MAZAK VTC-200B OPERATING MANUAL

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Quick Links

List of Related Manuals and Documents

Alarm List

Code List

Page 2

Table of Contents

List of Related Manuals and Documents

Pagination

Numbering of Figures and Tables

Rule

Basic Safety Items

Clothing and Personal Safety

Operational Safety

Safety Considerations Relating to Holding Workpieces and Tooling

Maintenance Safety

Workplace Safety

Safety Considerations Relating to Chip Conveyor

Safety Equipment

2-10 Remarks on the Cutting Conditions Recommended by the NC

2-11 Safety Nameplates

Axis Definitions

Names and Locations of Machine Units

Locations of Operation Panels

NC Operation Panel

Arrangement of Switches on the NC Operation Panel

Names and Functions of Switches and Other Controls on the NC Operation Panel

Auxiliary Operation Panel

Data Input/Output Panel

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Magazine Operation Panel

Main Power Disconnect Switch

Operator's Door Interlock

MACHINE SET UP Switch (Key-lock Type Switch)

Inspection before Starting Operation

Switching the Power ON

Inspection after Switching the Power ON

Switching the Power OFF

Zero-Point Return

Warmup Operation

Spindle Operation

Starting the Spindle

Stopping the Spindle

Jogging the Spindle

Changing the Direction of Spindle Rotation

Feed Operation

Rapid Traverse Operation

Cutting Feed Operation

Pulse Handle Feed Operation

Clearing the Soft-Limit Alarm

Coolant System Operation

3-10 ATC Operation

3-10-1 Manual ATC Operation

3-10-2 Recovering ATC Operation after Interruption

Chip Conveyor Operation (Optional Specifications)

Procedure for Mounting or Removing a Tool in the Tool Magazine

Procedure for Mounting Tools to the Magazine

Procedure for Removing Tools from the Magazine

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Restrictions on Tools

Mounting and Removing Workpieces

Dimensional Restrictions on Workpieces

Procedure for Mounting and Removing Workpieces

Measuring Coordinate Values

Preparing Coolant

Selection of Coolant

Replenishing Coolant

Adjustment of Coolant Nozzle Direction

(Appendix)

Major Machine Specifications

Stroke Diagram and Spindle Interference Diagrams

Spindle Speed-Power-Torque Diagrams

Sub table Dimensions

Workpiece Interference Diagram

ALARM LIST

CODE LIST

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Operating Manual

for

VTC-200B, VTC-200C & VTC-300C

(Mazatrol Fusion 640M)

Publication # C557SG0012E

7/99

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.

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Notes:

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VTC-200B,200C & 300C Operation....................................................

SAFETY PRECAUTIONS S-1....................................................................

LOCKOUT PROCEDURE S-4.................................................................................

INSTALLATION PRECAUTIONS S-5......................................................................

WARNINGS S-8.......................................................................................................

Sec. 1: Introduction...........................................................................

1 INTRODUCTION 1-1............................................................................................

1-1 List of Related Manuals and Documents 1-1.......................................................................

1-2 Pagination 1-1.....................................................................................................................

1-3 Numbering of Figures and Tables 1-2.................................................................................

2 SAFETY PRECAUTIONS 2-1..............................................................................

2-1 Rule 2-1...............................................................................................................................

2-2 Basic Safety Items 2-1.........................................................................................................

2-3 Clothing and Personal Safety 2-3........................................................................................

2-4 Operational Safety 2-3.........................................................................................................

2-5 Safety Considerations Relating to Holding Workpieces and Tooling 2-4............................

2-6 Maintenance Safety 2-5.......................................................................................................

2-7 Workplace Safety 2-6..........................................................................................................

2-8 Safety Considerations Relating to Chip Conveyor 2-6........................................................

2-9 Safety Equipment 2-7..........................................................................................................

2-10 Remarks on the Cutting Conditions Recommended by the NC 2-8..................................

2-11 Safety Nameplates 2-8......................................................................................................

Sec. 2: Machine Operation...............................................................

1 OUTLINE OF THE MACHINE 1-1........................................................................

1-1 Axis Definitions 1-1..............................................................................................................

1-2 Names and Locations of Machine Units 1-2........................................................................

2 OPERATION PANELS 2-1...................................................................................

2-1 Locations of Operation Panels 2-1......................................................................................

2-2 NC Operation Panel 2-2......................................................................................................

2-2-1 Arrangement of Switches on the NC Operation Panel 2-3........................................

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2-2-2 Names and Functions of Switches and Other Controls on the NC Operation 2-4.....

2-3 Auxiliary Operation Panel 2-9..............................................................................................

2-4 Data Input/Output Panel 2-10................................................................................................

2-5 Magazine Operation Panel 2-11............................................................................................

2-6 Main Power Disconnect Switch 2-12.....................................................................................

2-7 Operators Door Interlock 2-13..............................................................................................

2-7-1 MACHINE SET UP Switch (Key-lock Type Switch) 2-13.............................................

3 MANUAL OPERATION 3-1..................................................................................

3-1 Inspection before Starting Operation 3-1.............................................................................

3-2 Switching the Power ON 3-3...............................................................................................

3-3 Inspection after Switching the Power ON 3-5......................................................................

3-4 Switching the Power OFF 3-6..............................................................................................

3-5 Zero-Point Return 3-7..........................................................................................................

3-6 Warmup Operation 3-9........................................................................................................

3-7 Spindle Operation 3-10..........................................................................................................

3-7-1 Starting the Spindle 3-10.............................................................................................

3-7-2 Stopping the Spindle 3-10...........................................................................................

3-7-3 Jogging the Spindle 3-10.............................................................................................

3-7-4 Changing the Direction of Spindle Rotation 3-11.........................................................

3-8 Feed Operation 3-11.............................................................................................................

3-8-1 Rapid Traverse Operation 3-11...................................................................................

3-8-2 Cutting Feed Operation 3-11.......................................................................................

3-8-3 Pulse Handle Feed Operation 3-12.............................................................................

3-8-4 Clearing the Soft-Limit Alarm 3-13...............................................................................

3-9 Coolant System Operation 3-15............................................................................................

3-10 ATC Operation 3-16............................................................................................................

3-10-1 Manual ATC Operation 3-16......................................................................................

3-10-2 Recovering ATC Operation after Interruption 3-20....................................................

3-11 Chip Conveyor Operation (Optional Specifications) 3-22....................................................

4 PREPARING FOR MACHINING 4-1....................................................................

4-1 Procedure for Mounting or Removing a Tool in the Tool Magazine 4-1..............................

4-1-1 Procedure for Mounting Tools to the Magazine 4-1...................................................

4-1-2 Procedure for Removing Tools from the Magazine 4-4.............................................

4-1-3 Restrictions on Tools 4-5...........................................................................................

4-2 Mounting and Removing Workpieces 4-6............................................................................

4-2-1 Dimensional Restrictions on Workpieces 4-6............................................................

4-2-2 Procedure for Mounting and Removing Workpieces 4-7...........................................

4-2-3 Measuring Coordinate Values 4-7.............................................................................

4-3 Preparing Coolant 4-8.........................................................................................................

4-3-1 Selection of Coolant 4-8............................................................................................

4-3-2 Replenishing Coolant 4-8..........................................................................................

4-4 Adjustment of Coolant Nozzle Direction 4-9........................................................................

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Sec. 3: Operating NC Unit & Preparation for Auto Operation........

CONTENTS 4-2.......................................................................................................

1 PREPARATION FOR AUTOMATIC OPERATION 1-1.........................................

1-1 Preparation Steps for Automatic Operation 1-1...................................................................

2 DISPLAY OVERVIEW 2-1....................................................................................

2-1 Name of the Components of Each Display 2-1...................................................................

2-2 Types of Displays 2-3..........................................................................................................

2-3 Configuration of Displays 2-4..............................................................................................

2-3-1 DISPLAY MAP display 2-6........................................................................................

2-4 Windows 2-7........................................................................................................................

3 DATA SETTING METHODS 3-1..........................................................................

3-1 Setting Data and Address 3-2.............................................................................................

3-2 Selecting Menu Data 3-3.....................................................................................................

3-3 Erasing Data 3-3..................................................................................................................

3-4 Modifying Data 3-4..............................................................................................................

3-5 Incremental Input 3-4...........................................................................................................

3-6 Saving Data onto the Hard Disk 3-4....................................................................................

4 DISPLAYS RELATED TO THE MACHINE OPERATIONAL STATUS 4-1...........

4-1 POSITION Display 4-1........................................................................................................

4-1-1 Data display 4-1.........................................................................................................

4-1-2 Data registration 4-5..................................................................................................

4-1-3 Display operations 4-6...............................................................................................

4-2 TRACE Display 4-6.............................................................................................................

4-2-1 Data display 4-7.........................................................................................................

4-1-2 Displaying machining shape and tool tip 4-8.............................................................

4-1-3 Plane select 4-9.........................................................................................................

4-1-4 Change of scale values 4-9.......................................................................................

4-3 EIA MONITOR Display 4-11..................................................................................................

4-1-1 Data display 4-11.........................................................................................................

4-1-2 EIA/ISO monitor function 4-12.....................................................................................

4-1-3 Editing functions 4-12..................................................................................................

4-1-4 Restart 2 unmodal function 4-13..................................................................................

4-4 MACHINING - MONITORING Display 4-14..........................................................................

4-4-1 Data display 4-14.........................................................................................................

4-1-2 Display modes of the MACHINING - MONITORING display 4-17...............................

4-1-3 Selecting graphs to be displayed in the machining-monitoring mode 4-18.................

4-1-4 Setting the threshold in the drill-monitoring mode 4-19...............................................

4-1-5 Scale change in the drill-monitoring mode 4-20..........................................................

4-1-6 Setting the display time scale 4-20..............................................................................

5 DISPLAYS RELATED TO MACHINING SET UP 5-1...........................................

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5-1 TOOL LAYOUT Display 5-1................................................................................................

5-1-1 Data display 5-1.........................................................................................................

5-1-2 Tool layout procedure 5-2..........................................................................................

5-1-3 Clearing pocket numbers 5-7.....................................................................................

5-1-4 Specifying a spare tool 5-8........................................................................................

5-1-5 Erasing spare tool data 5-9........................................................................................

5-1-6 Erasing procedures for registered tool data 5-9........................................................

5-1-7 Other functions 5-10....................................................................................................

5-2 WORK OFFSET Display 5-11...............................................................................................

5-2-1 Data display 5-11.........................................................................................................

5-1-2 Data registration 5-12..................................................................................................

5-3 MACRO VARIABLE Display 5-15..........................................................................................

5-3-1 Data display 5-16.........................................................................................................

5-1-2 Data registration 5-17..................................................................................................

5-1-3 Display operations 5-18...............................................................................................

5-4 ADDITIONAL WPC Display 5-19...........................................................................................

5-1-1 Data display 5-19.........................................................................................................

5-1-2 Data registration 5-20..................................................................................................

5-1-3 Address setting 5-20....................................................................................................

5-1-4 Considerations to measurement 5-21..........................................................................

5-5 Manual Measurement 5-22....................................................................................................

5-5-1 Function overview 5-22................................................................................................

5-5-2 Use of manual measurement 5-22..............................................................................

5-1-3 Measurement pattern 5-23..........................................................................................

5-1-4 MEASURE display 5-27...............................................................................................

5-1-5 Mode changeover 5-29................................................................................................

5-1-6 Measuring procedure 5-30...........................................................................................

5-1-7 Other functions 5-33....................................................................................................

5-1-8 Graph of straightness data (option) 5-36.....................................................................

5-6 SPINDLE LOAD GRAPHIC DISPLAY Display 5-38..............................................................

5-6-1 Data display 5-38.........................................................................................................

5-1-2 Displaying spindle load data 5-39................................................................................

5-1-3 Display mode selection 5-39........................................................................................

5-1-4 Displaying additional data related to spindle load 5-40...............................................

5-7 MACHINING NAVIGATION - RESULT Display 5-41............................................................

5-7-1 Data display 5-41.........................................................................................................

5-1-2 Displaying data 5-43....................................................................................................

5-1-3 Display modes 5-43.....................................................................................................

6 DISPLAYS RELATED TO PROGRAM CREATION 6-1.......................................

6-1 PROGRAM Display 6-1.......................................................................................................

6-2 TOOL PATH CHECK Display 6-1........................................................................................

6-2-1 Data display 6-2.........................................................................................................

6-1-2 Displaying machining shape 6-3................................................................................

6-1-3 Displaying tool-tip path 6-3........................................................................................

6-1-4 Restarting tool path check 6-4...................................................................................

6-1-5 Block skip 6-4............................................................................................................

6-1-6 Other menu functions 6-4..........................................................................................

6-1-7 Solid Mode 6-5...........................................................................................................

6-3 SHAPE CHECK Display 6-19................................................................................................

6-3-1 Data display 6-19.........................................................................................................

6-1-2 Displaying machining shape 6-20................................................................................

6-1-3 Other menu functions 6-21..........................................................................................

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6-4 PLANE CHECK Window 6-22...............................................................................................

6-4-1 Data display 6-22.........................................................................................................

6-1-2 Displaying machining shape 6-23................................................................................

6-1-3 Others 6-23..................................................................................................................

6-5 SECTION CHECK Window 6-23...........................................................................................

6-5-1 Data display 6-24.........................................................................................................

6-1-2 Displaying sectional shapes 6-25................................................................................

6-1-3 Others 6-25..................................................................................................................

6-6 PROGRAM FILE Display 6-26..............................................................................................

6-6-1 Data display 6-26.........................................................................................................

6-1-2 Program name setting 6-27.........................................................................................

6-1-3 Work number change 6-28..........................................................................................

6-1-4 Program erasure 6-28..................................................................................................

6-1-5 Program copy 6-29......................................................................................................

6-1-6 All program erasure 6-29.............................................................................................

6-1-7 Converting MAZATROL program to EIA/ISO program 6-29........................................

6-1-8 Opening the shape drawing window 6-29....................................................................

6-1-9 Directory change 6-30.................................................................................................

6-1-10 Program transfer 6-31................................................................................................

6-1-11 Program management functions 6-31.......................................................................

6-7 PROCESS CONTROL Display 6-33.....................................................................................

6-7-1 Data display 6-33.........................................................................................................

6-1-2 Process-number search 6-34......................................................................................

6-1-3 Other functions 6-34....................................................................................................

6-8 PROGRAM LAYOUT Display 6-35........................................................................................

6-8-1 Data display 6-35.........................................................................................................

6-1-2 Priority number setting 6-36.........................................................................................

6-1-3 Delay priority designation 6-36....................................................................................

6-1-4 Priority number assignment 6-36.................................................................................

6-1-5 Priority number movement 6-37..................................................................................

6-1-6 Priority number all erase 6-38......................................................................................

6-1-7 Store 6-38....................................................................................................................

6-1-8 Program write 6-38......................................................................................................

6-1-9 Simultaneous use of functions 6-39.............................................................................

6-1-10 Program reference window 6-39................................................................................

6-9 MACHINING NAVIGATION - PREDICT Display 6-40...........................................................

6-9-1 Data display 6-40.........................................................................................................

6-1-2 Displaying data 6-43....................................................................................................

6-1-3 Display modes 6-44.....................................................................................................

6-1-4 Modifying the cutting conditions 6-46..........................................................................

7 DISPLAYS RELATED TO TOOLS 7-1.................................................................

7-1 TOOL DATA Display 7-1.....................................................................................................

7-1-1 Data display 7-1.........................................................................................................

7-1-2 Tool-data input procedures (for MAZATROL programs) 7-3.....................................

7-1-3 Interchanging pocket numbers (for MAZATROL programs) 7-7................................

7-1-4 Registering the tools to be used 7-8..........................................................................

7-1-5 Manual measurement of the tool lengths 7-9............................................................

7-1-6 Other functions (for MAZATROL programs) 7-10........................................................

7-1-7 Setting tool data (for EIA/ISO programs) 7-13.............................................................

7-1-8 Setting tool group numbers 7-16.................................................................................

7-1-9 Manual measurement of tool lengths (Setting tool length offset data 7-17..................

7-1-10 Other functions (for EIA/ISO programs) 7-17............................................................

7-1-11 MAZATROL tool data INVALIDATION (Option) 7-17..............................................

7-1-12 Tool length listing window 7-21..................................................................................

7-2 TOOL FILE Display 7-22.......................................................................................................

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7-1-1 Data display 7-23.........................................................................................................

7-1-2 Registering milling tool data 7-25................................................................................

7-1-3 Erasing a part of the registered data 7-29...................................................................

7-3 TOOL OFFSET Display 7-30.................................................................................................

7-3-1 Data display 7-30.........................................................................................................

7-1-2 Tool-compensation data setting procedures 7-31.......................................................

7-1-3 Setting the current position 7-33..................................................................................

7-1-4 EIA/ISO tool length measurement 7-33.......................................................................

8 DISPLAYS RELATED TO PARAMETERS 8-1....................................................

8-1 CUTTING CONDITION (W.-MAT./T.-MAT.) Display 8-1.....................................................

8-1-1 Data display 8-1.........................................................................................................

8-1-2 Registering data 8-2..................................................................................................

8-1-3 Read and Write of text file 8-3...................................................................................

8-2 CUTTING CONDITION Display 8-5....................................................................................

8-2-1 Data display 8-5.........................................................................................................

8-2-2 Data registration 8-7..................................................................................................

8-3 USER PARAMETER Display 8-8........................................................................................

8-3-1 Data display 8-8.........................................................................................................

8-4 MACHINE PARAMETER Display 8-10..................................................................................

8-4-1 Data display 8-10.........................................................................................................

9 DISPLAY RELATED TO DATA STORAGE 9-1...................................................

9-1 DATA I/O Display 9-1..........................................................................................................

9-1-1 Data display 9-1.........................................................................................................

9-1-2 DATA I/O operations (CARD) 9-2..............................................................................

9-1-3 DATA I/O operations (CMT) 9-6................................................................................

9-1-4 DATA I/O operations (TAPE) 9-10...............................................................................

9-1-5 DATA I/O operations (FLOPPY) 9-14..........................................................................

9-1-6 DATA I/O operations (DNC) 9-16................................................................................

9-1-7 DATA I/O operations (HARD DISK) 9-20....................................................................

9-2 Program Transfer from the Host PC to the Memory Card 9-23.............................................

9-2-1 Outline 9-23.................................................................................................................

9-2-2 Detailed description 9-23.............................................................................................

10 DISPLAYS RELATED TO DIAGNOSIS 10-1.......................................................

10-1 DIAGNOSIS (USER)  ALARM Display 10-1.......................................................................

10-1-1 Data display 10-2.......................................................................................................

10-2 DIAGNOSIS (USER)  ALARM HISTORY Display 10-5......................................................

10-2-1 Data display 10-5.......................................................................................................

10-3 DIAGNOSIS (USER)  PLC SIGNAL Display 10-6..............................................................

10-1-1 Data display 10-6.......................................................................................................

10-4 MAINTENANCE CHECK Display 10-7................................................................................

10-1-1 Data display 10-7.......................................................................................................

10-1-2 Data display for long-term check items (1500 and 3000 hours check items) 10-8....

10-1-3 Display operations 10-8.............................................................................................

10-1-4 Entry of the check items to be displayed 10-9...........................................................

10-5 PLC Display 10-11.................................................................................................................

10-5-1 Data display 10-11.......................................................................................................

10-6 RUNNING CONTROL Display 10-12....................................................................................

10-6-1 Data display 10-12.......................................................................................................

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10-1-2 Display modes 10-15...................................................................................................

10-7 DIAGNOSIS (MAKER)  VERSION Display 10-18................................................................

10-1-1 Data display 10-18.......................................................................................................

10-8 DIAGNOSIS (MAKER)  DIAGNOSIS MONITOR Display 10-19..........................................

10-1-1 Data display 10-19.......................................................................................................

10-1-2 Display operations 10-20.............................................................................................

10-9 DIAGNOSIS (MAKER)  OPTION Display 10-23...................................................................

10-9-1 Data display 10-23.......................................................................................................

11 OPTION 11-1........................................................................................................

11-1 Machining Management Functions 11-1.............................................................................

11-1-1 General 11-1..............................................................................................................

11-1-2 PALLET MANAGEMENT display 11-2......................................................................

11-1-3 Scheduled-operation function 11-3............................................................................

11-1-4 External unit skipping function 11-9...........................................................................

11-1-5 External multi-piece machining function 11-11............................................................

11-1-6 Jig offsetting function 11-13.........................................................................................

11-1-7 Parameters 11-16........................................................................................................

11-1-8 Machining management data writing macro-program 11-16.......................................

11-2 Function Relating EIA/ISO Program (Option) 11-21..............................................................

11-2-1 Configuration of displays 11-21...................................................................................

11-2-2 POSITION display 11-24.............................................................................................

11-3 Workpiece Measurement Printout System 11-26..................................................................

11-3-1 Function overview 11-26..............................................................................................

11-1-2 System configurations 11-32.......................................................................................

11-1-3 Parameter registration 11-34.......................................................................................

11-1-4 Program configuration 11-37.......................................................................................

11-1-5 Explanations of macro programs 11-42.......................................................................

11-1-6 Program and measurement pattern chart 11-64..........................................................

11-1-7 Output of measurement results 11-65.........................................................................

11-1-8 Alarm displays 11-68...................................................................................................

11-1-9 Program and printout example 11-69..........................................................................

11-4 Geometry Compensation Function 11-74..............................................................................

11-4-1 Function general 11-74................................................................................................

11-4-2 Detailed description 11-76...........................................................................................

11-1-3 Hold Status 11-81........................................................................................................

11-1-4 Notes 11-82.................................................................................................................

11-1-5 Parameters 11-82........................................................................................................

11-1-6 Appendix 11-83............................................................................................................

11-5 Hard Disk Operating Function 11-86.....................................................................................

11-5-1 Outline 11-86...............................................................................................................

11-5-2 Preparation for HD operation 11-86.............................................................................

11-5-3 Selection of operation mode 11-86..............................................................................

11-1-4 Program selection for HD operation 11-88..................................................................

11-1-5 Restart in the HD operation mode 11-89.....................................................................

11-1-6 Format for HD operation programs 11-89....................................................................

11-1-7 Alarms concerned 11-91..............................................................................................

11-6 IC Memory Card Operating Function 11-92..........................................................................

11-6-1 Outline 11-92...............................................................................................................

11-6-2 Preparation for CARD operation 11-92........................................................................

11-6-3 Selection of operation mode 11-92..............................................................................

11-1-4 Program selection for CARD operation 11-94.............................................................

11-1-5 Restart in the CARD operation mode 11-95................................................................

11-1-6 Format for CARD operation programs 11-95...............................................................

11-1-7 Alarms concerned 11-97..............................................................................................

Page 14

11-7 EIA/ISO Conversion 11-98....................................................................................................

11-7-1 Outline 11-98...............................................................................................................

11-7-2 EIA conversion program format 11-99.........................................................................

11-7-3 Output data unit11-99.................................................................................................

11-1-4 Operating procedure 11-100..........................................................................................

11-1-5 Supplementary description and precautions for conversion of 11-100..........................

11-1-6 Parameter and alarm lists 11-105..................................................................................

Sec. 4: Automatic Operation.............................................................

CONTENTS 2-7.......................................................................................................

1 AUTOMATIC OPERATION EXECUTION 1-1......................................................

1-1 Automatic Operation Execution Procedure 1-1...................................................................

1-2 Types of Automatic Operation Mode 1-3.............................................................................

1-2-1 Automatic operation 1-4.............................................................................................

1-2-2 Restart operation 1-8.................................................................................................

1-1-3 MDI operation 1-16......................................................................................................

2 SELECTING EXECUTION CONDITIONS 2-1.....................................................

2-1 Optional Stop 2-1.................................................................................................................

2-1-1 Procedure 2-1............................................................................................................

2-1-2 Description 2-2...........................................................................................................

2-2 Dry Run 2-2.........................................................................................................................

2-2-1 Procedure 2-2............................................................................................................

2-2-2 Description 2-3...........................................................................................................

2-3 Machine Lock 2-3................................................................................................................

2-3-1 Procedure 2-3............................................................................................................

2-3-2 Description 2-3...........................................................................................................

2-4 Work Light 2-3.....................................................................................................................

2-4-1 Procedure 2-3............................................................................................................

2-5 Block Skip 2-4......................................................................................................................

2-5-1 Procedure 2-4............................................................................................................

2-5-2 Description 2-4...........................................................................................................

2-6 Single Block 2-4...................................................................................................................

2-6-1 Procedure 2-4............................................................................................................

2-6-2 Description 2-4...........................................................................................................

2-7 Comparison Stop 2-5...........................................................................................................

2-7-1 Setting procedure 2-5................................................................................................

2-7-2 Description 2-5...........................................................................................................

2-8 Z-axis Cancel 2-7................................................................................................................

2-8-1 Procedure 2-7............................................................................................................

2-8-2 Description 2-7...........................................................................................................

2-9 MST Lock 2-7......................................................................................................................

2-9-1 Procedure 2-8............................................................................................................

2-9-2 Description 2-8...........................................................................................................

2-10 ATC Stop 2-8.....................................................................................................................

2-11 TUNING SV PARAM 2-8...................................................................................................

2-11-1 Operation procedure 2-9..........................................................................................

Page 15

2-11-2 Function description 2-10..........................................................................................

3 CHANGING THE CUTTING CONDITIONS 3-1...................................................

3-1 Rapid Feed Override 3-1.....................................................................................................

3-1-1 Procedure 3-1............................................................................................................

3-2 Cutting Feed Override 3-2...................................................................................................

3-2-1 Procedure 3-2............................................................................................................

3-3 Spindle Speed Override 3-3................................................................................................

3-3-1 Procedure 3-3............................................................................................................

3-4 VFC Function 3-4................................................................................................................

3-4-1 Procedure 3-4............................................................................................................

3-4-2 Description 3-4...........................................................................................................

3-5 AFC Function (Option) 3-6..................................................................................................

3-5-1 Setting the desired current load value 3-7.................................................................

3-5-2 Tools available with AFC and AFC supervisory modes 3-8.......................................

3-5-3 Functional operation 3-8............................................................................................

4 STOPPING AUTOMATIC OPERATION 4-1........................................................

4-1 Emergency Stop 4-1............................................................................................................

4-1-1 Emergency Stop 4-1..................................................................................................

4-1-2 Releasing the emergency stop status 4-1.................................................................

4-2 Reset 4-2.............................................................................................................................

4-3 Feed Hold 4-2......................................................................................................................

4-4 Stopping by Changeover to a Manual Operation Mode 4-3................................................

4-5 Single-block Stop 4-3..........................................................................................................

4-5-1 Single-block stop by changing within automatic operation modes 4-3......................

4-5-2 Single-block stop using the SINGLE BLOCK key 4-4................................................

4-6 Program Stop 4-4................................................................................................................

4-7 Stopping by Turning the Power Off 4-4...............................................................................

5 MANUAL INTERRUPTION 5-1............................................................................

5-1 Handle Interruption (Option) 5-1..........................................................................................

5-1-1 Handle interruption 5-1..............................................................................................

5-1-2 Clearing the manual handle interruption 5-1..............................................................

5-2 TPS Function 5-2.................................................................................................................

5-2-1 Storing the data of only the stop point of automatic operation 5-2............................

5-2-2 Storing the data of both the stop point of automatic operation and the 5-3...............

5-2-3 Storing the data of only the passage point(s) existing during manual 5-4.................

5-2-4 General remarks on TPS function 5-4.......................................................................

6 OPERATIONS POSSIBLE DURING AUTOMATIC OPERATION 6-1.................

6-1 Data Rewriting 6-1...............................................................................................................

6-1-1 Data writing conditions 6-1........................................................................................

Sec. 5: Appendix ...............................................................................

1 STANDARD MACHINE SPECIFICATIONS 1-1...................................................

Page 16

1-1 Major Machine Specifications - VTC-200B 1-1....................................................................

1-2 Stroke Diagram and Spindle Interference Diagrams - VTC-200B 1-3.................................

1-3 Spindle Speed-Power-Torque Diagrams 1-4.......................................................................

1-4 Table Dimensions 1-5..........................................................................................................

1-5 Sub table Dimensions 1-5...................................................................................................

1-6 Workpiece Interference Diagram 1-6...................................................................................

2 ALARM LIST - VTC-200/300 (MAZATROL FUSION 640M) 2-1..........................

3 M CODE LIST - VTC-200/300 (MAZATROL FUSION 640M) 3-1........................

Page 17

SAFETY PRECAUTIONS

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.

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.

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• AFTER CONTROL POWER IS TURNED ON

CAUTION:

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

• ROUTINE INSPECTIONS

WARNING:

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

CAUTION:

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.

• 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.

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.

• 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.

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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.

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.

000X717-KY 11/98

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WARNING

ALWAYS TURN THE MAIN CIRCUIT BREAKER TO THE “OFF” POSITION & USE AN APPROVED LOCKOUT DEVICE WHEN COMPLETING MAINTENANCE OR REPAIRS.

THE LOCKOUT PROCEDURE THAT FOLLOWS IS INTENDED TO SAFEGUARD PERSONNEL & EQUIPMENT DURING MAINTENANCE OPERATIONS, AND, REPRESENTS THE MINIMUM REQUIREMENTS. ANY ACTION SHOULD BE PRECEDED BY A “HAZARD ANALYSIS” TO DETERMINE ANY ADDITIONAL SAFETY PRECAUTIONS THAT MAY BE NECESSARY TO ENSURE THE SAFETY OF PERSONNEL AND EQUIPMENT.

NOTE

: USE OF THE FOLLOWING LOCKOUT PROCEDURE IS MANDATORY WHEN COMPLETING

MAINTENANCE OR REPAIRS.

LOCKOUT PROCEDURE

1) THE LOCKOUT PROCESS MUST BE PERFORMED BY AUTHORIZED PERSONNEL ONLY.

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

3) SHUT OFF MACHINE POWER USING NORMAL SHUT DOWN PROCEDURES.

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

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

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

7) COMPLETE THE REQUIRED MAINTENANCE OPERATIONS.

8) MAKE SURE ALL PERSONNEL ARE CLEAR OF THE MACHINE.

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

PADLOCK

FIGURE

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Page 21

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.

• ENVIRONMENTAL REQUIREMENTS Avoid the following places for installing the

machine:

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

2) Avoid areas where the humidity fluctuates greatly and/or if high humidity is present; normally 75% and below in relative humidity. A higher humidity deteriorates insulation and might accelerate the deterioration of parts.

3) Avoid areas that are especially dusty and/or where acid fumes, corrosive gases and salt are present.

4) Avoid areas of high vibration.

5) Avoid soft or weak ground (minimum load

bearing capacity of 1025 lbs./ft

)

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

Note:

The machine must be anchored to the foundation with J-bolts, expansion bolts or other suitable method.

The machine accuracy and alignment specifications quoted by Mazak can usually be obtained when the minimum foundation requirements are met. However, production of close tolerance parts requires the use of an appropriate certified foundation. Foundations that do not meet certified specifications may require more frequent machine re-leveling and re-alignment, which can not be provided under terms of warranty.

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

• FOUNDATION REQUIREMENTS

For high machining accuracy, the foundation must be firm and rigid. This is typically accomplished by securely fastening the machine to the foundation with anchor bolts. In addition, the depth of concrete should be as deep as possible (minimum 6 - 8 inches). Note the following:

1) There can be no cracks in the foundation concrete or surrounding area.

2) Vibration proofing material (such as asphalt) should be put all around the concrete pad.

3) Form a “cone” in the foundation for J-bolt anchors, or use expansion anchors.

4) With the foundation anchor bolt holes open pour the primary concrete at a minimum thickness of 6 - 8 inches. Typically, the concrete must have a minimum compression

rating of 2500 lbs. @ 250 lbs. compression

and strengthened with reinforcing rods. When the concrete has cured, rough level the machine, and install the J-bolts, leveling blocks, etc., and pour grout into foundation bolt holes.

5) Mix an anti-shrinkage agent such as Denka CSA with concrete, or use Embeco grout to fill the foundation bolt holes.

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Page 22

• WIRING

1)Use only electrical conductors with performance ratings equivalent or superior.

2)Do not connect any power cables for devices which can cause line noise to the power distribution panel, such as arc welders and high frequency machinery.

3)Arrange for a qualified electrician to connect the power lines.

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

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

[ CAUTION ]

VERIFY THE ACTUAL MACHINE ELECTRICAL POWER REQUIREMENT AND THE MAIN TRANSFORMER RATING (IF APPLICABLE), AS WELL AS THE LOCAL ELECTRICAL CODE

Desirable Independent Grounding:

N C Earth resistance: Machine Less than 100 ohms

Common Grounds:

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

Note: Never ground equipment as shown below:

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.

S-6

000X713-KY 11/98

Page 23

CAUTION

A step-down transformer is verify the transformer Kva rating (where applicable), as well as local electrical code requirements

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.

before

optional

sizing and installing the incoming power wiring.

on some machine models. Be certain to

S-7

Page 24

MAZA TROL CNC CONTROLLERS PROVIDE P ARAMETER SETTINGS TO LIMIT SPINDLE RPM. THESE SETTINGS ARE BASED ON THE MAXIMUM SPEED SPECIFIED BY THE CHUCK/ACTUA TOR MANUF ACTURER.

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 P ARAMETER MANUAL SUPPLIED WITH THE SPECIFIC MACHINE TOOL TO IDENTIFY THE REQUIRED PARAMETERS T O CHANGE.

FAILURE T O COMPL Y WITH THESE INSTRUCTIONS COULD RESUL T 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 INJUR Y AND DAMAGE.

DO NOT REMOVE, DISCONNECT , BYP ASS 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.

WARNING

S-8

Page 25

MAZAK MACHINES ARE ENGINEERED WITH A NUMBER OF SAFETY DEVICES TO PROTECT PERSONNEL AND EQUIPMENT FROM INJUR Y AND DAMAGE.

MACHINE OPERATOR DOORS AND COVERS ARE DESIGNED TO WITHSTAND ACCIDENT AL 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 SPECIFICA TIONS OR THA T 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.

WARNING

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

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Page 26

BEFORE ST ARTING OPERA TION, CHECK THA T THE WORKPIECE IS SECUREL Y MOUNTED IN A VISE OR A SUITABLE FIXTURE. BE CERTAIN THAT THE MOUNTING IS SUFFICIENT TO WITHST AND 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 SECUREL Y 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 RESUL T OF THE MAZATROL FUSION 640 AUTOMA TIC CUTTING DETERMINATION FUNCTION

- CUTTING CONDITIONS SUGGESTED BY THE MACHINING NAVAGA TION FUNCTION

- CUTTING CONDITIONS FOR TOOLS THAT ARE SUGGESTED TO BE USED BY THE MACHINING NA V AGA TION 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 SER VICE CENTER FOR ASSISTANCE.

WARNING

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Page 27

MACHINE DOCUMENTATION

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CUSTOMER EVALUATION

Your opinion is important to enable us to issue documentation that will fit your needs. Thank you for taking the time to supply this information.

Machine Type: Machine Serial#: NC Type: Customer: Reported By: Address: Position:

Manual Publication #:

How well is the documentation suited to your needs? Were you able to find the necessary information easily? How well are the manuals organized? How easy are the manuals to understand? Are the illustrations helpful? Overall, how do you rate the documentation?

What did you like about the documentation? How can it be improved?

RETURN TO: MAZAK Corporation

Technical Publication Dept. 8025 Production Drive Florence, Kentucky 41042

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SF-202Xa

The Other Thoroughbred From Kentucky

Date:

Telephone#:

Excellent Good Adequate Fair Poor

Page 28

Notes:

Page 29

Section 1:

Introduction

Page 30

Notes:

Page 31

TABLE OF CONTENTS (ABOUT THIS MANUAL)

1 INTRODUCTION ....................................................................................1-1

1-1 List of Related Manuals and Documents............................................................1-1

1-2 Pagination..........................................................................................................1-1

1-3 Numbering of Figures and Tables......................................................................1-2

2 SAFETY PRECAUTIONS.......................................................................2-1

2-1 Rule ...................................................................................................................2-1

2-2 Basic Safety Items.............................................................................................2-1

Page

2-3 Clothing and Personal Safety.............................................................................2-3

2-4 Operational Safety.............................................................................................2-3

2-5 Safety Considerations Relating to Holding Workpieces and Tooling.................2-4

2-6 Maintenance Safety...........................................................................................2-5

2-7 Workplace Safety...............................................................................................2-6

2-8 Safety Considerations Relating to Chip Conveyor.............................................2-6

2-9 Safety Equipment...............................................................................................2-7

2-10 Remarks on the Cutting Conditions Recommended by the NC.........................2-8

2-11 Safety Nameplates.............................................................................................2-8

C-1

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- MEMO -

C-2

Page 33

1 INTRODUCTION

1-1 List of Related Manuals and Documents

For this model of machine, the following manuals and documents are relevant to this model of machine.

• Operating manual

Describes operation procedure and other general information on operating the machine.

• Maintenance manual

Describes the general information on maintenance including inspection and adjustment

procedure.

• Programming manual

Describes the NC programming procedure and related information.

• Tooling manual

Gives the dimensional drawings of tool shank and retention bolt.

• Parameter list

Describes the details of parameters.

• Alarm list

Describes the details of alarms.

• Parts list

Describes the details of parts and the procedure for purchasing the necessary parts.

• Electric circuit diagrams

Shows the wiring diagrams.

• Instruction manuals for optional equipment

Describes operation procedure and other general information on the operation of the optional

equipment.

1-2 Pagination

Page numbers are given as two numerals joined by a hyphen. The first number indicates chapter number and the second indicates the page number within that chapter.

Example 1:

If a change, which necessitates altering the number of pages, arises, additional pages will be inserted. The numbers of these pages will be made up by appending a hyphen and sequential numbers to the number of the page before the addition.

215

Page numberChapter number

Example 2:

3-16-1

Additional page

1-1

Page 34

1-3 Numbering of Figures and Tables

1. Figure numbers

Figure numbers consist of the word “Fig.” followed by two numerals joined by a hyphen. The first number indicates the chapter number and the second indicate the serial number in that chapter. The figure number is followed by the title of the figure.

Example 1:

Fig. 3 1

Chapter number

2. Table numbers

Table numbers consist of the word “Table” followed by two numerals joined by a hyphen. The first number indicates the chapter number and the second indicate the serial number in that chapter. The table number is followed by the title of the table.

Example 1:

Table 2-1

Chapter number

Serial table number in chapter

Main Machine Components (1/2)

Serial figure number in chapter

Safety Nameplate Details

Title

The suffix shown here indicates that there are two figures with this title, as indicated by the denominator, and that this is the first of those figures, as indicated by the numerator.

(cont’d)

The suffix is added to the title on the second and subsequent pages if the table occupies more than one page.

Some of the figures and tables in this manual are not numbered.

1-2

Page 35

2 SAFETY PRECAUTIONS

The precautions to be observed to ensure safe operation of the machine are described here.

The machine must not be operated until these precautions have been thoroughly understood.

2-1 Rule

1. This section contains the precautions to be observed as to the working methods and states usually expected. Of course, however, unexpected operations and/or unexpected working states may take place at the user site.

During daily operation of the machine, therefore, the user must pay extra careful attention to its own

working safety as well as to observe the precautions described below.

2. The meanings of our safety precautions to DANGER, WARNING, and CAUTION are as follows:

: Failure to follow these instructions could result in loss of life.

DANGER

: Failure to observe these instructions could result in serious harm to a human

life or body.

WARNING

: Failure to observe these instructions could result in minor injuries or serious

CAUTION

2-2 Basic Safety Items

l There are high voltage terminals on the electrical control panel, transformer, motors,

junction boxes, and other equipment (with a battery warning mark

DANGER

l DO NOT touch any of them under any circumstances.

l Make sure that all doors and safety covers are fitted before switching on the power. If any

door or safety cover must be removed, cut off and lock the main breaker first.

machine damage.

attached).

HGMCGA0044E

2-1

Page 36

l Memorize the position of the EMERGENCY STOP button so that you can press it

immediately from any position.

WARNING

CAUTION

l Take care not to touch any of the switches accidentally while the machine is in operation.

l Take care not to catch your fingers in the chuck. (For lathes)

l Never touch a rotating workpiece or the tool with your bare hands or any other object.

l To prevent incorrect operation of the machine, carefully check the position of the switches

before operation.

l If in the slightest doubt about a procedure, ask the person in charge.

l Always switch off the main power switch on the operation panel and the main power

breaker when you are taking a break from work and are going to leave the machine.

l If more than one operator is using the machine, do not proceed to the next step without

indicating to the other operator(s) that you are about to do so.

l Do not modify the machine in any way that will affect its safety.

l Do not enter the machine. If you have to enter the machine, take measures such as

pressing the EMERGENCY STOP button that disable machine operation.

l If there is a power failure, switch off the main power breaker immediately.

l Do not subject the NC unit, the operation panel, or the electrical control panel to strong

shocks.

l Do not change the parameter values, volume values, or other electrical setting values

without good reason. If you need to change a value, first check that it is safe to do so, then make a note of the original value so that it can be reset if necessary.

l Do not paint, soil, damage, modify, or remove any of the safety nameplates. If the details

become illegible or the nameplate is lost, obtain a replacement by sending the part number stamped at the bottom right-hand corner of the nameplate to Mazak and mount the replacement in the original position. (If a nameplate has been lost, obtain the part number from the “Parts List” supplied separately.)

l Do not open any doors or safety covers while the machine is in automatic operation.

l Stop all machine operations before cleaning the machine or any of the peripheral

equipment.

l After a job has been completed, set up each part of the machine so that it is ready for the

next series of operations.

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2-3 Clothing and Personal Safety

l Tie back long hair which could become entangled in drive mechanisms.

l Wear safety equipment (helmet, goggles, safety shoes, etc.) whenever possible.

CAUTION

l Always wear a helmet if there are any overhead obstacles in the work area.

l Always wear a protective mask when machining magnesium alloys.

l Always use safety shoes with steel toecaps and oil-resistant soles.

l Never wear loose or baggy clothing.

l Always completely fasten buttons and hooks on the arms of clothing to avoid the danger of

entanglement in drive mechanisms.

l Always use gloves when loading or unloading workpieces or tools and when removing

chips from the work area to protect your hands from sharp edges and heat generated during machining.

l Do not operate the machine while under the influence of drugs with powerful effects,

unprescribed drugs, or alcohol.

l Do not operate the machine if you suffer from dizziness or fainting spells.

2-4 Operational Safety

l Close all doors and covers of the NC unit, operation panel, electrical control panel, and

junction boxes to prevent damage from water, chips, and oil.

WARNING

l Check all electrical cables for damage to prevent accidents due to current leakage or

electric shock.

l Do not handle coolant with bare hands since it is liable to cause irritation. Operators with

allergies should take special precautions.

l Do not operate the machine during violent thunderstorms.

l Check the safety covers regularly to make sure that they are properly filled and that they

are not damaged. Repair or replace any damaged covers immediately.

l Always obtain assistance in handling loads beyond your capacity.

l Do not operate fork lifts or cranes or carry out slinging work unless you have undergone

officially approved training.

l When using fork lifts or cranes, make sure that there are no obstructions in the vicinity of

these machines.

l Always use wire rope or slings of a standard suitable for the load to be supported.

l Wait until the machine has come to a complete stop before adjusting the position of the

coolant nozzle.

l Do not remove or otherwise interfere with safety equipment such as stop dogs, limit

switches, or interlocks in order to increase axis travel.

l Do not operate the machine with any of the safety covers removed.

l Always wear gloves and use a brush to clean chips off the tool tip; never use bare hands.

l Stop all machine operations before mounting or removing a tool.

l Check slings, chains, hoists, and other lifting gear for defects before use. Repair or replace

defective gear immediately.

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l Do not allow chips to accumulate during heavy-duty cutting since they will be hot and could

start a fire.

CAUTION

l Warm up the spindle and all of the axis motion mechanisms before operation. (Operate

the machine in the automatic mode for 10 to 20 minutes at maximum spindle speed or at 1/3 to 1/2 maximum axis motion speed.)

l Write the program for the warming-up operation so as to execute the functions of the full

range of machine components. If operation is to be performed at spindle speeds in excess of 4000 min

–1

, pay meticulous attention to the warming-up operation.

l Do not operate the operation panel switches while wearing gloves as this could lead to

incorrect operation or other mistakes.

l When one series of operations is completed, switch off the power switch on the NC

operation panel, the main power breaker, then the factory power supply.

2-5 Safety Considerations Relating to Holding Workpieces and Tooling

l Always use tools which are suitable for the work to be carried out and conform to the

machine specifications. Always observe the restrictions on weight of tool insert and tool

WARNING

diameter stipulated in the specifications. [Max. insert weight: 20 gf (0.04 lbs)]

l Replace tools promptly, since badly worn tools can cause accidents and injuries.

l Before starting operation, check that the workpiece is securely mounted and cannot

become detached by the cutting forces applied to it during machining.

l Before mounting a cutting tool in the machine, make sure that the tool and its stud bolt are

properly secured.

CAUTION

l Do not rotate a cutting tool or holder at speeds higher than the rated speed.

l Check the maximum safe operating speed with the manufacturer.

l Be very careful not to catch your fingers in workpiece holding devices.

l Always use the correct lifting gear for heavy fixtures and workpieces.

l Make sure that cutting tools will not interfere with the workpiece fixture, etc.

l Mount the tool holder in the correct orientation by aligning it with the drive key.

l Occasionally check for looseness after using a milling chuck.

l Make sure that the workpiece is correctly mounted on the pallet or table.

l Check that vices, fixtures, etc., have no overhang with respect to the table.

l Make sure that the tools are arranged in the tool magazine correctly in accordance with the

tool data set in the TOOL LAYOUT display.

l Check that the lengths of all tools to be used have been measured.

l Move the tool nose to the initial point (X0, Y0) to check the basic coordinate system.

l Perform a test operation after mounting a cutting tool and workpiece.

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2-6 Maintenance Safety

l Always switch off the main power breaker and lock it before carrying out any maintenance

work. This will eliminate the possibility of the machinery being accidentally started by

DANGER

someone else.

l After the power has been switched off for a short while, check the voltage with a multimeter

or similar instrument to make sure that there is no residual voltage. Also discharge the capacitors.

l Maintenance of electrical equipment must be carried out by qualified licensed electrical

engineers only.

WARNING

CAUTION

l Do not remove or modify limit switches, proximity switches, or other safety equipment.

l When carrying out maintenance in high places, always use a suitable ladder or a service

platform, and always wear a helmet.

l Always switch off the main power breaker and lock it before replacing bulbs or other

electrical equipment, and use products with the same specifications as the original.

l Do not start the machine until all of the covers removed for maintenance have been

refitted.

l Wipe up any water or oil spills immediately, and keep the maintenance area and the

workplace clean and tidy at all times.

l Maintenance work should be carried out by qualified personnel in accordance with the

instructions of the person in charge.

l Keep a stock of replacement parts and consumable items.

l Make sure you fully understand how to maintain the machine.

l Do not use compressed air to clean the machine or to remove chips.

l Always use gloves when clearing away chips; never touch chips with bare hands.

l Use only the specified grades of hydraulic oil, lubricating oil, and grease or their

equivalents

l When changing a fuse, check that the new fuse has the correct rating. (Using a fuse with

too high a rating could result in damage to the equipment.)

l Follow the instructions on the instruction plate concerning the brands of oil to be used,

lubrication points, amount to be used, and oil change intervals.

l Check the results of maintenance work in the presence of the person in charge.

l Stop all machine operation before cleaning the machine or the surrounding area.

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2-7 Workplace Safety

l Immediately remove all water and oil spills from the floor, and dry the floor to prevent

accidents.

WARNING

l Use strong service platforms only and make sure that nothing can slip off them.

l Keep combustible materials well away from the work area and any other place where there

are hot chips.

l Always provide sufficient lighting in the work area.

l Always provide sufficient working space and clear access to the machine and peripheral

equipment and store tools and other potential obstacles in a prescribed place away from the machine.

l Never place tools or other potentially dangerous objects on top of the headstock, turret

tool-post or covers. (For lathes)

l Make sure that the nominal cross-sectional area of the power supply cable between the

factory power supply switch and the machine main power breaker is such as to enable a stable supply for operation at the maximum output.

l Protect all cables which will run along the floor from being damaged by chips, since this

could cause short-circuiting.

2-8 Safety Considerations Relating to Chip Conveyor

Before attempting any kind of work related to the chip conveyor, make sure that the chip conveyor is in a complete stop state with power supply shut off. Ignoring this will cause serious

WARNING

injury. While the chip conveyor is operating, never touch or extend your hands into any part of the chip conveyor. Ignoring this will cause your hands or fingers to be caught into the chip conveyor and injured seriously.

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2-9 Safety Equipment

This machine is provided with various safety equipment to protect the operator and the machines.

The safety equipment include interlock devices and emergency stop switches, as well as doors and covers.

l The machine is provided with various devices for the operator’s safety.

Never cancel any of the devices.

WARNING

No. Name Function

1 Operator’s door interlock 1. If the operator’s door is opened during automatic operation, the machine enters

2 Magazine door interlock 1. If the magazine door is opened while the magazine is operating, the magazine

3 Emergency stop buttons

(2 places)

4 Safety plate 1. A safety plate is fixed to the machine with screws to give operators and persons

Failure to observe this instruction could result in serious harm to a human life or body.

Arrangement of Safety Devices

the feed hold state with the spindle stopped.

2. While the operator’s door is open, spindle speed is restricted by the preset safety speed.

stops operating.

2. While the magazine door is open, the magazine cannot be operated.

3. While the magazine door is open, the magazine stops and the axes stop movements.

1. The emergency stop button is provided on each operation panel.

2. When the emergency stop button is pressed, the machine stops in the emergency stop state independent of the selected operation mode (automatic, manual).

nearby warning information that standing near the movable area of equipment and devices is dangerous.

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Safety device locations

Fig. 2-1 Safety Devices

No. Name

1 Operator’s door interlock

2 Magazine door interlock

3 Pallet changer safety cover and door

interlock (2 places)

2-10 Remarks on the Cutting Conditions Recommended by the NC

l Before using the following cutting conditions:

- Cutting conditions that are the result of the Mazatrol Automatic Cutting Conditions

WARNING

Determination Function

- Cutting conditions suggested by the Machining Navigation Function

- Cutting conditions for tools that are suggested to be used by the Machining Navigation Function

Confirm that every necessary precaution in regards to safe machine setup has been taken – especially for workpiece fixturing/clamping and tool setup.

l Confirm that the machine door is securely closed before starting machining.

Failure to confirm safe machine setup may result in serious injury or death.

2-11 Safety Nameplates

Safety nameplates are mounted on the machine to protect the operators and the machine from danger.

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Section 2:

Machine Operation

Page 44

Notes:

Page 45

TABLE OF CONTENTS (MACHINE OPERATION)

1 OUTLINE OF THE MACHINE ................................................................1-1

1-1 Axis Definitions ..................................................................................................1-1

1-2 Names and Locations of Machine Units .............................................................1-2

2 OPERATION PANELS............................................................................2-1

2-1 Locations of Operation Panels...........................................................................2-1

2-2 NC Operation Panel...........................................................................................2-2

2-2-1 Arrang em e nt o f Switch es on the NC Op er atio n Panel...........................................2-3

Page

2-2-2 Names and Functions of Switches and Other Controls on the NC Operation

Panel.....................................................................................................................2-4

2-3 Auxiliary Operation Panel...................................................................................2-9

2-4 Data Input/Output Panel...................................................................................2-10

2-5 Magazine Operation Panel...............................................................................2-11

2-6 Main Power Disconnect Switch........................................................................2-12

2-7 Operator’s Door Interlock.................................................................................2-13

2-7-1 MACHINE SET UP Switch (Key-lock Type Switch).............................................2-13

3 MANUAL OPERATION........................................................................... 3-1

3-1 Inspection before Starting Operation..................................................................3-1

3-2 Switching the Power ON....................................................................................3-3

3-3 Inspection after Switching the Power ON...........................................................3-5

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3-4 Switching the Power OFF..................................................................................3-6

3-5 Zero-Point Return...............................................................................................3-7

3-6 Warmup Operation.............................................................................................3-9

3-7 Spindle Operation............................................................................................3-10

3-7-1 Starti ng th e Spi n dle.............................................................................................3-10

3-7-2 Stoppi ng th e Spi n dl e...........................................................................................3-10

3-7-3 Jogging the Spindle.............................................................................................3-10

3-7-4 Changing the Direction of Spindle Rotation.........................................................3-11

3-8 Feed Operation................................................................................................3-11

3-8-1 Rapid Traverse Operation...................................................................................3-11

3-8-2 Cutting Feed Operation.......................................................................................3-11

3-8-3 Pulse Handle Feed Operation.............................................................................3-12

3-8-4 Clearing the Soft-Limit Alarm...............................................................................3-13

3-9 Coolant System Operation...............................................................................3-15

3-10 ATC Operation.................................................................................................3-16

3-10-1 Manual ATC Operation........................................................................................3-16

3-10-2 Recovering ATC Operation a ft er Inter r u ption.......................................................3-20

3-11 Chip Conveyor Operation (Optional Specifications).........................................3-22

4 PREPARING FOR MACHINING ............................................................4-1

4-1 Procedure for Mounting or Removing a Tool in the Tool Magazine...................4-1

4-1-1 Procedure for Mounting Tools to the Magazine.....................................................4-1

4-1-2 Procedure for Removi ng Tools from th e Magaz ine................................................4-4

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4-1-3 Restrictions on Tools.............................................................................................4-5

4-2 Mounting and Removing Workpieces.................................................................4-6

4-2-1 Dimensional Restrictions on Workpieces...............................................................4-6

4-2-2 Procedure for Mounting and Rem ovi n g Workpi eces..............................................4-7

4-2-3 Measuring Coordinate Values...............................................................................4-7

4-3 Preparing Coolant..............................................................................................4-8

4-3-1 Selection of Coolant..............................................................................................4-8

4-3-2 Replenishing Coolant............................................................................................4-8

4-4 Adjustment of Coolant Nozzle Direction.............................................................4-9

C-3

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- MEMO -

C-4

Page 49

1 OUTLINE OF THE MACHINE

This chapter describes the definition of axes and arrangement of major units.

1-1 Axis Definitions

In the manuals supplied with the machine, the coordinate axes are defined as indicated below.

Note: The coordinate axes are defined assuming that an operator is standing in front of the

machine.

X-axis Saddle movements in the right-and-left direction

Positive direction (+): Saddle movement to the right

Negative direction (-): Saddle movement to the left

Y-axis Column movements in the back-and-forth direction

Positive direction (+): Column movement to the back

Negative direction (-): Column movement to the front

Z-axis Spindle head movements in the up-and-down direction

Positive direction (+): Spindle head movement to the top

Negative direction (-): Spindle head movement to the bottom

-X

-Y

-Z +X

Fig. 1-1 Axis Definitions

1-1

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1-2 Names and Locations of Machine Units

Fig. 1-2 Names and Locations of Machine Units

No. Name No. Name

1 Table 11 Electrical control cabinet

2 Operator’s door 12 Hydraulic unit

3 Spindle 13 Spindle cooling fluid unit

4 Auxiliary operation panel 14 Magazine operation panel

5 NC operation panel 15 ATC unit

6 Data input/output panel 16 Magazine

7 Air unit 17 Magazine door

8 Centralized lubrication unit 18 Coolant system

9 Main power disconnect 19 Tool measuring device

10 Column

1-2

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2 OPERATION PANELS

This chapter describes the arrangement and function of the switches, indicator lamps, and other controls.

2-1 Locations of Operation Panels

The machine has five operation panels as indicated below. Refer to Fig. 2-1.

1. NC operation panel

Used to select the display screen, input the data and operation condition, and to perform other NC related operations. The NC operation panel also has switches used to directly operate the machine in the manual mode.

2. Auxiliary operation panel

Has switches used for controlling the operation other than the operations controlled by the switches on the NC operation panel.

3. Data input/output panel

Used for connecting an external data input/output device.

4. Magazine operation panel

Used for mounting and removing a tool to and from the magazine.

Magazine

Fig. 2-1 Locations of Operation Panels

NC operati on p anel

Data input/output panel

uxiliary operation panel

2-1

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Cautions on using the operation panel

• The operation panel can be locked/unlocked using the stay provided at the lower section of the

operation panel.

• When moving the operation panel, pay attention so that you will not get your fingers caught by

the operation panel.

• When using the operation panel after pulling it out, lock it in the pulled out position. Do not try

to move the operation panel while it is locked, otherwise the lock mechanism may be damaged.

Lock position

NC operation panel

Lock release position

Auxiliary operation panel

Fig. 2-2 Operation Panel

2-2 NC Operation Panel

l Do not operate the switches on the NC operation panel with gloves on. If you operate the

switches with gloves on, it could cause troubles such as malfunctioning of the machine.

WARNING

l To prevent operation errors, make sure you press the switch you intend to press.

For details of NC operation, refer to Part 3 “OPERATING NC UNIT AND PREPARATION FOR AUTOMATIC OPERATION”.

Data input/output panel (inside the cover)

2-2

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2-2-1 Arrangement of Switches on the NC Operation Panel

Fig. 2-3 NC Operation Panel

13 6 16

2-3

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Membrane Keys on NC Operation Panel

22 25

1820 19 24

Fig. 2-4 Membrane Keys on NC Operation Panel

36 33

2623

2-2-2 Names and Functions of Switches and Other Controls on the NC Operation Panel

Some of the keys on the NC operation panel have small indicator lamps on the top left area.

If the function of such a key is valid, the indicator lamp in the key is lit. If the indicator lamp is unlit, it indicates that the function is invalid.

Example: Indicator lamp ON Indicator lamp OFF

The function is valid The function is invalid

Also, some of the buttons on the NC operation panel have indicator lamps built into them. W ith such buttons, the indicator lamp lights when the button is pressed or the function of that button is valid. The indicator lamp is unlit when the function of the button is invalid.

Note: The power ON which has the built in indicator lamp differs from the switches with built in

indicator lamp explained above.

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Table 2-1 Names and Functions of the Switches on the NC Operation Panel

The numbers in the table below correspond to the numbers given in Figs. 2-3 and 2-4.

No. Name Function

1 Power ON button • Used to switch on the power to the NC unit.

When this button is pressed, the “READY” indicator lamp comes on several

seconds after the pressing of it.

The indicator lamp in this button comes on when the main power disconnect is

switched to ON, indicating that the power is being supplied to the machine.

• The indicator lamp goes off when this button is pressed.

2 Power OFF button • Used to switch off the power to the NC unit.

The indicator lamp in the power ON button comes on when the power OFF button

is pressed.

3 Display selector key • Used to select the screen to be displayed.

When this key is pressed, the display selection menu is displayed.

4 Menu keys • Used to select one of menu items being displayed.

5 Menu selector key • Used to change the menu presently displayed over to another one.

6 Program protect switch (with key) • Used to protect the programs and data stored in the NC memory.

I ： Enables writing of the program and data. O ： Disables writing of the program and data.

7 CYCLE START button (green)

CYCLE START indicator lamp (green)

• Used to start the machine in the automatic operation mode.

While the machine is operating in the automatic mode, the CYCLE START

indicator lamp is lit.

The CYCLE START indicator goes off when the automatic operation is interrupted

or has been completed.

8 FEED HOLD button (red)

FEED HOLD indicator lamp (white)

9 Axis movement buttons • Used to move an axis in the manual operation mode.

• Used to suspend axis feed during automatic operation.

While the axes are stopped in the feed hold mode, the FEED HOLD indicator

lamp is lit. In this state, the CYCLE START indicator lamp is unlit.

The axis, selected by one of these buttons, keeps moving while the button is held

pressed and stops when it is released.

10 All-axis zero-point return button • Used to return all axes to the first zero-point in the manual operation mode.

• The button is valid only after executing the zero-point return operation once.

• Press this button after pressing the first zero-point return key (HOME 1), and the

axes return to the first zero-point in the following sequence: the Z-axis first returns to the zero-point. Once the Z-axis movement has completed, the X- and Y-axis (and the 4th-axis if additional axis is used) return to the zero-point simultaneously.

STOP button

START button

12 Emergency stop button • Used to stop the machine in case of emergency.

• Used to stop the spindle rotation in the manual operation mode.11

• Used to start the spindle rotation in the manual operation mode.

• The indicator lamp in the button lights while the spindle is rotating.

When this button is pressed, all machine operations are stopped immediately and

alarm message “003 EMERGENCY STOP” is displayed.

• To reset the emergency stop state, turn the button clockwise (indicated by the

arrow symbols) and press the RESET key.

13 MACHINE SET UP switch • Used to make the door interlock function (the function to prohibit opening of the

door) valid or invalid.

14 DOOR UNLOCK button (option) • Used to unlock the door.

15 CONVEYOR switch (option) • Used to start and stop the chip conveyor.

16 TOOL UNCLAMP switch • Used to clamp and unclamp a tool in the spindle in the manual operation mode.

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No. Name Function

17 RESET key • Used to reset the NC to the initial state.

If an alarm is displayed, eliminate the cause of the alarm and press this key to

clear the alarm display.

18 Spindle speed override keys • Use to adjust the spindle speed.

In manual operation: The keys are used to set the required spindle speed.

The spindle speed is set in increments of “10” rpm.

In automatic operation: The keys are used to change the spindle speed

specified in the program in increments of 10% in the range from 0 to 150%.

： Spindle speed increases.

： Spindle speed decreases. The actual spindle speed is displayed on the screen.

19 Cutting feedrate override keys • Used to adjust the feedrate.

In manual operation: The keys are used to set the required feedrate. In automatic operation: The keys are used to change the feedrate specified in

the program in increments of 10% in the range from 0 to 200%.

： Feedrate increases.

： Feedrate decreases. The actual spindle speed is displayed on the screen. NOTE: The term “override” means an operation in which spindle speed or

feedrate specified in a program is changed to meet the actual cutting conditions.

20 Rapid traverse override keys • Used to adjust the rapid traverse rate.

The override value, set in terms of the percent to the available maximum rapid

traverse rate, is displayed on the screen.

： Override value increases.

： Override value decreases.

21 Pulse handle feed multiplication ratio

setting keys

• Used to select the pulse handle feed mode and the pulse weight (distance to be

moved per pulse).

： Selects 0.001 mm (0.001° for the 4th-axis) per division of the

pulse handle.

： Selects 0.01 mm (0.01° for the 4th-axis) per division of the

pulse handle.

： Selects 0.1 mm (not selectable for the 4th-axis) per division of

the

pulse handle.

• To move an axis by using the pulse handle, press any of these keys and select

the axis to be moved with the AXIS SELECT switch. After that turn the pulse handle and the selected axis moves.

• If the AXIS SELECT switch is set in the “OFF” position with any of these keys

pressed, an axis moves precisely the set distance each time an axis movement button is pressed (step feed mode).

22 RAPID traverse key • Used to select the rapid traverse mode.

If an axis movement button is pressed after pressing this key, the selected axis

moves at a rapid traverse rate.

23 HOME 1 key • Used to return an axis to the first zero-point (machine origin) in the manual

operation mode.

• Press an axis movement button after pressing this key, and the selected axis

returns to the first zero-point.

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No. Name Function

24 MDI key • Used to select the MDI mode.

Press this key to automatically execute the manually set data.

25 MEMORY key • Used to select the memory operation mode.

Press this key to execute a program stored in the NC memory.

26 TAPE key • Used to select the tape operation mode.

Press this key to execute a program punched on paper tape, stored in an external

device such as micro disk.

NOTE: This mode of operation is selectable only for EIA/ISO programs.

27 SINGLE BLOCK key • Used to select the single block mode.

Press this key to select the single block mode in which a program is executed

block by block.

28 SHIFT key • Used to enter the address data indicated at the bottom right of an address key.

29 COOLANT STOP key • Used to switch on and off coolant supply.

30 COOLANT menu key • Used to display the coolant menu on the screen.

Coolant menu is displayed on the screen when the COOLANT menu key is

pressed.

31 MACHINE menu key • Used to display the menu of various machine operations.

The machine operation menu is displayed when the MACHINE menu key is

pressed.

32 MF1 (machine function) key • Used as an auxiliary key meeting the selected specifications.

33 INPUT key • Used to set the data entered and displayed in the data input area.

This key must be pressed after entering the data with the data keys.

34 CLEAR key • Used to cancel the data displayed in the data input area.

Press this key if incorrect data has been entered to the data input area.

• This is also used to release the machine alarm.

35 Address/numeric data keys • Used to enter the address data (alphabetic characters) and numeric data.

36 CANCEL key • Used to cancel the data displayed in the data display area.

• Press this key if incorrect data has been set by mistake or to delete the previously

set data.

37 Cursor keys • Used to call the cursor on the screen as well as to move the cursor on the screen.

How the cursor moves in response to the pressing of each of the cursor keys is

indicated below:

： The cursor moves to the left in the same line. If this key is pressed while the cursor is positioned at the left end, the cursor

moves to the right end of the preceding line.

： The cursor moves to the right in the same line. If this key is pressed while the cursor is positioned at the right end, the

cursor moves to the left end of the next line.

： The cursor moves up to the preceding line.

： The cursor moves down to the next line.

38 VFC key • Used update the cutting conditions (surface speed, feedrate) in a program to the

values adjusted using the override keys.

When this key is pressed after adjusting the spindle speed and/or feedrate during

automatic operation by using the override keys, the value in the program are updated to the adjusted value.

NOTE: This key is valid only for MAZATROL programs.

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No. Name Function

39 Machine

Status Indicator Lamps

40 WINDOW key • Used to display a window on the screen.

41 Page keys • Used to call the previous or next page of a display that consists of more than one

READY indicator lamp

HDD WARM UP indicator lamp

ALARM indicator lamp

• Comes on when the CNC gets ready for controlling the machine.

• Comes on when the hard disk is warmed by the heater.

If ambient temperature is low and the hard disk cannot start correctly, it is warmed by the heater.

• Comes on when an alarm occurred.

If an alarm is detected by the CNC, the contents of the detected alarm are displayed on the screen and, at the same time, this indicator lamp lights.

page.

： The previous page is called.

： The next page is called. These keys have different function on the MAZATROL program screen:

： The cursor moves to the beginning of the previous unit.

： The cursor moves to the beginning of the next unit.

42 Tablet pointer

43 TAB key • Provides the same function as a TAB key in a keyboard.

• Used instead of a mouse or a track ball.

Pad Cursor operation is possible by moving your finger on the pad.

Left button key Provides the same function as a mouse left button.

Right button key Provides the same function as a mouse right button.

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2-3 Auxiliary Operation Panel

Fig. 2-5 Auxiliary Operation Panel

Table 2-2 Names and Functions of the Switches on the Auxiliary Operation Panel

o. Name Function

1 Pulse handle Used to move the axis selected with the AXIS SELECT switch.

Axis movement distance is determined by the rotation amount of the pulse handle.

AXIS SELECT switch Used to select an axis to be operated by using the pulse handle.

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2-4 Data Input/Output Panel

Fig. 2-6 Data Input/Output Panel

Table 2-3 Names and Functions of Connectors on the Data Input/Output Panel

No. Name Function

1 Interface An interface used to connect an external device such as FDD (floppy disk

drive), PTP/PTR, and printer.

2 Service outlet (100 V AC) A service outlet supplying 100 V AC.

Do not connect a device whose rating is larger than 2 A.

3 No-fuse breaker A circuit interrupter having 2 A capacity.

This breaker is used to shut off the circuit of 100 V AC service outlet.

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2-5 Magazine Operation Panel

A U T O

R E V E R S E

F O R W A R D

M A N U A L

Fig. 2-7 Magazine Operation Panel

Table 2-4 Names and Functions of Switches on the Magazine Operation Panel

No. Name Function

1 TOOL SELECT switch Used to enable manual magazine rotation operation (manual magazine

operation interruption).

2 MANUAL indicator lamp Goes on when the TOOL SELECT switch is placed in the “MANUAL” position.

If the machine is in the standby state (manual magazine operation interruption), the indicator lamp flashes.

3 FORWARD button Used to rotate the magazine in the forward direction. The magazine rotates

continuously if the button is held pressed.

The button is valid only when the following conditions are satisfied:

1. The TOOL SELECT switch is in the “MANUAL” position.

2. The MANUAL indicator lamp is lit or flashing.

3. The magazine door is closed.

4 REVERSE button Used to rotate the magazine in the reverse direction.

With an exception of the direction in which the magazine rotates, the function and the conditions in which the button is valid are the same as the FORWARD button.

5 EMERGENCY STOP button Used to stop the machine immediately in an emergency.

Press this button if incorrect operation has been attempted, abnormal noise is observed, collision is going to take place, or in other emergency cases.

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2-6 Main Power Disconnect Switch

Main power disconnect switch

WARNING

Fig. 2-8 Location of Main Power Disconnect Switch

The functions of the main power disconnect switch are indicated below.

• The power is supplied to the machine via

the main power disconnect switch. Therefore, this switch shuts off power supply to the machine if the switch is set to the OFF position.

• In daily operation, this switch should be

turned ON first to enable machine operation and turned OFF last to completely stop the machine.

• The switch will be tripped if excessive load

current flows. To reset the switch after tripping, turn the switch lever into the RESET position and then back to the ON position.

• The switch has the holes to allow installation of a padlock when the switch is in the OFF

position.

l When maintenance work must be carried out in the electrical control cabinet or when

repairing the machine, be sure to set the main power disconnect switch in the OFF position and lock it in that position with the padlock

Fig. 2-9 Main Power Disconnect Switch

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2-7 Operator’s Door Interlock

2-7-1 MACHINE SET UP Switch (Key-lock Type Switch)

This switch is provided for set up work and test run of a new program. During daily production operation, place the switch in the “O” position and remove the key. A responsible person must keep the key.

1. Operator’s door interlock specification

Table 2-5 Operator’s Door Interlock Specification

MACHINE SET UP

Fig. 2-10 MACHINE SET UP Switch

Door State

Open

↓

Open

Operation Mode

Manual The following operations are disabled:

Automatic The machine is placed in the feed hold state and

Manual If the operator's door is opened during spindle

Automatic If the operator's door is opened during spindle

ManualClose

Automatic

SET UP Switch Position

- Spindle rotation

- ATC operation

If an attempt is made to carry out any of these operations, an alarm occurs and the following alarm message is displayed:

232 MACHINE DOOR INTERLOCK

NOTE: Axis rapid traverse is permitted at a safe

speed.

the cycle start of the program is not allowed.

If the CYCLE START switch is pressed, an alarm occurs and the following alarm message is displayed:

232 MACHINE DOOR INTERLOCK

rotation or ATC cycle, the operation in execution is stopped and the following alarm message is displayed:

232 MACHINE DOOR INTERLOCK

NOTE: Axis rapid traverse is permitted at a safe

speed.

rotation or ATC cycle, the operation in execution is stopped.

The axis movement is placed in the feed hold state, and the following alarm message is displayed:

232 MACHINE DOOR INTERLOCK

There are no restrictions on operation due to the door interlock function.

If an attempt is made to operate the machine using ATC menu keys, an alarm occurs and the following alarm message is displayed:

232 MACHINE DOOR INTERLOCK

NOTE: Axis rapid traverse is permitted at a safe

speed.

If the SET UP switch is in the " I " position, operation is executed in the single block mode.

NOTE: Axis rapid traverse is permitted at a safe

speed.

The single block mode can be canceled by pressing the CLEAR key after closing the door.

If the operator's door is opened during ATC cycle, this operation is stopped.

NOTE: Axis rapid traverse is permitted at a safe

speed.

If the operator's door is opened during ATC cycle, this operation is stopped.

Single block mode is permitted at a safe speed.

The single block mode can be canceled by pressing the CLEAR key after closing the door.

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2. Actions to be taken after an occurrence of door interlock function related alarm

To continue the operation after the occurrence of an alarm caused by opening the operator’s door, close the door and clear the alarm message. The procedure to be followed to continue the interrupted operation is indicated below.

• In automatic mode:

Press the cycle start switch.

• In manual mode:

Complete the interrupted operation by using the menu key or appropriate operation switch.

If the operation has stopped during ATC cycle, complete the cycle using the procedure indicated above.

If it is not necessary to continue the operation after the occurrence of an alarm, simply press the reset key to clear the alarm message.

l Before carrying out setup, make sure that the operator’s door is closed.

l In operation while the operator's door is open, pay sufficient care to avoid the following:

WARNING

- To be hit by scattering chips

- To be caught or crushed by moving unit

- To touch rotating tool

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3 MANUAL OPERATION

This chapter describes the items to be checked before starting the operation and also manual operation procedure.

3-1 Inspection before Starting Operation

Refer to Fig. 3-1.

＜Procedure＞

(1) Check the oil level for the oil tanks indicated below by the oil level gauges. If the oil level is

lower than the specified level, add the specified oil.

For the procedure used to add the oil, refer to the Maintenance Manual.

• Centralized lubrication unit oil tank

• Hydraulic unit oil tank

• Spindle cooling fluid tank

• Coolant tank

(2) Check that the doors and covers indicated below are securely closed.

• Operator’s door

Close the door so that there is no gap.

• Control panel door

Close the door and secure it in the closed position with the bolt.

• Magazine door

Lock the door with the handle so that the door cannot be opened.

(3) Make sure that all safety covers and safety devices are installed properly. For the safety

covers and safety devices, refer to Part 1, Section 2-9 “Safety Equipment”.

(4) Make sure that the compressed air is supplied to the machine. Also make sure that the

pressure gauge at the air inlet port indicates 5 kgf/cm than 5 kgf/cm lower than 4 kgf/cm

(71.1 PSI), the air source capacity must be increased. If the air pressure is

(56.9 PSI), never operate the machine since malfunctions will occur.

(5) Make sure that the pressure gauge of the hydraulic unit indicates 0 kgf/cm

If the pressure gauge indication is not 0 kgf/cm

(71.1 PSI). If the air pressure is lower

(0 PSI).

(0 PSI) while it is stopped, the pressure gauge will be faulty. In this case, it is necessary to change the pressure gauge. For the procedure of changing the pressure gauge, refer to the Maintenance Manual supplied separately.

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Magazine

gaug

Hydraulic pressure gauge

Hydraulic until oil level gauge

Control panel door

Coolant tank oil level gauge

Spindle cooling fluid level

Fig. 3-1 Inspection before Starting Operation

Operator’s door

Centralized lubrication unit oil level gauge

Air pressure gauge

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3-2 Switching the Power ON

l Cables or wires with damaged insulation could cause current leakage or electrical shocks.

Always check that the insulation is sound.

DANGER

WARNING

CAUTION

l There are high voltage terminals in the electrical control cabinet, transformers, motors,

relay boxes, etc. Never touch these terminals.

l Do not touch the switches with wet hands.

l In order to prevent the entry of water, oil, chips, dust, and other foreign matter into the

electrical control cabinet and other machine units, make sure to close the doors and covers of the CNC unit and the electrical control cabinet.

l If the instructions on the factory power distribution board are given on such as a safety

plate, follow these instructions.

＜Procedure＞

(1) Switch the power ON at the factory power distribution board.

(2) Turn the main power disconnect to the ON position.

→ The fan starts rotating and the

lights.

(POWER ON) button on the NC operation panel

(3) Press the

→ The indicator lamp in the → The READY lamp, which indicates that the machine is ready for operation, lights. → The POSITION display is given.

→ The

ZERO RETURN

* For the machine equipped with the absolute position detection specification (option), the

→ The hydraulic unit pump and the centralized lubrication unit pump start.

(POWER ON) button on the NC operation panel.

(POWER ON) button goes off.

(first zero-point return) key lights and the following message is displayed.

(memory operation) key lights.

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If an abnormality is found when the hydraulic unit starts, press the emergency stop button. The hydraulic unit stops operating.

If the “EMERGENCY STOP” message is displayed in red at the lower left area of the POSITION screen when the power is switched on, it indicates that one of the emergency stop buttons is locked in the activated position. In this case, clear the emergency stop status and unlock the emergency stop button.

To reset the emergency stop button, turn the emergency stop button in the direction indicated by the arrow symbols given in it. When it is turned approximately 90 degrees, the button comes out to be unlocked.

(POWER OFF) button or the

After that press the STOP” message is cleared. The hydraulic unit starts operating again.

Note: Before switching on the power for the first time after installation, carry out the inspection

that is indicated in the Maintenance Manual.

(RESET) key on the NC operation panel, and the red “EMERGENCY

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3-3 Inspection after Switching the Power ON

Refer to Fig. 3-2.

After switching the power ON as described in Section 3-2 “Switching the Power ON”, carry out the following inspection.

• Make sure that the “READY” indicator lamp is lit.

• Make sure that the POSITION screen is displayed.

• Make sure the hydraulic unit pressure and the air pressure regulated by the air unit are correct.

A. Hydraulic pressure: 70 kgf/cm

B. Air pressure: 5 kgf/cm

(996 PSI)

(71.1 PSI)

POSITION screen

Hydraulic pressure

ir pressure

Fig. 3-2 Inspection after Switching the Power ON

READY indicator lamp

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3-4 Switching the Power OFF

After finishing day’s operation, follow the procedure indicated below to shut off the power.

l There are high voltage terminals in the electrical control cabinet transformers, motors,

relay boxes, etc. Never touch these terminals.

DANGER

l Do not touch the switches with wet hands.

＜Procedure＞

(1) Make sure that all machine operations (program operation, input/output with external devices,

etc.) have been completed.

(2) Press the

→ The indicator lamp in the

(3) Turn the main disconnect to the OFF position after the screen display has been turned off

completely.

Note: If the main disconnect is turned OFF before the screen display is completely turned off,

correct NC functions cannot be guaranteed. It will take about one minute before the screen display is turned off completely.

(4) Shut off the power at the factory power distribution board.

* If the machine is equipped with the automatic power off function (option), refer to the manual

prepared separately for the option specifications.

(POWER OFF) button on the NC operation panel.

(POWER ON) button lights.

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3-5 Zero-Point Return

After switching on the power, it is necessary to carry out the zero-point return operation first to register the machine zero point to the NC.

The stored machine zero point is lost when the power is switched off.

Carry out zero-point return operation for all axes (X-, Y-, Z-, and 4th-axis (option)) to the first zero point.

l Do not press the switches while wearing gloves. This could cause machining malfunction

and other troubles.

WARNING

CAUTION

l To prevent machine malfunction, confirm the function of the switches before using them.

l With the machine equipped with the optional absolute position detection function, the

machine zero-point data is not lost even when the power is switched off. Accordingly, it is not necessary to carry out the zero-point return operation.

l If battery voltage is lowered, the machine zero-point data may be lost. If the “ZERO

RETURN” message is displayed, the machine zero-point data is lost. In this case, carry out the zero-point return operation.

The “ZERO RETURN” message is displayed in green at the lower right area of the POSITION screen when the power is switched on. Carry out the zero-point return operation for the X-, Y-, Zand 4th-axis (option) by pressing the axis movement button on the NC operation panel.

The procedure for the first zero-point return is indicated below.

＜Procedure＞

(1) Press the

Note that immediately after the power is switched on, the key is in the pressed state. The green lamp lights to indicate that the key has been pressed.

(2) If an axis is close to the zero-point, first momentarily press the -X, -Y, -Z or -4th (optional) key

corresponding the axis to be returned to the zero-point.

(first zero-point return) key.

→ The axis moves in the negative direction and then moves in the positive direction to the

zero-point. On completion of the zero-point return cycle, the green zero-point return indicator lamp on the NC operation panel will light. Refer to Fig. 2-3.

Once an axis starts moving in the positive direction, the axis will continue moving to the zero-point even if the axis movement key is released. The axis moves to the zero-point at the zero-point approach speed (0.2 m/min (11.8 IPM)). Refer to Fig. 3-3.

(3) If an axis is not close to the zero-point, momentarily press the -X, -Y, -Z or -4th (optional) key

corresponding the axis to be returned to the zero-point first. Next, hold the +X, +Y, +Z, or +4th (optional) key corresponding the axis to be returned to the zero-point pressed. Refer to Fig. 2-3.

• The axis will stop moving if the key is released.

• The key can be released after the axis feedrate is decelerated to the zero-point approach

speed (0.2 m/min (11.8 IPM)). The axis continues moving to the zero-point even if the key is released. Refer to Remark 3.

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Remark 1: If an axis is moved beyond the travel range by mistake, the soft-limit function operates

(

)

to stop the axis. If this occurs, the soft-limit alarm indication is displayed at the lower left area in the screen. The procedure to be followed for clearing the soft-limit alarm is explained in section 3-8-4 “Clearing the Soft-Limit Alarm”.

Remark 2: For the machine equipped with the optional absolute position detection function, the

first zero-point return operation is not necessary. In this case, the “ZERO RETURN” message is not displayed after switching on power.

Remark 3: Zero-point return speed

In the zero-point return cycle, axis feedrates are controlled in the manner as shown in Fig. 3-3 below.

If the machine zero-point data is lost

Fig. 3-3 Zero-point Return Cycle (If the machine zero-point data is lost)

• If the machine zero-point data is retained:

• If the machine zero-point data is lost:

Before the detection of machine zero-point dog:

After the detection of machine zero-point dog:

*1： The value set for machine parameter M2.

*2： The value set for machine parameter N8.

15 m/min (315 IPM)

0.2 m/min (11.8 IPM) zero-point approach speed

Zero-point dog Machine zero-point

NM210-00100

The axis moves to the zero-point at 15 m/min (315 IPM) (*1)

The axis moves at 15 m/min (315 IPM) (*1)

The axis moves at 0.2 m/min (11.8 IPM) (zero point approach speed) (*2)

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3-6 Warmup Operation

When starting the machine operation after it has been stopped for a long period, it is necessary to warm up the machine in the schedule as indicated below.

Since the machine has not been operated for a long period, the slideways are not lubricated appropriately which will cause stick-slip in axis movement as well as abnormal wear of the slideways if production is started immediately. In addition, thermal expansion must be taken into consideration. At the beginning of machine operation, thermal expansion is not stabilized and thus workpieces machined during such period cannot be finished accurately.

By conducting warm up, the slideways can be appropriately lubricated to ensure smooth and accurate axis movement. It also stabilizes the machine from the viewpoint of thermal expansion to give consistently high accuracy.

Warm up must be conducted before starting daily operation to produce accurate products from the first output. In cold areas, warm must be conducted sufficiently.

Recommended warm up schedule

Warm up period Approx. 30 minutes

Spindle speed 1000 min–1 (rpm) → 3000 min–1 (rpm) → 8000 min–1 (rpm) → Max. speed

Axis stroke range Entire axis stroke

l While carrying out warm up, observe the machine operating status, lubrication, and others.

CAUTION

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3-7 Spindle Operation

This section describes the procedure used for starting and stopping the spindle and also the procedure for changing the spindle rotating direction.

3-7-1 Starting the Spindle

To start the spindle when carrying out simple machining operation, follow the steps indicated below.

＜Procedure＞

(1) Press one of manual operation mode selector keys.

(2) Adjust the spindle speed by using the spindle override keys.

• The spindle speed can be adjusted in the range from 0 to maximum spindle speed in

increments of 10 min

： Spindle speed increases.

： Spindle speed decreases.

• Spindle speed is displayed in units of 10 min

• The set spindle speed is displayed below the menu on the NC screen.

(3) Press the

(SPINDLE START) button.

→ The spindle starts rotating.

While the spindle is rotating, the indicator lamp in the button remains lit.

3-7-2 Stopping the Spindle

To stop the spindle, follow the step indicated below.

(1) Press the

→ The spindle stops rotating.

Note 1: The spindle speed displayed below the menu on the NC screen remains unchanged even

when the spindle stops rotating.

(SPINDLE STOP) button.

–1

(rpm).

–1

(rpm).

Note 2: The spindle does not stop rotating even if the SPINDLE STOP button is pressed while in

automatic operation.

3-7-3 Jogging the Spindle

To jog the spindle for such as checking the tool mounting conditions in the spindle or measuring the tool nose position, follow the steps indicated below.

＜Procedure＞

(1) Press one of the manual operation mode selector keys.

(2) Select the POSITION screen and press the [SPDL JOG] menu key.

→ The spindle jogs while the button is held pressed, and stops jogging when the key is

released.

• Spindle jog speed is 50 min

–1

(rpm).

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3-7-4 Changing the Direction of Spindle Rotation

To change the direction of spindle rotation, follow the step indicated below.

(1) Select the spindle rotation direction by pressing the [SPNDL REV] menu key on the POSITION

screen.

• The lamp in the menu is lit: The spindle rotates in the forward direction.

• The lamp in the menu is unlit: The spindle rotates in the reverse direction.

3-8 Feed Operation

3-8-1 Rapid Traverse Operation

To move an axis at a rapid traverse rate for such as mounting a tool to the spindle or carrying out positioning, follow the steps indicated below.

(1) Press the

→ The rapid traverse mode is selected.

(2) Adjust the rapid traverse rate.

It is possible to adjust the rapid traverse rate with the rapid traverse override keys in the range from

6% to 100% of the maximum traverse rate 100％, 50％, 25％, 12％, 6％

The values of 25％, 12％, and 6％ are set for parameters and can be changed if required.

： The rapid traverse rate increases by one step.

： The rapid traverse rate decreases by one step.

(3) Move an axis to the required position by pressing the axis movement button.

• The axis is continuously moved while the axis movement button is held pressed and it

stops moving when the button is released.

• The actual axis position is displayed on the NC screen such as the POSITION display.

(RAPID) key.

3-8-2 Cutting Feed Operation

To move an axis at a controlled feedrate to carry out simple cutting, follow the steps indicated below.

(1) Select any of the

(2) Place the AXIS SELECT switch in the required axis position. (See Fig. 2-5.)

→ The jog (cutting feed) mode is selected.

(3) Adjust the feedrate.

• It is possible to adjust the feedrate in 29 steps of preset feedrate in the range from 0 to

2000 mm/min (0 to 78.74 IPM) by using the cutting feedrate override keys.

： The feedrate increases by one step.

： The feedrate decreases by one step.

• The actual feedrate is displayed below the menu on the NC screen.

(pulse handle feed multiplication ratio setting) keys.

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(4) Move an axis to the required position by pressing the axis movement button.

→ The axis is continuously moved while the axis movement button is held pressed and it stops

moving when the button is released.

• The actual axis position is displayed on the NC screen such as the POSITION display.

(5) Upon completion of cutting feed operation, be sure to set the AXIS SELECT switch in the

(OFF) position.

3-8-3 Pulse Handle Feed Operation

To move a cutting tool precisely by using the pulse handle, follow the steps indicated below.

(1) Press one of the pulse handle feed multiplication ratio setting keys.

• There are three such keys and they are used to determine axis movement distance per pulse

when the pulse handle is used to move an axis.

(2) Select the axis to be moved.

: Selects 0.001 mm (0.0001 in.) (0.001° for the 4th-axis) per division of the pulse

handle.

: Selects 0.01 mm (0.001 in.) (0.01° for the 4th-axis) per division of the pulse

handle.

: Selects 0.1 mm (0.01 in.) (not selectable for the 4th-axis) per division of the

pulse handle.

• Place the AXIS SELECT switch in the required

axis position.

“¡”

Fig. 3-4

(3) Turn the pulse handle clockwise or counterclockwise.

→ Clockwise rotation:

The axis moves in the positive direction. Counterclockwise rotation:

The axis moves in the negative direction.

• The selected axis moves at a feedrate

corresponding to the pulse handle rotating speed.

• The actual axis position is displayed on the NC

screen such as the POSITION display.

(4) Upon completion of pulse handle feed operation, be sure to set the AXIS SELECT switch in the

“¡” (OFF) position.

3-12

Fig. 3-5

Page 77

3-8-4 Clearing the Soft-Limit Alarm

1. Soft-limit

The soft-limit refers to the stroke limit that is monitored by the NC.

With X-, Y-, and Z-axis, movable range is defined so that an axis will not move to the “O.T. limits”.

If an attempt is made to move an axis beyond the movable range, soft-limit alarm occurs and further

axis movement is made impossible.

The soft-limit becomes valid when the power is switched on.

X-axis -O.T.

O.T

Z-axis+O.T

Z-axis -O.T.

Machine

Overtravel limit

Movable range

X=0,Z=0

X-axis +O.T.

Y-axis -O.T Y-axis +O.T.

Parameter

NOTE : Parameters M8

Movable range in the

Movable range in the negative direction

Second zero-point

and M9 are set for the individual axes

Y=0

ositive direction

Y-axis Second zero-point

Fig. 3-6 Soft-Limit

l Never try to change the setting for parameters M8 and M9. If setting of these parameters

is changed, it could cause serious damage to the machine.

CAUTION

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2. Cleaning the soft-limit alarm

If an axis fails to move continuously due to the occurrence of a soft-limit alarm, move the axis in the opposite direction.

Example: Soft-limit alarm has occurred during axis feed of the X-axis in the positive direction

by using the pulse handle.

(1) An axis does not move even when the pulse handle is rotated in the +X direction.

The following alarm message is displayed at the lower left area in the screen.

101 SOFT LIMIT +X

(2) Turn the pulse handle in the -X direction.

(3) The axis starts moving in the -X direction and the alarm message indicated above is

cleared.

(4) This completes the restoration from the soft-limit alarm state.

It is possible to clear the soft-limit alarm in the following operation modes.

: Manual pulse feed mode (includes cutting feed)

: Rapid traverse mode

: Zero-point return mode (includes second zero-point return)

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3-9 Coolant System Operation

1. (COOLANT MENU) key

The following menu is displayed when this menu key is pressed.

With an exception of [ALL COOL AUTO ON] and [ALL COOL AUTO OFF] menu keys, if a menu key is pressed, the characters in it are highlighted and they return to the normal display when it is pressed once again.

COOLANT

AUTO

COOLANT

MANUAL

ALL COOL

AUTO ON

ALL COOL

AUTO OFF

Note 1: All menu items of “△△△ AUTO” (only “COOLANT AUTO” with the standard specification)

are valid (menu keys are lit) when the power is turned on.

Note 2: To change the menu display between menu 1 and menu 2, press the menu selection key

at the right end.

• [COOLANT AUTO] menu key

Flood coolant is not supplied even when the M08 command is executed unless this menu key is lit.

• [COOLANT MANUAL] menu key

When this menu key is pressed, it illuminates and flood coolant is supplied.

• [ALL COOL AUTO ON] menu key

When this menu key is pressed, all menu keys of “△△△ AUTO” (only “COOLANT AUTO” with the standard specification) are lit and become valid.

• [ALL COOL AUTO OFF] menu key

When this menu key is pressed, all menu keys of “△△△ AUTO” (only “COOLANT AUTO” with the standard specification) return to the normal display and become invalid.

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3-10 ATC Operation

3-10-1 Manual ATC Operation

1. CNC Signal window

(1) Click the [Window] menu on the POSITION screen.

(2) In the pull-down menu, click the [CNC Signal] item.

(3) The CNC Signal window is displayed.

2. Axis movement

A. Move the Z-axis to the second zero-point.

(1) Press the (MACHINE MENU) key while the NC is in the manual mode, and the following

menu is displayed.

F0 ATC

F3 #2 ZERO

RETURN

(2) Press the [#2 ZERO RETURN] menu key.

(3) Hold the

(axis movement) key pressed.

(4) If the second zero-point return lamp in the CNC Signal window lights, it indicates that the Z-axis

has returned to the second zero point.

B. Move the Y-axis to the second zero-point.

(1) Press the

(MACHINE MENU) key while the NC is in the manual mode, and the following

menu is displayed.

F0 ATC

F3 #2 ZERO

RETURN

(2) Press the [#2 ZERO RETURN] menu key.

(3) Hold the (axis movement) key pressed.

(4) If the second zero-point return lamp in the CNC Signal window lights, it indicates that the Y-axis

has returned to the second zero point.

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3. ATC operation

A. Turning the ATC arm to 52ﾟﾟﾟﾟ

The ATC arm cannot be turned to 52ﾟ unless the following conditions are satisfied:

• X- and Y-axis are at the second zero point.

• Spindle is oriented.

• Tool is clamped.

• ATC cover is open.

(1) Follow the same step as (1) in item 2. A (to display the MACHINE menu).

(2) Press the [ATC MENU] menu key, and the following menu is displayed.

MAGAZINE

FORWARD

MAGAZINE

REVERSE

ATC ARM

0 deg.

ATC ARM

52 deg.

ATC ARM

180 CW

ATC ARM

180 CCW

ATC COVR

OPEN

UNCLAMP

(3) Keep pressing the [ATC ARM 52 deg.] menu key until the menu lamp comes on.

B. Turning the ATC arm to 180ﾟﾟﾟﾟ

The ATC arm cannot be turned by 180ﾟ unless the following conditions are satisfied:

• X- and Y-axis are at the second zero point.

• Spindle is oriented.

• Tool is unclamped.

• ATC cover is open.

(1) Follow the same step as (1) in item 2. A (to display the MACHINE menu).

(2) Press the [ATC MENU] menu key, and the following menu is displayed.

MAGAZINE

FORWARD

MAGAZINE

REVERSE

ATC ARM

0 deg.

ATC ARM

52 deg.

ATC ARM

180 CW

ATC ARM

180 CCW

ATC COVR

OPEN

UNCLAMP

(3) Keep pressing the [ATC ARM 180 CW] or [ATC ARM 180 CCW ] menu key until the menu lamp

comes on.

C. Returning the ATC arm to the stand-by position

The ATC arm cannot be returned to the stand-by position unless the following condition is satisfied:

• Tool is clamped.

(1) Follow the same step as (1) in item 2.A (to display the MACHINE menu).

(2) Press the [ATC MENU] menu key, and the following menu is displayed:

MAGAZINE

FORWARD

MAGAZINE

REVERSE

ATC ARM

0 deg.

ATC ARM

52 deg.

ATC ARM

180 CW

ATC ARM

180 CCW

ATC COVR

OPEN

UNCLAMP

(3) Keep pressing the [ATC ARM 0 deg.] menu key until the menu lamp comes on.

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4. Others

A. Perform the ATC cover open operation.

(1) Follow the same steps as (1) and (2) in item 3. A.

(2) Press the [ATC COVR OPEN] menu key.

B. Perform the ATC cover close operation.

(1) Follow the same steps as (1) and (2) in item 3. A.

(2) Press the [ATC COVR CLOSE] menu key.

C. Perform the magazine forward rotation.

(1) Follow the same steps as (1) and (2) in item 3.A.

(2) Press the [MAGAZINE FORW ARD] menu key.

D. Perform the magazine reverse rotation.

(1) Follow the same steps as (1) and (2) in item 3.A.

(2) Press the [MAGAZINE REVERSE] menu key.

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E. Unclamp the spindle tool.

＜If spindle orientation has not been completed＞

(1) Follow the same steps as (1) and (2) in item 3. A.

(2) Press the [UNCLAMP OK] menu key.

(3) Place the TOOL UNCLAMP switch in the

＜If spindle orientation has been completed＞

(1) The spindle can be unclamped only by the operation in

step (3).

F. Clamp the spindle tool.

(1) Place the TOOL UNCLAMP switch in the

G. Orient the spindle nose.

(1) Press the

(2) Press the [M CODE] menu key.

(3) Input “M19.”

(4) Press the CYCLE START button to start the machine in the automatic operation mode.

(MID) key to set the operation to the MDI mode.

position.

Fig. 3-7 TOOL UNCLAMP switch

position.

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3-10-2 Recovering ATC Operation after Interruption

1. Recovering an interrupted ATC operation by pressing the emergency stop button

A. If the emergency stop button has been pressed when the Y-axis and Z-axis were at the

second zero-point respectively:

(1) Select the MDI mode by pressing the

(MDI) key.

(2) Press the [TOOL CHANGE] menu key.

(3) Carry out tool change operation.

Refer to Part 4, section 1-2-3, item 3 “Tool change”.

B. If the emergency stop button has been pressed when the X-axis was moving from the first

zero-point to the second zero-point:

(1) Press the

(first zero-point return) key to select the manual mode.

(2) Confirm the clamp/unclamp of the spindle tool on the CNC Signal window. For the CNC Signal

window displaying method, refer to section 3-10-1, item 1 " CNC Signal window."

(3) Press the

(MACHINE MENU) key, and the following menu is displayed.

This key is not valid unless the operator’s door is closed.

F0 ATC

#2 ZERO

RETURN

(4) Press the [FO] menu key, and the following menu is displayed.

ATC ARM

MTR CW

ATC ARM

MTR CCW

ATC ARM

0 deg.

ATC ARM

52 deg.

ATC ARM

180 CW

ATC ARM

180 CCW

UNCLAMP

(5) When the spindle tool is unclamped (while the ATC arm is turning by 180ﾟ)

Keep pressing the [ATC ARM 180 CW] or [ATC ARM 180 CCW] menu key until the menu lamp comes on. Perform the tool clamp operation. (Refer to section 3-10-1 4-F "Spindle Tool Clamp.") Keep pressing the [ATC ARM 0 deg.] menu key until the menu lamp comes on.

(6) When the spindle tool is clamped (while the ATC arm is turning to 52ﾟ or returning to 0ﾟ)

Keep pressing the [ATC ARM 0 deg.] menu key until the menu lamp comes on.

(7) Press the

(MACHINE MENU) key.

The normal menu is displayed.

C. If the emergency stop button has been pressed while the magazine was rotating:

• Generally, there are no problems for rotating the magazine even if it is stopped halfway.

(1) Confirm that the ATC arm is positioned at 0ﾟ (stand-by position).

If the ATC arm is in any position other than the stand-by position, the magazine does not operate. Move the ATC arm to the stand-by position, then turn the magazine to the commanded position.

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(2) Manually turn the ATC arm to any position.

2. Recovering an interrupted ATC operation by pressing the reset switch

A. If the reset switch has been pressed when the Y-axis and Z-axis were at the second zero-

point respectively:

(1) Follow the same steps as explained in item 1. A.

B. If the RESET switch has been pressed during ATC arm operation (turning):

(1) Follow the same steps as explained in item 1. B.

C. If the reset switch has been pressed while the magazine was rotating:

(1) Follow the same steps as explained in item 1. C.

3. Recovering an interrupted ATC operation by shutting off the power

A. If the power has been shut off when the Y-axis and Z-axis were at the second zero-point

respectively:

(1) Carry out the zero-point return for the X-, Y- and Z-axis.

Refer to Part 2, section 3-5, “Zero-point Return”.

B. If the power has been shut off pressed during ATC arm operation (turning):

(1) Follow the same steps as explained in item 1. B.

(2) Carry out the zero-point return for the X-, Y- and Z-axis.

Refer to Part 2, section 3-5, “Zero-point Return”.

C. If the power has been shut off while the magazine was rotating:

(1) Follow the same steps as explained in item 1. C.

(2) Carry out the zero-point return for the X-, Y- and Z-axis.

Refer to Part 2, section 3-5, “Zero-point Return”.

4. Recovering an interrupted ATC operation by feed hold operation

If the FEED HOLD button is pressed during ATC cycle, the FEED HOLD indicator lamp comes on and all axes stop immediately.

Therefore, ATC does not operate if the FEED HOLD button is pressed. However, magazine operation, spindle orientation, and ATC cover operation are continuously performed. The CYCLE START indicator lamp begins flashing when the FEED HOLD button is pressed. Operation can be restarted by pressing the CYCLE START button.

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3-11 Chip Conveyor Operation (Optional Specifications)

1. Arrangement and function of the switches

NC operation panel

Auxiliary operation panel

Fig. 3-8 Chip Conveyor Operation

Table 3-1 Function of Chip Conveyor Switches

No. Name Function

1 FORWARD Used to run the chip conveyor belt in the forward direction to discharge chips.

2 STOP Used to stop the chip conveyor belt.

3 REVERSE Used to run the chip conveyor belt in the reverse direction.

4 CONVEYOR button

(on the auxiliary operation panel)

When the power is supplied to the conveyor, the indicator lamp above the switch is lit.

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2. Operation procedure

l In daily operation, the chip conveyor must be kept operating in the forward direction

disregarding of whether or not chips are being generated.

CAUTION

l If large volume of chips are put into the chip conveyor at a time, chips will be stuck in the

conveyor, causing the conveyor to stop.

＜Procedure＞

(1) Switch the power ON to the machine.

(2) Make sure that the conveyor can be operated safely.

(3) Press the FORWARD switch.

If this occurs, refer to the operating manual supplied with the chip conveyor to recover the chip conveyor operation.

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4 PREPARING FOR MACHINING

4-1 Procedure for Mounting or Removing a Tool in the Tool Magazine

4-1-1 Procedure for Mounting Tools to the Magazine

Magazine operation panel

R E V E R S E F O R W A R D

A U T O

M A N U A L

Fig. 4-1 Procedure for Mounting Tools to the Magazine

1. Magazine operation panel

＜Procedure＞

(1) Move the X-axis to the tool mountable position (X-axis stroke negative end) by using the

manual pulse handle.

(2) Set the TOOL SELECT switch on the magazine operation panel to the MANUAL position and

make sure that the MANUAL indicator lamp comes on continuously or blinks on and off. Refer to the explanation of the switches on the magazine operation panel.

(3) Use the FORWARD or REVERESE button on the magazine operation panel to rotate the

magazine. Release the button when the tool pocket for the tool to be mounted reaches the most appropriate position. Note that tools must be mounted in the magazine so that they are well balanced.

(4) Open the magazine door.

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(5) Align the tool pocket key with the keyway in the tool and insert the tool into the tool pocket.

(6) Confirm that the tool has been mounted completely in the tool pocket.

(7) Close the magazine door.

If the magazine door is left open, the magazine will not rotate in any operation mode, manual or automatic.

(8) Repeat steps (3) to (7) to mount other tools.

(9) After completing the operation, set the TOOL SELECT switch on the magazine operation panel

to the AUTO position.

(10) If the ATC command or magazine rotation command is given while mounting a tool in the

automatic mode, the MANUAL indicator lamp begins blinking and the machine enters the

standby state waiting for the completion of manual operation. Press the

(CYCLE START) button on the NC operation panel to continue automatic operation after completing the tool mounting operation.

Tool pocket

Key

Keyway

Fig. 4-2 Tool pocket and key

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2. Precautions on Mounting the Tools

When mounting a tool such as a back boring bar or fine boring bar which must be shifted at the bottom of finished hole so that the cutting tip will leave a scratch in tool retraction motion, care must be paid in the direction of the cutting bit.

Since the machine shifts the cutting tool in the +Y direction, mount such tools in the magazine in the manner as illustrated below.

Note: For tools that do not require shift after the completion of machining, the cutting bit may be

directed in any direction.

180

Tip direction

Magazine key

Fig. 4-3

Set the tool tip in the direction 180° from the magazine key.

Shifting direction

Fig. 4-4

-Y

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4-1-2 Procedure for Removing Tools from the Magazine

＜Procedure＞

(1) Tools can be removed from the magazine regardless of whether the NC operation panel is set

to the manual or automatic mode.

(2) Set the TOOL SELECT switch on the magazine operation panel to the MANUAL position and

make sure that the MANUAL indicator lamp comes on continuously or blinks on and off. Refer to the explanation of the switches on the magazine operation panel.

(3) Use the FORWARD or REVERSE button on the magazine operation panel to rotate the

magazine. Release the switch when the tool to be removed reaches the most appropriate position.

(4) Open the magazine door.

(5) Remove the tool from the gripper.

(6) Close the magazine door.

Note 1: If the magazine door is left open, the magazine will not rotate in any operation mode,

manual or automatic.

(7) Repeat steps (3) to (6) to remove other tools.

(8) After completing the operation, set the TOOL SELECT switch on the magazine operation panel

to the AUTO position.

(9) If the ATC command or magazine rotation command is given while removing a tool in the

automatic mode, the MANUAL indicator lamp begins blinking and the machine enters the standby state waiting for the completion of manual operation.

Press the operation after completing the tool removal.

(CYCLE START) button on the NC operation panel to continue automatic

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4-1-3 Restrictions on Tools

Only tools that conform to the dimensional restrictions indicated in the diagram below can be mounted in the magazine.

l Never use a tool or insert that exceeds the specification. Failure will cause a serious

accident.

WARNING

The operator door has the strength that can assure safety to the energy effused by a centrifugal force or other external force when an insert mounted around the periphery of a large diameter tool comes off by some reason during a high-speed rotation of the spindle.

Table 4-1 Restrictions on Tools

Number of Tools

Item

Pitch between pockets 95.25 mm (3.75 in) 95.25 mm (3.75 in)

Tool storage capacity 24 30

Tool selection method Random selection of magazine pocket number,

Tool shank size NT40

Retention bolt Yamazaki ANSI type

Max. tool diameter φ 80mm (3.15 in)

Max. tool diameter with adjacent tools

Max. tool length 350 mm (13.78 in) (from gage line)

Max. mass of tool (includes tool holder and retention bolt)

Magazine drive AC servo motor

Tool storage method Stored in tool clamber

Max. mass of tools stored in the magazine (NOTE 1)

Standard specifications Option

24 30

automatic shorter path selection (NOTE 4)

φ 110 mm (4.33 in) (NOTE 3)

8 kgf (18 lbs) (NOTE 2)

120 kgf (270 lbs) （Average 5 kg×24）

150 kgf (337.5 lbs) （Average 5 kg×30）

Note 1: The “max. mass of tools stored in the magazine” indicates the allowable weight of the tools

when they are set in the magazine so that the magazine is balanced.

Note 2: If a tool exceed a mass of 5 kg, be sure to register this tool as [HEAVY TOOL]

(Refer to section 7-1-4 "Registering the tools to be used" in the operating manual " Operating NC Unit and Preparation for Automatic Operation.")

WARNING

Note 3: If a tool exceeds a diameter of φ80 mm, this tool disables the adjacent tool to be mounted.

If a tool exceeds a diameter φ80 mm, be sure to register this tool as [LARGE L] (largediameter tool). (Refer to section 7-1-4 " Registering the tools to be used " in the operating manual " Operating of NC Unit and Preparation for Automatic Operation.")

Note 4: When a tool has been registered as [LARGE L] (large-diameter tool), this tool has its own

magazine pocket No.

The tools must be arranged in the magazine taking balance into consideration.

l Observe the above restrictions on tools. In registering a tool as [HEAVY TOOL] or

[LARGE L], carefully check the tool for correct identification and register the tool correctly, or the machine may be damaged.

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4-2 Mounting and Removing Workpieces

4-2-1 Dimensional Restrictions on Workpieces

The following illustrations show the allowable maximum dimensions of workpieces that can be mounted on a table.

A workpiece exceeding these limit values must not be mounted on a table.

There is no interference between tools handled by the ATC and a workpiece not exceeding these limit values.

510 (20.08)

(Overall table width

D 655 (25.79)

610 (24.02)

Fig. 4-5 Dimensional Restrictions on W orkpieces

1460 (57.48) (Overall table length)

W 2820 (111.02)

750 (29.53)

145 (7.71)

H 650 (25.59)

Table

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4-2-2 Procedure for Mounting and Removing Workpieces

Workpieces can be mounted or removed regardless of the operation mode (manual or automatic) set by the NC operation panel.

＜Procedure＞

(1) Set the SET UP switch (key-lock type switch) to "O" position, and remove the key.

(2) Open the operator's door.

When the operator's door is opened, spindle rotation, axis movement and ATC cycle are disabled.

(3) Mount or remove a workpiece to or from the pallet.

l Mounting or removing a workpiece must be carried out correctly only while the operator’s

door is open.

WARNING

4-2-3 Measuring Coordinate Values

Refer to the following manual:

Programming Manual (MAZATROL) Part 2, Chapter 6 “COORDINATES MEASUREMENT FUNCTION”

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4-3 Preparing Coolant

4-3-1 Selection of Coolant

Check the following points with the supplier when selecting a coolant.

1. Use a water based coolant

If oil based coolant is used, the coolant discharge quantity will be reduced and its temperature rise will be large, increasing the likelihood of thermal displacement in the machine. In addition, there is a fire hazard associated with oil-based coolant and precautions including the provision of fire-fighting equipment are required if it is used.

2. Take factors such as lubricity, anti-corrosive properties, and anti-foaming properties into account when making the selection.

3. Check if the coolant has any harmful effects on human beings.

Since water based coolant is likely to cause skin eruptions, pay due attention to the health management of the machine operators.

4. Check if the coolant will cause chemical products such as rubber and plastics to harden or expand.

5. Check if any problems will arise as a result of mixing of the coolant with the recommended lubricating oil for the machine.

In rare cases a chemical change can result from the mixing of coolant and lubricating oil, causing discoloration and coagulation of the coolant.

4-3-2 Replenishing Coolant

Refer to the following when replenishing coolant.

Maintenance manual Section 4-3-5, “Changing and Replenishing Coolant”.

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4-4 Adjustment of Coolant Nozzle Direction

The coolant nozzle has been tapped to M6.

To change the coolant nozzle direction, screw an M6 bolt in the coolant nozzle and adjust the bolt position.

M6 bolt

Coolant nozzle

Fig. 4-6 Adjustment of Coolant Nozzle Direction

Before adjusting the coolant nozzle, be sure to confirm that the machine is in full stop.

4-9

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4-10

Page 99

Section 3:

Operating NC Unit

and

Preparation for Auto Operation

Page 100

Notes: