Вы находитесь на странице: 1из 122

Applications Training

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

CAUTION

This Manual is published to assist experienced personnel on the operation, maintenance


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

Notes:

INTEGREX-100~400MkIII APPLICATIONS TRAINING


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

Notes:

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

The machine is provided with a number of safety


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

S-1

AFTER CONTROL POWER IS TURNED ON


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

4) Tools and other items around the machine or


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

1) Check pressure gages for proper readings.


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

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

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

S-2

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

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

000X717-KY 11/98

S-3

aaaaaaaaaa
aaaaa

WARNING

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

NOTE: USE OF THE FOLLOWING LOCKOUT PROCEDURE IS MANDATORY WHEN COMPLETING


MAINTENANCE OR REPAIRS.

LOCKOUT PROCEDURE
1)

THE LOCKOUT PROCESS MUST BE PERFORMED BY AUTHORIZED PERSONNEL ONLY.

2)

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

3)

SHUT OFF MACHINE POWER USING NORMAL SHUT DOWN PROCEDURES.

4)

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

5)

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

6)

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

7)

COMPLETE THE REQUIRED MAINTENANCE OPERATIONS.

8)

MAKE SURE ALL PERSONNEL ARE CLEAR OF THE MACHINE.

9)

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

PADLOCK
FIGURE

S-4

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

6)

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

In pouring grout, fasten the leveling block


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

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

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

S-5

WIRING
1) Use
only
electrical
conductors
with
performance ratings equivalent or superior.
2) Do not connect any power cables for devices
which can cause line noise to the power
distribution panel, such as arc welders and high
frequency machinery.
3) Arrange for a qualified electrician to connect
the power lines.
4) Incoming supply voltage should not deviate
more than 10% of specified supply voltage.
5) Source frequency should be2 Hz of nominal
frequency.

Desirable Independent Grounding:

NC
Machine

Earth resistance:
Less than 100 ohms

Common Grounds:

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

[ CAUTION ]

VERIFY THE ACTUAL MACHINE ELECTRICAL


Note: Never ground equipment as shown below:

POWER REQUIREMENT AND THE MAIN


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

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

000X713-KY 11/98

S-6

CAUTION

A step-down transformer is optional on some machine models. Be certain to


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

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

FAILURE TO COMPLY CAN RESULT IN PERSONAL INJURY AND DAMAGE TO THE


MACHINE. IF ANY QUESTION EXISTS, CONTACT THE NEAREST MAZAK SERVICE
CENTER FOR ASSISTANCE.

S-7

WARNING

MAZATROL CNC CONTROLLERS PROVIDE PARAMETER SETTINGS TO LIMIT SPINDLE


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

WARNING

MAZAK MACHINES ARE ENGINEERED WITH A NUMBER OF SAFETY DEVICES TO


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

S-8

WARNING

MAZAK MACHINES ARE ENGINEERED WITH A NUMBER OF SAFETY DEVICES TO


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

S-9

WARNING

BEFORE STARTING OPERATION, CHECK THAT THE WORKPIECE IS SECURELY MOUNTED


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

WARNING

CONFIRM PROPER WORKPIECE FIXTURING/CLAMPING, TOOL SETUP AND THAT THE


MACHINE DOOR IS SECURELY CLOSED BEFORE THE START OF MACHINING.
VERIFY ALL SAFETY PRECAUTIONS OUTLINED IN THIS MANUAL BEFORE USING THE
FOLLOWING CUTTING CONDITIONS:
-

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

CUTTING CONDITIONS SUGGESTED BY THE MACHINING NAVAGATION FUNCTION

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


MACHINING NAVAGATION FUNCTION

FAILURE TO COMPLY WITH THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO


THE MACHINE, SERIOUS INJURY OR DEATH.
IF ANY QUESTIONS EXIST, CONTACT THE NEAREST MAZAK SERVICE CENTER FOR
ASSISTANCE.

S-10

CENGDB0551E
DOOR INTERLOCK SAFTY SPEC.

Determined by YMW Eng. H.Q. 99/9/1


Revised by YMC Prod. Eng. 99.10.28

MACHINING CENTER
DOOR

MODE

OPEN

MANUAL

AUTO

CLOSE
I
V
OPEN

MANUAL

Prohibit
Prohibit
Prohibit
Prohibit
Prohibit

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

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

Prohibit cycle start.


Prohibit to run chip spiral conveyor.

Prohibit cycle start.


Prohibit to run chip spiral conveyor.

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

AUTO

CLOSE

SET UP SWITCH
O (OFF)

Limit the rapid override. Max is 12%.


Chip spiral conveyor would stop.
Can run spindle JOG.
Can run spindle Orient.
Can operate manual ATC.

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

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

Prohibit cycle start.


Chip spiral conveyor would stop.

MANUAL

No Limitation.

No Limitation.

AUTO

No Limitation.

Can not run auto operation.

TURNING CENTER
SET UP SWITCH
DOOR

MODE

O (OFF)

I (ON)

Can operate CHUCK, TAILSLEEVE ,


STEADY REST for Loading workpiece.

Can operate CHUCK, TAILSLEEVE ,


STEADY REST for Loading workpiece.

Can NOT operate Spindle, Axis, Turret,


MANUAL Coolant, ToolEye, Partscatcher,
Chip Conveyor.

Can not operate Spindle running, but


Can operate Spindle JOG and Spindle Orient.
Limitation of speed for axis movement .
(Override is 10% max.)
1 step index only for turret.

OPEN
AUTO
CLOSE
->
OPEN

Can operate CHUCK, TAILSLEEVE ,


STEADY REST for Loading workpiece.
Can not run Auto-operation.

Can operate CHUCK, TAILSLEEVE ,


STEADY REST for Loading workpiece.
Can not run Auto-operation.

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

CLOSE

AUTO

No Limitation.

No Limitation.

Can not run Auto-operation.

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

PED-EDS-001

S-11

CENGDB0551E
APPENDIX
SWITCH PANEL for M640M (Machining Center)

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

PED-EDS-001

S-12

DOOR UNLOCK
SWITCH

1 INTEGREX-100~400MkIII MANUAL ATC OPERATION

Set the B-axis at zero degrees.


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

R/V/2 and press.

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

1-1

Press the MDI key.


The MDI window will open:

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

desired tool number.


Press the MACHINE key to display the ATC menu screen.

Turn MDI off by pressing any manual operation key.


Press the ATC MAINTE. menu key.

Press the TOOL LOAD menu key.

1-2

Verify that that the MILL 0 ORIENT key is highlighted.

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

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

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

Press the ATC MENU key.

1-3

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

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

Press the ATC ARM SWING menu key.

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

1-4

Press the ATC ARM CHG POS key.

Turn the TOOL CLAMP/UNCLAMP key switch to CLAMP.

Press the ATC ARM HOME POS key.

1-5

Press the HOME key.

Move the Y-axis to the home position.

Press MDI menu key.

The MDI window will open:

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

1-6

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

Press the ATC MAINTE menu key.

Press the TOOL UNLOAD menu key.

1-7

Updating The Current Tool In the Turret Pocket


When the tool has been replaced by the ATC unit manually, set the number of the tool being mounted
on the turret on the TURRET TOOL window of the DIAGNOSTIC display.

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

1-8

Press the MDI key.

-The MDI window will open on the monitor.

Input MDI data: M65 (ATC TOOL No. MEMORY CLEAR)


Do a tool change. (Eg: T01000.0001)
If you get an alarm, Tool Number Mismatch you forgot the M65.
NOTE: If you get a Not in ATC Position alarm, make sure the shifter is at the magazine side and
issue a M602S0, this will set the Next Tool display to zero.

1-9

Notes:

1-10

2 UPPER TURRET ALIGNMENT

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

2. Measure parallelism between X-axis and the turret.


Tolerance: 0.01mm (0.0004 in.) or less per L=100mm (4 in.)

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

2-1

4. Place the turret in V direction, loosen all six mounting bolts,


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

5. Tolerance: 0.01mm (0.0004 in.) or less per L=100mm (4 in.)


After the turret mounting bolts are tightened, measure parallelism
between X-axis and the turret again.

2-2

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

Adjust by pushing or pulling a set screw (2 places,


arrow) in the two photos.

2-3

Notes:

2-4

3 LOWER TURRET ALIGNMENT


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

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

Loosen the eight bolts for mounting a turret coupling.

Using a plastic hammer, tap the turret in a


rotational direction for parallel adjustment of the grooves
for a boring bar holder.
<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.

1. Check the current alignments

Mount a jig with reference to the 1st spindle, and


measure the outer diameter of the 2nd spindle to check
whether any variance exists.

Mount a test bar to the 2nd spindle and a millimess dial


indicator to the test bar to check the parallelism in the
height direction.

4-5

2. Center height adjustment of 2nd spindle

Based on the data obtained in step 1, remove the shims


for grinding. Loosen the mounting bolts (6 places) on the
2nd spindle.

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

Re-install the shims that have been ground and


hand-tighten the mounting bolts on the 2nd spindle.
Re-check the parallelism in the height direction.

<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 (Contd)


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

Notes:

5-4

Turret Center of Rotation Adjustment Procedure (Parameter B234)


A
W- Axis Stroke

Reference
workpiece
origin
Turret center of rotation
100mm

A8
B234

A = The full W-axis stroke between head 1 & head 2.


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

R = The distance from the turret face to the center of rotation.


(See the adjustment procedure on the following page.)

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

6-1

Turret Center of Rotation Adjustment Procedure (Parameter B234)


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

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.

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

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

8-2

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

0, 2, 4, 6, 8

1, 3, 5, 7, 9

11

13

14

15

DIRECTION

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

11

12

13

ID code

14

15

16

17

18

19

21

22

23

24

25

26

ID code

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

9-1

9-2 Tool Function (6-Digit T-Code)


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

9-3 Next Tool Automatic Selection


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

9-2

10 EIA/ISO PROGRAMMING EXAMPLE

10-1

O00000001 (Integrex-200S

Programming Example)

#500=30. (SUB SHIFT )


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

N2(Mill Hex on Face HD1)


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

10-2

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

N3(Drill 1/8" hole 45 degree Face)


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

10-3

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

N5(Edge Face HD2)


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

10-4

N6(Mill 45 degree Face)


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

N7(Drill 1/8" hole 45 degree Face HD2)


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

10-5

Notes:

10-6

11 COORDINATE SYSTEM SETTING


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

Program coordinate system rotation ON

G69.5 ;

Program coordinate system rotation OFF


Xx0 Zz0 Yy0 :

Coordinates of the center of rotation


Specify in absolute dimensions the translation of the workpiece origin.

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

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

11-1

3. G125 Macro Program Example

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

11-2

G125 Macro Program Example (Contd)

N2(Drill .5" hole Solid Carbide)


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

11-3

11.2 G128.8 Coordinate System Setting Macro


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

Program coordinate system rotation ON


(If Xx. Yy or Zz omitted 0 is the default)

Xx0 Zz0 Yy0 :

Coordinates of the center of rotation


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

Rr :

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

Ss;

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

Q**

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

11-4

G128.8 Program position coordinate system rotation (Contd)


1)
2)
3)
4)
5)

Y axis must be at home position before commanding the macro program.


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

6)

(SET UP SCREEN)
Z Offset

Make sure parameters B234 and B263 are set properly.

11-5

Notes:

11-6

INTEGREX-100~400MkIII

PLC

ALARM

LISTS

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

D135W0049E

1.

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

2.

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

3.

250 SPINDLE START MISOPERATION


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

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

256 TURRET ROTATION PROHIBITED


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

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

H374S5B012E

APP-1

Alarm List for the INTEGREX 300/400-II


II
Alarm No. and message

Description

Check and remedy

Address

200: THERMAL TRIP


Thermal relay for the hydraulic unit has
(EMERGENCY STOP) tripped.

Check that the hydraulic unit motor is


normal, and then turn the power off and on.

X2

201: BREAKER TRIP

Power line on/off circuit breaker QF2, QP3,


QF4, QF81, or QF82 has tripped.

Check the circuit breakers within the control


panel and then reset the circuit breaker that
has tripped.

X3 X4

202: HYDRAULIC
PRESSURE DOWN

An oil pressure decrease below the


required level has activated the pressure
switch.

Check the hydraulic unit and piping for


abnormalities.

X447

203: AIR PRESSURE


DOWN

An air pressure decrease below the


required level has activated the pressure
switch SP30.

Check the air supply port and piping for


abnormalities.

X446

204: SPINDLE
CONTROLLER
MALFUNCTION

An alarm occurred at spindle controller.

Turn off the main circuit breaker and then


turn it back on.
If the alarm is not released, please contact
your MAZAK service representative.

205: MILLING
CONTROLLER
MALFUNCTION

An alarm occurred at milling spindle


controller.

Turn off the main circuit breaker and then


turn it back on.
If the alarm is not released, please contact
your MAZAK service representative.

206: OPEN FRONT DOOR


(EMERGENCY
STOP)

Coolant cover (front door) is opened during


automatic operation.

Close the coolant cover (front door) and


start the machine in automatic operation
mode.

211: NOT OPERATED MCODE SIMULTA.

M-codes which must not be used in


combination were selected at the same
time.

Correct the program.

212: CHUCK
OPEN/CLOSE
SWITCH MALF.

The signal from the chuck open/close foot


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

Fault in the chuck open/close foot switch


circuit

213: ILLEGAL
DESIGNATED TOOL
No.

T code that does not exist in the


specification is assigned.

Correct the program.

215: CHUCK SYSTEM


MALFUNCTION

An erroneous chucking action was detected


during chucking operation.

The chuck unit has failed to grip the


material.

XA

X44E
(X44F)

The chuck open/close end sensor


(SQ2/SQ3) is abnormal or faulty.
218: CHUCKING TYPE
NOT SELECTED

Type of chucking (inner/outer) of spindle


chuck is not selected.

Select the type of chucking.

220: TURRET POSITION


SENSOR MALF.

The milling head positioning /B-axis sensor


(encoder) signal has become invalid.

The milling head positioning /B-axis sensor


(encoder) is in trouble.

The milling head index /B-axis motor is


malfunctioning.

Turn off the main circuit breaker and then


turn it back on.
If the alarm is not released, please contact
your MAZAK service representative.

X440/
X441

221: TURRET CLAMP


SENSOR
MALFUNCTION

In spite of the fact that the milling head is


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

X460

224: CHUCK SENSOR


MALFUNCTION

The chuck open or close confirmation


sensor fails in function, or both of the
sensors are ON simultaneously.

X440/
X441

APP-2

The chuck open or close confirmation


sensor (SQ2/SQ3) is abnormal or faulty.

Alarm No. and message

Description

Check and remedy

Address

225: FRONT DOOR


SENSOR
MALFUNCTION

For the machine with an optional automatic


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

The front door open or close confirmation


sensor (SQ2/SQ3) is abnormal or faulty.

231: TOOL EYE


POSITION SENSOR
MALF.

The TOOL EYE extension or retraction


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

The TOOL EYE arm is likely to be


obstructed in the middle of its operation.

234: TOOL CLAMP


SENSOR
MALFUNCTION

The tool clamp check sensor fails to


function.

Adjust the setting of the TIM12 timer.

236: PARTS-CATCHER
SENSOR MALF.

For the machine with an optional automatic


parts catcher, the advance end confirmation
sensor or retract end confirmation sensor
does not turn on, or both of the sensors are
ON simultaneously.

The parts catcher advance/retract end


confirmation sensors are faulty or
malfunctioning.

243: MEASURING
CONTROLLER
MALF.

An error occurred at the workpiece


measurement controller (option).

Check the cause of error at the workpiece


measurement controller.

245: BAR-FEEDER
CONTROLLER
MALF.

An error occurred at the bar feeder


controller.

Check the cause of error at the bar feeder


controller.

248: EXTERNAL
CONTROLLER (No.1)
MALF.

Failure of controller of a peripheral unit


(option)

Check the cause of error at the controller of


a peripheral unit (option).

250: SPINDLE START


MISOPERATION

1. A spindle rotation command was given


during mis-chucking. (Chuck sensor
provided.)

1. Close the chuck and start operation


with the workpiece gripped.
Alternatively, the chuck open/close
check sensor may be improperly
adjusted.
Check the sensor.

2. A spindle rotation command was given


even though the chuck was not closed.

2. After closing the chuck using the chuck


clamp command, designate the spindle
rotation command.

3. A spindle rotation command was given


together with an orient command.

3. Take steps so that the commands are


not given together.

4. The M3, M4, M16, M17, M18 or M19


command was given in the milling mode.

4. 1) Program error Correct the


program.

Or the corresponding sensor is faulty.

X14/
XA

X444/
X445

X440/
X441

2) Switch to the turning mode and


then designate the command.
5. A spindle rotation command was given
without the TOOL EYE at the backward
end.

5. Retract the TOOL EYE. Also, check the


backward end sensor.

X445

6. A spindle rotation command was given


with the door not closed when the door
interlock switch was set to AUTO.

6. Close the door and start the spindle


rotation.

X15

7. Alarm 297 CHUCK PRESSURE DOWN


or 296 TAIL SLEEVE PRESSURE
DOWN is displayed.

7. Clear the alarm 297 or 296.

X442
X443
X480

APP-3

XA

Alarm No. and message

Description

Check and remedy

251: MILLING MOTOR


ROTATION PROHIB.

1. A milling spindle rotation command was


given even though the chuck was not
closed.

1. After closing the chuck using the chuck


clamp command, designate the milling
spindle rotation command.

2. A milling spindle rotation command was


given even though the milling tool was
not clamped.

2. After clamping the milling tool,


designate the milling spindle rotation
command.

3. A milling spindle rotation command was


given even though the milling head (Baxis) was not clamped.

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

4. The M203, M204 or M219 command


was given in the turning mode.

4. 1) Program error Correct the


program.

Address

X460

2) Switch to the milling mode and


then designate the command.

252: AXIS MOVE


MISOPERATION

5. A milling spindle rotation command was


given with the door not closed when the
door interlock switch was set to AUTO.
[When the door interlock option is
provided.]

5. Close the door and start the milling


spindle rotation.

X15
XA

6. Alarm 297 CHUCK PRESSURE DOWN


or 296 TAIL SLEEVE PRESSURE
DOWN is displayed.

6. Clear the alarm 297 or 296.

X442
X443
X480

7. The touch sensor for workpiece


measurement is mounted on the milling
head.

7. Change the touch sensor for a rotating


tool in the MDI or automatic mode.

8. The milling tool rotation command is


given though the TOOL EYE is not
placed at the backward end.

8. Retract the TOOL EYE. Also check the


backward end sensor.

X445

An attempt was made to execute an axis


movement under the axis movement
interdiction.

1. First close the magazine cover and


then execute the axis movement.

XD

1. An attempt was made to execute an axis


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

2. X-axis interlock is activated in the


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

APP-4

X460

XD

Alarm No. and message


252: AXIS MOVE
MISOPERATION

Description

Check and remedy

3. An attempt was made to execute a


movement along the Z-axis with the Zaxis interlock activated.

Address

3. Z-axis interlock is activated in the


following states:
1) Same as states 1) to 7) for the
X-axis interlock.

Note: An axis movement can be


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

4. C-axis interlock is activated in the


following states: When the C-axis is
clamped.

253: OVERLOAD
DETECTION

An overload has been detected in a


machine having an overload detection
option.

Check the overload detection level.

256: TURRET ROTATION


PROHIBITED

This alarm display lights when an attempt


has been made to turn the milling head or
when the conditions were unstable.

Reduce the cutting load.

1. Set the arm to the stand-by position by


using the ATC menu. (Refer to PART
2.)

2. The turning tool or milling tool has been


unclamped.

2. Clamp the tool using the clamp switch.

257: ILLEGAL M-CODE

An illegal M code has been specified.

Correct the program.

258: TNo. MISMATCH

Since ATC has been aborted by pressing


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

Change the TURRET TOOL number


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

259: MODE CHANGE


IMPOSSIBLE

The rapid feed mode or zero point return


mode switch on the operating panel has
been pressed during tool nose
measurement with the TOOL EYE.

The rapid feed or zero point return mode


cannot be selected during tool nose
measurement.

260: SLIDEWAY
LUBRICATION
ALARM

The pressure switch for slideway lubrication


(SP67) does not turn on within a fixed time.

Check the lubricating grease amount, and


replenish grease if required.

X465

261: HEAD LUBRICATION


ALARM

The pressure switch (SP25, SP26, SP27) in


the spindle cooling unit has worked.

Check the coolant level.

X485

264: THERMAL TRIP


(SINGLE BLOCK)

Thermal relay F13 for the coolant motor has


tripped.

Check the regarding unit (e.g. chip


conveyor for clogging with chips) and then
reset the thermal relay.

X5

1. When the arm is at the milling head side


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

Thermal relay F14 for the chip conveyor


has tripped.
267: BALL SCREW
LUBRICATION
ALARM

The pressure switch (SP7) for ball screw


and C-axis gear lubrication does not turn on
or off within a fixed time.

Check the lubrication oil level, and


replenish lubricating oil if required.

The float switch (SL1) has turned off.

X6
X44C

X44D

270: SPINDLE ORIENT


EXCEED TIME

Although a spindle orientation command is


given, the orientation confirmation signal
does not turn on within a predetermined
time.

The spindle motor detector/controller is


abnormal.

272: TURRET INDEX


EXCEED TIME

Although a milling head indexing command


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

The milling head index motor


detector/controller is abnormal.

APP-5

Alarm No. and message

Description

Check and remedy

275: ROBOT SERVICE


EXCEED TIME

For machines with an optional robot,


although a robot service command is given,
the confirmation signal does not turn on
within a predetermined time.

The robot is malfunctioning (check the


robot controller to examine the cause).

276: ATC CYCLE


EXCEED TIME

Although 120 seconds have passed since


the issuance of the ATC command, the
operation complete signal does not turn on.

Reset the ATC unit using either of the


following methods:

Address

(1) Cancel the ATC command by pressing


the emergency stop button.
(2) Release the emergency stop status by
pressing the RESET key.

(3) Execute the ATC reset function of the


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

For the machine with an optional automatic


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

The parts catcher advance/retract end


confirmation sensor are faulty or
malfunctioning.

282: CHUCK CLAMP


EXCEED TIME

Although a chuck open/close command is


given, the confirmation signal does not turn
on within a predetermined time.

Adjust the chuck open/close end sensor.


Or the sensor is in trouble.

286: FRONT DOOR


EXCEED TIME

For machines with an optional automatic


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

X440/
X441

The hydraulic system is abnormal.

Adjust the front door open/close end


sensor.
Or the sensor is in trouble.

The pneumatic system is abnormal.

292: SENSOR
MALFUNCTION No. 3

The correction value has exceeded the limit


set in the thermal displacement
compensation.

Check that the thermal sensor is correctly


wiring.

R1, R2,
R3

293: SENSOR
MALFUNCTION No. 4

The correction value has changed largely


than the previous one in the thermal
displacement compensation.

Check that the thermal sensor is correctly


wiring.

R1, R2,
R3

297: CHUCK PRESSURE


DOWN

The spindle chuck pressure remains


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

Check the spindle chuck pressure.

X442/
X443

300: START COND. ERR.


(DOOR OPEN)

The cycle start button was pressed while


the front cover (front door) was opened.

Close the front cover.

XA

301: START COND. ERR.


(TUR UNCLAMP)

The cycle start button was pressed while


the milling head was unclamped.

Clamp the milling head.

X460

302: START COND. ERR.


(EXT RESET)

The cycle start button was pressed while


the external reset signal was ON.

Check the controller of the external unit.

303: START COND. ERR.


(EXT FEED HOLD)

The start button was pressed while the


external feed hold signal was ON.

Check the controller of the external unit.

308: C/S ERROR (TOOL


EYE EXTEND)

The cycle start button has been pressed


with the TOOL EYE arm placed in a
measurement position.

Retract (restore) the TOOL EYE arm into


position.

310: C/S ERROR


(TNo.MISMATCH)

During the restart of operation after manual


interruption, a tool number different from
that which was valid before interruption has
been specified.

Specify the same tool number as that which


was valid before interruption.

311: C/S ERROR (TAIL


STOCK QUILL)

The cycle start button has been pressed


with the tail spindle not placed at its zero
point or advance end.

Place the tail spindle at its zero point or


advance end.

APP-6

X445

Alarm No. and message

Description

Check and remedy

Address

312: C/S ERROR (PTCATCHER EXTEND)

The cycle start button has been pressed


with the parts catcher (workpiece unloader)
extended.

Retract (restore) the parts catcher into the


position.

313: C/S ERROR (C/S


QUILL COMMAND)

A tailstock advance/retract command was


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

Place the tail spindle advance/retract


switch at the neutral position.

320: TOOL UNCLAMP


IMP. (M-SP ROT.)

A milling head unclamping command has


been given during rotation of the milling
spindle motor.

After the milling spindle motor has stopped,


perform the operations described at left.

321: MODE CHANGE


IMPOSSIBLE
(DURING ATC
CYCLE)

Mode changing has been attempted during


the ATC cycle.

The operation mode cannot be changed


during ATC. To change the mode, wait until
ATC has been completed.

322: RAPID MODE IMP.


(ORIGIN RET UNF)

The rapid feed mode was selected without


carrying out the zero point return operation
after the power supply had been turned on.

Carry out the zero-point return operation.

324: DIFF. MODE (ORIGIN


RET UNFIN.)

The automatic operation mode was


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

Carry out the zero-point return operation.

325: TL. EYE EXT. IMP.

A TOOL EYE extend/retract command has


been given with the SET UP switch
remaining set to O and the front door
remaining open.

Change the setting of the SET UP switch to


I. Or close the front door.

X11C/
XA

326: T/S QUILL EXT. IMP.

The tail spindle has advanced with the


TOOL EYE arm extended.

Retract the TOOL EYE arm.

X444

The tail spindle has advanced/retracted


during the spindle rotation.

Stop the spindle.

The tail spindle has advanced/retracted


during the milling spindle rotation.

Stop the milling spindle.

The condition to perform ATC is not


appropriate. The details are described at
the left. See D200/D201.

90
(D201)

The machine is under locking


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

91
(D201)

The tailstock is in the connection


state. After releasing the
connection of the tailstock,
perform the ATC.

97
(D201)

When the loading tool is


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

98
(D201)

The magazine cannot be rotated


because the specified tool is
different from the loading tool
and the shifter is not placed on
the ATC side. Move the shifter to
the ATC side manually.

327: NOT IN ATC START


POSITION

APP-7

Alarm No. and message


327: NOT IN ATC START
POSITION

329: CHUCKING
SELECTION
PROHIBITED

340: CONDITION No.1


MISSING

Description

Check and remedy

The condition to perform ATC is not


appropriate. The details are described at
the left. See D200/D201.

99
(D201)

The shifter is not placed in the


magazine side without the
loading tool when commanding
the ATC.
Move the shifter to the magazine
side/retract position manually.

9800
(D200)

The tool command is given


incorrectly. Perform again.

9900
(D200)

The ATC arm is not at the


reference point position. Move
the ATC arm to the reference
point position manually. Then
perform again the ATC.

The inside/outside chucking selection is


performed with the chuck not opened.

Open the chuck (and remove the


workpiece.)

The inside/outside chucking selection is


performed when the spindle or milling
spindle is not stopped.

Stop the spindle or milling spindle.

Address

In a machine having a warming-up option


- the warming-up program number is not
registered.

Register the warming-up program number


(1 9999) in the MACHINE PARAMETER
display.

R18

- the front cover (front door) is open.

Close the front cover (front door).

XA

- The axis had not yet been initialized


when the NC unit was turned off.

To warm up the machine, return all axes to


their zero points before turning off the NC
unit.

341: CONDITION No.2


MISSING

The M-code command for milling spindle


through air blowout has been issued during
coolant injection.

Correct the program.

361: TAIL ALARM

The tailstock amplifier has detected an


overload or too great an error.

If the alarm is not cleared, please contact


your MAZAK service representative.

The tailstock has moved during spindle


rotation.
365 CARRIER
CONTROLER
MALFUNCTION

An alarm signal has been sent from the


carrier-use amplifier to the NC unit.

After turning NC power off, turn the main


circuit breaker off and then turn it back on.

366: SHIFTER
CONTROLER
MALFUNCTION

An alarm signal has been sent from the


shifter-use amplifier to the NC unit.

374: OPERATING
SWITCH FAULT

A control (switch) on the operation panel


was ON upon turning-on.

The control is faulty unless it has been


inadvertently turned on.

375: MOTOR & SERVO


TURNING OFF ERR.

Since the electromagnetic switch OFF


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

After turning NC power off, turn the main


circuit breaker off and then turn it back on.

376: MAIN POWER


TURNING OFF
MALFUNCTION

When the front door of a CE specifications


machine was opened with the setup key
switch set to O, the electromagnetic
switch for spindle power did not turn off
within the required time.

After turning NC power off, turn the main


circuit breaker off and then turn it back on.

377: COOLANT LEVEL


LOW

The coolant level in the coolant unit of a


machine of the high-pressure coolant
specifications has decreased.

Check the coolant level in the coolant unit


and add coolant.

If the alarm is not cleared, please contact


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

APP-8

X10

If the alarm is not cleared, please contact


your MAZAK service representative.

X11

If the alarm is not cleared, please contact


your MAZAK service representative.
X492

Alarm No. and message

Description

Check and remedy

Address

378: HIGH PRESSURE


PUMP THERMAL
TRIP

The thermal relays in the coolant unit of a


machine of the high-pressure coolant
specifications have become tripped.

Check the thermal relays of the coolant


unit.

X490

379: TANK PRESSURE


LOW

The pressure in the coolant unit tank of a


machine of the high-pressure coolant
specifications has decreased.

Check and adjust the coolant unit tank


pressure.

X491

381: CONDITION
MISSING (SET UP
SWITCH)

The cycle start button has been pressed in


automatic operation mode with the front
door open and the setup key switch set to
O.

Change the setting of the setup key switch


to I and then press the cycle start button.
Single-block automatic operation will be
activated.

For a machine of the front door lock pin


specifications, a manual-starting button has
been pressed with the front door open and
the setup key switch set to O.

Change the setting of the setup key switch


to I and then press the desired manualstarting button. The override rate will be
reduced to 25%.

382: COOLANT SYSTEM


MALF.

An error signal has been sent from the


coolant unit of a machine of the highpressure coolant specifications.

Check the coolant unit for alarms.

383: ATC ALM:


CARRIER&SHIFT.
POS. MALF.

In a machine of the 80/120-tool magazine


specifications, the cycle start command or
the tool change command was issued when
the carrier and the shifter were not present
at their stand-by positions.

Before issuing the cycle start command or


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

385: START COND. ERR.


(Z-AXIS POS.)

Under 20- or 40-tool magazine


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

Move the Z-axis in the plus direction


relative to its zero point before opening the
ATC cover.

When the [ATC STOP] menu key in the


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

Cancel the ATC stop mode by pressing the


[ATC STOP] menu key in the machine
menu.

390: TOOL ON INTERFER


ALARM

An attempt has been made to return the tool


to a magazine pocket containing another
tool.

Check the tool number of the tool to be


returned and that of the tool stored within
the magazine pocket.

391: LD/ULD/ACHG
CONDITION ALARM

During ATC, although returning the tool was


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

Confirm whether the tool is mounted in the


ATC arm.
Check the magazine pocket tool
confirmation sensor for normal operation.

X475

392: MAGAZINE MANUAL


INTERR.

Under 20- or 40-tool magazine


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

Change the setting of the magazine manual


interruption switch to OFF.

X1C

394: ATC CONTROLLER


MALF.

An alarm signal has been received from the


ATC amplifier.

After turning NC power off, turn off the main


circuit breaker and then turn if back on.
If the alarm is not cleared, please contact
your MAZAK service representative.

386: ATC STOP

APP-9

X493

Alarm No. and message


395: CHECK SENSOR
MALF. (SEE D199)

Description

Check and remedy

The operational check sensors at both ends


of the stroke have turned on.

The positions of the operational check


sensors or watchdogs are not correct or the
sensors themselves are malfunctioning.

After the command has been issued, no


sensors did not turn on within the required
time.

Address

Confirm the value of D199 on the


DIAGNOSIS display and examine the
sensor causing the alarm.
D199

Corresponding sensor

Normal

The X470 limit switch at the ATC


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

X470
X471

The X472 limit switch at the


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

X472
X473

The chuck-clamping pressure


switch (X442) and the chuckunclamping pressure switch
(X443) are both on.

X442
X443

12

The top door open end sensor


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

X14
X15

397: MAGAZINE DOOR


INTERLOCK

The magazine door has been opened


during issuance of the tool change
command or the magazine rotation
command.

Close the magazine door.

XD

398: MAGAZINE COVER


OPEN

The magazine cover is open.

Close the magazine cover.

The machine of the CE specifications has


its magazine setup switch remaining set to
ON.

Change the setting of the magazine setup


switch to OFF.

XD
X1C

399: MAINTE./ADJUST
PARAM. ON

The maintenance/adjustment parameters


are validated.

After turning NC power off, turn off the main


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

APP-10

Alarm List for the INTEGREX 300/400-III


III
Alarm No. and message
204: SPINDLE
CONTROLLER
MALFUNCTION

S/III
IIIST
(Addition)
III

Description

Check and remedy

Address

An alarm occurred at secondary spindle


controller.

Turn off the main circuit breaker and then


turn it back on.
If the alarm is not released, please contact
your MAZAK service representative.

An erroneous chucking action was detected


during chucking operation on secondary
spindle.

The chuck unit on secondary spindle has


failed to grip the material.

SP2
215: CHUCK SYSTEM
MALFUNCTION
SP2

The chuck open/close end sensor on


secondary spindle (SQ62/SQ63) is
abnormal or faulty.

X483/
X484

Type of chucking (inner/outer) of secondary


spindle chuck is not selected.

Select the type of chucking.

The secondary spindle chuck open or


close confirmation sensor (SQ62/SQ63) is
abnormal or faulty.

X483/
X484

SP2

The secondary spindle chuck open or close


confirmation sensor fails in function, or both
of the sensors are ON simultaneously.

1. Close the chuck and start operation


with the workpiece gripped.
Alternatively, the chuck open/close
check sensor may be improperly
adjusted.
Check the sensor.

X483/
X484

SP2

1. A secondary spindle rotation command


was given during mis-chucking. (Chuck
sensor provided.)

2. A spindle rotation command was given


even though the chuck of secondary
spindle was not closed.

2. After closing the chuck of secondary


spindle using the chuck clamp
command, designate the spindle
rotation command.

3. A spindle rotation command was given


without the TOOL EYE placed at the
backward end.

3. Retract the TOOL EYE. Also, check


the backward end sensor.

X445

4. A secondary spindle rotation command


was given without the door closed.

4. Close the door and start the


secondary spindle rotation.

XA

5. Alarm 297 CHUCK PRESSURE DOWN


is displayed.

5. Clear the alarm 297.

X448
X449

218: CHUCKING TYPE


NOT SELECTED

SP2
224: CHUCK SENSOR
MALFUNCTION
250: SPINDLE START
MISOPERATION

252: AXIS MOVE


MISOPERATION
SP2

An attempt was made to execute an axis


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

1.

Perform the X- and Y-axes zero point


return operation.

2. An attempt was made to execute a


movement along the X-, Z- (milling head
traveling axis) and Y-axes without the Waxis (secondary spindle traveling axis)
placed at the zero point.

2.

Perform the W-axis zero point return


operation.

3. Though the W-axis zero point return is


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

3.

Retract the TOOL EYE. Also, check


the backward end sensor.

4 An attempt was made to execute a


movement along the W-axis with a bar
chucked both on main spindle and
secondary spindle.

Open the chuck on main spindle or


secondary spindle.

APP-11

X445

Alarm No. and message


270: SPINDLE ORIENT
EXCEED TIME
SP2
282: CHUCK CLAMP
EXCEED TIME
SP2
329: CHUCKING
SELECTION
PROHIBITED
SP2

Description

Check and remedy

Although a secondary spindle orientation


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

The secondary spindle motor


detector/controller is abnormal.

Although a chuck open/close command for


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

Adjust the chuck open/close end sensor.


Or the sensor is in trouble.
The hydraulic system is abnormal.

The inside/outside chucking selection was


performed without the chuck of secondary
spindle opened.

Open the chuck of secndary spindle (and


remove the workpiece).

The inside/outside chucking selection was


performed when the secondary spindle or
milling spindle is not stopped.

Stop the secondary spindle or milling


spindle.

APP-12

Address

X483/
X484

Alarm List for the INTEGREX 300/400-III


IIIT/III
(Addition)
III IIIST
III
Alarm No. and message
221: TURRET CLAMP
SENSOR
MALFUNCTION
TR2/SP2
256: TURRET ROTATION
PROHIBITED
TR2/SP2

258: TNo. MISMATCH


TR2/SP2

272: TURRET INDEX


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

Description

Check and remedy

In spite of the fact that the (lower) turret is


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

Address
X52

A turret indexing command was given during


tool nose measurement with the TOOL EYE.

Cancel the measurement mode.

A turret indexing command was given with


the SET UP switch remaining set to O and
the front door remaining open.

Change the setting of the SET UP switch


to I. Or close the front door.

For resuming automatic operation after a


manual interruption, the indexed face of the
turret is different from the face indexed
before the interruption.

Index the turret for the same face to


continue the automatic operation.

Although a turret indexing command is


given, the index confirmation signal does not
turn on within a predetermined time.

The detector/controller of the turret


indexing motor is abnormal.

The cycle start button was pressed while the


turet was unclamped.

Clamp the (lower) turret.

For resuming automatic operation after a


manual interruption, the number of the tool
in use differs from the number before the
interruption.

Use a tool of the same number to continue


the automatic operation.

X198
X1F8

X52

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

APP-13

- NOTE -

APP-14

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

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

M-codes

Description

Category

Remarks

M00

Program stop

M01

Optional stop

M02

Program end

M03

Spindle normal rotation

M04

Spindle reverse rotation

M05

Spindle stop

M06

Chuck unclamp (releasing workpiece)

"

M07

Chuck clamp (holding workpiece)

"

M08

Flood coolant ON

M09

Coolant OFF

Milling spindle mode cancel (Turning mode selection)

M13

Milling tool normal rotation

M14

Milling tool reverse rotation

M15

Milling tool stop

M16

Spindle orientation 0 (for AJC)

M17

Spindle orientation 120 (for AJC)

M18

Spindle orientation 240 (for AJC)

M19

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

"

M20

Robot service call

"

M21

Robot service call

"

M22

Robot service call

"

M23

Robot service call

"

M24

Robot service call

"

M25

Robot service call

"

M26

Robot service call

"

M27

Robot service call

"

M28

Robot service call

"

M29

Robot service call

"

M30

Reset & tape rewind

M31

Tail spindle & tailstock body advance

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

M10
M11
M12

M32

Tail spindle & tailstock body retract

M33

Low chuck pressure

M34

High chuck pressure

M35
M36
M37
M38
M39
M40

H374S5C010E

APP-15

M-codes

Description

Category

M41
M42
M43
M44
M45

Air coolant blow ON (coolant stop: M09)

"

M48

Parts catcher advance

"

M49

Parts catcher retract

"

M51

Error detect OFF

M52

Error detect ON

M53

Chamfering OFF

M54

Chamfering ON

M55

Piece count

M56

Front door open

"

M57

Front door close

"

M58

Chuck air blast

"

C-axis unclamp

M66

C-axis clamp

M67

C-axis brake (for machining by G01)

M68

Cycle bar feeder call 1

M69

Cycle bar feeder call 2

M72

Inside chuck clamp

M73

Outside chuck clamp

M74

Steady rest - milling head connection mode release

M75

Steady rest - milling head connection mode start

Workpiece measurement start

"

M82

Workpiece measurement end

"

M83

Tool measurement start

"

M84

Tool measurement end

"

M86

Steady rest 1 unclamp

"

M87

Steady rest 1 clamp

"

M46
M47

M50

M59
M60
M61
M62
M63
M64
M65

M70
M71

M76
M77
M78
M79
M80
M81

M85

APP-16

Remarks

M-codes

Description

Category

Remarks

M88

Steady rest 2 unclamp

M89

Steady rest 2 clamp

User macro interruption, valid

M97

User macro interruption, invalid

M98

EIA EIA Subprogram call

M99

EIA EIA Return to main EIA program

M100

Workpiece measurement DIA start

"

M101

Workpiece measurement DIA end

"

M102

Workpiece measurement STP start

"

M103

Workpiece measurement STP end

"

M104

Workpiece measurement GRV start

"

M105

Workpiece measurement GRV end

"

M106

Workpiece measurement WID start

"

M107

Workpiece measurement WID end

"

M108

Workpiece measurement DIS start (chuck barrier release)

"

M109

Workpiece measurement DIS end

"

M110

Tool tip measurement TOL start

M111

Tool tip measurement TOL end

M112

External tool compensation EXT start

"

M113

External tool compensation EXT end

"

M114

Z-axis offset measurement ZOF start

"

M115

Z-axis offset measurement ZOF end

"

M116

C-axis offset measurement COF start

"

M117

C-axis offset measurement COF end

"

Measurement data print out

"

M150

Workpiece unload demand to robot

M151

Milling spindle through air blow ON

Only for turning tools

M152

Milling spindle through air blow OFF

Only for turning tools

M153

Milling spindle through coolant ON

M154

Milling spindle through coolant OFF

M155

Chuck coolant ON (composed movement)

"

M156

Chuck coolant OFF (composed movement)

"

M157

Spindle through coolant blow ON (OFF: M159)

"

M158

Spindle through air blow ON (OFF: M159)

"

M159

M157, M158 OFF

"

M160

Shower coolant ON/chuck stopper extend

"

M90
M91
M92
M93
M94
M95
M96

M118
M119
M120
M121

M149

APP-17

M-codes

Description

Category

Remarks

M161

Shower coolant OFF/chuck stopper retract

"

M162

Workpiece rechucking (for a piece delivered by robot)

"

M163

Tail spindle thrust

low pressure

"

for 300/400-III/IIIT

M164

Tail spindle thrust

high pressure

"

for 300/400-III/IIIT

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

"

M172

Index 0(KOUYOU)

M173

Index 90(KOUYOU)

M174

Index 180(KOUYOU)

M175

Index 270(KOUYOU)

M176

Index 270(KOUYOU)

M177

Index 270(KOUYOU)

M178

Index 270(KOUYOU)

M179

Index 270(KOUYOU)

M198

EIA MAZATROL program call

"

M199

EIA MAZATROL program end

"

M200

Milling point machining start

M201

Milling line machining start

M202

Turning mode

M203

Milling tool normal rotation

M204

Milling tool reverse rotation

M205

Milling tool stop

M207

M208, M209 mode cancel

M208

ATC prohibition mode during finishing, coolant ON

M209

ATC prohibition mode during finishing, coolant OFF

M210

C-axis clamp (for milling)

M211

C-axis brake (for milling)

M212

C-axis unclamp (for milling)

M213

C-axis brake only (brake by M211)

M214

C-axis unclamp only (unclamp by M212)

M215

M213, M214 and M216 mode cancel

M216

C-axis unclamp neglect mode (cancel:

M165
M166
M167
M168
M169
M170
M171

M180

M197

M206

M215)

M217
M218
M219

Milling tool orient

M220

M229

APP-18

M-codes

Description

Category

M230

Grinding mode ON

"

M231

Grinding speed setting

"

M236

C-axis servo gain normal

M237

C-axis servo gain low

M238

C-axis servo gain middle

M239

C-axis servo gain high

M248

Spindle speed check (for interlocking the start of cutting)

M249

Milling head selection preparation

M250

Milling head/B-axis unclamp

M251

B-axis clamp

M252

Milling spindle unclamp

M253

Milling spindle clamp

M254

Milling head/B-axis clamp

Milling head air blow

M260

Polygon mode ON

"

M261

Polygon mode OFF

"

M274

Steady rest coolant ON

M275

Steady rest coolant OFF

M331

Spindle coil change fixed to high speed

M332

Spindle coil change, valid

M348

Yt-axis selection

M349

Y-axis selection

M232
M233
M234
M235

M240
M241
M242
M243
M244
M245
M246
M247

M255
M256
M257
M258
M259

M262

M273

M276

M330

M333

M347

APP-19

Remarks

M-codes

Description

Category

M350
M351

M352 cancel

M352

Spindle speed arrival signal check, valid

M353

M369
M370

Axis load detection, invalid

"

M371

Axis load detection, valid

"

M372

Axis load detection, temporarily invalid

"

M373

Axis load detection, re-start

"

M374

NC feed holding on overload detection

"

M375

NC feed holding & spindle stop on overload detection

"

M376

Overload detection level % setting

"

M377

Overload detection time setting (unit: 0.1 sec)

"

M378

Overload detection peak %/detection frequency setting

"

M379

Overload detection table No. registration

"

M390

M391 cancel

"

M391

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

"

M394

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

M395

M394 cancel

Magazine tool rotation

M731

Tail thrust 1 selection

M732

Tail thrust 2 selection

M733

Tail thrust 3 selection

M734

Tail thrust 4 selection

M735

Tail thrust 5 selection

M736

Tail thrust 6 selection

M737

Tail thrust 7 selection

M738

Tail thrust 8 selection

M739

Tail thrust 9 selection

M740

Tail thrust 10 selection

M741

Positioning tailstock to Position 1

M742

Positioning tailstock to Position 2

M743

Positioning tailstock to Retract

M380

M389

M392
M393

M396

M600
M601
M602

M730

APP-20

Remarks

M-codes

Description

Category

M744

M927
M928

Y-axis zero point return

Yt-axis moving to ATC position

M929
M930
M931

M999

APP-21

Remarks

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


(Addition)

S/IIIIST

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

Description

Category

Remarks

Secondary spindle selection

System M-code

Main spindle selection

System M-code

M303

Secondary spindle normal rotation

M304

Secondary spindle reverse rotation

M305

Secondary spindle stop

M306

Secondary spindle chuck unclamp (releasing workpiece)

M307

Secondary spindle chuck clamp (holding workpiece)

Secondary spindle orientation

"

M321

Increase of main spindle torque for synchronous rotation

"

M322

Cancellation of M321

"

M333

Torque limit of main spindle to 1/2

M334

Torque limit of main spindle

M335

Keeping of nominal torque of main spindle

M336

Cancellation of M337

M337

Torque limit of main spindle only at the starting and stopping

M351

Cancellation of M352

M352

Spindle speed arrival signal check

M357

Secondary spindle chuck air blast start

"

M358

Secondary spindle chuck air blast stop

"

M359

Cancellation of M360

"

M360

Secondary spindle orientation clamp mode

"

M361

Cancellation of M362

"

M362

Simultaneous chuck operation on main and secondary spindles in TRSCHK mode

"

M363

Cancellation of M364

"

M364

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

"

M380

Spindle synchronous rotation mode

M381

Spindle synchronous rotation mode cancel

Release of chuck open/close interlock during spindle rotation

M301
M302

M319
M320

M350

M500
M501

Cancellation of M500

M502

Main/secondary spindle synchronous rotation (Cross mode)

"

M503

APP-22

System M-code

M-codes

Description

Category

Remarks

M504
M505

Cancellation of M502

"

System M-code

M506

Master spindle chuck open after slave spindle chuck close

System M-code

M507

The slave spindle chuck open after master spindle chuck close

System M-code

M508

Pressing start

M509

Cancellation of M508

M511

Start of synchronous action of two spindles

System M-code

M512

Cancellation of M511

System M-code

M518

Interlock release during chucking of a bar workpiece by both spindles

M519

Spindle orientation

"

M527

Check for workpiece chucked in the spindle

"

M528

Modal workpiece check in TRS mode

"

M540

TRS-CHK mode start

System M-code

M541

Cancellation of TRS-CHK mode

System M-code

M542

TRS-BAR mode start

System M-code

M510

M543

Cancellation of TRS-BAR mode

System M-code

M544

Cross-machining start

"

System M-code

M545

Cancellation of cross-machining

"

System M-code

M546

TRS-MOV mode start

System M-code

M547

Cancellation of TRS-MOV mode

System M-code

APP-23

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


(Addition)

T/IIIIST

For the upper turret


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

Description

Category

M560

Spindle control and Constant cutting speed control for the upper turret

M561

Spindle control and Constant cutting speed control for the lower turret

M562

Axis movement synchronization

M563

Cancellation of axis movement synchronization

M950

Stand-by M-code

M951

Stand-by M-code

M952

Stand-by M-code

M953

Stand-by M-code

M954

Stand-by M-code

M955

Stand-by M-code

M956

Stand-by M-code

M957

Stand-by M-code

M958

Stand-by M-code

M959

Stand-by M-code

M960

Stand-by M-code

M961

Stand-by M-code

M962

Stand-by M-code

M963

Stand-by M-code

M964

Stand-by M-code

M965

Stand-by M-code

M966

Stand-by M-code

M967

Stand-by M-code

M968

Stand-by M-code

M969

Stand-by M-code

M970

Stand-by M-code

M971

Stand-by M-code

M972

Stand-by M-code

M973

Stand-by M-code

M974

Stand-by M-code

M975

Stand-by M-code

M976

Stand-by M-code

M977

Stand-by M-code

M978

Stand-by M-code

M979

Stand-by M-code

M980

Stand-by M-code

M981

Stand-by M-code

M982

Stand-by M-code

M949

APP-24

Remarks

M-codes

Description

Category

M983

Stand-by M-code

M984

Stand-by M-code

M985

Stand-by M-code

M986

Stand-by M-code

M987

Stand-by M-code

M988

Stand-by M-code

M989

Stand-by M-code

M990

Stand-by M-code

M991

Stand-by M-code

M992

Stand-by M-code

M993

Stand-by M-code

M994

Stand-by M-code

M995

Stand-by M-code

M996

Stand-by M-code

M997

Stand-by M-code

APP-25

Remarks

Integrex-100~400MkIII Lower Turret M-Codes


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

Description

Category

M00

Program stop

M01

Optional stop

M02

Program end

M03

Secondary spindle normal rotation (for ST)

M04

Secondary spindle reverse rotation (for ST)

M05

Secondary spindle stop (for ST)

M08

Coolant ON

M09

Coolant OFF

M30

Reset & tape rewind

M51

Error detect OFF

M52

Error detect ON

M53

Chamfering OFF

M54

Chamfering ON

M58

Secondary spindle chuck air blast

"

M300

Main spindle mode

M302

Secondary spindle mode

M303

Main spindle normal rotation

M304

Main spindle reverse rotation

M305

Main spindle stop

M358

Main spindle chuck air blast

"

M560

Spindle control and Constant cutting speed control for the upper turret

M561

Spindle control and Constant cutting speed control for the lower turret

M562

Axis movement synchronization

M563

Cancellation of axis movement synchronization

M950

Stand-by M-code

M951

Stand-by M-code

M952

Stand-by M-code

M953

Stand-by M-code

M954

Stand-by M-code

M301

M949

APP-26

Remarks

M-codes

Description

Category

M955

Stand-by M-code

M956

Stand-by M-code

M957

Stand-by M-code

M958

Stand-by M-code

M959

Stand-by M-code

M960

Stand-by M-code

M961

Stand-by M-code

M962

Stand-by M-code

M963

Stand-by M-code

M964

Stand-by M-code

M965

Stand-by M-code

M966

Stand-by M-code

M967

Stand-by M-code

M968

Stand-by M-code

M969

Stand-by M-code

M970

Stand-by M-code

M971

Stand-by M-code

M972

Stand-by M-code

M973

Stand-by M-code

M974

Stand-by M-code

M975

Stand-by M-code

M976

Stand-by M-code

M977

Stand-by M-code

M978

Stand-by M-code

M979

Stand-by M-code

M980

Stand-by M-code

M981

Stand-by M-code

M982

Stand-by M-code

M983

Stand-by M-code

M984

Stand-by M-code

M985

Stand-by M-code

M986

Stand-by M-code

M987

Stand-by M-code

M988

Stand-by M-code

M989

Stand-by M-code

M990

Stand-by M-code

M991

Stand-by M-code

M992

Stand-by M-code

M993

Stand-by M-code

M994

Stand-by M-code

M995

Stand-by M-code

M996

Stand-by M-code

M997

Stand-by M-code

APP-27

Remarks

- NOTE-

APP-28

Notes:

Stroke diagram (INTEGREX 100- - Metric -)

APP-29

Drawing No.

1372ST00012

Unit: mm

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

Stroke Diagram
INTEGREX 100-
(Metric)

Stroke diagram (INTEGREX 100- - Inch -)

APP-30

Notes:

Drawing No.

1372ST00041

Unit: in. (mm)

1. If B = 90, the tool lengths that can be


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

INTEGREX 100-
(Inch)

Stroke diagram (INTEGREX 100-S - Metric -)

APP-31

Notes:

Drawing No.

1372ST00022

Unit: mm

1. If B = 90, the tool lengths that can be


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

INTEGREX 100-
S
(Metric)

Stroke diagram (INTEGREX 100-S - Inch -)

APP-32

Notes:

Drawing No.

1372ST00051

Unit: in. (mm)

1. If B = 90, the tool lengths that can be


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

INTEGREX 100-
S
(Inch)

Stroke diagram (INTEGREX 100-ST - Metric -)

APP-33

Notes:

Drawing No.

1372ST00032

Unit: mm

1. If B = 90, the tool lengths that can be


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

INTEGREX 100-
ST
(Metric)

Stroke diagram (INTEGREX 100-ST - Inch -)

APP-34

Notes:

Drawing No.

1372ST00062

Unit: in. (mm)

1. If B = 90, the tool lengths that can be


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

INTEGREX 100-
ST
(Inch)

Stroke diagram (INTEGREX 200-III)

APP-35

Drawing No.

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

1373PGD0011

Unit: mm (in.)

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


*2: 40 mm (1.57")

Stroke Diagram
INTEGREX 200-III
III

Stroke diagram (INTEGREX 200-IIIS)

APP-36

Drawing No.

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

1373PGD0021

Unit: mm (in.)

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


*2: 40 mm (1.57")

INTEGREX 200-II
III
IIIS

Stroke diagram (INTEGREX 200-IIIT)

APP-37

Drawing No.

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

1373PGD0031

Unit: mm (in.)

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


*2: 40 mm (1.57")

INTEGREX 200-II
III
IIIT

Stroke diagram (INTEGREX 200-IIIST)

APP-38

Drawing No.

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

1373PGD0041

Unit: mm (in.)

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


*2: 40 mm (1.57")

INTEGREX 200-II
III
IIIST

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

APP-39

Drawing No.

1373PGD0110

Unit: mm (in.)

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

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


*2: 40 mm (1.57")

INTEGREX 200-III
III (with work rest)

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

APP-40

Drawing No.

1373PGD0120

Unit: mm (in.)

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

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


*2: 40 mm (1.57")

INTEGREX 200-III
IIIS
III (with work rest)

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

APP-41

1373PGD0050

Drawing No.

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

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


*2: 40 mm (1.57")

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

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

APP-42

Drawing No.

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

1373PGD0060

Unit: mm (in.)

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


*2: 40 mm (1.57")

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

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

APP-43

Drawing No.

MAIN SPINDLE

DOM./EX.

1374PGD0020

10" CHUCK
(THROUGH HOLE)

Unit: mm (in.)

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

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

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

APP-44

Drawing No.

MAIN SPINDLE

1374PGD0050

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

DOM./EX.

Unit: mm (in.)

*1: 165 mm (6.50")


*2: 40 mm (1.57")

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

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

APP-45

Drawing No.

MAIN SPINDLE

DOM./EX.

1374PGD0040

12" CHUCK
(THROUGH HOLE)

Unit: mm (in.)

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

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

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

APP-46

Drawing No.

MAIN SPINDLE

1374PGD0060

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

DOM./EX.

Unit: mm (in.)

*1: 165 mm (6.50")


*2: 40 mm (1.57")

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

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

APP-47

Drawing No.

MAIN SPINDLE

DOM./EX.

1374PGD0140

10" CHUCK
(THROUGH HOLE)

Unit: mm (in.)

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

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

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

APP-48

Unit: mm (in.)

Drawing No.

MAIN SPINDLE

1374PGD0170

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

DOM./EX.

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

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

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

APP-49

Drawing No.

MAIN SPINDLE

DOM./EX.

1374PGD0200

10" CHUCK
(THROUGH HOLE)

Unit: mm (in.)

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

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

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

APP-50

Unit: mm (in.)

Drawing No.

MAIN SPINDLE

1374PGD0230

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

DOM./EX.

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

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

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

APP-51

Drawing No.

MAIN SPINDLE

DOM./EX.

1374PGD0160

12" CHUCK
(THROUGH HOLE)

Unit: mm (in.)

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

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

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

APP-52

Unit: mm (in.)

Drawing No.

MAIN SPINDLE

1374PGD0180

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

DOM./EX.

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

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

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

APP-53

Drawing No.

MAIN SPINDLE

DOM./EX.

1374PGD0220

12" CHUCK
(THROUGH HOLE)

Unit: mm (in.)

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

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

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

APP-54

Unit: mm (in.)

Drawing No.

MAIN SPINDLE

1374PGD0240

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

DOM./EX.

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

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

Оценить