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 PRECAUTIONSThe machine is provided with a number of safetydevices to protect personnel and equipment frominjury and damage. Operators should not,however, rely solely upon these safety devices,but should operate the machine only after fullyunderstanding what special precautions to take byreading the following documentation thoroughly.

• BASIC OPERATING PRACTICESDANGER:

1) Some control panels, transformers, motors,junction boxes and other parts have highvoltage terminals. These should not be touchedor 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 switchlocation should be well known, so that it can beoperated at any time without having to look forit.

2) Before replacing a fuse, turn off the mainincoming power switch to the machine.

3) Provide sufficient working space to avoidhazardous falls.

4) Water or oil can make floors slippery andhazardous. All floors should be clean and dryto prevent accidents

5) Do not operated any switch without a thoroughunderstanding 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 onthem to prevent accidents. Articles should beprevented 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 eachstep of the operation. The next step should notbe taken unless a signal is given andacknowledged.

CAUTION:

1) In the event of power failure, turn off the maincircuit breaker immediately.

2) Use the recommended hydraulic oils, lubricantsand grease or acceptable equivalents.

3) Replacement fuses should have the propercurrent ratings.

4) Protect the NC unit, operating panel, electriccontrol panel, etc. from shocks, since thiscould cause a failure or malfunction.

5) Do not change parameters or electricalsettings. If changes are unavoidable, recordthe values prior to the change so that they canbe returned to their original settings, ifnecessary.

6) Do not deface, scratch or remove any cautionplate. Should it become illegible or missing,order another caution plate from the supplier,specifying the part number shown at the lowerright corner of the plate.

• BEFORE POWERING UPDANGER:

Cables, cords or electric wires whose insulationis damaged can produce current leaks andelectric shocks. Before using, check theircondition.

WARNING:

1) Be sure the instruction manual and theprogramming manual are fully understoodbefore operating the machine. Every functionand operating procedure should be completelyclear.

2) Use approved oil resistant safety shoes, safetygoggles with side covers, safe clothes, andother safety protection required.

3) Close all NC unit, operating panel, electriccontrol panel doors and covers.

CAUTION:

1) The power cable from the factory feeder switchto the machine main circuit breaker shouldhave a sufficient sectional area to handle theelectric power used.

2) Cables which must be laid on the floor must beprotected from hot chips, by using rigid orother approved conduit, so that short-circuitswill not occur.

3) Before first time operation of the machine afterunpacking it or from being idle for a long periodof time (several days or more), each slidingpart must be sufficiently lubricated. To do so,push and release the pump button severaltimes until the oil seeps out on the slidingparts. The pump button has a return spring, sodo not force it to return.

4) Oil reservoirs should be filled to indicatedlevels. Check and add oil, if needed.

5) For lubrication points, oil specification andappropriate levels, see the various instructionplates.

6) Switches and levers should operate smoothly.Check that they do.

7) When powering the machine on, turn on theswitches in the following order: first the factoryfeeder switch, then the machine main circuitbreaker, and then the control power on switchlocated on the operating panel.

8) Check the coolant level, and add coolant, ifneeded.

S-1

• AFTER CONTROL POWER IS TURNED ONCAUTION:

When the control power “ON” switch on theoperating panel is on, the "READY" lamp onthe operating panel should also be on (check tosee that it is).

• ROUTINE INSPECTIONSWARNING:

When checking belt tensions, do not get yourfingers caught between the belt and pulley.

CAUTION:

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 freshmatching set.

• WARM UPCAUTION:

1) Warm up the machine, especially the spindleand feed shaft, by running the machine for 10to 20 minutes at about one-half or one-third themaximum speed in the automatic operationmode.

2) The automatic operation program should causeeach machine component to operate. At thesame time, check their operations.

3) Be particularly careful to warm up the spindlewhich can turn above 4000 rpm.If the machine is used for actual machiningimmediately after being started up following along idle period, the sliding parts may be worndue to the lack of oil. Also, thermal expansionof the machine components can jeopardizemachining accuracy. To prevent this condition,always make sure that the machine is warmedup.

• PREPARATIONSWARNING:

1) Tooling should conform to the machinespecifications, dimensions and types.

2) Replace all seriously worn tools with new onesto prevent injuries.

3) The work area should be adequately lighted tofacilitate safety checks.

4) Tools and other items around the machine orequipment should be stored to ensure goodfooting and clear aisles.

5) Do not place tools or any other items on theheadstock, turret, covers and similar places(For T/M).

CAUTION:

1) Tool lengths should be within specifiedtolerances to prevent interference.

2) After installing a tool, make a trial run.

• OPERATIONWARNING:

1) Do not work with long hair that can be caughtby the machine. Tie it back, out of the way.

2) Do not operate switches with gloves on. Thiscould cause mis-operation.

3) Whenever a heavy workpiece must be moved,if there is any risk involved, two or more peopleshould work together.

4) Only trained, qualified workers should operateforklift trucks, cranes or similar equipment andapply slings.

5) Whenever operating a forklift truck, crane orsimilar equipment, special care should be takento prevent collisions and damage to thesurroundings.

6) Wire ropes or slings should be strong enoughto handle the loads to be lifted and shouldconform 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 andprovide plenty of distance between theworkpiece and the tool (for M/C).

11) While a workpiece or tool is turning, do notwipe it off or remove chips with a cloth or byhand. Always stop the machine first and thenuse a brush and a sweeper.

12) Do not operate the machine with the chuck andfront 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 orremoving a tool.

15) Whenever machining magnesium alloy parts,wear a protective mask.

S-2

CAUTION:

1) During automatic operation, never open themachine door. Machines equipped with thedoor interlock will set the program to singlestep.

2) When performing heavy-duty machining,carefully prevent chips from being accumulatedsince hot chips from certain materials cancause a fire.

• TO INTERRUPT MACHININGWARNING:

When leaving the machine temporarily aftercompleting a job, turn off the power switch onthe operation panel, and also the main circuitbreaker.

• COMPLETING A JOBCAUTION:

1) Always clean the machine or equipment.Remove and dispose of chips and clean coverwindows, etc.

2) Make sure the machine has stopped running,before cleaning.

3) Return each machine component to its initialcondition.

4) Check the wipers for breakage. Replacebroken wipers.

5) Check the coolant, hydraulic oils and lubricantsfor contamination. Change them if they areseriously contaminated.

6) Check the coolant, hydraulic oil and lubricantlevels. 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 operatingpanel, machine main circuit breaker and factoryfeeder switch in that order.

• SAFETY DEVICES1) 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 PREPARATIONS1) Do not proceed to do any maintenance

operation unless instructed to do so by theforeman.

2) Replacement parts, consumables (packing, oilseals, O rings, bearing, oil and grease, etc.)Should be arranged in advance.

3) Prepare preventive maintenance and recordmaintenance programs.

CAUTION:

1) Thoroughly read and understand the safetyprecautions in the instruction manual.

2) Thoroughly read the whole maintenancemanual and fully understand the principles,construction and precautions involved.

• MAINTENANCE OPERATIONDANGER:1) Those not engaged in the maintenance work

should not operate the main circuit breaker orthe control power "ON" switch on theoperating panel. For this purpose, "Do notTouch the Switch, Maintenance Operation inProgress!" or similar warning should beindicated on such switches and at any otherappropriate locations. Such indication shouldbe secured by a semi-permanent means in thereading direction.

2) With the machine turned on, any maintenanceoperation can be dangerous. In principle, themain circuit breaker should be turned offthroughout the maintenance operation.

WARNING:

1) The electrical maintenance should be done bya qualified person or by others competent to dothe job. Keep close contact with theresponsible person. Do not proceed alone.

2) Overtravel limit and proximity switches andinterlock mechanisms including functional partsshould not be removed or modified.

3) When working at a height, use steps or ladderswhich are maintained and controlled daily forsafety.

4) Fuses, cables, etc. made by qualifiedmanufacturers should be employed.

• BEFORE OPERATION & MAINTENANCE BEGINSWARNING:

1) Arrange things in order around the section toreceive the maintenance, including workingenvironments. Wipe water and oil off parts andprovide safe working environments.

2) All parts and waste oils should be removed bythe operator and placed far enough away fromthe machine to be safe.

CAUTION:

1) The maintenance person should check that themachine operates safely.

2) Maintenance and inspection data should berecorded and kept for reference.

000X717-KY 11/98

S-3

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.

FIGURE

WARNING

a a a

a a a

a a a

a a a

a a a!

PADLOCK

S-4

INSTALLATION PRECAUTIONSThe following subjects outline the items thatdirectly affect the machine installation and start-up. To ensure an efficient and timely installation,please follow these recommendations beforecalling to schedule a service engineer.

• ENVIRONMENTAL REQUIREMENTSAvoid the following places for installing themachine:

1) Avoid exposure to direct sunlight and/or near aheat source, etc. Ambient temperature duringoperation: 0° thru 45°C (32°F to 113°F).

2) Avoid areas where the humidity fluctuatesgreatly and/or if high humidity is present;normally 75% and below in relative humidity. Ahigher humidity deteriorates insulation andmight accelerate the deterioration of parts.

3) Avoid areas that are especially dusty and/orwhere acid fumes, corrosive gases and salt arepresent.

4) Avoid areas of high vibration.5) Avoid soft or weak ground (minimum load

bearing capacity of 1025 lbs./ft 2)

• FOUNDATION REQUIREMENTSFor high machining accuracy, the foundationmust be firm and rigid. This is typicallyaccomplished by securely fastening themachine to the foundation with anchor bolts. Inaddition, the depth of concrete should be asdeep as possible (minimum 6 - 8 inches). Notethe following:

1) There can be no cracks in the foundationconcrete 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-boltanchors, or use expansion anchors.

4) With the foundation anchor bolt holes openpour the primary concrete at a minimumthickness of 6 - 8 inches. Typically, theconcrete must have a minimum compressionrating of 2500 lbs. @ 250 lbs. compressionand strengthened with reinforcing rods. Whenthe concrete has cured, rough level themachine, and install the J-bolts, leveling blocks,etc., and pour grout into foundation bolt holes.

5) Mix an anti-shrinkage agent such as DenkaCSA with concrete, or use Embeco grout to fillthe foundation bolt holes.

6) In pouring grout, fasten the leveling blockbase plates with the collar retaining screwsto prevent the base plates from dropping. When the grout has completely hardened,level the machine properly, and tighten M24nuts to secure the machine to thefoundation.

Note:

The machine must be anchored to thefoundation with J-bolts, expansion bolts orother suitable method.

The machine accuracy and alignmentspecifications quoted by Mazak can usuallybe obtained when the minimum foundationrequirements are met. However, productionof close tolerance parts requires the use of anappropriate certified foundation. Foundationsthat do not meet certified specifications mayrequire more frequent machine re-leveling andre-alignment, which can not be providedunder terms of warranty.

If any of these conditions cannot be met,contact the nearest Mazak service officeimmediately.

S-5

• WIRING

1) Use only electrical conductors withperformance ratings equivalent or superior.

2) Do not connect any power cables for deviceswhich can cause line noise to the powerdistribution panel, such as arc welders and highfrequency machinery.

3) Arrange for a qualified electrician to connectthe power lines.

4) Incoming supply voltage should not deviatemore than ±10% of specified supply voltage.

5) Source frequency should be±2 Hz of nominalfrequency.

[ CAUTION ]

VERIFY THE ACTUAL MACHINE ELECTRICAL

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 toground of less than 100 ohms is required.Typically, a 5/8” copper rod, 8 feet long, andno more than 5 feet from the machine, issufficient. Building grounds or multiplemachines 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.

Desirable Independent Grounding:

N C Earth resistance:Machine Less than 100 ohms

Common Grounds:

Resistance to ground= 100 ÷ the number ofdevices connected tothe grounding (ohms)

Note: Never ground equipment as shown below:

000X713-KY 11/98

S-6

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 THEMACHINE. IF ANY QUESTION EXISTS, CONTACT THE NEAREST MAZAK SERVICECENTER FOR ASSISTANCE.

CAUTION!

S-7

MAZATROL CNC CONTROLLERS PROVIDE PARAMETER SETTINGS TO LIMIT SPINDLERPM. THESE SETTINGS ARE BASED ON THE MAXIMUM SPEED SPECIFIED BY THECHUCK/ACTUATOR MANUFACTURER.

MAKE SURE TO SET THESE PARAMETERS ACCORDING TO CHUCK SPECIFICATIONWHEN INSTALLING A CHUCKING PACKAGE. ALSO, STAMP THE MAXIMUM SPINDLERPM ON THE CHUCK IDENTIFICATION PLATE LOCATED ON THE MACHINE TOOLCOVERS.

REFERENCE THE CNC PARAMETER MANUAL SUPPLIED WITH THE SPECIFIC MACHINETOOL TO IDENTIFY THE REQUIRED PARAMETERS TO CHANGE.

FAILURE TO COMPLY WITH THESE INSTRUCTIONS COULD RESULT IN DAMAGE TOTHE MACHINE, SERIOUS INJURY OR DEATH.

IF ANY QUESTIONS EXIST, CONTACT THE NEAREST MAZAK SERVICE CENTER FORASSISTANCE.

S-8

MAZAK MACHINES ARE ENGINEERED WITH A NUMBER OF SAFETY DEVICES TOPROTECT 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 ORELECTRICALLY.



WARNING!

WARNING!

MAZAK MACHINES ARE ENGINEERED WITH A NUMBER OF SAFETY DEVICES TOPROTECT PERSONNEL AND EQUIPMENT FROM INJURY AND DAMAGE.

MACHINE OPERATOR DOORS AND COVERS ARE DESIGNED TO WITHSTANDACCIDENTAL IMPACT OF A BROKEN INSERT WHERE A MAXIMUM WEIGHT INSERT ATMAXIMUM TOOL DIAMETER IS RUNNING AT MAXIMUM SPINDLE RPM

NEVER USE A CUTTING TOOL OR TOOL INSERT THAT EXCEEDS MACHINESPECIFICATIONS 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 THEMACHINE AND BY THE TOOLING MANUFACTURER.

NOTE: THE MAXIMUM INSERT WEIGHT FOR MAZAK MACHINES IS 20 gf. (0.04 lbs.).



S-9

WARNING!

WARNING!CONFIRM PROPER WORKPIECE FIXTURING/CLAMPING, TOOL SETUP AND THAT THEMACHINE DOOR IS SECURELY CLOSED BEFORE THE START OF MACHINING.

VERIFY ALL SAFETY PRECAUTIONS OUTLINED IN THIS MANUAL BEFORE USING THEFOLLOWING CUTTING CONDITIONS:

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

- CUTTING CONDITIONS SUGGESTED BY THE MACHINING NAVAGATION FUNCTION

- CUTTING CONDITIONS FOR TOOLS THAT ARE SUGGESTED TO BE USED BY THEMACHINING NAVAGATION FUNCTION



BEFORE STARTING OPERATION, CHECK THAT THE WORKPIECE IS SECURELY MOUNTEDIN A VISE OR A SUITABLE FIXTURE. BE CERTAIN THAT THE MOUNTING IS SUFFICIENTTO WITHSTAND CUTTING FORCES DURING WORKPIECE MACHINING.



WARNING!

S-10

CENGDB0551E

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

MACHINING CENTERSET UP SWITCH

DOOR MODEO (OFF) I (ON)

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

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.

OPEN

AUTO 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.

MANUAL

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

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

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 programstop or M01 optional stop and spindle stop. If not, Alarm displayed “Door open invalid”.

CLOSEIV

OPEN

AUTO

If release the lock by note(*1), Alarm will occurthen stop the all motion.Chip spiral conveyor would stop.

Prohibit cycle start.Chip spiral conveyor would stop.

MANUAL No Limitation. No Limitation.CLOSEAUTO No Limitation. Can not run auto operation.

TURNING CENTER SET UP SWITCH

DOOR MODE O (OFF) I (ON)

MANUAL

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

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

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

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

AUTOCan 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.

CLOSE->

OPEN

MANUAL&

AUTO

Can not open the front door in Spindle running, Axis moving, Auto-running( Cycle start, Feed hold ) due toMechanical locking system. (Except Single Block Stop or M00 program stop or M01 optional stop)But, if release the lock by note(*1), Alarm will occur then stop the all motion.

MANUAL No Limitation. No Limitation.CLOSE AUTO 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 thesupplementary 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 S-11

CENGDB0551E

APPENDIX

SWITCH PANEL for M640M (Machining Center)

SWITCH PANEL for M640MT/T (Turning Center)

DOOR UNLOCKSWITCHMACHINE SET UP

SWITCH

PED-EDS-001 S-12

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.

1-2

1-3

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

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.

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

ress the “Display Select y (Left end of menu keys).

ress the “ATC MENU” key.

V

If

P

P ” Menu soft ke P

1-4

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

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

ress the “ATC ARM SWING” menu key.

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

V

P

P

T

1-5

ress the “ATC ARM CHG POS” key.

urn the TOOL CLAMP/UNCLAMP key switch to CLAMP.

ress the “ATC ARM HOME POS” key.

P

T

P

1-6

ress the HOME key.

ove the Y-axis to the home position.

ress MDI menu key.

The MDI window will open:

ey in M602 S___ (Where “S___” is the proper next tool number.)

P

M

P

K

Key in M601 S___ (Where “S___” is the proper magazine position.)

1-7

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

ress the “ATC MAINTE” menu key.

ress the “TOOL UNLOAD” menu key.

P

P

P

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

1-9

Press the MDI key.

he MDI window will open on the monitor.

put MDI da

match” you forgot the M65.

ter is at the magazine side and

-T

In ta: M65 (ATC TOOL No. MEMORY CLEAR)

Do a tool change. (Eg: T01000.0001)

If you get an alarm, “Tool Number Mis NOTE: If you get a “Not in ATC Position” alarm, make sure the shif

sue a M602S0, this will set the “Next Tool” display to zero. is

1-10

Notes:

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

2-4

Notes:

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. <Tolerance> 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.

<Tolerance> 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. <Tolerance>

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. <Tolerance>

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. <Tolerance> 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.

4-5

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.

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. <Tolerance>

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>

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

5-4

Notes:

W- Axis Stroke

100mmA8

Turret center of rotation

B234

Referenceworkpieceorigin

R

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 gaugec) 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.

= 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.

A

R

Turret Center of Rotation Adjustment Procedure (Parameter B234)

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.

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.

B

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. <Tolerance> 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

8-2

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.

9-1

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 offsetnumber. Of a four-digit integer at address T, upper and lower two digits are respectively used tospecify the tool number and offset number.

T !!"".△△◇◇ ;

Tool ID codeApplication directionTool offset numberTool number

Use two digits after the decimal point to specify the application direction of the tool in accordancewith 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, andcan 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 inaccordance with the registration on the TOOL DATA display on condition that the bit 6 of theparameter 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 isregistered 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 theapplication 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 themachine specifications. For further details, especially on how to number the actual tools to beused, 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 togetherwith an axis motion command is executed, depending upon the machine specifications, in one ofthe 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.

9-2

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 integerat address T, upper and lower three digits are respectively used to specify the tool number andoffset number. See the above description of the 4-digit T-code for the meaning of the decimalfractions.

The available range of T-codes depends on the machine specifications. For further details, referto the operating manual of the relevant machine.

Only one T-code can be included in a block.

T !!!""".△△◇◇ ;

Tool ID codeApplication directionTool offset numberTool 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 bycommanding T-code in the format shown below. The return tool refers to an unnecessary toolreturned to load another tool to be used. The assigned return tool is accomodated in themagazine. The next tool refers to a tool used for the next machining, which can be assignedwhen it is now accomodated in the magazine. The next tool in the magazine can be indexed atATC 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 toolReturn toolTool ID codeApplication direction

10 EIA/ISO PROGRAMMING EXAMPLE

10-1

10-2

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

10-3

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

10-4

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

10-5

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

10-6

Notes:

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

11-3

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

11.2 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) Y axis must be at home position before commanding the macro program. 2) B axis must be positioned to programming point before commanding the macro program. 3) X and Z axis do not require home position return before commanding the macro program. 4) Workpiece coordinate created by this macro program will be canceled by G53.5 or next tool change. 5) The following data is required in the TOOL DATA and SET UP SCREEN: (TOOL DATA SCREEN) (SET UP SCREEN) Tool Name Z Offset Actual Tool Diameter Tool Set X Tool Set Z 6) Make sure parameters B234 and B263 are set properly.

11-5

11-6

Notes:

APP-1

INTEGREX-100~400MkIII PLC ALARM LISTS

CAUTION

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

D135W0049E’

1. INTEGREX 300/400-IIINeither SP1 nor SP2 is displayed on the display.

2. INTEGREX 300/400-IIIS/IIISTSP1 or SP2 is displayed on the display. The alarm message related to the secondaryspindle or W-axis is displayed with SP2.

Example: 250 SPINDLE START MISOPERATION ( , , )SP1

An alarm message related to the main spindle. SP1 is replaced with SP2 for analarm of the same message but related to the secondary spindle.

3. INTEGREX 300/400-IIITTR1 or TR2 is displayed on the display. The alarm message related to the lower turret isdisplayed 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 replacedwith 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 300/400-III/IIIT/IIIS/IIIST” are all displayed with “SP1” in the INTEGREX 300/400-IIIS.

H374S5B012E

APP-2

Alarm List for the INTEGREX 300/400-IIII

Alarm No. and message Description Check and remedy Address

200: THERMAL TRIP(EMERGENCY STOP)

Thermal relay for the hydraulic unit hastripped.

Check that the hydraulic unit motor isnormal, 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 controlpanel and then reset the circuit breaker thathas tripped.

X3 X4

202: HYDRAULICPRESSURE DOWN

An oil pressure decrease below therequired level has activated the pressureswitch.

Check the hydraulic unit and piping forabnormalities.

X447

203: AIR PRESSUREDOWN

An air pressure decrease below therequired level has activated the pressureswitch SP30.

Check the air supply port and piping forabnormalities.

X446

204: SPINDLECONTROLLERMALFUNCTION

An alarm occurred at spindle controller. Turn off the main circuit breaker and thenturn it back on.If the alarm is not released, please contactyour MAZAK service representative.

―

205: MILLINGCONTROLLERMALFUNCTION

An alarm occurred at milling spindlecontroller.

Turn off the main circuit breaker and thenturn it back on.If the alarm is not released, please contactyour MAZAK service representative.

―

206: OPEN FRONT DOOR(EMERGENCYSTOP)

Coolant cover (front door) is opened duringautomatic operation.

Close the coolant cover (front door) andstart the machine in automatic operationmode.

XA

211: NOT OPERATED M-CODE SIMULTA.

M-codes which must not be used incombination were selected at the sametime.

Correct the program.―

212: CHUCKOPEN/CLOSESWITCH MALF.

The signal from the chuck open/close footswitch has been input during chuckopen/close command (M6, M7) in theautomatic operation.

Fault in the chuck open/close foot switchcircuit

X44E(X44F)

213: ILLEGALDESIGNATED TOOLNo.

T code that does not exist in thespecification is assigned.


The chuck unit has failed to grip thematerial.

―215: CHUCK SYSTEM

MALFUNCTIONAn erroneous chucking action was detectedduring chucking operation.

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

X440/X441

218: CHUCKING TYPENOT SELECTED

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

Select the type of chucking.―

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

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

220: TURRET POSITIONSENSOR MALF.

The milling head index /B-axis motor ismalfunctioning.


―

221: TURRET CLAMPSENSORMALFUNCTION

In spite of the fact that the milling head isactually clamped, the clamping confirmationsensor (SQ18) does not turn on.In spite of the fact that the milling head isactually unclamped, the clampingconfirmation sensor (SQ18) does not turnoff.

The clamping confirmation sensor isabnormal or faulty.

X460

224: CHUCK SENSORMALFUNCTION

The chuck open or close confirmationsensor fails in function, or both of thesensors are ON simultaneously.

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

X440/X441

APP-3


225: FRONT DOORSENSORMALFUNCTION

For the machine with an optional automaticdoor, the front door open or closeconfirmation sensor fails in function, or bothof the sensors are ON simultaneously.

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

X14/XA

The TOOL EYE arm is likely to beobstructed in the middle of its operation. ―

231: TOOL EYEPOSITION SENSORMALF.

The TOOL EYE extension or retractionconfirmation sensor (SQ7/SQ8) does notturn on, or both of the sensors are ONsimultaneously. Or the corresponding sensor is faulty. X444/

X445

234: TOOL CLAMPSENSORMALFUNCTION

The tool clamp check sensor fails tofunction.

Adjust the setting of the TIM12 timer.―

236: PARTS-CATCHERSENSOR MALF.

For the machine with an optional automaticparts catcher, the advance end confirmationsensor or retract end confirmation sensordoes not turn on, or both of the sensors areON simultaneously.

The parts catcher advance/retract endconfirmation sensors are faulty ormalfunctioning. ―

243: MEASURINGCONTROLLERMALF.

An error occurred at the workpiecemeasurement controller (option).

Check the cause of error at the workpiecemeasurement controller. ―

245: BAR-FEEDERCONTROLLERMALF.

An error occurred at the bar feedercontroller.

Check the cause of error at the bar feedercontroller. ―

248: EXTERNALCONTROLLER (No.1)MALF.

Failure of controller of a peripheral unit(option)

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

250: SPINDLE STARTMISOPERATION

1. A spindle rotation command was givenduring mis-chucking. (Chuck sensorprovided.)

1. Close the chuck and start operationwith the workpiece gripped.Alternatively, the chuck open/closecheck sensor may be improperlyadjusted.→ Check the sensor.

X440/X441

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

2. After closing the chuck using the chuckclamp command, designate the spindlerotation command.

3. A spindle rotation command was giventogether with an orient command.

3. Take steps so that the commands arenot given together.

4. The M3, M4, M16, M17, M18 or M19command was given in the milling mode.

4. 1) Program error → Correct the program.

2) Switch to the turning mode andthen designate the command.

―

5. A spindle rotation command was givenwithout the TOOL EYE at the backwardend.

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

X445

6. A spindle rotation command was givenwith the door not closed when the doorinterlock switch was set to AUTO.

6. Close the door and start the spindlerotation.

X15

XA

7. Alarm 297 CHUCK PRESSURE DOWNor 296 TAIL SLEEVE PRESSUREDOWN is displayed.

7. Clear the alarm 297 or 296. X442X443X480

APP-4


251: MILLING MOTORROTATION PROHIB.

1. A milling spindle rotation command wasgiven even though the chuck was notclosed.

1. After closing the chuck using the chuckclamp command, designate the millingspindle rotation command.

2. A milling spindle rotation command wasgiven even though the milling tool wasnot clamped.

2. After clamping the milling tool,designate the milling spindle rotationcommand.

―

3. A milling spindle rotation command wasgiven even though the milling head (B-axis) was not clamped.

3. After clamping the milling head (B-axis), designate the milling spindlerotation command and check themilling head clamp sensor.

X460

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

4. 1) Program error → Correct the program.

2) Switch to the milling mode andthen designate the command.

―

5. A milling spindle rotation command wasgiven with the door not closed when thedoor interlock switch was set to AUTO.[When the door interlock option isprovided.]

5. Close the door and start the millingspindle rotation.

X15XA

6. Alarm 297 CHUCK PRESSURE DOWNor 296 TAIL SLEEVE PRESSUREDOWN is displayed.

6. Clear the alarm 297 or 296. X442X443X480

7. The touch sensor for workpiecemeasurement is mounted on the millinghead.

7. Change the touch sensor for a rotatingtool in the MDI or automatic mode. ―

8. The milling tool rotation command isgiven though the TOOL EYE is notplaced at the backward end.

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

X445

252: AXIS MOVEMISOPERATION

An attempt was made to execute an axismovement under the axis movementinterdiction.

1. An attempt was made to execute an axismovement with the magazine coveropened.

1. First close the magazine cover andthen execute the axis movement.

XD

2. An attempt was made to execute amovement along the X-axis with the X-axis interlock activated.

2. X-axis interlock is activated in thefollowing 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-byposition and the swinging-inposition.

5) When the magazine cover isopened.

Note:When states 1) to 5) occur, an axismovement can be executed by themanual pulse handle and the [ATCMENU] → [INTERLOCK NEG.] menukey operation. (Refer to PART 2.)6) When the steady rest is connected.7) When the tailstock body is

connected.

X460

XD

APP-5



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

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

X-axis interlock.

Note: An axis movement can beexecuted by the manual pulsehandle and the [ATC MENU] →[INTERLOCK NEG.] menu keyoperation. (Refer to PART 2.)

―

4. An attempt was made to execute a C-axis movement with the C-axis interlockactivated.

4. C-axis interlock is activated in thefollowing states: When the C-axis isclamped.

―

Check the overload detection level.253: OVERLOADDETECTION

An overload has been detected in amachine having an overload detectionoption.

Reduce the cutting load. ―

This alarm display lights when an attempthas been made to turn the milling head orwhen the conditions were unstable.

― ―

1. When the arm is at the milling head sideor at a swinging-in position betweenstand-by and the milling head side.

1. Set the arm to the stand-by position byusing the ATC menu. (Refer to PART2.)

―

256: TURRET ROTATIONPROHIBITED

In the automatic/manual mode:

2. The turning tool or milling tool has beenunclamped.

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 pressingthe emergency stop button in the middle ofthe ATC process, the number of the toolmounted on the milling head is differentfrom that displayed on the NC display.

Change the “TURRET TOOL” numberdisplayed in the DIAGNOSIS display to thenumber of the current tool (that is, theparenthesized numerals in alarmmessages).

―

259: MODE CHANGEIMPOSSIBLE

The rapid feed mode or zero point returnmode switch on the operating panel hasbeen pressed during tool nosemeasurement with the TOOL EYE.

The rapid feed or zero point return modecannot be selected during tool nosemeasurement.

―

260: SLIDEWAYLUBRICATIONALARM

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

Check the lubricating grease amount, andreplenish grease if required.

X465

261: HEAD LUBRICATIONALARM

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

Check the coolant level. X485

Thermal relay F13 for the coolant motor hastripped.

X5264: THERMAL TRIP(SINGLE BLOCK)

Thermal relay F14 for the chip conveyorhas tripped.

Check the regarding unit (e.g. chipconveyor for clogging with chips) and thenreset the thermal relay. X6

The pressure switch (SP7) for ball screwand C-axis gear lubrication does not turn onor off within a fixed time.

X44C267: BALL SCREWLUBRICATIONALARM

The float switch (SL1) has turned off.

Check the lubrication oil level, andreplenish lubricating oil if required.

X44D

270: SPINDLE ORIENTEXCEED TIME

Although a spindle orientation command isgiven, the orientation confirmation signaldoes not turn on within a predeterminedtime.

The spindle motor detector/controller isabnormal.

―

272: TURRET INDEXEXCEED TIME

Although a milling head indexing commandis given, the index confirmation signal doesnot turn on within a predetermined time.

The milling head index motordetector/controller is abnormal. ―

APP-6


275: ROBOT SERVICEEXCEED TIME

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

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

―

276: ATC CYCLEEXCEED TIME

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

Reset the ATC unit using either of thefollowing methods:

(1) Cancel the ATC command by pressingthe emergency stop button.

(2) Release the emergency stop status bypressing the RESET key.

(3) Execute the ATC reset function of themachine menu.

If the ATC unit cannot be reset, pleasecontact your MAZAK servicerepresentative.

―

279: PARTS CATCHERCYCLE EXCEEDTIME

For the machine with an optional automaticparts catcher, although a parts catcheradvance/retract command is given, theadvance end confirmation sensor or retractend confirmation sensor does not turn onwithin a predetermined time.

The parts catcher advance/retract endconfirmation sensor are faulty ormalfunctioning.

―

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

X440/X441

282: CHUCK CLAMPEXCEED TIME

Although a chuck open/close command isgiven, the confirmation signal does not turnon within a predetermined time.

The hydraulic system is abnormal. ―

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

―286: FRONT DOOR

EXCEED TIMEFor machines with an optional automaticdoor, although a door open/close commandis given, the confirmation signal does notturn on within a predetermined time. The pneumatic system is abnormal. ―

292: SENSORMALFUNCTION No. 3

The correction value has exceeded the limitset in the thermal displacementcompensation.

Check that the thermal sensor is correctlywiring.

R1, R2,R3

293: SENSORMALFUNCTION No. 4

The correction value has changed largelythan the previous one in the thermaldisplacement compensation.

Check that the thermal sensor is correctlywiring.

R1, R2,R3

297: CHUCK PRESSUREDOWN

The spindle chuck pressure remainsreduced in a machine having a spindlechuck pressure guarantee option.

Check the spindle chuck pressure. X442/X443

300: START COND. ERR.(DOOR OPEN)

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

Close the front cover. XA

301: START COND. ERR.(TUR UNCLAMP)

The cycle start button was pressed whilethe milling head was unclamped.

Clamp the milling head. X460

302: START COND. ERR.(EXT RESET)

The cycle start button was pressed whilethe 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 theexternal feed hold signal was ON.

Check the controller of the external unit.―

308: C/S ERROR (TOOLEYE EXTEND)

The cycle start button has been pressedwith the TOOL EYE arm placed in ameasurement position.

Retract (restore) the TOOL EYE arm intoposition.

X445

310: C/S ERROR(TNo.MISMATCH)

During the restart of operation after manualinterruption, a tool number different fromthat which was valid before interruption hasbeen specified.

Specify the same tool number as that whichwas valid before interruption.

―

311: C/S ERROR (TAILSTOCK QUILL)

The cycle start button has been pressedwith the tail spindle not placed at its zeropoint or advance end.

Place the tail spindle at its zero point oradvance end. ―

APP-7


312: C/S ERROR (PT-CATCHER EXTEND)

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

Retract (restore) the parts catcher into theposition. ―

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

A tailstock advance/retract command wasgiven with the tail spindle advance/retractswitch (SA2) not placed at the neutralposition.

Place the tail spindle advance/retractswitch at the neutral position.

―

320: TOOL UNCLAMPIMP. (M-SP ROT.)

A milling head unclamping command hasbeen given during rotation of the millingspindle motor.

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

321: MODE CHANGEIMPOSSIBLE(DURING ATCCYCLE)

Mode changing has been attempted duringthe ATC cycle.

The operation mode cannot be changedduring ATC. To change the mode, wait untilATC has been completed.

―

322: RAPID MODE IMP.(ORIGIN RET UNF)

The rapid feed mode was selected withoutcarrying out the zero point return operationafter the power supply had been turned on.

Carry out the zero-point return operation.―

324: DIFF. MODE (ORIGINRET UNFIN.)

The automatic operation mode wasselected without carrying out the zero-pointreturn operation after the power supply hadbeen turned on.

Carry out the zero-point return operation.

―

325: TL. EYE EXT. IMP. A TOOL EYE extend/retract command hasbeen given with the SET UP switchremaining set to “O” and the front doorremaining open.

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

X11C/XA

The tail spindle has advanced with theTOOL EYE arm extended.

Retract the TOOL EYE arm. X444

The tail spindle has advanced/retractedduring the spindle rotation.

Stop the spindle.

326: T/S QUILL EXT. IMP.

The tail spindle has advanced/retractedduring the milling spindle rotation.

Stop the milling spindle.

The condition to perform ATC is notappropriate. The details are described atthe left. See D200/D201.

90(D201)

The machine is under lockingstate. After releasing themachine lock, press the cyclestart button. The ATC will beexecuted.

91(D201)

The tailstock is in the connectionstate. After releasing theconnection of the tailstock,perform the ATC.

97(D201)

When the loading tool isspecified in the ATC, the shifteris not placed at the ATC side.Move the shifter manually on theATC side.

327: NOT IN ATC STARTPOSITION

98(D201)

The magazine cannot be rotatedbecause the specified tool isdifferent from the loading tooland the shifter is not placed onthe ATC side. Move the shifter tothe ATC side manually.

―

APP-8


The condition to perform ATC is notappropriate. The details are described atthe left. See D200/D201.

99(D201)

The shifter is not placed in themagazine side without theloading tool when commandingthe ATC.Move the shifter to the magazineside/retract position manually.

9800(D200)

The tool command is givenincorrectly. Perform again.

327: NOT IN ATC STARTPOSITION

9900(D200)

The ATC arm is not at thereference point position. Movethe ATC arm to the referencepoint position manually. Thenperform again the ATC.

―

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

Open the chuck (and remove theworkpiece.)

329: CHUCKINGSELECTIONPROHIBITED The inside/outside chucking selection is

performed when the spindle or millingspindle is not stopped.

Stop the spindle or milling spindle. ―

In a machine having a warming-up option340: CONDITION No.1MISSING - the warming-up program number is not

registered.Register the warming-up program number(1 – 9999) in the MACHINE PARAMETERdisplay.

R18

- the front cover (front door) is open. Close the front cover (front door). XA

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

To warm up the machine, return all axes totheir zero points before turning off the NCunit.

―

341: CONDITION No.2MISSING

The M-code command for milling spindlethrough air blowout has been issued duringcoolant injection.


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

361: TAIL ALARM

The tailstock has moved during spindlerotation.

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

―

365 CARRIERCONTROLERMALFUNCTION

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

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


―

366: SHIFTERCONTROLERMALFUNCTION

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



―

374: OPERATINGSWITCH FAULT

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

The control is faulty unless it has beeninadvertently turned on.

―

375: MOTOR & SERVOTURNING OFF ERR.

Since the electromagnetic switch OFFcommand for the motor and servo systemhas been issued by activation of theemergency stop or door interlock functionunder CE machine specifications, theelectromagnetic switches did not turn offwithin the required time.



X10

376: MAIN POWERTURNING OFFMALFUNCTION

When the front door of a CE specificationsmachine was opened with the setup keyswitch set to “O”, the electromagneticswitch for spindle power did not turn offwithin the required time.



X11

377: COOLANT LEVELLOW

The coolant level in the coolant unit of amachine of the high-pressure coolantspecifications has decreased.

Check the coolant level in the coolant unitand add coolant.

X492

APP-9


378: HIGH PRESSUREPUMP THERMALTRIP

The thermal relays in the coolant unit of amachine of the high-pressure coolantspecifications have become tripped.

Check the thermal relays of the coolantunit.

X490

379: TANK PRESSURELOW

The pressure in the coolant unit tank of amachine of the high-pressure coolantspecifications has decreased.

Check and adjust the coolant unit tankpressure.

X491

The cycle start button has been pressed inautomatic operation mode with the frontdoor open and the setup key switch set to“O”.

Change the setting of the setup key switchto “I” and then press the cycle start button.Single-block automatic operation will beactivated.

381: CONDITIONMISSING (SET UPSWITCH)

For a machine of the front door lock pinspecifications, a manual-starting button hasbeen pressed with the front door open andthe setup key switch set to “O”.

Change the setting of the setup key switchto “I” and then press the desired manual-starting button. The override rate will bereduced to 25%.

―

382: COOLANT SYSTEMMALF.

An error signal has been sent from thecoolant unit of a machine of the high-pressure coolant specifications.

Check the coolant unit for alarms. X493

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

In a machine of the 80/120-tool magazinespecifications, the cycle start command orthe tool change command was issued whenthe carrier and the shifter were not presentat their stand-by positions.

Before issuing the cycle start command orthe tool change command, move the carrierand the shifter to their stand-by positionsusing the required switch of the magazinemanual operations box.

―

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

Under 20- or 40-tool magazinespecifications, executing the machine menufunction for opening the ATC cover hasbeen attempted with the Z-axis existing inthe minus direction relative to its zero point.

Move the Z-axis in the plus directionrelative to its zero point before opening theATC cover. ―

386: ATC STOP When the [ATC STOP] menu key in themachine menu was pressed (that is, whenthe menu was displayed in reverse mode),the axis was moved to the ATC position bythe ATC command.

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

390: TOOL ON INTERFERALARM

An attempt has been made to return the toolto a magazine pocket containing anothertool.

Check the tool number of the tool to bereturned and that of the tool stored withinthe magazine pocket.

―

391: LD/ULD/ACHGCONDITION ALARM

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

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

X475

392: MAGAZINE MANUALINTERR.

Under 20- or 40-tool magazinespecifications, the tool change commandhas been entered or the cycle start buttonpressed with the magazine manualinterruption switch set to ON.

Change the setting of the magazine manualinterruption switch to OFF.

X1C

394: ATC CONTROLLERMALF.

An alarm signal has been received from theATC amplifier.

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

―

APP-10


The positions of the operational checksensors or watchdogs are not correct or thesensors themselves are malfunctioning.

Confirm the value of D199 on theDIAGNOSIS display and examine thesensor causing the alarm.

―

D199 Corresponding sensor ―

0 Normal ―

1 The X470 limit switch at the ATCside of the shifter has not turnedon 20 seconds after the Y4F0command for moving the shifterto the ATC side has been issued.The X471 limit switch at themagazine side of the shifter hasnot turned on 20 seconds afterthe Y4F1 command for movingthe shifter to the magazine sidehas been issued.

X470X471

2 The X472 limit switch at theextending side of the shifter hasnot turned on 20 seconds afterthe Y4F2 command for extendingthe shifter has been issued.The X473 limit switch at theretracting side of the shifter hasnot turned on 20 seconds afterthe Y4F3 command for retractingthe shifter has been issued.

X472X473

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

X442X443

395: CHECK SENSORMALF. (SEE D199)

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

After the command has been issued, nosensors did not turn on within the requiredtime.

12 The top door open end sensorswitch (X14) and closed endsensor switch (X15) of themachine of the GL specificationsare both on.

X14X15

397: MAGAZINE DOORINTERLOCK

The magazine door has been openedduring issuance of the tool changecommand or the magazine rotationcommand.

Close the magazine door. XD

398: MAGAZINE COVEROPEN

The magazine cover is open.

The machine of the CE specifications hasits magazine setup switch remaining set toON.

Close the magazine cover.

Change the setting of the magazine setupswitch to OFF.

XDX1C

399: MAINTE./ADJUSTPARAM. ON

The maintenance/adjustment parametersare validated.

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


―

APP-11

Alarm List for the INTEGREX 300/400-IIIIIIIIIIII S/IIIIIIIIIIIIST (Addition)


204: SPINDLECONTROLLERMALFUNCTION

SP2

An alarm occurred at secondary spindlecontroller.


―

The chuck unit on secondary spindle hasfailed to grip the material.

―215: CHUCK SYSTEM

MALFUNCTIONSP2

An erroneous chucking action was detectedduring chucking operation on secondaryspindle. The chuck open/close end sensor on

secondary spindle (SQ62/SQ63) isabnormal or faulty.

X483/X484

218: CHUCKING TYPENOT SELECTED

SP2

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

Select the type of chucking.―

224: CHUCK SENSORMALFUNCTION

SP2

The secondary spindle chuck open or closeconfirmation sensor fails in function, or bothof the sensors are ON simultaneously.

The secondary spindle chuck open orclose confirmation sensor (SQ62/SQ63) isabnormal or faulty.

X483/X484

250: SPINDLE STARTMISOPERATION

SP2

1. A secondary spindle rotation commandwas given during mis-chucking. (Chucksensor provided.)

1. Close the chuck and start operationwith the workpiece gripped.Alternatively, the chuck open/closecheck sensor may be improperlyadjusted.→ Check the sensor.

X483/X484

2. A spindle rotation command was giveneven though the chuck of secondaryspindle was not closed.

2. After closing the chuck of secondaryspindle using the chuck clampcommand, designate the spindlerotation command.

―

3. A spindle rotation command was givenwithout the TOOL EYE placed at thebackward end.

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

X445

4. A secondary spindle rotation commandwas given without the door closed.

4. Close the door and start thesecondary spindle rotation.

XA

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

5. Clear the alarm 297. X448X449


SP2

An attempt was made to execute an axismovement under the axis movementinterdiction.

1. An attempt was made to execute amovement along the W-axis (secondaryspindle traveling axis) without the X- andY-axes placed at the zero point.

1. Perform the X- and Y-axes zero pointreturn operation.

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

2. Perform the W-axis zero point returnoperation.

―

3. Though the W-axis zero point return isnot completed after power on, an attemptwas made to execute a movement alongthe W-axis in – direction at rapid feedwithout the TOOL EYE placed at thebackward end.

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

X445

4 An attempt was made to execute amovement along the W-axis with a barchucked both on main spindle andsecondary spindle.

4 Open the chuck on main spindle orsecondary spindle.

―

APP-12


270: SPINDLE ORIENTEXCEED TIME

SP2

Although a secondary spindle orientationcommand was given, the orientationconfirmation signal does not turn on within apredetermined time.

The secondary spindle motordetector/controller is abnormal.

―

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

X483/X484

282: CHUCK CLAMPEXCEED TIME

SP2

Although a chuck open/close command forsecondary spindle was given, theconfirmation signal does not turn on within apredetermined time. The hydraulic system is abnormal. ―

The inside/outside chucking selection wasperformed without the chuck of secondaryspindle opened.

Open the chuck of secndary spindle (andremove the workpiece).

329: CHUCKINGSELECTIONPROHIBITED

SP2 The inside/outside chucking selection wasperformed when the secondary spindle ormilling spindle is not stopped.

Stop the secondary spindle or millingspindle.

―

APP-13

Alarm List for the INTEGREX 300/400-IIIIIIIIIIIIT/IIIIIIIIIIIIST (Addition)


221: TURRET CLAMPSENSORMALFUNCTION

TR2/SP2

In spite of the fact that the (lower) turret isactually clamped, the clamping confirmationsensor (SQ39) does not turn on.In spite of the fact that the (lower) turret isactually unclamped, the clampingconfirmation sensor (SQ39) does not turn off.

The clamping confirmation sensor isabnormal or faulty.

X52

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

Cancel the measurement mode.256: TURRET ROTATIONPROHIBITED

TR2/SP2 A turret indexing command was given withthe SET UP switch remaining set to “O” andthe front door remaining open.

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

X198X1F8

258: TNo. MISMATCH

TR2/SP2

For resuming automatic operation after amanual interruption, the indexed face of theturret is different from the face indexedbefore the interruption.

Index the turret for the same face tocontinue the automatic operation.

―

272: TURRET INDEXEXCEED TIME

TR2/SP2

Although a turret indexing command isgiven, the index confirmation signal does notturn on within a predetermined time.

The detector/controller of the turretindexing motor is abnormal. ―

301: START COND. ERR.(TUR UNCLAMP)

TR2/SP2

The cycle start button was pressed while theturet was unclamped.

Clamp the (lower) turret. X52

310: C/S ERROR(TNo.MISMATCH)

TR2/SP2

For resuming automatic operation after amanual interruption, the number of the toolin use differs from the number before theinterruption.

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

―

APP-14

- NOTE -

APP-15

M-CODE TABLE

Miscellaneous Function (M-Code) for the INTEGREX 300/400-IIIIIIIIIIII/IIIIIIIIIIII T/IIIIIIIIIIIIS/IIIIIIIIIIIIST!: 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 !

M10

M11

M12 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) —



M19 Spindle orientation position (for the robot to insert a workpiece) "

M20 Robot service call "










M30 Reset & tape rewind !

M31 Tail spindle & tailstock body advance ! for 300/400-III/IIIT

M32 Tail spindle & tailstock body retract ! for 300/400-III/IIIT

M33 Low chuck pressure —

M34 High chuck pressure —

M35

M36

M37

M38

M39

M40

H374S5C010E

APP-16


M41

M42

M43

M44

M45 Air coolant blow ON (coolant stop: M09) "

M46

M47

M48 Parts catcher advance "

M49 Parts catcher retract "

M50

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 "

M59

M60 C-axis unclamp !

M61

M62

M63

M64

M65

M66 C-axis clamp !

M67 C-axis brake (for machining by G01) !

M68 Cycle bar feeder call 1 —

M69 Cycle bar feeder call 2 —

M70

M71

M72 Inside chuck clamp —

M73 Outside chuck clamp —

M74 Steady rest - milling head connection mode release —

M75 Steady rest - milling head connection mode start —

M76

M77

M78

M79

M80

M81 Workpiece measurement start "

M82 Workpiece measurement end "

M83 Tool measurement start "

M84 Tool measurement end "

M85

M86 Steady rest 1 unclamp "

M87 Steady rest 1 clamp "

APP-17


M88 Steady rest 2 unclamp —

M89 Steady rest 2 clamp —

M90

M91

M92

M93

M94

M95

M96 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 "

M118

M119

M120 Measurement data print out "

M121

↓

M149

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 "

APP-18


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

M165

M166

M167

M168

M169 35K, 70K high pressure coolant ON (OFF: M9, M154) "

M170

M171

M172 Index 0°(KOUYOU) —








M180

↓

M197

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 !

M206

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: M215) !

M217

M218

M219 Milling tool orient !

M220

↓

M229

APP-19


M230 Grinding mode ON "

M231 Grinding speed setting "

M232

M233

M234

M235

M236 C-axis servo gain normal !

M237 C-axis servo gain low !

M238 C-axis servo gain middle !

M239 C-axis servo gain high !

M240

M241

M242

M243

M244

M245

M246

M247

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 !

M255

M256

M257

M258 Milling head air blow !

M259

M260 Polygon mode ON "

M261 Polygon mode OFF "

M262

↓

M273

M274 Steady rest coolant ON —

M275 Steady rest coolant OFF —

M276

↓

M330

M331 Spindle coil change fixed to high speed !

M332 Spindle coil change, valid !

M333

↓

M347

M348 Yt-axis selection !

M349 Y-axis selection !

APP-20


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 "

M380

↓

M389

M390 M391 cancel "

M391 Spindle mis-chucking cancel (M3/M4 completed with chuck open) "

M392

M393

M394 TOOL EYE extension possible during chuck close (when robot valid) !

M395 M394 cancel !

M396

↓

M600

M601 Magazine tool rotation !

M602

↓

M730

M731 Tail thrust 1 selection !










M741 Positioning tailstock to “Position 1” !

M742 Positioning tailstock to “Position 2” !

M743 Positioning tailstock to “Retract” !

APP-21


M744

↓

M927

M928 Y-axis zero point return !

M929

M930 Yt-axis moving to ATC position !

M931

↓

M999

APP-22

Miscellaneous Function (M-Code) for the INTEGREX 300/400-IIIIIIIIIIII S/IIIIIIIIIIIIST(Addition)

!: Standard": Optional—: Special order


M300 Secondary spindle selection ! System M-code

M301

M302 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) !

↓

M319 Secondary spindle orientation "

M320

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 !

↓

M350


M352 Spindle speed arrival signal check !

↓

M357 Secondary spindle chuck air blast start "

M358 Secondary spindle chuck air blast stop "


M360 Secondary spindle orientation clamp mode "


M362Simultaneous chuck operation on main and secondary spindles in TRS-CHK mode

"


M364Immediate completion of spindle/milling spindle start commands (M-code) in TRS mode

"

↓

M380 Spindle synchronous rotation mode !

M381 Spindle synchronous rotation mode cancel !

↓

M500 Release of chuck open/close interlock during spindle rotation !


M502 Main/secondary spindle synchronous rotation (Cross mode) " System M-code

M503

APP-23


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 !


M510

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

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-24

Miscellaneous Function (M-Code) for the INTEGREX 300/400-IIIIIIIIIIII T/IIIIIIIIIIIIST(Addition)

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


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 !

M949

M950 Stand-by M-code !

































APP-25

















APP-26

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


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 !

M301

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 !

M949






APP-27













































APP-28

- NOTE-

APP-29

Stroke Diagram1. INTEGREX 100-ΙΙΙΙΙΙΙΙΙΙΙΙ (Metric)

1372

ST0

0012

Uni

t: m

m

Dra

win

g N

o.

Not

es:

1. I

f B =

90°

, the

tool

leng

ths

that

can

be

m

easu

red

usin

g th

e TO

OL

EY

E a

re

lim

ited.

2. I

f B =

0°,

whe

n a

spec

ial c

huck

or l

ong

ja

ws

are

mou

nted

the

tool

leng

ths

that

can

be m

easu

red

usin

g th

e TO

OL

EYE

m

ay b

e lim

ited.

3.

B

T40

spec

.

Stroke diagram (INTEGREX 100-ΙΙΙ - Metric -)

APP-30

INTEGREX 100-ΙΙΙΙΙΙΙΙΙΙΙΙ (Inch)

1372

ST0

0041

Uni

t: in

. (m

m)

Dra

win

g N

o.

Not

es:

1. I

f B =

90°

, the

tool

leng

ths

that

can

be

m

easu

red

usin

g th

e TO

OL

EYE

are

limite

d.2.

If B

= 0

°, w

hen

a sp

ecia

l chu

ck o

r lon

g

jaw

s ar

e m

ount

ed th

e to

ol le

ngth

s th

at

ca

n be

mea

sure

d us

ing

the

TOO

L EY

E

may

be

limite

d.

3.

BT4

0 sp

ec.

Stroke diagram (INTEGREX 100-ΙΙΙ - Inch -)

APP-31

INTEGREX 100-ΙΙΙΙΙΙΙΙΙΙΙΙS (Metric)

1372

ST0

0022

Uni

t: m

m

Dra

win

g N

o.

Not

es:

1. I

f B =

90°

, the

tool

leng

ths

that

can

be

m

easu

red

usin

g th

e TO

OL

EY

E a

re

lim

ited.

2. I

f B =

0°,

whe

n a

spec

ial c

huck

or l

ong

ja

ws

are

mou

nted

the

tool

leng

ths

that

can

be m

easu

red

usin

g th

e TO

OL

EYE

m

ay b

e lim

ited.

3.

B

T40

spec

.

Stroke diagram (INTEGREX 100-ΙΙΙS - Metric -)

APP-32

INTEGREX 100-ΙΙΙΙΙΙΙΙΙΙΙΙS (Inch)

1372

ST0

0051

Dra

win

g N

o.

Uni

t: in

. (m

m)

Not

es:

1. I

f B =

90°

, the

tool

leng

ths

that

can

be

m

easu

red

usin

g th

e TO

OL

EYE

are

limite

d.2.

If B

= 0

°, w

hen

a sp

ecia

l chu

ck o

r lon

g

jaw

s ar

e m

ount

ed th

e to

ol le

ngth

s th

at

ca

n be

mea

sure

d us

ing

the

TOO

L EY

E

may

be

limite

d.

3.

BT4

0 sp

ec.

Stroke diagram (INTEGREX 100-ΙΙΙS - Inch -)

APP-33

INTEGREX 100-ΙΙΙΙΙΙΙΙΙΙΙΙST (Metric)

1372

ST0

0032

Uni

t: m

m

Dra

win

g N

o.

Not

es:

1. I

f B =

90°

, the

tool

leng

ths

that

can

be

m

easu

red

usin

g th

e TO

OL

EY

E a

re

lim

ited.

2. I

f B =

0°,

whe

n a

spec

ial c

huck

or l

ong

ja

ws

are

mou

nted

the

tool

leng

ths

that

can

be m

easu

red

usin

g th

e TO

OL

EYE

m

ay b

e lim

ited.

3.

B

T40

spec

.

Stroke diagram (INTEGREX 100-ΙΙΙST - Metric -)

APP-34

INTEGREX 100-ΙΙΙΙΙΙΙΙΙΙΙΙST (Inch)

1372

ST0

0062

Dra

win

g N

o.

Uni

t: in

. (m

m)

Not

es:

1. I

f B =

90°

, the

tool

leng

ths

that

can

be

m

easu

red

usin

g th

e TO

OL

EYE

are

limite

d.2.

If B

= 0

°, w

hen

a sp

ecia

l chu

ck o

r lon

g

jaw

s ar

e m

ount

ed th

e to

ol le

ngth

s th

at

ca

n be

mea

sure

d us

ing

the

TOO

L EY

E

may

be

limite

d.

3.

BT4

0 sp

ec.

Stroke diagram (INTEGREX 100-ΙΙΙST - Inch -)

APP-35

Stroke Diagram

INTEGREX 200-IIIIIIIIIIII

Dra

win

g N

o .13

73P

GD

0011

Uni

t: m

m (i

n.)

Not

e: F

or B

T Sp

ec

*1: 1

65 m

m (6

.5")

*2:

40

mm

(1.5

7")

DO

M./E

X.M

ain

spin

dle

Hol

low

chu

ck o

f 8"

Stroke diagram (INTEGREX 200-III)

APP-36

INTEGREX 200-IIIIIIIIIIIIS

1373

PG

D00

21D

raw

ing

No .

Uni

t: m

m (i

n.)

Not

e: F

or B

T Sp

ec

*1: 1

65 m

m (6

.5")

*2:

40

mm

(1.5

7")

DO

M./E

X.M

ain

spin

dle

Hol

low

chu

ck o

f 8"

Sec

onda

ry s

pind

leH

ollo

w c

huck

of

8"

Stroke diagram (INTEGREX 200-IIIS)

APP-37

INTEGREX 200-IIIIIIIIIIIIT

1373

PG

D00

31D

raw

ing

No .

Uni

t: m

m (i

n.)

Not

e: F

or B

T Sp

ec

*1: 1

65 m

m (6

.5")

*2:

40

mm

(1.5

7")

DO

M./E

X.M

ain

spin

dle

Hol

low

chu

ck o

f 8"

Stroke diagram (INTEGREX 200-IIIT)

APP-38

INTEGREX 200-IIIIIIIIIIIIST

1373

PG

D00

41D

raw

ing

No .

Uni

t: m

m (i

n.)

Not

e: F

or B

T Sp

ec

*1: 1

65 m

m (6

.5")

*2:

40

mm

(1.5

7")

DO

M./E

X.M

ain

spin

dle

Hol

low

chu

ck o

f 8"

Sec

onda

ry s

pind

leH

ollo

w c

huck

of

8"

Stroke diagram (INTEGREX 200-IIIST)

APP-39

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

Dra

win

g N

o.13

73P

GD

0110

Uni

t: m

m (i

n.)

Not

e: F

or B

T Sp

ec

*1: 1

65 m

m (6

.5")

*2:

40

mm

(1.5

7")

DO

M./E

X.M

ain

spin

dle

Hol

low

chu

ck o

f 8"

Wor

k re

st s

pec.

: SLU

2Z/S

MW

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

APP-40

INTEGREX 200-IIIIIIIIIIIIS (with work rest)

Dra

win

g N

o.13

73P

GD

0120

Uni

t: m

m (i

n.)

Not

e: F

or B

T Sp

ec

*1: 1

65 m

m (6

.5")

*2:

40

mm

(1.5

7")

DO

M./E

X.M

ain

spin

dle

Hol

low

chu

ck o

f 8"

Sec

onda

ry s

pind

leH

ollo

w c

huck

of

8"W

ork

rest

spe

c.: S

LU2Z

/SM

W

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

APP-41

INTEGREX 200-IIIIIIIIIIIIT (for Lower turret with milling capability)

1373

PG

D00

50D

raw

ing

No .

Uni

t: m

m (i

n.)

Not

e: F

or B

T Sp

ec

*1: 1

65 m

m (6

.5")

*2:

40

mm

(1.5

7")

DO

M./E

X.M

ain

spin

dle

Hol

low

chu

ck o

f 8"

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

APP-42

INTEGREX 200-IIIIIIIIIIIIST (for Lower turret with milling capability)

1373

PG

D00

60

Uni

t: m

m (i

n.)

Dra

win

g N

o.

DO

M./E

X.M

ain

spin

dle

Hol

low

chu

ck o

f 8"

Sec

onda

ry s

pind

leH

ollo

w c

huck

of

8"

Not

e: F

or B

T Sp

ec

*1: 1

65 m

m (6

.5")

*2:

40

mm

(1.5

7")

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

APP-43

Stroke DiagramINTEGREX 300-ΙΙΙΙΙΙΙΙΙΙΙΙ (1000U, 10" hollow chuck)

1374

PG

D00

20D

raw

ing

No.

DO

M./E

X.

Uni

t: m

m (i

n.)

Not

e:　

BT s

pec.

*1:

165

mm

(6.5

0")

*2:

40

mm

(1.5

7")

10" C

HU

CK

(TH

RO

UG

H H

OLE

)M

AIN

SPI

ND

LE

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

APP-44

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

1374

PG

D00

50D

raw

ing

No.

DO

M./E

X.

MA

IN S

PIN

DLE

10" C

HU

CK

(TH

RO

UG

H H

OLE

)

SEC

ON

DA

RY

SPIN

DLE

10" C

HU

CK

(TH

RO

UG

H H

OLE

)

Uni

t: m

m (i

n.)

*1:

165

mm

(6.5

0")

*2:

40

mm

(1.5

7")

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

APP-45

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

1374

PG

D00

40D

raw

ing

No.

DO

M./E

X.

12" C

HU

CK

(TH

RO

UG

H H

OLE

)M

AIN

SPI

ND

LE

Uni

t: m

m (i

n.)

Not

e:　

BT s

pec.

*1:

165

mm

(6.5

0")

*2:

40

mm

(1.5

7")


APP-46

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

1374

PG

D00

60D

raw

ing

No.

DO

M./E

X.

Uni

t: m

m (i

n.)

*1:

165

mm

(6.5

0")

*2:

40

mm

(1.5

7")

MA

IN S

PIN

DLE

10" C

HU

CK

(TH

RO

UG

H H

OLE

)

SEC

ON

DA

RY

SPIN

DLE

10" C

HU

CK

(TH

RO

UG

H H

OLE

)


APP-47


Dra

win

g N

o.13

74P

GD

0140

Uni

t: m

m (i

n.)

Not

e:　

BT s

pec.

* 1: 1

65 m

m (6

.50"

)* 2

: 4

0 m

m (1

.57"

)

DO

M./E

X.

MA

IN S

PIN

DLE

10" C

HU

CK

(TH

RO

UG

H H

OLE

)


APP-48

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

1374

PG

D01

70

Uni

t: m

m (i

n.)

Dra

win

g N

o.

*1:

165

mm

(6.5

0")

*2:

40

mm

(1.5

7")

DO

M./E

X.

MA

IN S

PIN

DLE

10" C

HU

CK

(TH

RO

UG

H H

OLE

)

SEC

ON

DAR

Y S

PIN

DLE

10" C

HU

CK

(TH

RO

UG

H H

OLE

)

Not

e:　

BT s

pec.


APP-49

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

1374

PG

D02

00D

raw

ing

No.

Uni

t: m

m (i

n.)

* 1: 1

65 m

m (6

.50"

)* 2

: 4

0 m

m (1

.57"

)

DO

M./E

X.

MA

IN S

PIN

DLE

10" C

HU

CK

(TH

RO

UG

H H

OLE

)

Not

e:　

BT s

pec.

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

APP-50

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

1374

PG

D02

30

Uni

t: m

m (i

n.)

Dra

win

g N

o.

*1:

165

mm

(6.5

0")

*2:

40

mm

(1.5

7")

DO

M./E

X.

10" C

HU

CK

(TH

RO

UG

H H

OLE

)10

" CH

UC

K(T

HR

OU

GH

HO

LE)

MA

IN S

PIN

DLE

SEC

ON

DAR

Y S

PIN

DLE

Not

e:　

BT s

pec.

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

APP-51


1374

PG

D01

60

Uni

t: m

m (i

n.)

Dra

win

g N

o.

* 1: 1

65 m

m (6

.50"

)* 2

: 4

0 m

m (1

.57"

)

DO

M./E

X.

MA

IN S

PIN

DLE

12" C

HU

CK

(TH

RO

UG

H H

OLE

)

Not

e:　

BT s

pec.


APP-52

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

1374

PG

D01

80

Uni

t: m

m (i

n.)

Dra

win

g N

o.

*1:

165

mm

(6.5

0")

*2:

40

mm

(1.5

7")

DO

M./E

X.

12" C

HU

CK

(TH

RO

UG

H H

OLE

)10

" CH

UC

K(T

HR

OU

GH

HO

LE)

Not

e:　

BT s

pec.

MA

IN S

PIN

DLE

SEC

ON

DAR

Y S

PIN

DLE


APP-53

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

1374

PG

D02

20

Uni

t: m

m (i

n.)

Dra

win

g N

o.

* 1: 1

65 m

m (6

.50"

)* 2

: 4

0 m

m (1

.57"

)

DO

M./E

X.

MA

IN S

PIN

DLE

12" C

HU

CK

(TH

RO

UG

H H

OLE

)

Not

e:　

BT s

pec.

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

APP-54

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

1374

PG

D02

40D

raw

ing

No.

Uni

t: m

m (i

n.)

*1:

165

mm

(6.5

0")

*2:

40

mm

(1.5

7")

DO

M./E

X.

12" C

HU

CK

(TH

RO

UG

H H

OLE

)10

" CH

UC

K(T

HR

OU

GH

HO

LE)

MA

IN S

PIN

DLE

SEC

ON

DAR

Y S

PIN

DLE

Not

e:　

BT s

pec.

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

Documents

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