for
Integrex-100~400MkIII Series
Mazatrol Fusion 640MT-Pro
Publication # C373AT1000E
3/2005
CAUTION
Notes:
Notes:
SAFETY PRECAUTIONS
6) Do not deface, scratch or remove any caution
plate. Should it become illegible or missing,
order another caution plate from the supplier,
specifying the part number shown at the lower
right corner of the plate.
BEFORE POWERING UP
DANGER:
Cables, cords or electric wires whose insulation
is damaged can produce current leaks and
electric shocks.
Before using, check their
condition.
WARNING:
1) Be sure the instruction manual and the
programming manual are fully understood
before operating the machine. Every function
and operating procedure should be completely
clear.
2) Use approved oil resistant safety shoes, safety
goggles with side covers, safe clothes, and
other safety protection required.
3) Close all NC unit, operating panel, electric
control panel doors and covers.
CAUTION:
1) The power cable from the factory feeder switch
to the machine main circuit breaker should
have a sufficient sectional area to handle the
electric power used.
2) Cables which must be laid on the floor must be
protected from hot chips, by using rigid or
other approved conduit, so that short-circuits
will not occur.
3) Before first time operation of the machine after
unpacking it or from being idle for a long period
of time (several days or more), each sliding
part must be sufficiently lubricated. To do so,
push and release the pump button several
times until the oil seeps out on the sliding
parts. The pump button has a return spring, so
do not force it to return.
4) Oil reservoirs should be filled to indicated
levels. Check and add oil, if needed.
5) For lubrication points, oil specification and
appropriate levels, see the various instruction
plates.
6) Switches and levers should operate smoothly.
Check that they do.
7) When powering the machine on, turn on the
switches in the following order: first the factory
feeder switch, then the machine main circuit
breaker, and then the control power on switch
located on the operating panel.
8) Check the coolant level, and add coolant, if
needed.
S-1
OPERATION
WARNING:
1) Do not work with long hair that can be caught
by the machine. Tie it back, out of the way.
2) Do not operate switches with gloves on. This
could cause mis-operation.
3) Whenever a heavy workpiece must be moved,
if there is any risk involved, two or more people
should work together.
4) Only trained, qualified workers should operate
forklift trucks, cranes or similar equipment and
apply slings.
5) Whenever operating a forklift truck, crane or
similar equipment, special care should be taken
to prevent collisions and damage to the
surroundings.
6) Wire ropes or slings should be strong enough
to handle the loads to be lifted and should
conform to the mandatory provisions.
7) Grip workpieces securely.
8) Stop the machine before adjusting the coolant
nozzle at the tip.
9) Never touch a turning workpiece in the spindle
with bare hands, or in any other way.
10) To remove a workpiece from the machine other
than by a pallet changer, stop the tool and
provide plenty of distance between the
workpiece and the tool (for M/C).
11) While a workpiece or tool is turning, do not
wipe it off or remove chips with a cloth or by
hand. Always stop the machine first and then
use a brush and a sweeper.
12) Do not operate the machine with the chuck and
front safety covers removed (For T/M).
13) Use a brush to remove chips from the tool tip,
do not use bare hands .
14) Stop the machine whenever installing or
removing a tool.
15) Whenever machining magnesium alloy parts,
wear a protective mask.
WARM UP
CAUTION:
1) Warm up the machine, especially the spindle
and feed shaft, by running the machine for 10
to 20 minutes at about one-half or one-third the
maximum speed in the automatic operation
mode.
2) The automatic operation program should cause
each machine component to operate. At the
same time, check their operations.
3) Be particularly careful to warm up the spindle
which can turn above 4000 rpm.
If the machine is used for actual machining
immediately after being started up following a
long idle period, the sliding parts may be worn
due to the lack of oil. Also, thermal expansion
of the machine components can jeopardize
machining accuracy. To prevent this condition,
always make sure that the machine is warmed
up.
PREPARATIONS
WARNING:
1) Tooling should conform to the machine
specifications, dimensions and types.
2) Replace all seriously worn tools with new ones
to prevent injuries.
3) The work area should be adequately lighted to
facilitate safety checks.
S-2
CAUTION:
1) Thoroughly read and understand the safety
precautions in the instruction manual.
2) Thoroughly read the whole maintenance
manual and fully understand the principles,
construction and precautions involved.
MAINTENANCE OPERATION
DANGER:
1) Those not engaged in the maintenance work
should not operate the main circuit breaker or
the control power "ON" switch on the
operating panel. For this purpose, "Do not
Touch the Switch, Maintenance Operation in
Progress!" or similar warning should be
indicated on such switches and at any other
appropriate locations. Such indication should
be secured by a semi-permanent means in the
reading direction.
2) With the machine turned on, any maintenance
operation can be dangerous. In principle, the
main circuit breaker should be turned off
throughout the maintenance operation.
WARNING:
1) The electrical maintenance should be done by
a qualified person or by others competent to do
the job.
Keep close contact with the
responsible person. Do not proceed alone.
2) Overtravel limit and proximity switches and
interlock mechanisms including functional parts
should not be removed or modified.
3) When working at a height, use steps or ladders
which are maintained and controlled daily for
safety.
4) Fuses, cables, etc. made by qualified
manufacturers should be employed.
BEFORE OPERATION & MAINTENANCE BEGINS
WARNING:
1) Arrange things in order around the section to
receive the maintenance, including working
environments. Wipe water and oil off parts and
provide safe working environments.
2) All parts and waste oils should be removed by
the operator and placed far enough away from
the machine to be safe.
CAUTION:
1) The maintenance person should check that the
machine operates safely.
2) Maintenance and inspection data should be
recorded and kept for reference.
CAUTION:
1) During automatic operation, never open the
machine door. Machines equipped with the
door interlock will set the program to single
step.
2) When performing heavy-duty machining,
carefully prevent chips from being accumulated
since hot chips from certain materials can
cause a fire.
TO INTERRUPT MACHINING
WARNING:
When leaving the machine temporarily after
completing a job, turn off the power switch on
the operation panel, and also the main circuit
breaker.
COMPLETING A JOB
CAUTION:
1) Always clean the machine or equipment.
Remove and dispose of chips and clean cover
windows, etc.
2) Make sure the machine has stopped running,
before cleaning.
3) Return each machine component to its initial
condition.
4) Check the wipers for breakage.
Replace
broken wipers.
5) Check the coolant, hydraulic oils and lubricants
for contamination. Change them if they are
seriously contaminated.
6) Check the coolant, hydraulic oil and lubricant
levels. Add if necessary.
7) Clean the oil pan filter.
8) Before leaving the machine at the end of the
shift, turn off the power switch on the operating
panel, machine main circuit breaker and factory
feeder switch in that order.
SAFETY DEVICES
1) Front cover, rear cover and coolant cover.
2) Chuck barrier, tail barrier and tool barrier (NC
software).
3) Stored stroke limit (NC software).
4) Emergency stop pushbutton switch.
MAINTENANCE OPERATION PREPARATIONS
1) Do not proceed to do any maintenance
operation unless instructed to do so by the
foreman.
2) Replacement parts, consumables (packing, oil
seals, O rings, bearing, oil and grease, etc.)
Should be arranged in advance.
3) Prepare preventive maintenance and record
maintenance programs.
000X717-KY 11/98
S-3
aaaaaaaaaa
aaaaa
WARNING
ALWAYS TURN THE MAIN CIRCUIT BREAKER TO THE OFF POSITION & USE AN APPROVED
LOCKOUT DEVICE WHEN COMPLETING MAINTENANCE OR REPAIRS.
THE LOCKOUT PROCEDURE THAT FOLLOWS IS INTENDED TO SAFEGUARD PERSONNEL &
EQUIPMENT DURING MAINTENANCE OPERATIONS, AND, REPRESENTS THE MINIMUM
REQUIREMENTS. ANY ACTION SHOULD BE PRECEDED BY A HAZARD ANALYSIS TO DETERMINE
ANY ADDITIONAL SAFETY PRECAUTIONS THAT MAY BE NECESSARY TO ENSURE THE SAFETY OF
PERSONNEL AND EQUIPMENT.
LOCKOUT PROCEDURE
1)
2)
INFORM ALL EFFECTED PERSONNEL OF YOUR INTENT TO LOCKOUT AND SERVICE THE
SPECIFIED MACHINE.
3)
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)
8)
9)
REMOVE THE LOCKOUT DEVICE. MAKE SURE ALL PERSONNEL ARE AT A SAFE LOCATION
BEFORE RESTORING MACHINE POWER.
PADLOCK
FIGURE
S-4
INSTALLATION PRECAUTIONS
The following subjects outline the items that
directly affect the machine installation and startup. To ensure an efficient and timely installation,
please follow these recommendations before
calling to schedule a service engineer.
6)
ENVIRONMENTAL REQUIREMENTS
Avoid the following places for installing the
machine:
1) Avoid exposure to direct sunlight and/or near a
heat source, etc. Ambient temperature during
operation: 0 thru 45C (32F to 113F).
2) Avoid areas where the humidity fluctuates
greatly and/or if high humidity is present;
normally 75% and below in relative humidity. A
higher humidity deteriorates insulation and
might accelerate the deterioration of parts.
3) Avoid areas that are especially dusty and/or
where acid fumes, corrosive gases and salt are
present.
4) Avoid areas of high vibration.
5) Avoid soft or weak ground (minimum load
bearing capacity of 1025 lbs./ft2)
Note:
The machine must be anchored to the
foundation with J-bolts, expansion bolts or
other suitable method.
The machine accuracy and alignment
specifications quoted by Mazak can usually
be obtained when the minimum foundation
requirements are met. However, production
of close tolerance parts requires the use of an
appropriate certified foundation. Foundations
that do not meet certified specifications may
require more frequent machine re-leveling and
re-alignment, which can not be provided
under terms of warranty.
If any of these conditions cannot be met,
contact the nearest Mazak service office
immediately.
FOUNDATION REQUIREMENTS
For high machining accuracy, the foundation
must be firm and rigid.
This is typically
accomplished by securely fastening the
machine to the foundation with anchor bolts. In
addition, the depth of concrete should be as
deep as possible (minimum 6 - 8 inches). Note
the following:
1) There can be no cracks in the foundation
concrete or surrounding area.
2) Vibration proofing material (such as asphalt)
should be put all around the concrete pad.
3) Form a cone in the foundation for J-bolt
anchors, or use expansion anchors.
4) With the foundation anchor bolt holes open
pour the primary concrete at a minimum
thickness of 6 - 8 inches. Typically, the
concrete must have a minimum compression
rating of 2500 lbs. @ 250 lbs. compression
and strengthened with reinforcing rods. When
the concrete has cured, rough level the
machine, and install the J-bolts, leveling blocks,
etc., and pour grout into foundation bolt holes.
5) Mix an anti-shrinkage agent such as Denka
CSA with concrete, or use Embeco grout to fill
the foundation bolt holes.
S-5
WIRING
1) Use
only
electrical
conductors
with
performance ratings equivalent or superior.
2) Do not connect any power cables for devices
which can cause line noise to the power
distribution panel, such as arc welders and high
frequency machinery.
3) Arrange for a qualified electrician to connect
the power lines.
4) Incoming supply voltage should not deviate
more than 10% of specified supply voltage.
5) Source frequency should be2 Hz of nominal
frequency.
NC
Machine
Earth resistance:
Less than 100 ohms
Common Grounds:
Resistance to ground
= 100 the number of
devices connected to
the grounding (ohms)
[ CAUTION ]
GROUNDING
1) An isolated earth ground with a resistance to
ground of less than 100 ohms is required.
Typically, a 5/8 copper rod, 8 feet long, and
no more than 5 feet from the machine, is
sufficient.
Building grounds or multiple
machines grounded to the same ground rod,
are not acceptable.
2) The wire size should be greater than AWG
(American Wire Gauge) No. 5 and SWG
(British Legal Standard Wire Gauge) No. 6.
000X713-KY 11/98
S-6
CAUTION
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.
S-7
WARNING
WARNING
S-8
WARNING
S-9
WARNING
WARNING
CUTTING CONDITIONS THAT ARE THE RESULT OF THE MAZATROL FUSION 640
AUTOMATIC CUTTING DETERMINATION FUNCTION
S-10
CENGDB0551E
DOOR INTERLOCK SAFTY SPEC.
MACHINING CENTER
DOOR
MODE
OPEN
MANUAL
AUTO
CLOSE
I
V
OPEN
MANUAL
Prohibit
Prohibit
Prohibit
Prohibit
Prohibit
I (ON)
Limit the rapid override. Max is 12%.
Prohibit to run chip spiral conveyor.
Can run spindle JOG.
Can run spindle Orient.
Can operate manual ATC.
to move axis.
to start spindle running.
to operate manual ATC.
to operate manual Pallet Changer.
to run chip spiral conveyor.
Door is always locked. Door lock can be released by pushing DOOR UNLOCK SW on operator panel.
But, it can not release in operating ATC/Pallet changer/Axis/Spindle.
Prohibit
Prohibit
Prohibit
Prohibit
Prohibit
AUTO
CLOSE
SET UP SWITCH
O (OFF)
to move axis.
to start spindle running.
to operate manual ATC.
to operate manual Pallet Changer.
to run chip spiral conveyor.
Door is always locked. Door lock can be released by pushing DOOR UNLOCK SW on operator panel.
But, it can not release in auto operation running except single block stop or feed hold stop or M00 program
stop or M01 optional stop and spindle stop. If not, Alarm displayed Door open invalid.
If release the lock by note(*1), Alarm will occur
then stop the all motion.
Chip spiral conveyor would stop.
MANUAL
No Limitation.
No Limitation.
AUTO
No Limitation.
TURNING CENTER
SET UP SWITCH
DOOR
MODE
O (OFF)
I (ON)
OPEN
AUTO
CLOSE
->
OPEN
MANUAL Can not open the front door in Spindle running, Axis moving, Auto-running( Cycle start, Feed hold ) due to
&
Mechanical locking system. (Except Single Block Stop or M00 program stop or M01 optional stop)
AUTO
But, if release the lock by note(*1), Alarm will occur then stop the all motion.
MANUAL No Limitation.
CLOSE
AUTO
No Limitation.
No Limitation.
*1 : Door lock mechanism can not be released in machine stop by NC power OFF.
If it is necessary to release the lock such as emergencies, the lock can be released by operating the
supplementary lock release mechanism of the main body of the safety door lock switch.
*2 : Override Limitation of Rapid speed of AXIS
Machining Center : 12%. Turning Center : 10%.
*3 : Chip Conveyor and Coolant should stop in the door open.
PED-EDS-001
S-11
CENGDB0551E
APPENDIX
SWITCH PANEL for M640M (Machining Center)
MACHINE SET UP
SWITCH
SWITCH PANEL for M640MT/T (Turning Center)
PED-EDS-001
S-12
DOOR UNLOCK
SWITCH
Press the HOME key and move the axes to home position as shown below:
Move X-axis to home position.
Move Y-axis to home position.
Move Z-axis to home position.
1-1
Key in: M601S__ (where S__ is the desired tool number) to index the tool magazine to the
1-2
If it is not, press the MILLAXIS UNCLAMP key, then the MILL 0 ORIENT key to orient the mill
spindle. Next press the MILLAXIS CLAMP key to re-clamp the mill spindle.
Press the AXIS ATC POS key to position the Y axis to the ATC position.
Press the Display Select Menu soft key (Left end of menu keys).
1-3
Verify that the shifter is at the ATC side. Move to the ATC side if currently at the Magazine side.
Press the Menu Select soft key (Right end of menu keys.)
1-4
1-5
Key in M602 S___ (Where S___ is the proper next tool number.)
Key in M601 S___ (Where S___ is the proper magazine position.)
1-6
Press the Menu Select menu soft key (Left end of menu keys).
1-7
When TNo 5 is mounted as shown above, perform operation following the procedure described below:
(1) Open the TURRET TOOL window and move the cursor to the first line of Tno. using the cursor keys
1-8
1-9
Notes:
1-10
1.Turret adjustment
Mount a test bar to the mill spindle.
3. If the turret is off center, mount a test bar as shown in the photo
and loosen all six turret mounting bolts.
(The photo shows the turret in H direction, but it will be easier to
do this with the turret in V direction.)
2-1
2-2
Note:
The INTEGREX-100MKIII series only uses a set
screw for adjustment.
It will not move even if it is tapped with a soft
hammer.
2-3
Notes:
2-4
1. Rotational Alignment
Select the turret No. 2 and place it toward the secondary
spindle. Then mount a magnet stand to the upper turret.
Mount a dial indicator as shown to measure parallelism
of the grooves for installing a boring bar holder.
3-1
<Tolerance>
Measure at the main spindle and at the secondary spindle. Tolerance must be 2/100 mm (0.0008inch) or less.
3-2
3-3
3-4
1st spindle (standard specifications): 22kw/350N.m and dia. 76 bore in 0.0001-deg. C-axis encoder
2nd spindle (standard specifications): 18.5kw/326N.m and dia. 76 bore in 0.001-deg. PLG encoder Secondary
spindle (optional specifications): 18.5kw/326N.m and dia. 76 bore in 0.0001-deg. C-axis encoder.
4.2
1. Check the current vertical alignment (spindle centerline parallelism to Z1 axis movement)
Mount a test bar to the 1st spindle and mount a millimess indicator on the test bar as shown below.
Note: The indicator is mounted on the top of test bar for this measurement.
4-1
Lift the 1st. spindle using a crane, and remove the shims
(4 places) to grind.
Note:
Viewed from the chuck cylinder side and at the left side
of the 1st spindle.
The positioning pin (indicated by a red arrow) is located
between the spindle mounting bolts. Remove the pin
using an M6 pin puller and lift the spindle. After the shims
are ground, remember to put the positioning pin back.
4-2
3. Check the current horizontal alignment (spindle centerline parallelism to Z1 axis movement)
Mount a test bar in the 1st spindle and a millimess dial indicator to the side of the test bar as shown.
Note: The indicator is on the back of test bar for this measurement.
4-3
<Tolerance>
L = 300 mm (11.811 inch) A = 1/100 mm (0.0004 inch) or less B = 5/1000 mm (0.0002 inch) or less
Tighten the 1st. spindle mounting bolts firmly and check parallelism both in the height direction and in the
horizontal direction again.
5. Center horizontal adjustment of the 1st spindle
Put a workpiece in the chuck for a test cut. Using a micrometer, measure the outer diameter at each end to check
for taper. Re-adjust as shown above to remove any taper.
<Tolerance>
0.0003 inch or less
Note:
Adjust in the following order:
X & Yt axis home position
X & Yt ATC position
Tool Eye parameter adjustment
Tailstock alignment or concentricity adjustment between the first & second spindle
4-4
4.3
NOTE: Make this adjustment after the 1st. spindle alignment is completed.
4-5
Lift the 2nd spindle using a crane, and remove the shims
(4 places) to grind.
<Tolerance>
4-6
4-7
<Tolerance>
4-8
5-1
5-2
5.1
As shown in the illustration below, the tool shank has four adjusting screws. Unscrew all the lock screws
and make an adjustment with the adjusting screws.
As shown in the picture below, set a lever indicator to the edge of the stylus and tighten or loosen the four adjusting
screws while turning the tool. With the four adjusting screws tightened, the runout of the lever indicator must be
within 0.02 mm (0.0008 in.) or less. After the adjustment is completed, tighten all the lock screws firmly.
5-3
Notes:
5-4
Reference
workpiece
origin
Turret center of rotation
100mm
A8
B234
Parameters:
A8 = The distance from the turret face to the reference workpiece origin.
B234 = The distance from the turret center of rotation to the reference workpiece origin.
Reference workpiece origin = 100mm from the chuck face.
6-1
f) Add B to C and subtract from the Z1 axis stroke value A to determine the turret rotation diameter.
g) Divide by 2 for value R.
2) Add value R to the value of parameter A8.
3) Enter this value into parameter B234.
Formula:
B234 = A8 + R
R = [ A - (B +C) ] / 2
6-2
Parallelism measurement between the tool eye sensors is taken with respect to points A and B as indicated by the
red arrows in the photo below.
It is unnecessary to check parallelism between the sensors between the upper turret and the lower turret.
7-1
7-2
7.2
The upper turret parameters are shown in blue and the lower turret are in red.
Note:
Tool eye parameters must be adjusted whenever a home position confirmation sensor is replaced or accuracy
needs to be assured after a collision.
The address names and adjusting procedure are the same as for earlier Integrex machines.
For parameters B61 & B62, the measured value is entered. For parameter B63, one half of the measured value is
entered.
The input unit is 0.001mm (metric only). These parameters become valid immediately after the setting change.
7-3
7.3
The parameter drawing on the previous page shows the same parameter address names for the upper and lower
turrets. Use the [TURRET SELECT] switch as shown below to select the parameter page for the desired turret.
7-4
Note: Make sure the X-axis and Yt-axis are in a position where no interference occurs before performing
the ATC arm swing-in operation.
Press the ATC ARM SWING menu key to swing in the ATC arm
as shown.
Mount the alignment tool B to the arm No. 1 and the alignment tool
C to the mill spindle respectively.
Move the X-axis and Yt-axis close to the ATC arm with the manual
hand wheel, and find a position where alignment tool A passes
through the alignment tools B and C smoothly.
Make note of the machine position value for input into parameter
data.
Remove the alignment tool A, and press the
ATC ARM HOME POS menu key to return the arm.
Remove the alignment tools B and C.
From the ATC menu, select the INTERLOCK NEG. menu key to
cancel the interlock neglect function.
8-1
Parameter Change
Input the values of the machine position noted above for X-axis and Yt-axis to the following parameters:
RL-16 (tool change position for Yt-axis)
RL-17 (tool change position for X-axis)
Note: Unlike previous M640, the parameter input unit of M640 MT-Pro is changed from 1/1000 to 1/10000.
8-2
9 TOOL FUNCTIONS
9-1 Tool Function (4-Digit T-Code)
Tool function, also referred to as T-code function, is used to designate the tool number and offset
number. Of a four-digit integer at address T, upper and lower two digits are respectively used to
specify the tool number and offset number.
T !!"". ;
Tool ID code
Application direction
Tool offset number
Tool number
Use two digits after the decimal point to specify the application direction of the tool in accordance
with the registration on the TOOL DATA display.
0, 2, 4, 6, 8
1, 3, 5, 7, 9
11
13
14
15
DIRECTION
Note 1: The directions shown above may not all apply to some machine models.
Note 2: The reverse-display directions refer to a milling spindle orientation of 180 degrees, and
can be used for the application of a turning tool with the tip reversely directed.
In addition to the application direction, the ID code (A to Z) of the tool can also be designated in
accordance with the registration on the TOOL DATA display on condition that the bit 6 of the
parameter P111 is set to 1.
11
12
13
ID code
14
15
16
17
18
19
21
22
23
24
25
26
ID code
Note 3: An alarm will result if no corresponding tool for the specified direction and ID code is
registered on the TOOL DATA display.
Note 4: Depending on the number of the decimal places, the T-code is processed as follows:
1) A designation of a single or two decimal places is always processed as that of the
application direction. It is not possible, therefore, to merely designate the ID code.
2) The T-code with three or five and more decimal places causes an alarm.
3) The default attribute of the T-code is of
direction without ID code.
Only one T-code can be included in a block, and the available range of T-codes depends on the
machine specifications. For further details, especially on how to number the actual tools to be
used, refer to the operating manual of the relevant machine.
The T-code can be given with any other commands in one block, and the T-code given together
with an axis motion command is executed, depending upon the machine specifications, in one of
the following two timings:
- The T-code is not executed till completion of the motion command, or
- The T-code is executed simultaneously with the motion command.
9-1
9-2
10-1
O00000001 (Integrex-200S
Programming Example)
10-2
M211
M153
M250
B45.
M251
G125 X1. Y0 Z-1. R1
G17 UV
G00 Z.5
X0 Y1.616
G01 Z0 F20.
G41 G01 X1. Y.866 F10.
Y-.866
G40 Y-1.616 F10.
G0 Z.5
M212
M205
G69.5
10-3
N4 ( TRANSFER )
G28 U0 Y0
M202
M05 M305 G110
Z2 M306 G00 Z-#500 ( TRANSFER POSITION )
M544
M508 G98
G31 W-.1 F20.
M307
M06
G28 W0
G111
M545
M509 G50 W-#500 ( SUB SHIFT )
M300
10-4
10-5
Notes:
10-6
G69.5 ;
After the selection of the G17 (X-Y) plane, the workpiece origin is shifted to the point
(X, Z, Y) = (1, 2, 0) and the plane is rotated by 30 degrees on the Y-axis. The new coordinate system (X, Y, Z)
has thus been established. The sub spindle shift is zero.
-The cancel command G69.5 will set again the coordinate system subjected to the translation and rotation by the
preceding G125 command.
-In the G125 mode all the dimensions must be entered in radius values.
11-1
O00000001 (sample 1)
N1(Mill Slot)
G53 ( T32 MODE )
M201
T0101.8 B2
G97 S2000 M203
G28 U0
M250
G00 B30.
M251
G17
G125 X2.5 Y0 Z-2. R1 S0.
G98 G00 C0
Z1.
G0 X4. Y0M08
Z.1
M211
G01 Z-.25 F20.
X-4. F10.
M212
G00 Z1.0
M205
G69.5
G28 U0Y0
11-2
11-3
Rr :
Ss;
Q**
Calculating point
0:
Tip of tool
1.0:
Center of ball nose (for mold machining)
2.0:
Center of turret (for B axis contouring)
(Data Q is not necessary to command if choosing tip of tool for calculating point)
11-4
6)
(SET UP SCREEN)
Z Offset
11-5
Notes:
11-6
INTEGREX-100~400MkIII
PLC
ALARM
LISTS
! As shown below, the alarm message in the DIAGNOSIS display varies between models
INTEGREX 300/400-III/IIIT and INTEGREX 300/400-IIIS/IIIST.
CAUTION
D135W0049E
1.
INTEGREX 300/400-III
Neither SP1 nor SP2 is displayed on the display.
2.
INTEGREX 300/400-IIIS/IIIST
SP1 or SP2 is displayed on the display. The alarm message related to the secondary
spindle or W-axis is displayed with SP2.
Example:
3.
INTEGREX 300/400-IIIT
TR1 or TR2 is displayed on the display. The alarm message related to the lower turret is
displayed with TR2. (Only SP1/SP2 is used for IIIST.)
Example:
Remark: Alarms shown in Section 2-1 Alarm List for the INTEGREX 300/400III/IIIT/IIIS/IIIST are all displayed with SP1 in the INTEGREX 300/400-IIIS.
H374S5B012E
APP-1
Description
Address
X2
X3 X4
202: HYDRAULIC
PRESSURE DOWN
X447
X446
204: SPINDLE
CONTROLLER
MALFUNCTION
205: MILLING
CONTROLLER
MALFUNCTION
212: CHUCK
OPEN/CLOSE
SWITCH MALF.
213: ILLEGAL
DESIGNATED TOOL
No.
XA
X44E
(X44F)
X440/
X441
X460
X440/
X441
APP-2
Description
Address
236: PARTS-CATCHER
SENSOR MALF.
243: MEASURING
CONTROLLER
MALF.
245: BAR-FEEDER
CONTROLLER
MALF.
248: EXTERNAL
CONTROLLER (No.1)
MALF.
X14/
XA
X444/
X445
X440/
X441
X445
X15
X442
X443
X480
APP-3
XA
Description
3. After clamping the milling head (Baxis), designate the milling spindle
rotation command and check the
milling head clamp sensor.
Address
X460
X15
XA
X442
X443
X480
X445
XD
APP-4
X460
XD
Description
Address
253: OVERLOAD
DETECTION
260: SLIDEWAY
LUBRICATION
ALARM
X465
X485
X5
X6
X44C
X44D
APP-5
Description
Address
X440/
X441
292: SENSOR
MALFUNCTION No. 3
R1, R2,
R3
293: SENSOR
MALFUNCTION No. 4
R1, R2,
R3
X442/
X443
XA
X460
APP-6
X445
Description
Address
X11C/
XA
X444
90
(D201)
91
(D201)
97
(D201)
98
(D201)
APP-7
329: CHUCKING
SELECTION
PROHIBITED
Description
99
(D201)
9800
(D200)
9900
(D200)
Address
R18
XA
366: SHIFTER
CONTROLER
MALFUNCTION
374: OPERATING
SWITCH FAULT
APP-8
X10
X11
Description
Address
X490
X491
381: CONDITION
MISSING (SET UP
SWITCH)
391: LD/ULD/ACHG
CONDITION ALARM
X475
X1C
APP-9
X493
Description
Address
Corresponding sensor
Normal
X470
X471
X472
X473
X442
X443
12
X14
X15
XD
XD
X1C
399: MAINTE./ADJUST
PARAM. ON
APP-10
S/III
IIIST
(Addition)
III
Description
Address
SP2
215: CHUCK SYSTEM
MALFUNCTION
SP2
X483/
X484
X483/
X484
SP2
X483/
X484
SP2
X445
XA
X448
X449
SP2
224: CHUCK SENSOR
MALFUNCTION
250: SPINDLE START
MISOPERATION
1.
2.
3.
APP-11
X445
Description
APP-12
Address
X483/
X484
Description
Address
X52
X198
X1F8
X52
TR2/SP2
310: C/S ERROR
(TNo.MISMATCH)
TR2/SP2
APP-13
- NOTE -
APP-14
M-CODE TABLE
Miscellaneous Function (M-Code) for the INTEGREX 300/400-III
III/I
III III
T/IIIIS/IIIIST
!: Standard
": Optional
: Special order
M-codes
Description
Category
Remarks
M00
Program stop
M01
Optional stop
M02
Program end
M03
M04
M05
Spindle stop
M06
"
M07
"
M08
Flood coolant ON
M09
Coolant OFF
M13
M14
M15
M16
M17
M18
M19
"
M20
"
M21
"
M22
"
M23
"
M24
"
M25
"
M26
"
M27
"
M28
"
M29
"
M30
M31
for 300/400-III/IIIT
for 300/400-III/IIIT
M10
M11
M12
M32
M33
M34
M35
M36
M37
M38
M39
M40
H374S5C010E
APP-15
M-codes
Description
Category
M41
M42
M43
M44
M45
"
M48
"
M49
"
M51
M52
Error detect ON
M53
Chamfering OFF
M54
Chamfering ON
M55
Piece count
M56
"
M57
"
M58
"
C-axis unclamp
M66
C-axis clamp
M67
M68
M69
M72
M73
M74
M75
"
M82
"
M83
"
M84
"
M86
"
M87
"
M46
M47
M50
M59
M60
M61
M62
M63
M64
M65
M70
M71
M76
M77
M78
M79
M80
M81
M85
APP-16
Remarks
M-codes
Description
Category
Remarks
M88
M89
M97
M98
M99
M100
"
M101
"
M102
"
M103
"
M104
"
M105
"
M106
"
M107
"
M108
"
M109
"
M110
M111
M112
"
M113
"
M114
"
M115
"
M116
"
M117
"
"
M150
M151
M152
M153
M154
M155
"
M156
"
M157
"
M158
"
M159
"
M160
"
M90
M91
M92
M93
M94
M95
M96
M118
M119
M120
M121
M149
APP-17
M-codes
Description
Category
Remarks
M161
"
M162
"
M163
low pressure
"
for 300/400-III/IIIT
M164
high pressure
"
for 300/400-III/IIIT
"
M172
Index 0(KOUYOU)
M173
Index 90(KOUYOU)
M174
Index 180(KOUYOU)
M175
Index 270(KOUYOU)
M176
Index 270(KOUYOU)
M177
Index 270(KOUYOU)
M178
Index 270(KOUYOU)
M179
Index 270(KOUYOU)
M198
"
M199
"
M200
M201
M202
Turning mode
M203
M204
M205
M207
M208
M209
M210
M211
M212
M213
M214
M215
M216
M165
M166
M167
M168
M169
M170
M171
M180
M197
M206
M215)
M217
M218
M219
M220
M229
APP-18
M-codes
Description
Category
M230
Grinding mode ON
"
M231
"
M236
M237
M238
M239
M248
M249
M250
M251
B-axis clamp
M252
M253
M254
M260
Polygon mode ON
"
M261
"
M274
M275
M331
M332
M348
Yt-axis selection
M349
Y-axis selection
M232
M233
M234
M235
M240
M241
M242
M243
M244
M245
M246
M247
M255
M256
M257
M258
M259
M262
M273
M276
M330
M333
M347
APP-19
Remarks
M-codes
Description
Category
M350
M351
M352 cancel
M352
M353
M369
M370
"
M371
"
M372
"
M373
"
M374
"
M375
"
M376
"
M377
"
M378
"
M379
"
M390
M391 cancel
"
M391
"
M394
TOOL EYE extension possible during chuck close (when robot valid)
M395
M394 cancel
M731
M732
M733
M734
M735
M736
M737
M738
M739
M740
M741
M742
M743
M380
M389
M392
M393
M396
M600
M601
M602
M730
APP-20
Remarks
M-codes
Description
Category
M744
M927
M928
M929
M930
M931
M999
APP-21
Remarks
S/IIIIST
!: Standard
": Optional
: Special order
M-codes
M300
Description
Category
Remarks
System M-code
System M-code
M303
M304
M305
M306
M307
"
M321
"
M322
Cancellation of M321
"
M333
M334
M335
M336
Cancellation of M337
M337
M351
Cancellation of M352
M352
M357
"
M358
"
M359
Cancellation of M360
"
M360
"
M361
Cancellation of M362
"
M362
"
M363
Cancellation of M364
"
M364
"
M380
M381
M301
M302
M319
M320
M350
M500
M501
Cancellation of M500
M502
"
M503
APP-22
System M-code
M-codes
Description
Category
Remarks
M504
M505
Cancellation of M502
"
System M-code
M506
System M-code
M507
The slave spindle chuck open after master spindle chuck close
System M-code
M508
Pressing start
M509
Cancellation of M508
M511
System M-code
M512
Cancellation of M511
System M-code
M518
M519
Spindle orientation
"
M527
"
M528
"
M540
System M-code
M541
System M-code
M542
System M-code
M510
M543
System M-code
M544
Cross-machining start
"
System M-code
M545
Cancellation of cross-machining
"
System M-code
M546
System M-code
M547
System M-code
APP-23
T/IIIIST
Description
Category
M560
Spindle control and Constant cutting speed control for the upper turret
M561
Spindle control and Constant cutting speed control for the lower turret
M562
M563
M950
Stand-by M-code
M951
Stand-by M-code
M952
Stand-by M-code
M953
Stand-by M-code
M954
Stand-by M-code
M955
Stand-by M-code
M956
Stand-by M-code
M957
Stand-by M-code
M958
Stand-by M-code
M959
Stand-by M-code
M960
Stand-by M-code
M961
Stand-by M-code
M962
Stand-by M-code
M963
Stand-by M-code
M964
Stand-by M-code
M965
Stand-by M-code
M966
Stand-by M-code
M967
Stand-by M-code
M968
Stand-by M-code
M969
Stand-by M-code
M970
Stand-by M-code
M971
Stand-by M-code
M972
Stand-by M-code
M973
Stand-by M-code
M974
Stand-by M-code
M975
Stand-by M-code
M976
Stand-by M-code
M977
Stand-by M-code
M978
Stand-by M-code
M979
Stand-by M-code
M980
Stand-by M-code
M981
Stand-by M-code
M982
Stand-by M-code
M949
APP-24
Remarks
M-codes
Description
Category
M983
Stand-by M-code
M984
Stand-by M-code
M985
Stand-by M-code
M986
Stand-by M-code
M987
Stand-by M-code
M988
Stand-by M-code
M989
Stand-by M-code
M990
Stand-by M-code
M991
Stand-by M-code
M992
Stand-by M-code
M993
Stand-by M-code
M994
Stand-by M-code
M995
Stand-by M-code
M996
Stand-by M-code
M997
Stand-by M-code
APP-25
Remarks
Description
Category
M00
Program stop
M01
Optional stop
M02
Program end
M03
M04
M05
M08
Coolant ON
M09
Coolant OFF
M30
M51
M52
Error detect ON
M53
Chamfering OFF
M54
Chamfering ON
M58
"
M300
M302
M303
M304
M305
M358
"
M560
Spindle control and Constant cutting speed control for the upper turret
M561
Spindle control and Constant cutting speed control for the lower turret
M562
M563
M950
Stand-by M-code
M951
Stand-by M-code
M952
Stand-by M-code
M953
Stand-by M-code
M954
Stand-by M-code
M301
M949
APP-26
Remarks
M-codes
Description
Category
M955
Stand-by M-code
M956
Stand-by M-code
M957
Stand-by M-code
M958
Stand-by M-code
M959
Stand-by M-code
M960
Stand-by M-code
M961
Stand-by M-code
M962
Stand-by M-code
M963
Stand-by M-code
M964
Stand-by M-code
M965
Stand-by M-code
M966
Stand-by M-code
M967
Stand-by M-code
M968
Stand-by M-code
M969
Stand-by M-code
M970
Stand-by M-code
M971
Stand-by M-code
M972
Stand-by M-code
M973
Stand-by M-code
M974
Stand-by M-code
M975
Stand-by M-code
M976
Stand-by M-code
M977
Stand-by M-code
M978
Stand-by M-code
M979
Stand-by M-code
M980
Stand-by M-code
M981
Stand-by M-code
M982
Stand-by M-code
M983
Stand-by M-code
M984
Stand-by M-code
M985
Stand-by M-code
M986
Stand-by M-code
M987
Stand-by M-code
M988
Stand-by M-code
M989
Stand-by M-code
M990
Stand-by M-code
M991
Stand-by M-code
M992
Stand-by M-code
M993
Stand-by M-code
M994
Stand-by M-code
M995
Stand-by M-code
M996
Stand-by M-code
M997
Stand-by M-code
APP-27
Remarks
- NOTE-
APP-28
Notes:
APP-29
Drawing No.
1372ST00012
Unit: mm
1.
1. If B = 90, the tool lengths that can be
measured using the TOOL EYE are
limited.
2. If B = 0, when a special chuck or long
jaws are mounted the tool lengths that
can be measured using the TOOL EYE
may be limited.
3.
BT40 spec.
Stroke Diagram
INTEGREX 100-
(Metric)
APP-30
Notes:
Drawing No.
1372ST00041
INTEGREX 100-
(Inch)
APP-31
Notes:
Drawing No.
1372ST00022
Unit: mm
INTEGREX 100-
S
(Metric)
APP-32
Notes:
Drawing No.
1372ST00051
INTEGREX 100-
S
(Inch)
APP-33
Notes:
Drawing No.
1372ST00032
Unit: mm
INTEGREX 100-
ST
(Metric)
APP-34
Notes:
Drawing No.
1372ST00062
INTEGREX 100-
ST
(Inch)
APP-35
Drawing No.
DOM./EX.
Main spindle
Hollow chuck of 8"
1373PGD0011
Unit: mm (in.)
Stroke Diagram
INTEGREX 200-III
III
APP-36
Drawing No.
DOM./EX.
Main spindle
Hollow chuck of 8"
Secondary spindle
Hollow chuck of 8"
1373PGD0021
Unit: mm (in.)
INTEGREX 200-II
III
IIIS
APP-37
Drawing No.
DOM./EX.
Main spindle
Hollow chuck of 8"
1373PGD0031
Unit: mm (in.)
INTEGREX 200-II
III
IIIT
APP-38
Drawing No.
DOM./EX.
Main spindle
Hollow chuck of 8"
Secondary spindle
Hollow chuck of 8"
1373PGD0041
Unit: mm (in.)
INTEGREX 200-II
III
IIIST
APP-39
Drawing No.
1373PGD0110
Unit: mm (in.)
DOM./EX.
Main spindle
Hollow chuck of 8"
Work rest spec.: SLU2Z/SMW
INTEGREX 200-III
III (with work rest)
APP-40
Drawing No.
1373PGD0120
Unit: mm (in.)
DOM./EX.
Main spindle
Hollow chuck of 8"
Secondary spindle
Hollow chuck of 8"
Work rest spec.: SLU2Z/SMW
INTEGREX 200-III
IIIS
III (with work rest)
Stroke diagram (INTEGREX 200-IIIT) - for Lower turret with milling capability -
APP-41
1373PGD0050
Drawing No.
Unit: mm (in.)
DOM./EX.
Main spindle
Hollow chuck of 8"
INTEGREX 200-III
IIIT
III (for Lower turret with milling capability)
Stroke diagram (INTEGREX 200-IIIST) - for Lower turret with milling capability -
APP-42
Drawing No.
DOM./EX.
Main spindle
Hollow chuck of 8"
Secondary spindle
Hollow chuck of 8"
1373PGD0060
Unit: mm (in.)
INTEGREX 200-III
IIIST
(for Lower turret with milling capability)
III
APP-43
Drawing No.
MAIN SPINDLE
DOM./EX.
1374PGD0020
10" CHUCK
(THROUGH HOLE)
Unit: mm (in.)
Note:BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")
Stroke Diagram
INTEGREX 300-
(1000U, 10" hollow chuck)
APP-44
Drawing No.
MAIN SPINDLE
1374PGD0050
10" CHUCK
(THROUGH HOLE)
10" CHUCK
SECONDARY SPINDLE (THROUGH HOLE)
DOM./EX.
Unit: mm (in.)
INTEGREX 300-
S
(1000U, 10" hollow chuck)
APP-45
Drawing No.
MAIN SPINDLE
DOM./EX.
1374PGD0040
12" CHUCK
(THROUGH HOLE)
Unit: mm (in.)
Note:BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")
INTEGREX 400-
(1000U, 12" hollow chuck)
APP-46
Drawing No.
MAIN SPINDLE
1374PGD0060
10" CHUCK
(THROUGH HOLE)
10" CHUCK
SECONDARY SPINDLE (THROUGH HOLE)
DOM./EX.
Unit: mm (in.)
INTEGREX 400-
S
(1000U, 12" hollow chuck)
APP-47
Drawing No.
MAIN SPINDLE
DOM./EX.
1374PGD0140
10" CHUCK
(THROUGH HOLE)
Unit: mm (in.)
Note:BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")
INTEGREX 300-
(1500U, 10" hollow chuck)
APP-48
Unit: mm (in.)
Drawing No.
MAIN SPINDLE
1374PGD0170
10" CHUCK
(THROUGH HOLE)
10" CHUCK
SECONDARY SPINDLE
(THROUGH HOLE)
DOM./EX.
Note:BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")
INTEGREX 300-II
II
IS (1500U, 10" hollow chuck)
Fig. 1-13 Stroke diagram (INTEGREX 300-T [1500U, 10" hollow chuck])
APP-49
Drawing No.
MAIN SPINDLE
DOM./EX.
1374PGD0200
10" CHUCK
(THROUGH HOLE)
Unit: mm (in.)
Note:BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")
INTEGREX 300-II
II
IT (1500U, 10" hollow chuck)
APP-50
Unit: mm (in.)
Drawing No.
MAIN SPINDLE
1374PGD0230
10" CHUCK
(THROUGH HOLE)
10" CHUCK
SECONDARY SPINDLE (THROUGH HOLE)
DOM./EX.
Note:BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")
INTEGREX 300-II
II
IST (1500U, 10" hollow chuck)
APP-51
Drawing No.
MAIN SPINDLE
DOM./EX.
1374PGD0160
12" CHUCK
(THROUGH HOLE)
Unit: mm (in.)
Note:BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")
INTEGREX 400-
(1500U, 12" hollow chuck)
APP-52
Unit: mm (in.)
Drawing No.
MAIN SPINDLE
1374PGD0180
12" CHUCK
(THROUGH HOLE)
10" CHUCK
SECONDARY SPINDLE
(THROUGH HOLE)
DOM./EX.
Note:BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")
INTEGREX 400-II
II
I S (1500U, 12" hollow chuck)
APP-53
Drawing No.
MAIN SPINDLE
DOM./EX.
1374PGD0220
12" CHUCK
(THROUGH HOLE)
Unit: mm (in.)
Note:BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")
INTEGREX 400-II
II
IT (1500U, 12" hollow chuck)
APP-54
Unit: mm (in.)
Drawing No.
MAIN SPINDLE
1374PGD0240
12" CHUCK
(THROUGH HOLE)
10" CHUCK
SECONDARY SPINDLE
(THROUGH HOLE)
DOM./EX.
Note:BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")
INTEGREX 400-II
II
IST (1500U, 12" hollow chuck)