs are not correct or the sensors themselves are malfunctioning.

After the command has been issued, no sensors did not turn on within the required time.

Address

―

Confirm the value of D199 on the DIAGNOSIS display and examine the sensor causing the alarm. D199

Corresponding sensor

―

0

Normal

1

The X470 limit switch at the ATC side of the shifter has not turned on 20 seconds after the Y4F0 command for moving the shifter to the ATC side has been issued. The X471 limit switch at the magazine side of the shifter has not turned on 20 seconds after the Y4F1 command for moving the shifter to the magazine side has been issued.

X470 X471

2

The X472 limit switch at the extending side of the shifter has not turned on 20 seconds after the Y4F2 command for extending the shifter has been issued. The X473 limit switch at the retracting side of the shifter has not turned on 20 seconds after the Y4F3 command for retracting the shifter has been issued.

X472 X473

8

The chuck-clamping pressure switch (X442) and the chuckunclamping pressure switch (X443) are both on.

X442 X443

12

The top door open end sensor switch (X14) and closed end sensor switch (X15) of the machine of the GL specifications are both on.

X14 X15

―

397: MAGAZINE DOOR INTERLOCK

The magazine door has been opened during issuance of the tool change command or the magazine rotation command.

Close the magazine door.

XD

398: MAGAZINE COVER OPEN

The magazine cover is open.

Close the magazine cover.

The machine of the CE specifications has its magazine setup switch remaining set to ON.

Change the setting of the magazine setup switch to OFF.

XD X1C

399: MAINTE./ADJUST PARAM. ON

The maintenance/adjustment parameters are validated.

After turning NC power off, turn off the main circuit breaker and then turn it back on. If the alarm is not cleared, please contact your MAZAK service representative.

APP-10

―

Alarm List for the INTEGREX 300/400-III III Alarm No. and message 204: SPINDLE CONTROLLER MALFUNCTION

S/III IIIST (Addition) III

Description

Check and remedy

Address

An alarm occurred at secondary spindle controller.

Turn off the main circuit breaker and then turn it back on. If the alarm is not released, please contact your MAZAK service representative.

―

An erroneous chucking action was detected during chucking operation on secondary spindle.

The chuck unit on secondary spindle has failed to grip the material.

―

SP2 215: CHUCK SYSTEM MALFUNCTION SP2

The chuck open/close end sensor on secondary spindle (SQ62/SQ63) is abnormal or faulty.

X483/ X484

Type of chucking (inner/outer) of secondary spindle chuck is not selected.

Select the type of chucking.

The secondary spindle chuck open or close confirmation sensor (SQ62/SQ63) is abnormal or faulty.

X483/ X484

SP2

The secondary spindle chuck open or close confirmation sensor fails in function, or both of the sensors are ON simultaneously.

1. Close the chuck and start operation with the workpiece gripped. Alternatively, the chuck open/close check sensor may be improperly adjusted. → Check the sensor.

X483/ X484

SP2

1. A secondary spindle rotation command was given during mis-chucking. (Chuck sensor provided.)

2. A spindle rotation command was given even though the chuck of secondary spindle was not closed.

2. After closing the chuck of secondary spindle using the chuck clamp command, designate the spindle rotation command.

3. A spindle rotation command was given without the TOOL EYE placed at the backward end.

3. Retract the TOOL EYE. Also, check the backward end sensor.

X445

4. A secondary spindle rotation command was given without the door closed.

4. Close the door and start the secondary spindle rotation.

XA

5. Alarm 297 “CHUCK PRESSURE DOWN” is displayed.

5. Clear the alarm 297.

X448 X449

218: CHUCKING TYPE NOT SELECTED

―

SP2 224: CHUCK SENSOR MALFUNCTION 250: SPINDLE START MISOPERATION

252: AXIS MOVE MISOPERATION SP2

―

An attempt was made to execute an axis movement under the axis movement interdiction. 1. An attempt was made to execute a movement along the W-axis (secondary spindle traveling axis) without the X- and Y-axes placed at the zero point.

1.

Perform the X- and Y-axes zero point return operation.

2. An attempt was made to execute a movement along the X-, Z- (milling head traveling axis) and Y-axes without the Waxis (secondary spindle traveling axis) placed at the zero point.

2.

Perform the W-axis zero point return operation.

3. Though the W-axis zero point return is not completed after power on, an attempt was made to execute a movement along the W-axis in – direction at rapid feed without the TOOL EYE placed at the backward end.

3.

Retract the TOOL EYE. Also, check the backward end sensor.

4 An attempt was made to execute a movement along the W-axis with a bar chucked both on main spindle and secondary spindle.

4

Open the chuck on main spindle or secondary spindle.

APP-11

―

X445

―

Alarm No. and message 270: SPINDLE ORIENT EXCEED TIME SP2 282: CHUCK CLAMP EXCEED TIME SP2 329: CHUCKING SELECTION PROHIBITED SP2

Description

Check and remedy

Although a secondary spindle orientation command was given, the orientation confirmation signal does not turn on within a predetermined time.

The secondary spindle motor detector/controller is abnormal.

Although a chuck open/close command for secondary spindle was given, the confirmation signal does not turn on within a predetermined time.

Adjust the chuck open/close end sensor. Or the sensor is in trouble. The hydraulic system is abnormal.

The inside/outside chucking selection was performed without the chuck of secondary spindle opened.

Open the chuck of secndary spindle (and remove the workpiece).

The inside/outside chucking selection was performed when the secondary spindle or milling spindle is not stopped.

Stop the secondary spindle or milling spindle.

APP-12

Address

―

X483/ X484 ―

―

Alarm List for the INTEGREX 300/400-III IIIT/III (Addition) III IIIST III Alarm No. and message 221: TURRET CLAMP SENSOR MALFUNCTION TR2/SP2 256: TURRET ROTATION PROHIBITED TR2/SP2

258: TNo. MISMATCH TR2/SP2

272: TURRET INDEX EXCEED TIME TR2/SP2 301: START COND. ERR. (TUR UNCLAMP)

Description

Check and remedy

In spite of the fact that the (lower) turret is The clamping confirmation sensor is actually clamped, the clamping confirmation abnormal or faulty. sensor (SQ39) does not turn on. In spite of the fact that the (lower) turret is actually unclamped, the clamping confirmation sensor (SQ39) does not turn off.

Address X52

A turret indexing command was given during tool nose measurement with the TOOL EYE.

Cancel the measurement mode.

A turret indexing command was given with the SET UP switch remaining set to “O” and the front door remaining open.

Change the setting of the SET UP switch to “I”. Or close the front door.

For resuming automatic operation after a manual interruption, the indexed face of the turret is different from the face indexed before the interruption.

Index the turret for the same face to continue the automatic operation.

―

Although a turret indexing command is given, the index confirmation signal does not turn on within a predetermined time.

The detector/controller of the turret indexing motor is abnormal.

―

The cycle start button was pressed while the turet was unclamped.

Clamp the (lower) turret.

For resuming automatic operation after a manual interruption, the number of the tool in use differs from the number before the interruption.

Use a tool of the same number to continue the automatic operation.

X198 X1F8

X52

TR2/SP2 310: C/S ERROR (TNo.MISMATCH) TR2/SP2

APP-13

―

- NOTE -

APP-14

M-CODE TABLE Miscellaneous Function (M-Code) for the INTEGREX 300/400-III III/I III III

T/IIIIS/IIIIST !: Standard ": Optional —: Special order

M-codes

Description

Category

Remarks

M00

Program stop

!

M01

Optional stop

!

M02

Program end

!

M03

Spindle normal rotation

!

M04

Spindle reverse rotation

!

M05

Spindle stop

!

M06

Chuck unclamp (releasing workpiece)

"

M07

Chuck clamp (holding workpiece)

"

M08

Flood coolant ON

!

M09

Coolant OFF

!

Milling spindle mode cancel (Turning mode selection)

!

M13

Milling tool normal rotation

!

M14

Milling tool reverse rotation

!

M15

Milling tool stop

!

M16

Spindle orientation 0° (for AJC)

—

M17

Spindle orientation 120° (for AJC)

—

M18

Spindle orientation 240° (for AJC)

—

M19

Spindle orientation position (for the robot to insert a workpiece)

"

M20

Robot service call

"

M21

Robot service call

"

M22

Robot service call

"

M23

Robot service call

"

M24

Robot service call

"

M25

Robot service call

"

M26

Robot service call

"

M27

Robot service call

"

M28

Robot service call

"

M29

Robot service call

"

M30

Reset & tape rewind

!

M31

Tail spindle & tailstock body advance

!

for 300/400-III/IIIT for 300/400-III/IIIT

M10 M11 M12

M32

Tail spindle & tailstock body retract

!

M33

Low chuck pressure

—

M34

High chuck pressure

—

M35 M36 M37 M38 M39 M40

H374S5C010E

APP-15

M-codes

Description

Category

M41 M42 M43 M44 M45

Air coolant blow ON (coolant stop: M09)

"

M48

Parts catcher advance

"

M49

Parts catcher retract

"

M51

Error detect OFF

!

M52

Error detect ON

!

M53

Chamfering OFF

!

M54

Chamfering ON

!

M55

Piece count

—

M56

Front door open

"

M57

Front door close

"

M58

Chuck air blast

"

C-axis unclamp

!

M66

C-axis clamp

!

M67

C-axis brake (for machining by G01)

!

M68

Cycle bar feeder call 1

—

M69

Cycle bar feeder call 2

—

M72

Inside chuck clamp

—

M73

Outside chuck clamp

—

M74

Steady rest - milling head connection mode release

—

M75

Steady rest - milling head connection mode start

—

Workpiece measurement start

"

M82

Workpiece measurement end

"

M83

Tool measurement start

"

M84

Tool measurement end

"

M86

Steady rest 1 unclamp

"

M87

Steady rest 1 clamp

"

M46 M47

M50

M59 M60 M61 M62 M63 M64 M65

M70 M71

M76 M77 M78 M79 M80 M81

M85

APP-16

Remarks

M-codes

Description

Category

Remarks

M88

Steady rest 2 unclamp

—

M89

Steady rest 2 clamp

—

User macro interruption, valid

—

M97

User macro interruption, invalid

—

M98

EIA → EIA Subprogram call

!

M99

EIA → EIA Return to main EIA program

!

M100

Workpiece measurement DIA start

"

M101

Workpiece measurement DIA end

"

M102

Workpiece measurement STP start

"

M103

Workpiece measurement STP end

"

M104

Workpiece measurement GRV start

"

M105

Workpiece measurement GRV end

"

M106

Workpiece measurement WID start

"

M107

Workpiece measurement WID end

"

M108

Workpiece measurement DIS start (chuck barrier release)

"

M109

Workpiece measurement DIS end

"

M110

Tool tip measurement TOL start

!

M111

Tool tip measurement TOL end

!

M112

External tool compensation EXT start

"

M113

External tool compensation EXT end

"

M114

Z-axis offset measurement ZOF start

"

M115

Z-axis offset measurement ZOF end

"

M116

C-axis offset measurement COF start

"

M117

C-axis offset measurement COF end

"

Measurement data print out

"

M150

Workpiece unload demand to robot

—

M151

Milling spindle through air blow ON

!

Only for turning tools

M152

Milling spindle through air blow OFF

!

Only for turning tools

M153

Milling spindle through coolant ON

!

M154

Milling spindle through coolant OFF

!

M155

Chuck coolant ON (composed movement)

"

M156

Chuck coolant OFF (composed movement)

"

M157

Spindle through coolant blow ON (OFF: M159)

"

M158

Spindle through air blow ON (OFF: M159)

"

M159

M157, M158 OFF

"

M160

Shower coolant ON/chuck stopper extend

"

M90 M91 M92 M93 M94 M95 M96

M118 M119 M120 M121 ↓ M149

APP-17

M-codes

Description

Category

Remarks

M161

Shower coolant OFF/chuck stopper retract

"

M162

Workpiece rechucking (for a piece delivered by robot)

"

M163

Tail spindle thrust

low pressure

"

for 300/400-III/IIIT

M164

Tail spindle thrust

high pressure

"

for 300/400-III/IIIT

35K, 70K high pressure coolant ON (OFF: M9, M154)

"

M172

Index 0°(KOUYOU)

—

M173

Index 90°(KOUYOU)

—

M174

Index 180°(KOUYOU)

—

M175

Index 270°(KOUYOU)

—

M176

Index 270°(KOUYOU)

—

M177

Index 270°(KOUYOU)

—

M178

Index 270°(KOUYOU)

—

M179

Index 270°(KOUYOU)

—

M198

EIA → MAZATROL program call

"

M199

EIA → MAZATROL program end

"

M200

Milling point machining start

!

M201

Milling line machining start

!

M202

Turning mode

!

M203

Milling tool normal rotation

!

M204

Milling tool reverse rotation

!

M205

Milling tool stop

!

M207

M208, M209 mode cancel

!

M208

ATC prohibition mode during finishing, coolant ON

!

M209

ATC prohibition mode during finishing, coolant OFF

!

M210

C-axis clamp (for milling)

!

M211

C-axis brake (for milling)

!

M212

C-axis unclamp (for milling)

!

M213

C-axis brake only (brake by M211)

!

M214

C-axis unclamp only (unclamp by M212)

!

M215

M213, M214 and M216 mode cancel

!

M216

C-axis unclamp neglect mode (cancel:

M165 M166 M167 M168 M169 M170 M171

M180 ↓ M197

M206

M215)

!

M217 M218 M219

Milling tool orient

!

M220 ↓ M229

APP-18

M-codes

Description

Category

M230

Grinding mode ON

"

M231

Grinding speed setting

"

M236

C-axis servo gain normal

!

M237

C-axis servo gain low

!

M238

C-axis servo gain middle

!

M239

C-axis servo gain high

!

M248

Spindle speed check (for interlocking the start of cutting)

!

M249

Milling head selection preparation

!

M250

Milling head/B-axis unclamp

!

M251

B-axis clamp

!

M252

Milling spindle unclamp

!

M253

Milling spindle clamp

!

M254

Milling head/B-axis clamp

!

Milling head air blow

!

M260

Polygon mode ON

"

M261

Polygon mode OFF

"

M274

Steady rest coolant ON

—

M275

Steady rest coolant OFF

—

M331

Spindle coil change fixed to high speed

!

M332

Spindle coil change, valid

!

M348

Yt-axis selection

!

M349

Y-axis selection

!

M232 M233 M234 M235

M240 M241 M242 M243 M244 M245 M246 M247

M255 M256 M257 M258 M259

M262 ↓ M273

M276 ↓ M330

M333 ↓ M347

APP-19

Remarks

M-codes

Description

Category

M350 M351

M352 cancel

!

M352

Spindle speed arrival signal check, valid

!

M353 ↓ M369 M370

Axis load detection, invalid

"

M371

Axis load detection, valid

"

M372

Axis load detection, temporarily invalid

"

M373

Axis load detection, re-start

"

M374

NC feed holding on overload detection

"

M375

NC feed holding & spindle stop on overload detection

"

M376

Overload detection level % setting

"

M377

Overload detection time setting (unit: 0.1 sec)

"

M378

Overload detection peak %/detection frequency setting

"

M379

Overload detection table No. registration

"

M390

M391 cancel

"

M391

Spindle mis-chucking cancel (M3/M4 completed with chuck open)

"

M394

TOOL EYE extension possible during chuck close (when robot valid)

!

M395

M394 cancel

!

Magazine tool rotation

!

M731

Tail thrust 1 selection

!

M732

Tail thrust 2 selection

!

M733

Tail thrust 3 selection

!

M734

Tail thrust 4 selection

!

M735

Tail thrust 5 selection

!

M736

Tail thrust 6 selection

!

M737

Tail thrust 7 selection

!

M738

Tail thrust 8 selection

!

M739

Tail thrust 9 selection

!

M740

Tail thrust 10 selection

!

M741

Positioning tailstock to “Position 1”

!

M742

Positioning tailstock to “Position 2”

!

M743

Positioning tailstock to “Retract”

!

M380 ↓ M389

M392 M393

M396 ↓ M600 M601 M602 ↓ M730

APP-20

Remarks

M-codes

Description

Category

M744 ↓ M927 M928

Y-axis zero point return

!

Yt-axis moving to ATC position

!

M929 M930 M931 ↓ M999

APP-21

Remarks

Miscellaneous Function (M-Code) for the INTEGREX 300/400-IIII (Addition)

S/IIIIST

!: Standard ": Optional —: Special order M-codes M300

Description

Category

Remarks

Secondary spindle selection

!

System M-code

Main spindle selection

!

System M-code

M303

Secondary spindle normal rotation

!

M304

Secondary spindle reverse rotation

!

M305

Secondary spindle stop

!

M306

Secondary spindle chuck unclamp (releasing workpiece)

!

M307

Secondary spindle chuck clamp (holding workpiece)

!

Secondary spindle orientation

"

M321

Increase of main spindle torque for synchronous rotation

"

M322

Cancellation of M321

"

M333

Torque limit of main spindle to 1/2

!

M334

Torque limit of main spindle

!

M335

Keeping of nominal torque of main spindle

!

M336

Cancellation of M337

!

M337

Torque limit of main spindle only at the starting and stopping

!

M351

Cancellation of M352

!

M352

Spindle speed arrival signal check

!

M357

Secondary spindle chuck air blast start

"

M358

Secondary spindle chuck air blast stop

"

M359

Cancellation of M360

"

M360

Secondary spindle orientation clamp mode

"

M361

Cancellation of M362

"

M362

Simultaneous chuck operation on main and secondary spindles in TRSCHK mode

"

M363

Cancellation of M364

"

M364

Immediate completion of spindle/milling spindle start commands (Mcode) in TRS mode

"

M380

Spindle synchronous rotation mode

!

M381

Spindle synchronous rotation mode cancel

!

Release of chuck open/close interlock during spindle rotation

!

M301 M302

↓ M319 M320

↓

↓ M350

↓

↓

↓ M500 M501

Cancellation of M500

!

M502

Main/secondary spindle synchronous rotation (Cross mode)

"

M503

APP-22

System M-code

M-codes

Description

Category

Remarks

M504 M505

Cancellation of M502

"

System M-code

M506

Master spindle chuck open after slave spindle chuck close

!

System M-code

M507

The slave spindle chuck open after master spindle chuck close

!

System M-code

M508

Pressing start

!

M509

Cancellation of M508

!

M511

Start of synchronous action of two spindles

!

System M-code

M512

Cancellation of M511

!

System M-code

M518

Interlock release during chucking of a bar workpiece by both spindles

!

M519

Spindle orientation

"

M527

Check for workpiece chucked in the spindle

"

M528

Modal workpiece check in TRS mode

"

M540

TRS-CHK mode start

!

System M-code

M541

Cancellation of TRS-CHK mode

!

System M-code

M542

TRS-BAR mode start

!

System M-code

M510

↓

↓

↓

M543

Cancellation of TRS-BAR mode

!

System M-code

M544

Cross-machining start

"

System M-code

M545

Cancellation of cross-machining

"

System M-code

M546

TRS-MOV mode start

!

System M-code

M547

Cancellation of TRS-MOV mode

!

System M-code

APP-23

Miscellaneous Function (M-Code) for the INTEGREX 300/400-IIII (Addition)

T/IIIIST

For the upper turret !: Standard ": Optional —: Special order M-codes

Description

Category

M560

Spindle control and Constant cutting speed control for the upper turret

!

M561

Spindle control and Constant cutting speed control for the lower turret

!

M562

Axis movement synchronization

!

M563

Cancellation of axis movement synchronization

!

M950

Stand-by M-code

!

M951

Stand-by M-code

!

M952

Stand-by M-code

!

M953

Stand-by M-code

!

M954

Stand-by M-code

!

M955

Stand-by M-code

!

M956

Stand-by M-code

!

M957

Stand-by M-code

!

M958

Stand-by M-code

!

M959

Stand-by M-code

!

M960

Stand-by M-code

!

M961

Stand-by M-code

!

M962

Stand-by M-code

!

M963

Stand-by M-code

!

M964

Stand-by M-code

!

M965

Stand-by M-code

!

M966

Stand-by M-code

!

M967

Stand-by M-code

!

M968

Stand-by M-code

!

M969

Stand-by M-code

!

M970

Stand-by M-code

!

M971

Stand-by M-code

!

M972

Stand-by M-code

!

M973

Stand-by M-code

!

M974

Stand-by M-code

!

M975

Stand-by M-code

!

M976

Stand-by M-code

!

M977

Stand-by M-code

!

M978

Stand-by M-code

!

M979

Stand-by M-code

!

M980

Stand-by M-code

!

M981

Stand-by M-code

!

M982

Stand-by M-code

!

M949

APP-24

Remarks

M-codes

Description

Category

M983

Stand-by M-code

!

M984

Stand-by M-code

!

M985

Stand-by M-code

!

M986

Stand-by M-code

!

M987

Stand-by M-code

!

M988

Stand-by M-code

!

M989

Stand-by M-code

!

M990

Stand-by M-code

!

M991

Stand-by M-code

!

M992

Stand-by M-code

!

M993

Stand-by M-code

!

M994

Stand-by M-code

!

M995

Stand-by M-code

!

M996

Stand-by M-code

!

M997

Stand-by M-code

!

APP-25

Remarks

Integrex-100~400MkIII Lower Turret M-Codes !: Standard ": Optional —: Special order M-codes

Description

Category

M00

Program stop

!

M01

Optional stop

!

M02

Program end

!

M03

Secondary spindle normal rotation (for ST)

!

M04

Secondary spindle reverse rotation (for ST)

!

M05

Secondary spindle stop (for ST)

!

M08

Coolant ON

!

M09

Coolant OFF

!

M30

Reset & tape rewind

!

M51

Error detect OFF

!

M52

Error detect ON

!

M53

Chamfering OFF

!

M54

Chamfering ON

!

M58

Secondary spindle chuck air blast

"

M300

Main spindle mode

!

M302

Secondary spindle mode

!

M303

Main spindle normal rotation

!

M304

Main spindle reverse rotation

!

M305

Main spindle stop

!

M358

Main spindle chuck air blast

"

M560

Spindle control and Constant cutting speed control for the upper turret

!

M561

Spindle control and Constant cutting speed control for the lower turret

!

M562

Axis movement synchronization

!

M563

Cancellation of axis movement synchronization

!

M950

Stand-by M-code

!

M951

Stand-by M-code

!

M952

Stand-by M-code

!

M953

Stand-by M-code

!

M954

Stand-by M-code

!

M301

M949

APP-26

Remarks

M-codes

Description

Category

M955

Stand-by M-code

!

M956

Stand-by M-code

!

M957

Stand-by M-code

!

M958

Stand-by M-code

!

M959

Stand-by M-code

!

M960

Stand-by M-code

!

M961

Stand-by M-code

!

M962

Stand-by M-code

!

M963

Stand-by M-code

!

M964

Stand-by M-code

!

M965

Stand-by M-code

!

M966

Stand-by M-code

!

M967

Stand-by M-code

!

M968

Stand-by M-code

!

M969

Stand-by M-code

!

M970

Stand-by M-code

!

M971

Stand-by M-code

!

M972

Stand-by M-code

!

M973

Stand-by M-code

!

M974

Stand-by M-code

!

M975

Stand-by M-code

!

M976

Stand-by M-code

!

M977

Stand-by M-code

!

M978

Stand-by M-code

!

M979

Stand-by M-code

!

M980

Stand-by M-code

!

M981

Stand-by M-code

!

M982

Stand-by M-code

!

M983

Stand-by M-code

!

M984

Stand-by M-code

!

M985

Stand-by M-code

!

M986

Stand-by M-code

!

M987

Stand-by M-code

!

M988

Stand-by M-code

!

M989

Stand-by M-code

!

M990

Stand-by M-code

!

M991

Stand-by M-code

!

M992

Stand-by M-code

!

M993

Stand-by M-code

!

M994

Stand-by M-code

!

M995

Stand-by M-code

!

M996

Stand-by M-code

!

M997

Stand-by M-code

!

APP-27

Remarks

- NOTE-

APP-28

Notes:

Stroke diagram (INTEGREX 100-ΙΙΙ - Metric -)

APP-29

Drawing No.

1372ST00012

Unit: mm

1. 1. If B = 90°, the tool lengths that can be measured using the TOOL EYE are limited. 2. If B = 0°, when a special chuck or long jaws are mounted the tool lengths that can be measured using the TOOL EYE may be limited. 3. BT40 spec.

Stroke Diagram INTEGREX 100-ΙΙΙ ΙΙΙ (Metric)

Stroke diagram (INTEGREX 100-ΙΙΙ - Inch -)

APP-30

Notes:

Drawing No.

1372ST00041

Unit: in. (mm)

1. If B = 90°, the tool lengths that can be measured using the TOOL EYE are limited. 2. If B = 0°, when a special chuck or long jaws are mounted the tool lengths that can be measured using the TOOL EYE may be limited. 3. BT40 spec.

INTEGREX 100-ΙΙΙ ΙΙΙ (Inch)

Stroke diagram (INTEGREX 100-ΙΙΙS - Metric -)

APP-31

Notes:

Drawing No.

1372ST00022

Unit: mm

1. If B = 90°, the tool lengths that can be measured using the TOOL EYE are limited. 2. If B = 0°, when a special chuck or long jaws are mounted the tool lengths that can be measured using the TOOL EYE may be limited. 3. BT40 spec.

INTEGREX 100-ΙΙΙ ΙΙΙS ΙΙΙ (Metric)

Stroke diagram (INTEGREX 100-ΙΙΙS - Inch -)

APP-32

Notes:

Drawing No.

1372ST00051

Unit: in. (mm)

1. If B = 90°, the tool lengths that can be measured using the TOOL EYE are limited. 2. If B = 0°, when a special chuck or long jaws are mounted the tool lengths that can be measured using the TOOL EYE may be limited. 3. BT40 spec.

INTEGREX 100-ΙΙΙ ΙΙΙS ΙΙΙ (Inch)

Stroke diagram (INTEGREX 100-ΙΙΙST - Metric -)

APP-33

Notes:

Drawing No.

1372ST00032

Unit: mm

1. If B = 90°, the tool lengths that can be measured using the TOOL EYE are limited. 2. If B = 0°, when a special chuck or long jaws are mounted the tool lengths that can be measured using the TOOL EYE may be limited. 3. BT40 spec.

INTEGREX 100-ΙΙΙ ΙΙΙST (Metric) ΙΙΙ

Stroke diagram (INTEGREX 100-ΙΙΙST - Inch -)

APP-34

Notes:

Drawing No.

1372ST00062

Unit: in. (mm)

1. If B = 90°, the tool lengths that can be measured using the TOOL EYE are limited. 2. If B = 0°, when a special chuck or long jaws are mounted the tool lengths that can be measured using the TOOL EYE may be limited. 3. BT40 spec.

INTEGREX 100-ΙΙΙ ΙΙΙST (Inch) ΙΙΙ

Stroke diagram (INTEGREX 200-III)

APP-35

Drawing No.

DOM./EX. Main spindle Hollow chuck of 8"

1373PGD0011

Unit: mm (in.)

Note: For BT Spec *1: 165 mm (6.5") *2: 40 mm (1.57")

Stroke Diagram INTEGREX 200-III III

Stroke diagram (INTEGREX 200-IIIS)

APP-36

Drawing No.

DOM./EX. Main spindle Hollow chuck of 8" Secondary spindle Hollow chuck of 8"

1373PGD0021

Unit: mm (in.)

Note: For BT Spec *1: 165 mm (6.5") *2: 40 mm (1.57")

INTEGREX 200-II III IIIS

Stroke diagram (INTEGREX 200-IIIT)

APP-37

Drawing No.

DOM./EX. Main spindle Hollow chuck of 8"

1373PGD0031

Unit: mm (in.)

Note: For BT Spec *1: 165 mm (6.5") *2: 40 mm (1.57")

INTEGREX 200-II III IIIT

Stroke diagram (INTEGREX 200-IIIST)

APP-38

Drawing No.

DOM./EX. Main spindle Hollow chuck of 8" Secondary spindle Hollow chuck of 8"

1373PGD0041

Unit: mm (in.)

Note: For BT Spec *1: 165 mm (6.5") *2: 40 mm (1.57")

INTEGREX 200-II III IIIST

Stroke diagram (INTEGREX 200-III) - with work rest -

APP-39

Drawing No.

1373PGD0110

Unit: mm (in.)

DOM./EX. Main spindle Hollow chuck of 8" Work rest spec.: SLU2Z/SMW

Note: For BT Spec *1: 165 mm (6.5") *2: 40 mm (1.57")

INTEGREX 200-III III (with work rest)

Stroke diagram (INTEGREX 200-IIIS) - with work rest -

APP-40

Drawing No.

1373PGD0120

Unit: mm (in.)

DOM./EX. Main spindle Hollow chuck of 8" Secondary spindle Hollow chuck of 8" Work rest spec.: SLU2Z/SMW

Note: For BT Spec *1: 165 mm (6.5") *2: 40 mm (1.57")

INTEGREX 200-III IIIS III (with work rest)

Stroke diagram (INTEGREX 200-IIIT) - for Lower turret with milling capability -

APP-41

1373PGD0050

Drawing No.

Unit: mm (in.) DOM./EX. Main spindle Hollow chuck of 8"

Note: For BT Spec *1: 165 mm (6.5") *2: 40 mm (1.57")

INTEGREX 200-III IIIT III (for Lower turret with milling capability)

Stroke diagram (INTEGREX 200-IIIST) - for Lower turret with milling capability -

APP-42

Drawing No.

DOM./EX. Main spindle Hollow chuck of 8" Secondary spindle Hollow chuck of 8"

1373PGD0060

Unit: mm (in.)

Note: For BT Spec *1: 165 mm (6.5") *2: 40 mm (1.57")

INTEGREX 200-III IIIST (for Lower turret with milling capability) III

Stroke diagram (INTEGREX 300-ΙΙΙ [1000U, 10" hollow chuck])

APP-43

Drawing No.

MAIN SPINDLE

DOM./EX.

1374PGD0020

10" CHUCK (THROUGH HOLE)

Unit: mm (in.)

Note:　BT spec. *1: 165 mm (6.50") *2: 40 mm (1.57")

Stroke Diagram INTEGREX 300-ΙΙΙ ΙΙΙ (1000U, 10" hollow chuck)

Stroke diagram (INTEGREX 300-ΙΙΙS [1000U, 10" hollow chuck])

APP-44

Drawing No.

MAIN SPINDLE

1374PGD0050

10" CHUCK (THROUGH HOLE) 10" CHUCK SECONDARY SPINDLE (THROUGH HOLE)

DOM./EX.

Unit: mm (in.)

*1: 165 mm (6.50") *2: 40 mm (1.57")

INTEGREX 300-ΙΙΙ ΙΙΙS ΙΙΙ (1000U, 10" hollow chuck)

Stroke diagram (INTEGREX 400-ΙΙΙ [1000U, 12" hollow chuck])

APP-45

Drawing No.

MAIN SPINDLE

DOM./EX.

1374PGD0040

12" CHUCK (THROUGH HOLE)

Unit: mm (in.)

Note:　BT spec. *1: 165 mm (6.50") *2: 40 mm (1.57")

INTEGREX 400-ΙΙΙ ΙΙΙ (1000U, 12" hollow chuck)

Stroke diagram (INTEGREX 400-ΙΙΙS [1000U, 12" hollow chuck])

APP-46

Drawing No.

MAIN SPINDLE

1374PGD0060

10" CHUCK (THROUGH HOLE) 10" CHUCK SECONDARY SPINDLE (THROUGH HOLE)

DOM./EX.

Unit: mm (in.)

*1: 165 mm (6.50") *2: 40 mm (1.57")

INTEGREX 400-ΙΙΙ ΙΙΙS ΙΙΙ (1000U, 12" hollow chuck)

Stroke diagram (INTEGREX 300-ΙΙΙ [1500U, 10" hollow chuck])

APP-47

Drawing No.

MAIN SPINDLE

DOM./EX.

1374PGD0140

10" CHUCK (THROUGH HOLE)

Unit: mm (in.)

Note:　BT spec. *1: 165 mm (6.50") *2: 40 mm (1.57")

INTEGREX 300-ΙΙΙ ΙΙΙ (1500U, 10" hollow chuck)

Stroke diagram (INTEGREX 300-ΙΙΙS [1500U, 10" hollow chuck])

APP-48

Unit: mm (in.)

Drawing No.

MAIN SPINDLE

1374PGD0170

10" CHUCK (THROUGH HOLE) 10" CHUCK SECONDARY SPINDLE (THROUGH HOLE)

DOM./EX.

Note:　BT spec. *1: 165 mm (6.50") *2: 40 mm (1.57")

INTEGREX 300-II II IS (1500U, 10" hollow chuck)

Fig. 1-13 Stroke diagram (INTEGREX 300-ΙΙΙT [1500U, 10" hollow chuck])

APP-49

Drawing No.

MAIN SPINDLE

DOM./EX.

1374PGD0200

10" CHUCK (THROUGH HOLE)

Unit: mm (in.)

Note:　BT spec. *1: 165 mm (6.50") *2: 40 mm (1.57")

INTEGREX 300-II II IT (1500U, 10" hollow chuck)

Stroke diagram (INTEGREX 300-ΙΙΙST [1500U, 10" hollow chuck])

APP-50

Unit: mm (in.)

Drawing No.

MAIN SPINDLE

1374PGD0230

10" CHUCK (THROUGH HOLE) 10" CHUCK SECONDARY SPINDLE (THROUGH HOLE)

DOM./EX.

Note:　BT spec. *1: 165 mm (6.50") *2: 40 mm (1.57")

INTEGREX 300-II II IST (1500U, 10" hollow chuck)

Stroke diagram (INTEGREX 400-ΙΙΙ [1500U, 12" hollow chuck])

APP-51

Drawing No.

MAIN SPINDLE

DOM./EX.

1374PGD0160

12" CHUCK (THROUGH HOLE)

Unit: mm (in.)

Note:　BT spec. *1: 165 mm (6.50") *2: 40 mm (1.57")

INTEGREX 400-ΙΙΙ ΙΙΙ (1500U, 12" hollow chuck)

Stroke diagram (INTEGREX 400-ΙΙΙS [1500U, 12" hollow chuck])

APP-52

Unit: mm (in.)

Drawing No.

MAIN SPINDLE

1374PGD0180

12" CHUCK (THROUGH HOLE) 10" CHUCK SECONDARY SPINDLE (THROUGH HOLE)

DOM./EX.

Note:　BT spec. *1: 165 mm (6.50") *2: 40 mm (1.57")

INTEGREX 400-II II I S (1500U, 12" hollow chuck)

Stroke diagram (INTEGREX 400-ΙΙΙT [1500U, 12" hollow chuck])

APP-53

Drawing No.

MAIN SPINDLE

DOM./EX.

1374PGD0220

12" CHUCK (THROUGH HOLE)

Unit: mm (in.)

Note:　BT spec. *1: 165 mm (6.50") *2: 40 mm (1.57")

INTEGREX 400-II II IT (1500U, 12" hollow chuck)

Stroke diagram (INTEGREX 400-ΙΙΙST [1500U, 12" hollow chuck])

APP-54

Unit: mm (in.)

Drawing No.

MAIN SPINDLE

1374PGD0240

12" CHUCK (THROUGH HOLE) 10" CHUCK SECONDARY SPINDLE (THROUGH HOLE)

DOM./EX.

Note:　BT spec. *1: 165 mm (6.50") *2: 40 mm (1.57")

INTEGREX 400-II II IST (1500U, 12" hollow chuck)