Maintenance, Operation

& Programming (Primer)

for
VTC-16 / 20 / 30 Machining Centers
(Mazatrol M-Plus)
Publication # C430MA0526E

4/97

CAUTION:
• This manual is published to assist experienced personnel in the operation,
maintenance and/or programming of Mazak machine tools, and is not intended
to be used as training documentation.
• 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.
SAFETY PRECAUTIONS
The machine is provided with a number of safety 6) Do not deface, scratch or remove any caution
devices to protect personnel and equipment from plate. Should it become illegible or missing,
injury and damage. Operators should not, order another caution plate from the supplier,
however, rely solely upon these safety devices, specifying the part number shown at the lower
but should operate the machine only after fully right corner of the plate.
understanding what special precautions to take by • BEFORE POWERING UP
reading the following documentation thoroughly.
DANGER:
• BASIC OPERATING PRACTICES
Cables, cords or electric wires whose insulation
DANGER: is damaged can produce current leaks and
1) Some control panels, transformers, motors, electric shocks. Before using, check their
junction boxes and other parts have high condition.
voltage terminals. These should not be touched WARNING:
or a severe electric shock may be sustained. 1) Be sure the instruction manual and the
2) Do not touch any switches with wet hands. programming manual are fully understood
This too, can produce an electric shock. before operating the machine. Every function
WARNING: and operating procedure should be completely
1) The emergency stop pushbutton switch clear.
location should be well known, so that it can be 2) Use approved oil resistant safety shoes, safety
operated at any time without having to look for goggles with side covers, safe clothes, and
it. other safety protection required.
2) Before replacing a fuse, turn off the main 3) Close all NC unit, operating panel, electric
incoming power switch to the machine. control panel doors and covers.
3) Provide sufficient working space to avoid CAUTION:
hazardous falls. 1) The power cable from the factory feeder switch
4) Water or oil can make floors slippery and to the machine main circuit breaker should
hazardous. All floors should be clean and dry have a sufficient sectional area to handle the
to prevent accidents electric power used.
5) Do not operated any switch without a thorough 2) Cables which must be laid on the floor must be
understanding of the actions about to be taken. protected from hot chips, by using rigid or
other approved conduit, so that short-circuits
6) Avoid accidental operation of switches.
will not occur.
7) Work benches near the machine must be
3) Before first time operation of the machine after
strong enough to hold materials placed on
unpacking it or from being idle for a long period
them to prevent accidents. Articles should be
of time (several days or more), each sliding
prevented from slipping off the bench surface.
part must be sufficiently lubricated. To do so,
8) If a job is to be done by two or more persons, push and release the pump button several
coordinating signals should be given at each times until the oil seeps out on the sliding
step of the operation. The next step should not parts. The pump button has a return spring, so
be taken unless a signal is given and do not force it to return.
acknowledged.
4) Oil reservoirs should be filled to indicated
CAUTION: levels. Check and add oil, if needed.
1) In the event of power failure, turn off the main 5) For lubrication points, oil specification and
circuit breaker immediately. appropriate levels, see the various instruction
2) Use the recommended hydraulic oils, lubricants plates.
and grease or acceptable equivalents. 6) Switches and levers should operate smoothly.
3) Replacement fuses should have the proper Check that they do.
current ratings. 7) When powering the machine on, turn on the
4) Protect the NC unit, operating panel, electric switches in the following order: first the factory
control panel, etc. from shocks, since this feeder switch, then the machine main circuit
could cause a failure or malfunction. breaker, and then the control power on switch
5) Do not change parameters or electrical located on the operating panel.
settings. If changes are unavoidable, record 8) Check the coolant level, and add coolant, if
the values prior to the change so that they can needed.
be returned to their original settings, if
necessary.

S-1
• AFTER CONTROL POWER IS TURNED ON
CAUTION:
When the control power “ON” switch on the 4) Tools and other items around the machine or
operating panel is on, the "READY" lamp on equipment should be stored to ensure good
the operating panel should also be on (check to footing and clear aisles.
see that it is). 5) Do not place tools or any other items on the
• ROUTINE INSPECTIONS headstock, turret, covers and similar places
WARNING: (For T/M).
When checking belt tensions, do not get your CAUTION:
fingers caught between the belt and pulley. 1) Tool lengths should be within specified
CAUTION: tolerances to prevent interference.
1) Check pressure gages for proper readings. 2) After installing a tool, make a trial run.
2) Check motors, gear boxes and other parts for • OPERATION
abnormal noises. WARNING:
3) Check the motor lubrication, and sliding parts 1) Do not work with long hair that can be caught
for evidence of proper lubrication. by the machine. Tie it back, out of the way.
4) Check safety covers and safety devices for 2) Do not operate switches with gloves on. This
proper operation. could cause mis-operation.
5) Check belt tensions. Replace any set of belts 3) Whenever a heavy workpiece must be moved,
that have become stretched with a fresh if there is any risk involved, two or more people
matching set. should work together.
• WARM UP 4) Only trained, qualified workers should operate
CAUTION: forklift trucks, cranes or similar equipment and
apply slings.
1) Warm up the machine, especially the spindle
and feed shaft, by running the machine for 10 5) Whenever operating a forklift truck, crane or
to 20 minutes at about one-half or one-third the similar equipment, special care should be taken
maximum speed in the automatic operation to prevent collisions and damage to the
mode. surroundings.
2) The automatic operation program should cause 6) Wire ropes or slings should be strong enough
each machine component to operate. At the to handle the loads to be lifted and should
same time, check their operations. conform to the mandatory provisions.
3) Be particularly careful to warm up the spindle 7) Grip workpieces securely.
which can turn above 4000 rpm. 8) Stop the machine before adjusting the coolant
If the machine is used for actual machining nozzle at the tip.
immediately after being started up following a 9) Never touch a turning workpiece in the spindle
long idle period, the sliding parts may be worn with bare hands, or in any other way.
due to the lack of oil. Also, thermal expansion 10) To remove a workpiece from the machine other
of the machine components can jeopardize than by a pallet changer, stop the tool and
machining accuracy. To prevent this condition, provide plenty of distance between the
always make sure that the machine is warmed workpiece and the tool (for M/C).
up.
11) While a workpiece or tool is turning, do not
• PREPARATIONS wipe it off or remove chips with a cloth or by
WARNING: hand. Always stop the machine first and then
1) Tooling should conform to the machine use a brush and a sweeper.
specifications, dimensions and types. 12) Do not operate the machine with the chuck and
2) Replace all seriously worn tools with new ones front safety covers removed (For T/M).
to prevent injuries. 13) Use a brush to remove chips from the tool tip,
3) The work area should be adequately lighted to do not use bare hands .
facilitate safety checks. 14) Stop the machine whenever installing or
removing a tool.
15) Whenever machining magnesium alloy parts,
wear a protective mask.

S-2
 CAUTION:
CAUTION: 1) Thoroughly read and understand the safety
1) During automatic operation, never open the precautions in the instruction manual.
machine door. Machines equipped with the 2) Thoroughly read the whole maintenance
door interlock will set the program to single manual and fully understand the principles,
step. construction and precautions involved.
2) When performing heavy-duty machining, • MAINTENANCE OPERATION
carefully prevent chips from being accumulated DANGER:
since hot chips from certain materials can 1) Those not engaged in the maintenance work
cause a fire. should not operate the main circuit breaker or
• TO INTERRUPT MACHINING the control power "ON" switch on the
WARNING: operating panel. For this purpose, "Do not
When leaving the machine temporarily after Touch the Switch, Maintenance Operation in
completing a job, turn off the power switch on Progress!" or similar warning should be
the operation panel, and also the main circuit indicated on such switches and at any other
breaker. appropriate locations. Such indication should
be secured by a semi-permanent means in the
• COMPLETING A JOB reading direction.
CAUTION:
2) With the machine turned on, any maintenance
1) Always clean the machine or equipment. operation can be dangerous. In principle, the
Remove and dispose of chips and clean cover main circuit breaker should be turned off
windows, etc. throughout the maintenance operation.
2) Make sure the machine has stopped running, WARNING:
before cleaning. 1) The electrical maintenance should be done by
3) Return each machine component to its initial a qualified person or by others competent to do
condition. the job. Keep close contact with the
4) Check the wipers for breakage. Replace responsible person. Do not proceed alone.
broken wipers. 2) Overtravel limit and proximity switches and
5) Check the coolant, hydraulic oils and lubricants interlock mechanisms including functional parts
for contamination. Change them if they are should not be removed or modified.
seriously contaminated. 3) When working at a height, use steps or ladders
6) Check the coolant, hydraulic oil and lubricant which are maintained and controlled daily for
levels. Add if necessary. safety.
7) Clean the oil pan filter. 4) Fuses, cables, etc. made by qualified
manufacturers should be employed.
8) Before leaving the machine at the end of the
shift, turn off the power switch on the operating • BEFORE OPERATION & MAINTENANCE BEGINS
panel, machine main circuit breaker and factory WARNING:
feeder switch in that order. 1) Arrange things in order around the section to
• SAFETY DEVICES receive the maintenance, including working
1) Front cover, rear cover and coolant cover. environments. Wipe water and oil off parts and
provide safe working environments.
2) Chuck barrier, tail barrier and tool barrier (NC
software). 2) All parts and waste oils should be removed by
the operator and placed far enough away from
3) Stored stroke limit (NC software). the machine to be safe.
4) Emergency stop pushbutton switch. CAUTION:
• MAINTENANCE OPERATION PREPARATIONS 1) The maintenance person should check that the
1) Do not proceed to do any maintenance machine operates safely.
operation unless instructed to do so by the 2) Maintenance and inspection data should be
foreman. recorded and kept for reference.
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

S-3
 aaaaaaaa
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! WARNING

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

THE LOCKOUT PROCEDURE THAT FOLLOWS IS INTENDED TO SAFEGUARD PERSONNEL &

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

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

MAINTENANCE OR REPAIRS.

LOCKOUT PROCEDURE
1) THE LOCKOUT PROCESS MUST BE PERFORMED BY AUTHORIZED PERSONNEL ONLY.
2) INFORM ALL EFFECTED PERSONNEL OF YOUR INTENT TO LOCKOUT AND SERVICE THE
SPECIFIED MACHINE.
3) SHUT OFF MACHINE POWER USING NORMAL SHUT DOWN PROCEDURES.
4) TURN OFF THE MACHINE AND INDIVIDUAL BUILDING CIRCUIT BREAKERS. MAKE SURE ALL
STORED ELECTRICAL ENERGY IS RELIEVED. (EG: SPINDLE & AXIS SERVO CONTROLLERS)
5) CONNECT THE LOCKOUT DEVICE AS SHOWN IN FIGURE 1, AND ATTACH THE APPROPRIATE
TAG AT THE MACHINE CIRCUIT BREAKER. THE TAG MUST IDENTIFY THE PERSON
RESPONSIBLE FOR THE LOCKOUT. THIS WILL ENSURE THAT POWER CANNOT BE
RESTORED BY ANYONE ELSE.
6) TEST THE MACHINE TO VERIFY THAT MACHINE SYSTEMS DO NOT OPERATE IN ANY WAY.
ONCE TESTING IS COMPLETE, MAKE SURE ALL SWITCHES ARE IN THE “OFF” POSITION.
CONFIRM THAT THE LOCKOUT DEVICES REMAIN PROPERLY INSTALLED.
7) COMPLETE THE REQUIRED MAINTENANCE OPERATIONS.
8) MAKE SURE ALL PERSONNEL ARE CLEAR OF THE MACHINE.
9) REMOVE THE LOCKOUT DEVICE. MAKE SURE ALL PERSONNEL ARE AT A SAFE LOCATION
BEFORE RESTORING MACHINE POWER.

PADLOCK

FIGURE

S-4
INSTALLATION PRECAUTIONS
The following subjects outline the items that 6) In pouring grout, fasten the leveling block
directly affect the machine installation and start- base plates with the collar retaining screws
up. To ensure an efficient and timely installation, to prevent the base plates from dropping.
please follow these recommendations before When the grout has completely hardened,
calling to schedule a service engineer. level the machine properly, and tighten M24
nuts to secure the machine to the
foundation.
• ENVIRONMENTAL REQUIREMENTS
Note:
Avoid the following places for installing the
machine: The machine must be anchored to the
foundation with J-bolts, expansion bolts or
1) Avoid exposure to direct sunlight and/or near a other suitable method.
heat source, etc. Ambient temperature during
operation: 0° thru 45°C (32°F to 113°F). The machine accuracy and alignment
specifications quoted by Mazak can usually
2) Avoid areas where the humidity fluctuates be obtained when the minimum foundation
greatly and/or if high humidity is present; requirements are met. However, production
normally 75% and below in relative humidity. A of close tolerance parts requires the use of an
higher humidity deteriorates insulation and appropriate certified foundation. Foundations
might accelerate the deterioration of parts. that do not meet certified specifications may
3) Avoid areas that are especially dusty and/or require more frequent machine re-leveling and
where acid fumes, corrosive gases and salt are re-alignment, which can not be provided
present. under terms of warranty.
4) Avoid areas of high vibration. If any of these conditions cannot be met,
5) Avoid soft or weak ground (minimum load contact the nearest Mazak service office
bearing capacity of 1025 lbs./ft2) 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 Desirable Independent Grounding:
distribution panel, such as arc welders and high
frequency machinery.
3) Arrange for a qualified electrician to connect NC Earth resistance:
the power lines. Machine Less than 100 ohms
4) Incoming supply voltage should not deviate
more than ±10% of specified supply voltage.
5) Source frequency should be±2 Hz of nominal Common Grounds:
frequency.

Resistance to ground
= 100 ÷ the number of
[ CAUTION ] devices connected to
the grounding (ohms)
VERIFY THE ACTUAL MACHINE ELECTRICAL
Note: Never ground equipment as shown below:
POWER REQUIREMENT AND THE MAIN
TRANSFORMER RATING (IF APPLICABLE), AS

WELL AS THE LOCAL ELECTRICAL CODE

BEFORE SIZING AND INSTALLING THE

INCOMING POWER WIRING.

PLEASE SEE THE ADDITIONAL CAUTIONS ON

THE FOLLOWING PAGE.

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

000X713-KY

S-6
 ! CAUTION

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

verify the transformer Kva rating (where applicable), as well as local electrical
code requirements before sizing and installing the incoming power wiring.
Machines not equipped with a main transformer are wired for 230 VAC, 3 phase.
The end user must supply a step-down transformer where factory electrical
power varies more than ± 10% of the 230 VAC rating.
NOTE:
Step-down or voltage regulating transformers are external (peripheral) to the
machine tool and are considered the primary input line (source) for the machine.
Local electrical code or practice may require a circuit breaker or other switching
device for the isolation of electrical power when this type of transformer is used.
In such cases, the machine tool end user is required to supply the necessary
circuit breaker or switching device.
FAILURE TO COMPLY CAN RESULT IN PERSONAL INJURY AND DAMAGE TO THE
MACHINE. IF ANY QUESTION EXISTS, CONTACT THE NEAREST MAZAK SERVICE
CENTER FOR ASSISTANCE.

S-7
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MACHINE DOCUMENTATION
CUSTOMER EVALUATION The Other Thoroughbred From Kentucky

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.
Date:
Machine Type: Machine Serial#: NC Type:
Customer: Reported By:
Address: Position:
Telephone#:
Manual Publication #: Excellent Good Adequate Fair Poor
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
Maintenance, Operation & Programming (Primer) for VTC-16 / 20 / 30 (M-Plus) Index
Table of Contents
Introduction (Specifications) 1
Machine Installation Requirements 2
Machine Operation Panel 3
(Maintenance)
Machine Systems (Maintenance) 4
Preventative Maintenance (Schedule) 5
Mazatrol Programming (Primer) 6
Appendix (PLC Alarms) Appx
 Maintenance & Operation
for
VTC-16 / 20 / 30 Machining Centers
(MAZATROL M-PLUS)

Table of Contents
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-1 PURPOSE OF THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-2 OPTIMUM CUSTOMER SERVICE & SUPPORT NETWORK . . . . . . . . . . . . . . . . . . . 1-2
1-3 MACHINE DESCRIPTION AND SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-3-1 MACHINE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-3-2 AXIS ORIENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-3-3 MACHINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6E
1-4 MACHINE LIFTING & TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8E
1-5 LIST OF RELATED DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10E
2. MACHINE INSTALLATION REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-1 ENVIRONMENTAL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-2 FOUNDATION REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-3 INSTALLATION CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-4 ELECTRICAL POWER REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-4-1 POWER CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-4-2 CHECKING THE MACHINE BEFORE POWER ON . . . . . . . . . . . . . . . . . . . . 2-7
2-5 INITIAL MACHINE TEST RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-5-1 CHECKING THE MACHINE BEFORE OPERATION . . . . . . . . . . . . . . . . . . . . 2-8
2-5-2 CHECKING PARAMETER SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-5-3 CHECKING MANUAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-5-4 CHECKING IN AUTOMATIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
3. MACHINE OPERATION PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-1 CRT DISPLAY AREA DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-2 LAYOUT OF SPECIAL FUNCTION KEYS, PUSHBUTTONS, SWITCHES &
INDICATOR LAMPS ON THE M-PLUS OPERATING PANEL . . . . . . . . . . . . . . . . . . . 3-3
3-3 DESCRIPTION OF FUNCTION KEYS, PUSHBUTTONS & SWITCHES . . . . . . . . . . . 3-5
3-4 MACHINE OPERATION PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3-4-1 INITIAL MACHINE POWER ON & ZERO RETURN . . . . . . . . . . . . . . . . . . . . . 3-18
3-4-2 AXIS RETURN TO #1 HOME POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3-4-3 TOOL CHANGE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3-4-3a AUTO TOOL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3-4-3b MANUAL TOOL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3-4-4 MANUAL AXIS MOVEMENT USING THE HANDWHEEL . . . . . . . . . . . . . . . . . 3-26
3-4-5 RUNNING THE MACHINE IN AUTOMATIC CYCLE . . . . . . . . . . . . . . . . . . . . 3-27
3-4-6 TOOL LENGTH MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3-4-6a AUTOMATIC TOOL LENGTH MEASUREMENT . . . . . . . . . . . . . . . . . 3-30
3-4-6b SEMIAUTOMATIC TOOL LENGTH MEASUREMENT . . . . . . . . . . . . . 3-32

Publication # C430MA0526E
3/97

C-1
 3-4-7 SETTING THE SPINDLE TOOL NO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3-4-8 TEACHING WPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3-4-8a TEACHING WPC (Using a tool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3-4-8b MEASURING WPC (Using the Probe) . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3-4-9 COMPLETING TOOL LAYOUT & TOOL DATA . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3-4-9a COMPLETING THE TOOL LAYOUT PAGE . . . . . . . . . . . . . . . . . . . . 3-41
3-4-9b COMPLETING THE TOOL DATA PAGE . . . . . . . . . . . . . . . . . . . . . . . 3-43
3-4-10 TOOL PATH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
3-5 INSERTING TOOLS INTO THE TOOL MAGAZINE . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
3-6 MACHINE OPERATION MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3-6-1 MACHINE WARM-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3-6-2 AUTOMATIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3-6-3 CHANGING THE CUTTING CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3-6-4 WORK AREA SHIFT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
3-6-5 STOPPING AUTOMATIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
3-6-6 INSPECTION DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
3-7 STOPPING MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
3-7-1 EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
3-7-2 FEED HOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
3-7-3 OPERATION STOP BY POWER OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
4. MACHINE SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-1 ELECTRICAL - VTC-16A, B & VTC-20B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-1-1 ELECTRICAL PARTS LAYOUT (Location of switches & solenoids) . . . . . . . . . 4-1
4-1-2 ELECTRICAL DEVICE LISTS - VTC-16A, B & VTC-20B . . . . . . . . . . . . . . . . . 4-3
4-2 ELECTRICAL - VTC-20C & 30C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-2-1 ELECTRICAL PARTS LAYOUT (Location of switches & solenoids) . . . . . . . . . 4-5
4-2-2 ELECTRICAL DEVICE LISTS - VTC-20C & 30C . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-3 PROXIMITY SWITCH ADJUSTMENT & SPECIFICATION . . . . . . . . . . . . . . . . . . . . . 4-10
4-4 #1 HOME POSITION GRID ADJUSTMENT PROCEDURE (Zero Return Limit Switch) . 4-10
4-5 #2 HOME POSITION ADJUSTMENT PROCEDURE (Tool change position) . . . . . . . . 4-13
4-5-1 X AXIS #2 HOME POSITION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4-5-2 Y AXIS #2 HOME POSITION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4-5-3 Z AXIS #2 HOME POSITION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4-6 LUBRICATION SYSTEM (Sliding surfaces & ballscrews) . . . . . . . . . . . . . . . . . . . . . 4-17
4-6-1 LUBRICATION UNIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4-6-2 LUBRICATION SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4-6-3 LUBRICATION SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4-6-4 LUBRICATION PUMP COMPONENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-6-5 LUBRICATION SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-7 PNEUMATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-7-1 PNEUMATIC SYSTEM SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-7-2 PNEUMATIC SYSTEM COMPONENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4-7-3 PNEUMATIC SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4-7-4 AIR FILTER / REGULATOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4-8 COOLANT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

C-2
 4-9 MECHANICAL ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4-9-1 COLUMN & SPINDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4-9-1a SPINDLE HEAD CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4-9-1b TOOL CLAMP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4-9-1c SPINDLE COOLING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4-9-2 TOOL STORAGE MAGAZINE & CHANGER (ATC) . . . . . . . . . . . . . . . . . . . . . 4-27
4-9-2a TOOL STORAGE MAGAZINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 4-27
4-9-2b TOOL STORAGE MAGAZINE & ATC TROUBLESHOOTING . . . . . . . . 4-28
5. PREVENTATIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-1 MAINTENANCE CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-2 PERIDODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
6. INTRODUCTION TO MAZATROL PROGRAMMING ............................ 6-1
6-1 COMPONENTS OF A MAZATROL PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2 COORDINATE SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-2-1 MACHINE COORDINATES SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-2-2 WORKPIECE COORDINATES SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-2-3 MACHINE COORDINATES SYSTEM AND WORKPIECE COORDINATES SYSTEM 6-5
6-2-4 BASIC COORDINATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-2-5 AUXILIARY COORDINATES (Offsets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-3 PREPARING FOR MACHINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6-3-1 MACHINING PREPARATION FLOWCHART . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6-3-2 PART DRAWINGS AND STOCK MATERIAL . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6-4 REGISTRATION OF TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6-4-1 DISPLAYING THE TOOL FILE SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6-5 CREATING SIMPLE PROGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6-5-1 PROGRAM STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6-5-2 CALLING UP THE WK. PROGRAM DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . 6-20
6-5-3 ASSIGNING WORKPIECE NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
6-5-4 CREATING A PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
6-5-5 CREATING THE COMMON UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
6-5-6 CREATING THE BASIC COORDINATES SYSTEM UNIT . . . . . . . . . . . . . . . . 6-26
6-5-7 CREATING A FACE MACHINING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
6-5-8 LINE MACHINING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
6-5-9 POINT MACHINING UNIT (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
6-5-10 POINT MACHINING UNIT (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
6-5-11 END UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
6-5-12 END OF THE PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
6-6 REGISTRATION OF TOOLS IN THE TOOL DATA FILE . . . . . . . . . . . . . . . . . . . . . . 6-63
6-6-1 POCKET NUMBERS AND TOOL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
6-6-2 TOOL DATA DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
6-6-3 TOOL LAYOUT DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
6-6-4 REGISTRATION OF TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68
6-7 CHECKING THE MACHINING PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-71
7. APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appx-1
7-1 MACHINE PLC ALARMS (200 - 400 series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appx-1
7-2 M CODE LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appx-27
7-3 CNC MISOPERATION RECOVERY REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . Appx-30

C-3
Notes:

C-4
1. INTRODUCTION
1-1 PURPOSE OF THIS MANUAL
Mazak is committed to the highest levels of customer service and support. If a

machine problem is encountered, contact the nearby service office of the Mazak
Optimum customer service and support network for assistance.

This manual is provided as a quick reference to basic machine and CNC functions. It
should, however, be used in conjunction with the operation and programming manuals

also supplied.

[ NOTE ]

Level 1, and level 2 advanced maintenance classes covering

Mazak machines and Mazatrol CNC control systems are

available at the Technical Training Center in Florence, Kentucky.

These classes provide in-depth troubleshooting procedures not

shown in this manual, that can be carried out only by qualified

personnel.

Contact the nearest Mazak service center or the national training

center for additional information.

Mazak machines are engineered 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 machine documentation

thoroughly.

[ CAUTION ]

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 questions exist, contact the nearest

Mazak service center for assistance.

1>1
1-2 OPTIMUM CUSTOMER SERVICE & SUPPORT NETWORK

1. North Central Technical Center (Florence, Ky.) ............................ (606) 342-1775

Technical Training Center (Florence, Ky.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (606) 342-1482

2. Midwest Technical Center (Chicago, Il.) ................................. (847) 885-8311

3. Canada Service Center (Mississauga, Ont.) .............................. (905) 670-0201

4. East Technical Center (Hartford, CT.) .................................. (860) 528-9511

5. Southeast Technical Center (Atlanta, Ga.) ............................... (770) 996-1030

6. Southwest Technical Center (Houston, Tx.) .............................. (281) 931-7770

7. West Technical Center (Los Angeles, Ca.) ............................... (310) 327-7172

MAZAK After Hours Customer Support Hotline . . . . . . . . . . . . . . . . . . . . . . . (800) 231-1456

1>2
1-3 MACHINE DESCRIPTION AND SPECIFICATION
1-3-1 MACHINE LAYOUT

Tool Storage Magazine

Counterbalance cylinder

Z Axis servo motor Mazatrol M-Plus

CNC Control

Work Table

Spindle

Coolant tank

Counterbalance
accumulator

X Axis servo motor Column

Lubrication
Electrical Control Panel pressure switch

Spindle
cooling unit

Lubrication unit Y Axis servo

motor
Base
Pneumatic unit Saddle
(air filter/regulator)

1>3
1-3-2 AXIS ORIENTATION

Machine Coordinate System

1>4
1-3-3 MACHINE SPECIFICATIONS

VTC-16A VTC-16B
Strokes
X axis (table) 22 inches (560mm) 44 inches (1120mm)
Y axis (column) 16.14 inches (410mm)
Z axis (headstock) 20.79 inches (510mm)
Table top to Spindle nose 4.33 inches to 24.4 inches (110mm-620mm)
From Column to Spindle center 18.1 inches(460mm)
Table
Table Size 35.4" x 16.1" (900mmx410mm) 37.5"x16.1" (1460mmx410mm)
Load Capacity 660 lbs. (300kg) 1210 lbs. (549kg)
Spindle
Spindle speed range 60--8,000 rpm (10,000 optional)
Spindle taper No. 40 taper
Spindle cooling unit 4 gallon capacity, Mobil Velocite No. 3
Feed Rates
Rapid traverse X, Y=787 IPM (20m/min) ; Z=590 IPM (15m/min)
Cutting feed rate 0.04--196.9 IPM (1--5000 mm/min)
Jog feed rate 0.08--78.7 IPM (1--2000 mm/min)
Automatic Tool Change System
Tool shank Cat No. 40
Tool magazine capacity 24
Max. tool diameter 3.1 inches (80mm)
Max. tool length 13.8 inches (350 mm)
Max. tool weight 17.6 lbs. (8kg)
Motors
Spindle (5 min/30 min /continuous) AC11kW (15 HP) / 7.5 kW (10HP) / 5.5kW (7.5HP)
Coolant pump 180W
Power Requirements
Electrical power 230 VAC, 3 phase, 30 KVA
Air supply 5kgf/cm2 (71 PSI) @ 28 CFM minimum
(6.4 CFM when not using the workpiece air blast)
Tank Capacity
Coolant reservoir 37 gal. (140 L) 81 gal. (306 L)
Lubrication
Tank capacity: 1.8 liter ( .48 gallon)
Specified lubricant: Mobil Vactra 2 or equivalent
Machine Dimensions
Height 103.5 inches
Floor space 88.8"x105.9"(2200mmx2730mm) 119.7x105.9(3040mmx2730mm)
Weight 8580 lbs. (3900kg) 11,700 lbs. (5307kg)

1>6E
MACHINE SPECIFICATIONS (Cont’d)

VTC-20B VTC-20C
Strokes
X axis (table) 44 inches (1120mm) 65.35 inches (1660 mm)
Y axis (column) 16.1 inches (510mm)
Z axis (headstock) 20.1 inches (510mm)
Table top to Spindle nose 4.3 inches to 24.4 inches (110mm-620mm)
From Column to Spindle center 22.1 inches(560mm)
Table
Table Size 57.48" x 20.08" 78.74" x 20.08"
Load Capacity 1764 lbs.
Spindle
Spindle speed range 60--8,000 rpm (10,000 optional)
Spindle taper No. 40 taper
Spindle cooling unit 4 gallon capacity, Mobil Velocite No. 3
Feed Rates
Rapid traverse X, Y=787 IPM (20m/min) ; Z=590 IPM (15m/min)
Cutting feed rate 0.04--196.9 IPM (1--5000 mm/min)
Jog feed rate 0.08--78.7 IPM (1--2000 mm/min)
Automatic Tool Change System
Tool shank Cat No. 40
Tool magazine capacity 24 24 x 2
Max. tool diameter 3.1 inches (80mm)
Max. tool length 13.8 inches (350 mm)
Max. tool weight 17.6 lbs. (8kg)
Motors
Spindle (5 min/30 min /continuous) AC11kW (15 HP) / 7.5 kW (10HP) / 5.5kW (7.5HP)
Coolant pump 180W
Power Requirements
Electrical power 230VAC , 3 phase, 30 KVA
Air supply 5kgf/cm2 (71 PSI) @ 28 CFM minimum
(6.4 CFM when not using the workpiece air blast)
Tank Capacity
Coolant reservoir 37 gal. (140 L) 81 gal. (306 L)
Lubrication
Tank capacity: 1.8 liter ( .48 gallon)
Specified lubricant: Mobil Vactra 2 or equivalent
Machine Dimensions
Height 106 inches
Floor space 119.7 x 105.9(3040mmx2730mm) 222.83 x 165.84(5660mmx4212.5mm)
Weight 12,000 lbs. 13,600 lbs.

1>7E
MACHINE SPECIFICATIONS (Cont’d)

VTC-30C
Strokes
X axis (table) 65.35 inches
Y axis (column) 29.92 inches
Z axis (headstock) 26 inches
Table top to Spindle nose 8.07 inches to 228.94 inches
From Column to Spindle center 31.8 inches
Table
Table Size 78.74" x 29.92"
Load Capacity 3000 lbs.
Spindle
Spindle speed range 40--8,000 rpm (10,000 optional)
Spindle taper No. 40 taper
Spindle cooling unit 4 gallon capacity, Mobil Velocite No. 3
Feed Rates
Rapid traverse X, Y=787 IPM (20m/min) ; Z=590 IPM (15m/min)
Cutting feed rate 0.04--196.9 IPM (1--5000 mm/min)
Jog feed rate 0.08--78.7 IPM (1--2000 mm/min)
Automatic Tool Change System
Tool shank Cat No. 40
Tool magazine capacity 24 x 2
Max. tool diameter 3.1 inches (80mm)
Max. tool length 13.8 inches (350 mm)
Max. tool weight 17.6 lbs. (8kg)
Motors
Spindle (5 min/30 min /continuous) AC11kW (15 HP) / 7.5 kW (10HP) / 5.5kW (7.5HP)
Coolant pump 180W
Power Requirements
Electrical power 230VAC , 3 phase, 30 KVA
Air supply 5kgf/cm2 (71 PSI) @ 28 CFM minimum
(6.4 CFM when not using the workpiece air blast)
Tank Capacity
Coolant reservoir 108 gal.
Lubrication
Tank capacity: 1.8 liter ( .48 gallon)
Specified lubricant: Mobil Vactra 2 or equivalent
Machine Dimensions
Height 112 inches
Floor space 222.83 x 165.84(5660mmx4212.5mm)
Weight 18,600 lbs.

1>8E
1-4 MACHINE LIFTING & TRANSPORTATION
Machine gross weight:

VTC-16A: 8,580 lbs. VTC-20C: 13,600 lbs.

VTC-16B: 11,700 lbs. VTC-30C: 18,600 lbs.
VTC-20B: 12,000 lbs.

Cable carrier
Electrical
control Cable carrier
cabinet
Electrical
control
cabinet

Steel bars

Steel bars

NOTE: To prevent possible damage to the cable carrier, remove the front mounting

screws before lifting the machine.

[ WARNING ]

The machine is slightly heavier on the electrical control cabinet

side (right, rear corner). Make sure the machine is properly

balanced when lifting.

1>9E
Lift the machine as described below:

1) Position the spindle head to the lower position, the saddle to the middle,

and the column to the forward position, and secure them with the
shipping clamps.

2) Insert two steel bars, 2 1/4” in diameter and a minimum of 6 feet long,

into the holes in the base. For safe lifting of the machine, use slings or

cables of sufficient capacity.

3) When lifting the machine, be sure no slings or cables exert strain on any
weak or projecting parts (hoses and components, NC control panel or

any other devices). Rags or wooden block should be placed at all points

where lifting wires or cable contact finished surfaces.

4) Tighten all filler caps and drain plugs before lifting the machine.

5) When moving the machine and equipment using rollers placed on the

floor, utmost care should be taken not to give any detrimental shock to
the equipment. Special care is required to prevent damaging any control

switches and indicators.

1>10E
1-5 LIST OF RELATED DOCUMENTATION
The following documentation is provided for use with the VTC-16/20 machining center.

Please use the Manual Evaluation form supplied with this manual for any comments and
suggestions for improvement. Thank you for your interest.

Machine and NC Control Manuals

Manual Name Description

* Pre-Installation Guide General information and installation

instuctions.

VTC-16/20/30 Operating manual General information and operation

procedures. Includes tooling information.

MAZATROL M-Plus Operating All aspects of CNC programming

manual

MAZATROL M-Plus Conversational All aspects of Mazatrol programming

Programming manual

MAZATROL M-Plus EIA/ISO All aspects of EIA/ISO programming

Programming manual

MAZATROL M-Plus Alarm and NC & machine alarms and setting

Parameter manual parameters

Mechanical Parts list Part procurement

Electric wiring diagram Electrical connections, PLC and NC electrical

parts

Optional Equipment manuals Programming and operation information for

machine optional equipment

1>11E
Notes:

1>12E
2. MACHINE INSTALLATION REQUIREMENTS
The following subjects outline the items that directly affect the machine installation and

start-up. To ensure an efficient and timely installation, please follow these

recommendations before calling to schedule a service engineer.

2-1 ENVIRONMENTAL REQUIREMENTS

Avoid the following places for installing the machine:

1) Avoid exposure to direct sunlight and/or near to 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 / weak ground (minimum load bearing capacity of 1025 lbs./ft2)

2-2 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).

This method is accomplished as follows:

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.

2-1
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.

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.

[ CAUTION ]

ANCHORING THE MACHINE TO THE FOUNDATION IS REQUIRED TO

ENSURE CONSISTANT MACHINE ACCURACY AND RELIABILITY.

This can be accomplished using a suitable anchoring method of the

customer’s choosing.
The machine accuracy and alignment specifications quoted by Mazak can

usually be obtained when minimum foundation requirements are met.

However, foundations that do not meet basic specifications may require

more frequent machine re-leveling and re-alignment, not normally provided

under terms of warranty.

If any of these conditions cannot be met, please contact the nearest

Mazak service center for assistance.

[ NOTE ]

For the machine foundation diagram, see the VTC-16/20/30 Pre-Installation

Guide, publication # C430GA0520E.

2-2
2-3 INSTALLATION CONSIDERATIONS
To ensure safe operation and accuracy of the VTC-16/20/30, please note the following

during installation:

1) Wiring

a) Use only electrical conductors with performance ratings equivalent or superior

to those described on page 2-6.

b) 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.

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

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

supply voltage.

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

2) Grounding

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.

The wire size should be greater than AWG (American Wire Gauge) No. 5 and
SWG (British Legal Standard Wire Gauge) No. 6.

2-3
 Desirable Independent Grounding:

Earth resistance:
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:

3) Air supply

The incoming air supply pressure should be at least 5 kgf/cm2 (71.1 PSI) at 28

CFM minimum flow rate. (6.4 CFM when not using workpiece air blast)

[ CAUTION ]

Excessive moisture in the incoming air supply will damage

pneumatic components resulting in premature failure and

machine malfunction. To prevent this, the incoming air supply

line should be equipped with a water trap and air dryer/lubricator

system.

2-4
4) Centralized Lubrication System

The centralized lubrication system supplies a metered amount of oil to the linear

guides and axis ballscrews. System specifications are as follows:

Tank capacity: 1.8 liter (.48 gallon)

Specified lubricant: Mobil Vactra #2

Tonna T68 (SHELL)

Febis K68 (ESSO)

5) Cleaning and Preparation

Machined (non-painted) portions are coated with a rust preventing grease for

protection in shipment. Remove it with rags dipped in a kerosene based solvent

after setting the secondary concrete. After cleaning, lightly coat the sliding surfaces

with the specified lubrication oil.

[ CAUTION ]

Take care while cleaning so that the cleaning solvent does not
penetrate the way wipers.

6) Spindle Cooling Unit

The temperature of the spindle is controlled by coolant circulated through the

cartridge housing. The spindle cooling unit, consisting of a pump and heat

exchanger, is mounted at the rear of the column. The fluid specification is as

follows:

Tank capacity: 4 gallons

Fluid specification: Mobil Velocite No. 3

[ CAUTION ]

Use only the oils or lubricants specified in the maintenance

manual or machine tag. The use of substitute fluids is not

recommended.

2-5
2-4 ELECTRICAL POWER REQUIREMENTS
2-4-1 POWER CAPACITY

Power capacity 30 KVA

Frequency 50/60 Hz ±1%

Voltage 230 VAC ± 10%, 3-Phase

Wire Size at 230v #4

Note 1: In addition to the above conditions, there should be no external noise (due to
electric welding, etc.). A ground rod of the grounding class 3 or above,

separated from the commercial power source must be provided near the
machine.

Note 2: The above figures are applicable only to the standard machine, without
optional equipment.

! CAUTION

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

verify the transformer Kva rating (where applicable), as well as local electrical
code requirements before sizing and installing the incoming power wiring.
Machines not equipped with a main transformer are wired for 230 VAC, 3 phase.
The end user must supply a step-down transformer where factory electrical
power varies more than ± 10% of the 230 VAC rating.
NOTE:
Step-down or voltage regulating transformers are external (peripheral) to the
machine tool and are considered the primary input line (source) for the machine.
Local electrical code or practice may require a circuit breaker or other switching
device for the isolation of electrical power when this type of transformer is used.
In such cases, the machine tool end user is required to supply the necessary
circuit breaker or switching device.
FAILURE TO COMPLY CAN RESULT IN PERSONAL INJURY AND DAMAGE TO THE
MACHINE. IF ANY QUESTION EXISTS, CONTACT THE NEAREST MAZAK SERVICE
CENTER FOR ASSISTANCE.

2-6
2-4-2 CHECKING THE MACHINE BEFORE POWER ON

1) Check wiring and hoses.

2) Check supply voltage and frequency. The machine is set to meet the customer's

specifications. For confirmation, verify that the voltage and frequency of the power
source to be used conform to the specifications of the machine.

3) Check relays and connectors in NC unit and main transformer terminals.

Connections are securely tightened before shipment. However, they may be

loosened during transportation.

4) Phase sequence confirmation of the main power supply

Applying power to the NC unit with the incoming main power supply phase order
incorrect may cause problems, such as uncontrolled motor rotation and blown

fuses. Never turn NC unit power on until the main power supply phase order is
confirmed.

a) Using phase rotation meter:

Connect U-R, V-S and W-T as in the figure below, so that the phase tester

shows clockwise rotation.

Transformer
Phase Tester.

2-7
2-5 INITIAL MACHINE TEST RUN
2-5-1 CHECKING THE MACHINE BEFORE OPERATION

1) Verify that the lifting fixtures and shipping clamps are removed:

[ CAUTION ]

Operation without removing the shipping clamps may cause

personal injury and/or damage the machine.

Locations of Shipping Clamps

Tool Magazine
Y Axis

VTC-16A/B & 20B

X Axis

Z Axis (wood block)

Y Axis
VTC- 20C

Z Axis
(wood block) Tool
Tool Magazine Magazine
X Axis

2-8
 Locations of Shipping Clamps

VTC- 30C Y Axis

Z Axis
(wood block) Tool
Tool Magazine Magazine
X Axis

2-9
 2) Check for missing parts or accessories.

3) Check each part of the machine to be lubricated, to be sure that it is provided with

the specified amount of lubricating oil (centralized lubrication or lubrication for the
spindle head, table and magazine).

4) Drain any water from the air filter / regulator.

5) Check all hoses and piping connections.

6) Check the chip conveyor for proper installation and wiring.

2-5-2 CHECKING PARAMETER SETTINGS

Check the standard parameter settings by referring to the parameter table provided in

the control enclosure. (See the M-Plus Parameter & Alarm manual for details)

2-5-3 CHECKING MANUAL OPERATION

1) Check the following functions in manual operation:

° Spindle rotation

° X, Y and Z axis travel (both directions)

° Zero return

2) When in manual operation, use extreme care so that the tool does not contact the
workpiece or table.

3) Read the instruction manual carefully before making a manual tool change.

2-5-4 CHECKING IN AUTOMATIC OPERATION

1) Do not use a new program tape for automatic operation immediately. First,

perform single block operation or dry run to see that the tool does not interfere with
the workpiece, stroke is sufficient and the program has no errors. Also, see that

the program contains no useless actions.

2) Make sure that the tools in the tool magazine are placed in the correct pocket and

that the tool shank is free of chips or debris.

3) Is the workpiece securely fixed to the table or jig? Is it mounted accurately?

4) Do not overspray coolant or oil, if used.

5) Is the air supply pressure set at 5 kgf/cm2 (71 PSI) @ 28 CFM minimum? (6.4

CFM when not using the workpiece air blast)

6) Does the machine start position in automatic operation conform to the program?
(Generally, the machine zero point is used as the start point.)

2 - 10
3. MACHINE OPERATION PANEL
3-1 CRT DISPLAY AREA DESCRIPTIONS

The M-Plus operating panel consists of the NC and machine operating panels built into

one consol.

The screen above the operating panel is referred to as the CRT Screen. This screen

displays required information for programming and machine operation.

’ Cursor

X 0. W 1
Y 0. ( )
Z 0. U 0
‘ Data Display Area
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LIGHT LOCK

◊ Menu Display Area

÷ Alarm Display
“ Message Display Area

— Display Title Area ” Input Data Display Area

3-1
CRT Display Area Descriptions (Cont’d)

DISPLAY TITLE AREA

The title of the display is indicated.

MESSAGE DISPLAY AREA

Directions to the operator and messages are displayed in inquiry form.

INPUT DATA DISPLAY AREA

The value specified using a numeric key(s) is displayed (data specification).

DATA DISPLAY AREA

The main types of display data (such as the machining program contents,

information on machining shapes, tools, etc.) are indicated.

CURSOR

The cursor can be moved vertically or horizontally to input, change or erase data.

ALARM DISPLAY AREA

An alarm is displayed in this area when a machine or operation failure occurs.

MENU DISPLAY AREA

The names of the functions of the nine keys directly below the display screen are

displayed. The nine individual function names are referred to as menus.

[ NOTE ]

In this manual, the term “Data Specifications” refers to use of the numeric

keys to input data that is displayed in the Input Data Display Area (3), and
the term “Data Input” refers to the use of the INPUT key for

specified data displayed in the Data Display Area (4).

3-2
 3-2
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Feed hold
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pushbutton
Power ON
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pushbutton
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Power OFF
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Display select key

pushbuttons
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3-3
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Menu keys (9)

INDICATOR LAMPS ON THE M-PLUS OPERATING PANEL

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LAYOUT OF SPECIAL FUNCTION KEYS, PUSHBUTTONS, SWITCHES &

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Machine Operating Panel

Note: A small indicator lamp is located to the left side of each key on the operating

panel. These indicators are referred to as “key” lamps, and light up when

the keys are pressed or when the functions of the keys are available. The

function of that key is not available when the key lamp is off. Similar lamps

are also provided on the individual pushbuttons of the operating panel. They

light up when the pushbuttons are pressed or when the functions of the

pushbuttons are available. The function of that pushbutton is not available

when the key lamp is off.

3-4
3-3 DESCRIPTION OF FUNCTION KEYS, PUSHBUTTONS & SWITCHES
Please reference the M-Plus illustrations on pages 3-3 & 3-4 to locate the following:

1) CNC POWER ON pushbutton

Used to turn NC power ON.

2) CNC POWER OFF pushbutton

Used to turn NC power OFF.

3) DISPLAY SELECTOR Key

Used to change the display being indicated on the CRT screen to another

display. Pressing this key causes the display selection menu to be indicated

in the menu display area. Setting the desired display from the menu will

present a display on the CRT screen.

4) MENU Keys

Used to select special functions provided for each menu displayed in the

menu display area. The desired menu can be selected by pressing the

appropriate menu key.

5) MENU SELECTOR Key

Used to change menu displays. Although up to nine menus can normally be

displayed in the menu display area, it is possible to display the tenth and

subsequent menus by pressing this key. Note, however, that the maximum

number of menus that can be displayed varies with the type of display or with

operating requirements. This results in a condion where even if the menu

select key is pressed, it may not be possible to display all menus.

6) PROGRAM EDIT ENABLE switch

Used to specify whether or not a new program or new data is to be written. When

the key is inserted into this switch and then the switch is set to the ENABLE

position, it becomes possible to write a new program or new data. When this

switch is set to the LOCK position, no programs or data can be written.

7) CYCLE START pushbutton

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

operation, the green lamp of this button stays lit. The lamp of this button goes out

when automatic operation is aborted or terminated.

3-5
8) FEED HOLD pushbutton

Used to stop axis movement in the automatic operation mode. During a FEED

HOLD condition, the red pushbutton light stays on. At this time, the CYCLE

START pushbutton light will be off. To resume automatic cycle after it has been

stopped, press the CYCLE START pushbutton mentioned above.

9) AXIS MOVEMENT pushbuttons

Used to move an axis in the manual mode. Using these buttons, select the axis to

be moved and the direction of movement (+ or - ). The appropriate axis

continues moving while a button is held pressed, and stops moving when the

button is released.

10) ALL AXIS ZERO POINT RETURN pushbutton

Used to return all to the first zero point in the manual mode. When this button is

pressed and held down after pressing the first zero point return key , the Z-

axis will automatically return to the first zero point and all other axes (X, Y etc.) will

also return to the first zero point together. (When an additional axis provided,

fourth axis will also return).

11) SPINDLE START pushbutton

Used to rotate the spindle in the manual mode. The button indicator lamp stays lit

when the spindle is rotating.

SPINDLE STOP pushbutton

Used to stop the spindle in the manual mode.

SPINDLE ROTATION DIRECTION CHANGE pushbutton

Used to change the rotational direction of the spindle in the manual mode. The

rotational direction of the spindle changes each time this button is pressed. The

pushbutton light stays on while the spindle is rotating in a reverse direction, and is

off while the spindle is rotating in a normal (clockwise) direction.

SPINDLE JOG pushbutton

Used to jog the spindle in the manual mode. The spindle continues rotating while

this button is pressed, and stops rotating when this button is released.

3-6
12) EMERGENCY STOP pushbutton

Used to stop all machine actions in emergencies such as those where machine

trouble occurs. Pressing this button causes all machine actions to stop

immediately.

Releasing the EMERGENCY STOP

1) Turn the EMERGENCY STOP pushbutton “mushroom head” in the

direction of the arrow indicated on the switch (clockwise).

The EMERGENCY STOP switch lock should be released and the switch

returned to its original position.

2) To clear all alarms, press and hold the OT Clear Key then press

the RESET key on the NC operation panel.

3) Press the POWER ON pushbutton on the NC operating panel.

4) Carry out the ZERO POINT RETURN operation (See section 3-4-1)

13) MACHINE SETUP switch

If the switch is set to the TEST (invalid) position:

Opening the machine door during automatic operation will place the machine

into single block operation.

Opening the door during manual operation allows manual operations to be

carried out.

To automatically operate the machine under normal conditions, set this switch to

the AUTO position.

To operate the machine for trial, for example, set this switch to the TEST position.

14) (Not Specified)

3-7
15) RESET key

Used to reset the NC to its initial state. In the event of an alarm, the alarm display

can be cleared by pressing this key after the cause of the alarm has been

eliminated. If this key is pressed during automatic operation, all machine actions

will stop immediately and control of the NC will be returned to the head position of

the program being executed.

16) OT RELEASE key

Used to return a control axis to its moving area if the axis has reached a stroke

end (i.e. In the event of an axis overtravel). This key is also used to clear an

Emergency Stop state.

17) SCREEN OFF key

Used to temporarily blank out the CRT screen, thus prolonging the life of the CRT.

When this key is pressed, the entire display will disappear. If an alarm occurs,

however, details of the alarm will be displayed. The display will reappear once the

key is pressed again.

18) SPINDLE SPEED DISPLAY UNIT

Displays the actual spindle speed in automatic operation, or value of 1/10 of the

specified speed is displayed in manual operation.

19) SPINDLE SPEED OVERRIDE keys

Used to change the spindle speed in revolutions per minute (rpm) during automatic

operation or manual mode. The spindle speed increases by pressing the

key, and decreases by pressing the key.

In the automatic operation mode, the % lamp above the spindle speed display

section remains lit. By pressing the or key, the pre programmed

spindle speed is changed in 10% increments in the range from 0% to 150%. If

the pre programmed spindle speed is 2,000 rpm, the actual rotation speed of the

spindle becomes 2,000 x 150/100 = 3,000 rpm.

In the manual mode, the RPM lamp above the spindle speed display section stays

lit as shown below. By pressing the or key, the spindle speed is

overridden in 1 rpm increments from 0 to the maximum available value.

3-8
 In the following examples, — shows the spindle speed override in automatic mode

is set to 50% while example “ shows the override in manual mode is set to 500

rpm.

— “

Spindle speed override Spindle speed override

(Automatic operation mode) (Manual operation mode)

20) CUTTING SPEED DISPLAY UNIT

Displays the actual feedrate in automatic operation, or manual feedrate is displayed

in manual operation mode.

21) CUTTING FEED OVERRIDE keys

Used to change the cutting feedrate in the automatic operation mode or in the

manual mode. The cutting feedrate increases by pressing the key, and

decreases by pressing the key.

In the automatic operation mode, the % lamp above the cutting feedrate display

section remains lit as shown in Example —. By pressing the or key,

the pre programmed cutting feedrate is changed in 10% increments, in the range

from 0% to 200%.

Example — shows the cutting feedrate is overridden by 50%. That is, if the pre

programmed cutting feedrate is 1,000 mm/min (39.37 in/min), the actual cutting

feedrate becomes 1,000 x 150/100 = 1,500 mm/min (59.06 in/min).

In the manual mode, the 1/min lamp above the cutting feedrate display section

stays lit as shown in Example “. By pressing the or key, the cutting

feedrate is changed in the range from 0 to 2,000 mm/min (78.4 in/min).

3-9
 In the following examples, — shows the cutting feed override in automatic mode is

set to 150% while example “ shows the override in manual mode is set to 800

rpm.

— “

Cutting feedrate override Cutting feedrate override

(Automatic operation mode) (Manual operation mode)

[ WARNING ]

When operating the machine, take special care not to confuse the linear

axis Cutting Feedrate Override keys with the Spindle Speed Override

keys .

22) RAPID TRAVERSE RATE DECELERATION Indicator lamps

23) RAPID FEEDRATE OVERRIDE keys & Indicator lamps

Used to decrease the rapid feedrate, and lamps that indicate different rapid

feedrates. Usually, the 100% indicator lamp stays lit. Each time the RAPID

DECREASE key is pressed, indicator lamps 50%, R2, R1 and R0 come on,

in that order, and the rapid feedrate decreases to 50%, R2, R1, and R0,

respectively. (The R2, R1 and R0 values are set by parameter. Usually, R2 is

preset to 25%, R1 to 12% and R0 to 6%.) Each time the RAPID INCREASE key

is pressed, the indicator lamp directly above comes on. Pressing this key

resets the rapid feedrate that was changed.

3 - 10
24) MANUAL PULSE HANDLE FEED keys

Used to select the manual pulse feed function in the manual mode.

Pressing the x100 key allows an axis to be moved 0.01 inch per manual

pulse handle scale graduation.

Pressing the x10 key allows an axis to be moved 0.001 inch per manual

pulse handle scale graduation.

Pressing the x1 key allows an axis to be moved 0.0001 inch per manual

pulse handle scale graduation.

After pressing one of these three keys, a control axis can be moved through the

desired distance by first selecting the desired axis with the pulse feed axis selector

switch and then turning the manual pulse handle.

Note 1: For a 4 axis rotary turntable, the x100 key is not available.

Note 2: If the pulse feed axis selector switch is set to the OFF position, the

movement distance that has been specified using the , ,

keys become the step movement distance.

25) RAPID FEED key

Used to select the rapid feed function key in the manual mode. The rapid feedrate

can be increased or decreased by pressing this key and then pressing one of the

rapid feedrate override keys or ).

26) JOG FEED key

Used to select the cutting feed function key in the manual mode. The cutting

feedrate can be adjusted by pressing this key and then pressing one of the cutting

feed override keys . or

27) SECOND ZERO POINT RETURN key

Used to return an axis to the second zero point (zero point for ATC, zero point for

pallet change, etc.) in the manual mode. When an axis movement button is

pressed after pressing this key, the corresponding axis will return to the second

zero point.

3 - 11
28) FIRST ZERO-POINT RETURN key

Used to return an axis to the first zero point (machine zero point) in the manual

mode. When an axis movement button is pressed following depression of this key,

the corresponding axis will return to the first zero point. When the all axis zero

point return pushbutton is pressed after pressing this key, the Z-axis will return to

the first zero point and then all the other axes will return to the first zero point at

the same time.

29) MDI key

Used to select the MDI run mode. Press this key to auto run in accordance with

manually set data.

30) MEMORY key

Used to select the memory run mode. Press this key to auto run a program that is

pre stored within the NC equipment.

31) TAPE key

Used to select the tape run mode. Press this key to auto run a program that is pre

stored on paper tape.

32) SINGLE BLOCK key

The program will be excuted block by block when active.

33) SHIFT Key

Used to enter the address data value on the lower right corner of an address key.

34) COOLANT STOP key

Used to turn off the coolant supply pump.

35) COOLANT MENU key

Used to display the coolant menu in the menu display area.

36) MACHINE MENU key

Used to display various machine operations menu (ATC, Pallet, etc.)

38) INPUT key

Used to register the numeric data that has been displayed in the data specification

area. (INPUT refers to the loading of data into NC memory and display of the data

in the data display area.) Data is stored only when the INPUT key is pressed

following data entry using the numeric key(s).

3 - 12
39) CLEAR key

Used to clear the numeric data currently being displayed in the data specification

area. Press this key if incorrect data has been specified in the data specification

area. After clearing incorrect data with this key, specify correct data by using the

numeric key(s).

40) ADDRESS & NUMERIC keys

Used to specify alphanumeric values and display it in the data specifications area.

If a value less than one is to be displayed, the zero preceding the decimal point is

omitted.

Example: To display 0.005 in, press keys < . > < 0 > < 0 > < 5 > in
that order.

41) DATA CANCELLATION key

Used to clear data that has been set in the data display area. Press this key if

incorrect data has been specified or when clearing input data.

42) CURSOR keys

Used to call the cursor in the data display area or to move the blinking cursor in

the data display area. Press the CURSOR UP or CURSOR DOWN

key to move the cursor in the data display area. Use these keys to move the

cursor as shown.

Moves the cursor up to the line directly above.

Moves the cursor down to the next line.

Moves the cursor to the right on that line. If the cursor is already

positioned at the right end, pressing this key will move the cursor to the

left end of the next line.

Moves the cursor to the left on that line. If the cursor is already

positioned at the left end, pressing this key will move the cursor to the

right end of the line directly above.

When a cursor key is pressed and held down, the cursor will move continuously in

the corresponding direction.

3 - 13
43) SECOND ZERO POINT RETURN Indicator lamps

These lamps correspond to a linear axis and light up when an axis has been

returned to the second zero point. A lamp is provided for each axis. If the second

zero point is already set in the same position as the first zero point, the appropriate

second zero point return indicator lamp will also light up when an axis has been

returned to the first zero point.

44) FIRST ZERO POINT RETURN Indicator lamps

These lamps correspond to a linear axis and light up when an axis has been

returned to the first zero point. A lamp is provided for each axis.

45) VFC key

Used to change the preprogrammed cutting feedrate. During automatic operation,

the preprogrammed cutting feedrate may need to be changed using the SPINDLE

SPEEDOVERRIDE and the CUTTING FEEDOVERRIDE

keys. When the VFC key is pressed, the preprogrammed value being used is

replaced by the feedrate specified by the override keys.

NOTE: The VTC key is valid only with MAZATROL programs.

46) TPS key

Used to store tool tip position data into NC memory when a manual interruption

occurs. If a manual interruption occurs during automatic operation, pressing this

key to move an axis will cause the tool tip position data existing at that time to be

stored into NC memory. This key is used in cases such as those where automatic

operation will be restarted from the position in where a manual interruption

occured.

3 - 14
 47) M-PLUS NC STATUS INDICATOR LAMPS

The following table outlines NC status indicator lamps on the operating panel.

Name Description

READY Ready Status • This lamp takes a few seconds to light up after power is turned on,
indicator lamp indicating that the machine is ready for operation.
• No NC operations can be carried out until then.
BUSY Processor busy • This lamp lights up when the NC processor is in a calculation mode.
status indicator lamp When active, all machine functions are idle.
[Link] Program head • This lamp lights up when the NC is placed in its initial state in the
indicator light automatic operation mode.
• When this lamp is lit, the machining program will run from its head
position.
[Link] Program stop • This lamp lights up when machine actions come to a stop following
indicator lamp the completion of reading of M00 (program stop) or M01 (optional
stop) during automatic operation.
[Link] Machine failure • This lamp lights up in the event of a machine failure or NC
indicator light misoperation.
• The type of alarm will determine the actual machine state
(eg.: Feed hold or Emergency stop)
Please reference the M-Plus Parameter & Alarm manual for more
detailed information on a specific alarm.
[Link] Tool unclamped • This lamp lights up when the spindle unclamps a tool.
status indicator lamp
[Link] Spindle locked status • This lamp lights up when the spindle is in an oriented state.
indicator lamp • Tool unclamping by hand is possible while this lamp is lit.
NC ALARM NC alarm status • This lamp lights up if an alarm state occurs in the NC . At the
indicator lamp same time, details of the alarm are displayed in the alarm display
area.
Please reference the M-Plus Parameter & Alarm manual for more
detailed information on a specific alarm.

3 - 15
48) TOUCH SENSOR STATUS INDICATOR LAMPS (OPTION)

1) This lamp stays lit while power is being supplied to the touch sensor unit.

2) This lamp will light up when the touch sensors are mounted on the spindle and

preparations for measurement are completed. This lamp will go out when lamp (4)

lights up.

3) This lamp stays lit until the touch sensors have been removed from the spindle.

That is, the measurement cycle continues running until this lamp has gone out.

4) This lamp will light up when the probe at the end of a touch sensor comes into

contact with that portion of a workpiece or jig which is to be detected. When this

lamp lights up, lamp (2) will go out.

49) WINDOW key

Used to display a window on a screen.

50) PAGE keys

Used to call the previous or next page of a display.

51) DISPLAY SELECTION keys

Used to display varous operation & maintenance displays on the CRT screen:

Postion Display

Program Display

Tool Data Display

Selects the Calculator ON/OFF

User Parameter Display

Data I/O Display

3 - 16
3-4 MACHINE OPERATION PROCEDURES

The following procedures are supplied as a quick reference to common machine

operations. Please read the machine and CNC operation manuals for detailed

descriptions of all MAZATROL M-Plus functions.

The following procedures are included:

INITIAL MACHINE POWER ON & ZERO RETURN

AXIS RETURN TO #1 HOME POSITION

MDI TOOL CHANGE

MANUAL TOOL CHANGE

MANUAL AXIS MOVEMENT USING THE HANDWHEEL

RUNNING THE MACHINE IN AUTOMATIC CYCLE

AUTOMATIC TOOL LENGTH MEASUREMENT

SEMIAUTOMATIC TOOL LENGTH MEASUREMENT

COMPLETING TOOL LAYOUT & TOOL DATA

TEACHING WPC (Using a tool)

MEASURING WPC (Using a probe)

SETTING THE SPINDLE TOOL NO.

TOOL PATH CHECK

[ CAUTION ]

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 questions exist, contact the nearest Mazak service

center for assistance.

3 - 17
3-4-1 INITIAL MACHINE POWER ON & ZERO RETURN

Power ON
pushbutton

#1 Home position
lights

Rapid feedrate
override keys & lights

#1 Home position
Door interlock mode key
switch
NC Emergency stop
pushbutton
Axis movement
pushbuttons

Program edit
enable switch All-Axis zero point
return pushbutton

Notes:

3 - 18
1) Turn ON the main circuit breaker and make sure all EMERGENCY STOP

pushbuttons are reset.

2) Press the POWER ON pushbutton (green).

3) Using the RAPID FEEDRATE OVERRIDE keys , verify that the rapid feedrate

is set to the R2 level.

4) Zero return the Z, X and Y axes (in that order) as follows:

Using the axis movement pushbuttons, press the AXIS MINUS (-) pushbutton for

the desired axis until the axis stops moving minus and begins moving plus (+).

Note: If the axis is at or near the end of minus stroke, use the handwheel in

X10 mode to move the axis in the plus direction before attempting

the zero return procedure.

If the axis moves more than 5 inches during zero return, release the

AXIS MINUS pushbutton and press the AXIS PLUS (+) pushbutton until

the axis #1 HOME POSITION indicator light illuminates.

X
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5) If an alarm occurs, make sure all doors are closed, the tool storage magazine is in

position and air is on.

3 - 19
3-4-2 AXIS RETURN TO #1 HOME POSITION

Power ON
pushbutton

#1 Home position
lights

Reset key

Rapid feedrate
override keys & lights

#1 Home position
Door interlock mode key
switch
NC Emergency stop
pushbutton
Axis movement
pushbuttons

Program edit
enable switch All-Axis zero point
return pushbutton

Notes:

3 - 20
1) Make sure the spindle head is in a safe place to move the axes to home position.

2) Press the RESET key .

3) Using the RAPID FEEDRATE OVERRIDE keys , slow the rapid feedrate to the

R2 level.

4) Press the #1 HOME POSITION MODE key .

5) Push and hold the ALL-AXIS ZERO POINT RETURN pushbutton until the #1

HOME POSITION INDICATORS light up.

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6) The Z axis will go home first and then X and Y at the same time.

3 - 21
3-4-3 TOOL CHANGE PROCEDURES

3) Command Screen key

9) Tool Change key

#1 Home position
Display Selector key lights

Menu Selector key

Reset key
#1 & #2 Home position
indicator lights

Rapid Feedrate
Override keys & lights

Input key

#2 Home Mode key

Axis Movement
pushbuttons
NC Emergency Stop
Cycle Start pushbutton pushbutton
Feed Hold pushbutton
All-Axis Zero Point
Return pushbutton

3-4-3a AUTO TOOL CHANGE

Note: The AUTO TOOL CHANGE procedure can not be completed until the the

ZERO RETURN procedure is completed and the magazine is at home

position. See the MANUAL TOOL CHANGE procedure, section 3-4-3b if a

problem occurs.

1) Make sure the spindle head is in a safe place to move the axes to home position.

2) Press the DISPLAY SELECTOR key.

3 - 22
 3) Press the COMMAND SCREEN menu key.

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POSITION COMMAND TRACE PROGRAM TOOL TOOL TOOL PAR DATA
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FILE DATA LAYOUT I/O

4) Press the RESET key .

5) Press the #1 HOME MODE key .

6) Press the ALL-AXIS ZERO POINT RETURN pushbutton and hold until all axes

have returned to the #1 HOME POSITION.

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7) Press the MDI MODE key .

8) Press the MENU SELECTOR key.

9) Press TOOL CHANGE menu key.

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TOOL TOOL M CODE T MSR T MSR MSR UNIT MSR UNIT

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SELECT CHANGE AUTO SEMIAUTO IN OUT

10) Enter the desired tool no. using the numeric key pad and press the INPUT key

3 - 23
 11) Using the RAPID FEEDRATE OVERRIDE keys , slow the rapid feedrate to the

R2 level.

12) Press the CYCLE START pushbutton.

13) The tool change is completed when the CYCLE START pushbutton is no longer

lighted.

14) The tool number will be displayed on either the POSITION or COMMAND display.

[ CAUTION ]

The auto tool change procedure will not be possible if the FEED

HOLD or EMERGENCY STOP pushbuttons are pressed during a tool

change. Use the manual tool change procedure to reposition the

axes, spindle and magazine to their positions.

3-4-3b MANUAL TOOL CHANGE

NOTE: Use this procedure only when the AUTO TOOL CHANGE procedure does not

work or in event of a FEED HOLD or EMERGENCY STOP condition while

attempting to change tools.

1) Take corrective action for any alarm displayed before proceeding. (See the M-Plus

Parameter & Alarm manual for detailed information.)

2) Rotate the tool magazine until the desired tool pocket is in position to accept the

tool. Make sure that the magazine pocket that is going to store the tool is empty.

3 - 24
 3) Move the Z and Y axes to the #2 home position.

4) Move the X axis to the #1 home position.

The HOME POSITION INDICATOR X

lights will illuminate as shown.

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5) Press the ATC MENU mode key.

6) Press the SPINDLE ORIENT menu key

( )
MAGAZINE MAGAZINE MAGAZINE MAGAZINE SPINDLE ATC COVR ATC COVR TOOL UN-
EXTEND RETRACT FORWARD REVERSE ORIENT OPEN CLOSE CLAMP OK

7) Press the ATC COVR OPEN menu key.

8) Press the MAGAZINE EXTEND Menu key.

9) Turn the TOOL CLAMP selector switch to the UNCLAMP position.

10) Move the Z axis to the #1 home position.

11) Press the MAGAZINE RETRACT menu key.

12) Press the ATC COVR CLOSE menu key.

13) Make sure the command screen has the correct information for the tool currently in

the spindle (See Setting The Spindle Tool No., section 3-4-7).

3 - 25
3-4-4 MANUAL AXIS MOVEMENT USING THE HANDWHEEL

1) In the handle mode, the handwheel is used to incrementally move the spindle head

(Z and Y axis) or work table (X axis).

2) Press the RESET key .

3) Press the desired X100, X10, or X1 mode key:

a) X100 Moves .01" per division.

b) X10 Moves .001" per division.

c) X1 Moves .0001" per division.

4) Turn the AXIS SELECTOR switch to the X, Y or Z position.

5) Move the handle (handwheel) slowly in the desired direction (+ or -).

6) When finished, turn the axis select to the OFF position.

[ CAUTION ]

To prevent accidental machine movement, make sure to always

return the axis selector switch to the OFF position at the end of an

operation.

3 - 26
3-4-5 RUNNING THE MACHINE IN AUTOMATIC CYCLE

Work No. menu key

3) Command Screen key

10) Coolant keys

Display Selector key

Menu Selector key

Reset key

Rapid feedrate
override keys & lights

Input key

Coolant Menu key

Memory Mode key

Cycle Start pushbutton

Feed Hold pushbutton

All-Axis zero point
return pushbutton

Complete the following before running the machine program in automatic cycle:

• Make the part program

• Load the proper tools into the magazine

• Make sure all tools are measured (See the AUTO TOOL LENGTH

MEASUREMENT procedure, section 3-4-6).

• Check the program using TOOL PATH CHECK (See section 3-4-11)

• Teach and/or measure the workpiece coordinates (See the TEACHING WPC

(Using a Tool) procedure, section 3-4-8 & MEASURING WPC (Using the

probe), section 3-4-9).

NOTE: Please see the M-Plus Operation Manual for a detailed explanation of

the workpiece coordinate system and WPC.

3 - 27
• Reduce the RAPID FEEDRATE OVERRIDE to R0

• Run through the program in the SINGLE BLOCK mode.

• Pressing the CYCLE START pushbutton, single step through the program

once very carefully while watching the screen on the POSITION display.

[ CAUTION ]

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 questions exist, contact the nearest Mazak service

center for assistance.

• Watch the distance remaining, buffer and next command on the COMMAND

DISPLAY screen.

3 - 28
 RUNNING THE MACHINE IN AUTOMATIC CYCLE (Cont’d)

1) Press the DISPLAY SELECTOR key.

2) Press the COMMAND SCREEN menu key.

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POSITION COMMAND TRACE PROGRAM TOOL TOOL TOOL PAR DATA
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FILE DATA LAYOUT I/O

3) Press the MEMORY MODE key .

4) Press the WORK NO. menu key.

5) Using the numeric keys, enter the program No.

WORK PIECE PROGRAM NUMBER? ( 1234 )

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WORK NO. WORK MACHINE SINGLE OPTIONAL DRYRUN BLOCK TEST RESTART
LIGHT LOCK BLOCK BLOCK SKIP

6) Press the INPUT key .

7) Press the RESET key .

8) Press the COOLANT MENU key .

9) Make sure all auto coolant selections are highlighted. If not, press the AUTO

COOLANT ON menu key.

10) Press the COOLANT MENU key .

11) Press the CYCLE START pushbutton.

3 - 29
3-4-6 TOOL LENGTH MEASUREMENT

3) Tool Data key

T MSR Auto key

Display Selector key T MSR Unit Out key

T MSR Unit In key

Reset key
Menu Selector key

Rapid Feedrate
Override keys & lights

Input key

MDI Mode key

#1 Home Mode key
Cycle Start pushbutton
Spindle Jog pushbutton
Feed Hold pushbutton
All-Axis zero point
return pushbutton

3-4-6a AUTOMATIC TOOL LENGTH MEASUREMENT

1) Press the DISPLAY SELECTOR key.

2) Press the TOOL DATA menu key.

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FILE DATA LAYOUT I/O

3) Press the #1 HOME MODE key .

4) Press the ALL-AXIS ZERO POINT RETURN pushbutton.

3 - 30
 5) Press the RESET key .

6) Press the MDI MODE key .

7) Press the MENU SELECTOR key.

8) Press the T MSR AUTO menu key.

TOOL NUMBER ? ( )

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TOOL TOOL M CODE T MSR T MSR MSR UNIT MSR UNIT

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SELECT CHANGE AUTO SEMIAUTO IN OUT

9) Enter the desired tool number to measure and press the INPUT key .

10) Using the RAPID FEEDRATE OVERRIDE keys , slow the rapid feedrate to the

R1 level.

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12) Press the CYCLE START pushbutton.

13) Wait until all machine and axis movement stops.

14) The number under length for the specified tool will change.

15) If the alarm, UNSUITABLE FOR MSR AUTO occurs, use the SEMIAUTOMATIC

TOOL MEASUREMENT Procedure that follows.

3 - 31
3-4-6b SEMIAUTOMATIC TOOL LENGTH MEASUREMENT

1) Move machine to the #1 Home position.

2) Place the desired tool to measure in the spindle (see AUTO TOOL CHANGE)

3) Press the RESET key .

4) Press the DISPLAY SELECTOR key.

5) Press the TOOL DATA menu key.

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FILE DATA LAYOUT I/O

6) Unorient the spindle by pressing the SPINDLE JOG pushbutton.

7) Press the X10 HANDLE MODE key .

8) Use the handwheel to position the cutter blade on the center of the tool measure

unit.

9) * Press the MDI MODE key .

10) * Press the MENU SELECTOR key.

11) * Press the MRS UNIT OUT menu key.

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SELECT CHANGE AUTO SEMIAUTO IN OUT

12) Use the handwheel to move the tool tip into position with the tool measurement

sensor. Position the tool tip so it will touch the tool measurement sensor when the

Z axis is moved in the negative direction.

13) Move the tool 4 inches away from the measurement sensor in the Z axis (+Z

moves up or away)

14) Press the MDI MODE key .

3 - 32
 15) Press the MENU SELECTOR key.

16) Press the T MSR SEMI AUTO menu select key.

MEAS. WITH SPINDLE TOOL<INPUT>? ( )

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TOOL TOOL M CODE T MSR T MSR MSR UNIT MSR UNIT

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17) Press the INPUT key .

18) Press the CYCLE START pushbutton (wait until all movement stops).

19) Move the machine to #1 Home position.

20) * Press the MDI MODE key .

21) * Press the MENU SELECTOR key.

22) * Press the MRS UNIT IN menu key.

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SELECT CHANGE AUTO SEMIAUTO IN OUT

* For machines with a retractable type tool measuring unit only.

3 - 33
3-4-7 SETTING THE SPINDLE TOOL NO.

This procedure is used to change the spindle tool number on the command screen so it

matches the tool in the spindle.

Display Selector key SP tool No. set key

Menu Selector key

Reset key
Numeric key pad

Input key

MDI Mode key

Cycle Start pushbutton

Feed Hold pushbutton

Notes:

3 - 34
1) Press the RESET key .

2) Press the MDI MODE key .

3) Press the MENU SELECTOR key twice.

4) Press the SP TOOL NO. SET menu key.

5) Enter the correct tool number from numeric key pad.

TOOL NUMBER ? ( 8)

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6) Press the INPUT key .

In this example, the current tool in the spindle will be shown on the COMMAND display

as “TNO. 8”.

3 - 35
3-4-8 TEACHING WPC

Menu keys

Display Selector key

Menu Selector key

Reset key

Handle mode
increment keys

Input key

MDI Mode key

Cycle Start pushbutton

3 - 36
3-4-8a TEACHING WPC (Using a tool)

This procedure is used to establish the workpiece coordinates for a specific part using a

tool. (See MEASURING WPC (Using a probe), section 3-4-8b )

1) Using the AUTO TOOL CHANGE procedure, section 3-4-3a, load a previously

measured tool where the exact center point is known. (EG.: Drill, edge

finder, etc.)

2) Using the handwheel, move the tool to the zero point of the part in the X axis.

Note: Turn the AXIS SELECTOR switch OFF when done.

3) Press the DISPLAY SELECTOR key.

4) Press the PROGRAM menu key.

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POSITION COMMAND TRACE PROGRAM TOOL TOOL TOOL PAR DATA

FILE DATA LAYOUT I/O

5) Press the WPC MSR menu key.

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WORK NO. SEARCH PROGRAM TOOL PROGRAM WPC DETAILED
EDIT PATH FILE MSR INFORM

6) Press the WPC SEARCH menu key.

WPC SEARCH <INPUT>? ( )

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WPC TEACH +X -X +Y -Y -Z
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SEARCH SENSOR SENSOR SENSOR SENSOR SENSOR

7) Press the INPUT key .

8) The CURSOR will flash at “0” under the “X” in the basic coordinates unit. If

not, use the CURSOR keys to position the cursor over X.

3 - 37
 9) Using the handwheel, slowly move the axis to lightly touch off the part.

Note: Turn the AXIS SELECTOR switch OFF when done.

10) Press the TEACH menu key.

WORK PIECE COORDINATE, WPC.X? ( )

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SEARCH SENSOR SENSOR SENSOR SENSOR SENSOR

11) Enter the compensation amount and direction that the axis would move to

place the center of the spindle over the center of the workpiece coordinates

and press the INPUT key . (This is the distance from the machine zero

point to the workpiece zero point in the specified axis.)

12) Once the X value is entered, the cursor will move and flash at “0” under the

“Y” in the basic coordinates unit.

13) Repeat steps 2 through 7 for the Y axis.

14) Once the Y value is entered, the cursor will move and flash at “0” under the

“Z” in the basic coordinates unit.

15) Repeat steps 2 through 7 for the Z axis.

3-4-8b MEASURING WPC (Using the Probe)

1) Load the probe into the spindle using the AUTO TOOL CHANGE procedure,

section 3-4-3a.

2) Press the X100 INCREMENTAL FEED DISTANCE key .

3) Using the handwheel, move the probe close to the part Z axis face.

4) Press the DISPLAY SELECTOR key.

5) Press the WPC MSR menu key.

NEW PROGRAM <PROGRAM>? ( )

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EDIT PATH FILE MSR INFORM

3 - 38
 6) Press the WPC SEARCH menu key.

WORK PIECE COORDINATE, WPC.Z? ( )

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WPC TEACH +X -X +Y -Y -Z
a
a
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SEARCH SENSOR SENSOR SENSOR SENSOR SENSOR

7) Press the INPUT key .

Note: If more than one WPC is used, press the WPC SEARCH menu key to

move to the next WPC.

8) Press the MDI MODE key .

9) Press the MENU SELECTOR key three times only. (If the MENU SELECTOR

key is pressed too many times, repeat step 4)

10) Press the -Z SENSOR menu key.

WORK PIECE COORDINATE, WPC.Z? ( )

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WPC TEACH +X -X +Y -Y -Z
SEARCH SENSOR SENSOR SENSOR SENSOR SENSOR

11) Enter the coordinate value (distance) and direction (+ or -) of the part at the

current position and press the INPUT key .

12) Press the CYCLE START pushbutton. The probe will move down until it

touches the part, then move back to the starting position.

13) Using the handwheel, move the probe close to the part X axis face with the

probe tip low enough to touch the side.

14) Press the MDI MODE key .

15) Press the MENU SELECTOR key three times only.

3 - 39
 16) Press the -X SENSOR or +X SENSOR menu key, depending on which

direction the axis should move.

WORK PIECE COORDINATE, WPC.X? ( )

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WPC TEACH +X -X +Y -Y -Z

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SEARCH SENSOR SENSOR SENSOR SENSOR SENSOR

17) Enter the coordinate value (distance) and direction (+ or -) of the part at the

current position and press the INPUT key .

18) Press the CYCLE START pushbutton. The probe will move until it touches

the part, then move back to the starting position.

Note: The machine will enter the SINGLE BLOCK mode automatically when

the operator door is open.

19) Repeat steps 13 through 18 for the Y axis using the +Y SENSOR and -Y

SENSOR keys.

3 - 40
3-4-9 COMPLETING TOOL LAYOUT & TOOL DATA

The tool layout page shows which tools are required in a program and allows the

operator to assign them to the appropriate magazine pocket.

Menu keys

Display Selector key

Menu Selector key

Reset key

Input key

3-4-9a COMPLETING THE TOOL LAYOUT PAGE

1) Press the DISPLAY SELECTOR key.

2) Press the TOOL LAYOUT menu key.

( )
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POSITION COMMAND TRACE PROGRAM TOOL TOOL TOOL PAR DATA

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FILE DATA LAYOUT I/O

3 - 41
 3) Enter the desired workpiece number and press the INPUT key .

Note: Use PKNO SHIFT only, PKNO ASSIGN will automatically assign a

magazine pocket number sequentially to all tools with a “0”

(undetermined) in the NEXT PKNO. column.

POCKET [Link] <INPUT>? ( )

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WORK NO. DRUM NO. SPARE T PKNO. PKNO. PKNO. SPARE T LAYOUT NEXT

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ERASE CLEAR SHIFT ASSIGN ADDITION FINISH PAGE

4) The tools already assigned to a pocket number will show as highlighted. If all

tools are highlighted, then proceed to step #7.

5) Use the CURSOR keys to position the cursor on the tool not

highlighted.

6) Enter the correct tool pocket number for each unlit tool.

7) Press the LAYOUT FINISH menu key and press the INPUT key .

Notes:

3 - 42
3-4-9b COMPLETING THE TOOL DATA PAGE

1) Press the DISPLAY SELECTOR key.

2) Press the TOOL DATA menu key.

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POSITION COMMAND TRACE PROGRAM TOOL TOOL TOOL PAR DATA

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FILE DATA LAYOUT I/O

3) Use the CURSOR keys to position the cursor on required data.

4) Enter a tool length value of 15." for each unmeasured tool. This value will

prevent a crash in the event that a tool is not measured.

5) Enter all required data.

NOTE: Thrust and horsepower, assume 100% when a “0” is showing.

These do not need to be changed until parts are cut and the results

indicate adjustment is necessary.

When using a TAP, be sure to place the correct data in the AUX. column.

0 = Floating holder 1 = Fixed holder

3 - 43
3-4-10 TOOL PATH CHECK

Menu keys

Display Selector key

Menu Selector key

Reset key

Input key

Tool path is used to check the program to see if tools are on the correct side and check

for alarms that may occur in the program.

1) Press the DISPLAY SELECTOR key.

2) Press the PROGRAM menu key.

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POSITION COMMAND TRACE PROGRAM TOOL TOOL TOOL PAR DATA

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FILE DATA LAYOUT I/O

3 - 44
 3) Press the TOOL PATH menu key.

NEW PROGRAM <PROGRAM>? ( )

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WORKNO. SEARCH PROGRAM TOOL PROGRAM WPC DETAILED

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EDIT PATH FILE MSR INFORM

4) Press the SHAPE CONTINUE menu key.

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PATH PATH SHAPE SHAPE PATH PROGRAM STORE PLANE SCALE

CONTINUE STEP CONTINUE ERASE ERASE SELECT

5) Press the PATH CONTINUE menu key.

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PATH PATH SHAPE SHAPE PATH PROGRAM STORE PLANE SCALE

CONTINUE STEP CONTINUE ERASE ERASE SELECT

3-5 INSERTING TOOLS INTO THE TOOL MAGAZINE

This section describes the procedure for placing tools into the tool magazine. Be

extremely careful in handling the tools and take the following into consideration.

* Arrange tools in the magazine so they are evenly distributed and well

balanced.

* The maximum weight of a tool is 17.6 lb (8 kg).

Insert tools into the magazine as follows:

1) Press the MDI key.

2) Open the machine operator’s doors and the tool access panel on the

magazine.

3 - 45
 3) Press and hold the MAGAZINE FORWARD or REVERSE key to rotate the

magazine in the desired direction until the required tool pocket arrives at the

tool setting position.

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MAGAZINE MAGAZINE MAGAZINE MAGAZINE SPINDLE ATC COVR ATC COVR TOOL UN-

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EXTEND RETRACT FORWARD REVERSE ORIENT OPEN CLOSE CLAMP OK

4) Insert the CAT type tool holder into the magazine so that the tool holder with

the “dimpled“ keyway is towards the magazine (drive keyway faces out) as

shown below.

Note position of the drive keyway

Dimpled keyway
CORRECT

INCORRECT

3 - 46
 [ CAUTION ]

When inserting a CAT type tool holder into the magazine, make

certain that the drive keyway faces out. The “drive keyway“ is

deeper than the “dimpled keyway”. Failure to follow these

instructions can result in machine damage or personal injury.

5) Position the groove of the tool at the end of the tool holder and so that the

tool is at right angles.

6) While holding the tool in both hands, push it into the tool holder.

[ WARNING ]

Never try to operate the switches on the operation panel when

wearing gloves. This may cause a machine malfunction or activate

an unwanted function.
Wearing gloves is recommended ONLY when inserting or removing

tools into the magazine.

[ NOTE ]

When inserting a tool, push it along the center line of the tool holder.

Never twist or turn the tool during insertion. Take care not to hit the
key on the tool holder with the keyway of the tool.

3 - 47
3-6 MACHINE OPERATION MODES
3-6-1 MACHINE WARM-UP

After completing the inspection procedure (see section 2-5), warm-up the machine as

follows:

1) Carry out automatic operation in steps of one-third to one-half to the

maximum speed, for 10 to 20 minutes.

2) The program for automatic operation should execute all the functions of every

unit.

3) Be extremely careful when warming up at spindle speeds above 4,000 rpm.

3-6-2 AUTOMATIC OPERATION

If a program and tool data has been proven in single block mode, the operator only has

to press the CYCLE START pushbutton to start the machine automatic cycle. During

automatic operation, however, the operator can change cutting conditions, temporarily

interrupt cycle or stop automatic operation.

This section describes the operations that can be performed during automatic operation

and the condition required to execute automatic operation.

3-6-3 CHANGING THE CUTTING CONDITION

During automatic operation, especially during trial cutting, cutting conditions may require

change depending upon the shape or volume of chips, the load status of the spindle

motor and Z axis servo motor indicated on the load meter and the roughness of finished

surfaces.

1) RAPID FEEDRATE OVERRIDE

Adjust the rapid feed speed using the 4 steps of 100%, 50%, 25% and F0,

with the RAPID FEEDRATE OVERRIDE keys . (See page 3-9 for

detailed information)

2) CUTTING FEED OVERRIDE

Adjust the cutting feed rate instructed in the program within the range of 0%

to 200%, with the FEEDRATE OVERRIDE keys . (See page 3-8

for detailed information)

3 - 48
 3) SPINDLE SPEED OVERRIDE

Adjust the spindle speed instructed on the program within the range of 50%

to 120%, with the SPINDLE SPEED OVERRIDE keys . (See

page 3-7 for detailed information)

3-6-4 WORK AREA SHIFT OPERATION

Two CYCLE pushbuttons are provided corresponding to machining areas 1 and 2.

These pushbuttons are used as a safety item to prevent remachining workpieces already

completed in the automatic operation mode and unexpected machine movement during

workpiece setup.

Once a workpiece setup is complete, press the appropriate CYCLE pushbutton to enable

machining. Note the corresponding light will illuminate. After machining is completed,

the indicator light will go out.

Work Area Shift

Placing a center plate on the table allows workpiece setup in one machining area while

the machine is in automatic operation on the other machining area.

[ CAUTION ]

Work area shift cannot be performed with a tool mounted in the

spindle. For example, a tool used in work area 1 must be returned to

tool magazine 1 before moving to work area 2.

Sample Machining Program

O1000
M71
Workpiece coordinate system setting in machining are 1
Machining program 1
T0
M72
Workpiece coordinate system setting in machining area 2
Machining program 2
T0
M99

3 - 49
 Note that work area shift is performed by the M71 / M72 M - Code commands or

automatic tool change (ATC) command. When using ATC commands, operation is

performed in the following sequence:

1) Spindle tool returned to tool magazine

2) Y / Z zero point return

3) X axis movement to adjacent work area

4) Load new tool into the spindle

The following conditions must be met to shift from one work area to the other:

1) All doors must be closed.

2) Any tool in the spindle must have been returned to the appropriate tool

magazine.

3) The appropriate CYCLE pushbutton for the new work area is active

(illuminated).

The following illustration shows work area safety devices:

Door Interlock switch Door Interlock switch

(Left door closed confirmation) (Right door closed
confirmation)

Work area center plate

CYCLE Pushbuttons
(Work Areas 1 & 2)

The headstock can pass to the adjacent workpiece setup once the following conditions

are met in the manual operation mode:

1) The Y and Z axes were returned to their #1 home position.

2) Both the HANDLE and JOG modes are active (valid).

3 - 50
3-6-5 STOPPING AUTOMATIC OPERATION

Automatic cycle may be interrupted to confirm the finish of a workpiece or in the event

of a more serious problem. Methods available for stopping automatic operation are

described below. Operators should practice such operations and be able to carry them

out rapidly in an emergency.

1) Press the EMERGENCY STOP pushbutton

2) Press the FEED HOLD pushbutton

3) Enable the SINGLE BLOCK function.

Automatic cycle will stop after completion of the block currently being

executed.

a) Press the DISPLAY SELECTOR key.

b) Press the POSITION or COMMAND menu key.

( )
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POSITION COMMAND TRACE PROGRAM TOOL TOOL TOOL PAR DATA

FILE DATA LAYOUT I/O

c) Press the SINGLE BLOCK menu key.

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WORK NO. WORK MACHINE SINGLE OPTIONAL DRYRUN BLOCK TEST RESTART
LIGHT LOCK BLOCK STOP SKIP

3 - 51
 4) OPTIONAL STOP

The optional stop function will stop automatic operation when a block with an

M01 command inserted is executed. However, even if M01 is inserted in a

block in a program, M01 is invalid without the following operations being

performed, that is even after the block is executed, the machine will not stop.

a) Prepare an M01 command inserted program, or edit an existing program

to insert M01 in a block at a location where you want to stop operation.

b) Press the DISPLAY SELECTOR key.

c) Press the POSITION or COMMAND menu key.

( )
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POSITION COMMAND TRACE PROGRAM TOOL TOOL TOOL PAR DATA

FILE DATA LAYOUT I/O

d) Press the OPTIONAL STOP key.

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WORK NO. WORK MACHINE SINGLE OPTIONAL DRYRUN BLOCK TEST RESTART
LIGHT LOCK BLOCK STOP SKIP

e) Begin automatic cycle by pressing the CYCLE START pushbutton.

1) The CYCLE START indicator lamp (green) will come on and

automatic cycle begin.

2) When the block with an M01 command inserted is complete,

automatic operation will stop. The CYCLE START indicator lamp

remains lit.

3) Pressing the CYCLE START pushbutton again restarts automatic

operation and the remaining blocks are executed.

3 - 52
 4) Each time the CYCLE START pushbutton is pressed, the

remaining blocks are executed, and, each time a block with an

M01 command inserted has been completely executed, automatic

operation will stop.

5) Program stop

When an M00 command is inserted in a block, automatic operation stops

when the block has been executed. This function is called the program stop.

a) Prepare an M00 command inserted program, or edit an existing program

to insert M00 in a block at a location where you want to stop the

automatic operation.

b) Press the CYCLE START pushbutton

1) The CYCLE START indicator lamp (green) comes on and

automatic operation starts.

2) When the execution of a block with an M00 command is complete,

auto operation stops. The CYCLE START indicator lamp goes out.

3) Pressing the CYCLE START pushbutton again restarts automatic

operation and the remaining blocks are executed.

4) If there is another block with an M00 command inserted in the

remaining blocks, automatic operation stops again when that block

has been executed completely.

5) Each time the CYCLE START pushbutton is pressed, the

remaining blocks are executed, and each time a block with an

M00 command inserted is completely executed, automatic

operation will stop.

6) When execution of the whole program has been completed, the

CYCLE START indicator lamp (green) will go out.

3 - 53
3-6-6 INSPECTION DURING OPERATION

Carry out the following inspections during machine operation.

1) Check whether any alarm message is displayed on the CRT screen.

a) If an alarm message is displayed, clear it by taking the appropriate action.

(See the M-Plus Parameter & Alarm manual for detailed information.)

b) Machine operation is stopped to reset an alarm.

c) If no alarm message is displayed, move on to the next step.

2) Check for abnormal noises in the pump mounted on the coolant tank.

a) If abnormal noises are heard, stop machine operation.

b) Investigate the cause by trouble shooting according to the separately provided

maintenance manual.

c) Take appropriate countermeasures.

3) Check whether any tool in the tool magazine or spindle is broken.

If a broken tool is found, stop the machine at the most suitable time to replace the

broken tool.

4) Check the machine and remove any misplaced tools or unnecessary items laying

on and around the machine work surface.

3-7 STOPPING MACHINE OPERATION

Normal machine operation can be stopped by pressing the EMERGENCY STOP

pushbutton, FEED HOLD pushbutton or the POWER OFF pushbutton.

3-7-1 EMERGENCY STOP

Press the EMERGENCY STOP pushbutton.

a) The EMERGENCY STOP pushbutton should lock in the depressed position.

b) An alarm message will be displayed on the CRT screen.

c) All machine operations and functions will stop.

3 - 54
3-7-2 FEED HOLD

Press the FEED HOLD pushbutton.

a) The FEED HOLD pushbutton indicator lamp (red) will come on.

b) All machine axes will decelerate and stop.

3-7-3 OPERATION STOP BY POWER OFF

Press the POWER OFF button on the NC operating panel.

a) All machine operations, including the NC will stop.

[ NOTE ]

Use the POWER OFF pushbutton only when the machine does not
stop by pressing the EMERGENCY STOP pushbutton.

3 - 55
Notes:

3 - 56
4. MACHINE SYSTEMS
4-1 ELECTRICAL - VTC-16A, B & VTC-20B
4-1-1 ELECTRICAL PARTS LAYOUT (Location of switches & solenoids)

4-1
ELECTRICAL PARTS LAYOUT - VTC-16A, B & VTC-20B

4-2
4-1-2 ELECTRICAL DEVICE LISTS - VTC-16A, B & VTC-20B
Device List: Pressure Switch (SPS)

Diagnostics
Device # Description Wire # Mazak Part # Vendor Part #
Address
1740 Lube Pressure X1D 1740 G23NL000150 PO.3-6

2504 Air Pressure X2E 2504 G23MSV00210 IS1000-C1-X201

Device List: Proximity Switch (SQP)

Diagnostics
Device # Description Wire # Mazak Part # Vendor Part #
Address
802 Tool Clamp X10 802 R25YB002610 FL7M-2J6D-L1
804 Tool Unclamp X11 804 R25YB002610 FL7M-2J6D-L1

814 Magazine Zero Point X00 814 R25YB002610 FL7M-2J6D-L1

816 Magazine In position X01 816 R25YB002610 FL7M-2J6D-L1

238 Tool Length Measure X24 238 R25YB002610 FL7M-2J6D-L1
Deceleration

239 Tool Length Measure Skip X17D 239 R25YB002610 FL7M-2J6D-L1

Device List: Limit Switch (SQL)

Diagnostics
Device # Description Wire # Mazak Part # Vendor Part #
Address
806 Z Axis Zero Point X1A 806 R25YB001110 SL1-EK

808 Y Axis Zero Point X19 808 R25YB001110 SL1-EK

810 X Axis Zero Point X18 810 R25YB001110 SL1-EK

812 4th Axis Zero Point X1B 810 R25YB001110 SL1-EK

828 4th Axis Unclamp X2D 828 R25YB001110 SL1-EK

846 Door Interlock Close X14 846

848 Door Interlock Open X15 848

Device List: Reed Switch (SQR)

Diagnostics
Device # Description Wire # Mazak Part # Vendor Part #
Address
818 Magazine Extend X02 818 R27SV000140 A57L
820 Magazine Retract X03 820 R27SV000140 A57L

819 Magazine Extend Decel X04 819 R27SV000140 A57L

821 Magazine Retract Decel X05 821 R27SV000140 A57L

824 Magazine Cover Open X06 824 G20SV01461A C73

826 Magazine Cover Close X07 826 G20SV01461A C73

4-3
ELECTRICAL DEVICE LISTS - VTC-16A, B & VTC-20B
Device List: Solenoid (YVS)

Diagnostics
Device # Description Wire # Mazak Part # Vendor Part #
Address
513 Tool Unclamp Y10 513 G50SV007410 VFS3420-1D-02

514 Tool Clamp Y11 514 G50SV007410 VFS3420-1D-02

516 Work Air Blast Y16 516 G50SV005950 VP542-1D-02A-B

523 Magazine Extend Decel Y00 523 G20SV014610 DZ323-1D-03

524 Magazine Retract Decel Y01 524 G20SV014610 DZ323-1D-03

525 Magazine Extend Y12 525 G50SV007420 VFS3220-1D-03

526 Magazine Retract Y14 526 G50SV007420 VFS3220-1D-03

1016 Magazine Cover Open Y1B 1844 G50SV006390 VFS1220-1D-01

1018 Magazine Cover Close Y1C 1848 G50SV006390 VFS1220-1D-01

AEX Measuring Arm Extend Y2C AEX

2504 Main Air --- AC1

Device List: Photo Switch (SQ)

Diagnostics
Device # Description Wire # Mazak Part # Vendor Part #
Address
181 Tool In Magazine X2F 381

Device List: Pumps & Motors

Diagnostics
Device # Description Wire # Mazak Part # Vendor Part #
Address
MTR-LU1 Lubrication Unit (Bijur) Y18 528-AC2 G06MBL00410 TM-1

MTR-LU Spindle Cooling Unit Y17 U2-V2-W2 G04ZZ001220 KSP-MA27J-100WCL

MTR-MG Magazine Forward Y02 520-AC2

MTR-MG Magazine Reverse Y03 522-AC2

MTR-CO Coolant pump Y19 U3-V3-W3

MTR-CH Chip conveyor Y20 U41-V41-

W41

4-4
4-2 ELECTRICAL - VTC-20C & 30C
4-2-1 ELECTRICAL PARTS LAYOUT (Location of switches & solenoids)

4-5
ELECTRICAL PARTS LAYOUT - VTC-20C & 30C

4-6
4-2-2 ELECTRICAL DEVICE LISTS - VTC-20C & 30C
Device List: Pressure Switch (SPS)

Diagnostics
Device # Description Wire # Mazak Part # Vendor Part #
Address
1740 Lube Pressure X1D 1740 G23NL000150 PO.3-6

2504 Air Pressure X2E 2504 G23MSV00210 IS1000-C1-X201

Device List: Proximity Switch (SQP)

Diagnostics
Device # Description Wire # Mazak Part # Vendor Part #
Address
802 Tool Clamp X10 802 R25YB002610 FL7M-2J6D-L1
804 Tool Unclamp X11 804 R25YB002610 FL7M-2J6D-L1

814 #1 Magazine Zero Point X00 814 R25YB002610 FL7M-2J6D-L1

816 #1 Magazine In position X01 816 R25YB002610 FL7M-2J6D-L1

864 #2 Magazine Zero Point X30 864 R25YB002610 FL7M-2J6D-L1

866 #2 Magazine In position X31 866 R25YB002610 FL7M-2J6D-L1

238 Tool Length Measure X24 238 R25YB002610 FL7M-2J6D-L1
Deceleration

239 Tool Length Measure Skip X17D 239 R25YB002610 FL7M-2J6D-L1

Device List: Limit Switch (SQL)

Diagnostics
Device # Description Wire # Mazak Part # Vendor Part #
Address
806 Z Axis Zero Point X1A 806 R25YB001110 SL1-EK

808 Y Axis Zero Point X19 808 R25YB001110 SL1-EK

810 X Axis Zero Point X18 810 R25YB001110 SL1-EK

812 4th Axis Zero Point X1B 810 R25YB001110 SL1-EK

828 X Axis Interlock #1 X38 828 R25YB001110 SL1-EK

830 Center Cover X3A 830 R25YB001110 SL1-EK

878 X Axis Interlock #2 X39 878 R25YB001110 SL1-EK

846 Door Interlock Close #1 X14 846

848 Door Interlock Open #1 X15 848

894 Door Interlock Close #2 X3D 894

896 Door Interlock Open #2 X3E 896

4-7
ELECTRICAL DEVICE LISTS - VTC-20C & 30C
Device List: Reed Switch (SQR)

Diagnostics
Device # Description Wire # Mazak Part # Vendor Part #
Address
818 Magazine #1 Extend X02 818 R27SV000140 A57L

820 Magazine #1 Retract X03 820 R27SV000140 A57L

819 Magazine #1 X04 819 R27SV000140 A57L
Extend Decel
821 Magazine #1 X05 821 R27SV000140 A57L
Retract Decel

824 Magazine #1 Cover Open X06 824 G20SV01461A C73

826 Magazine #1 Cover Close X07 826 G20SV01461A C73

868 Magazine #2 Extend X32 868 R27SV000140 A57L

870 Magazine #2 Retract X33 870 R27SV000140 A57L

869 Magazine #2 X34 869 R27SV000140 A57L
Extend Decel
871 Magazine #2 X35 871 R27SV000140 A57L
Retract Decel

874 Magazine #2 Cover Open X36 874 G20SV01461A C73

876 Magazine #2 Cover Close X37 876 G20SV01461A C73

Device List: Photo Switch (SQ)

Diagnostics
Device # Description Wire # Mazak Part # Vendor Part #
Address
181 Tool In Magazine #1 X2F 381
382 Tool In Magazine #2 X3F 382

Device List: Pumps & Motors

Diagnostics
Device # Description Wire # Mazak Part # Vendor Part #
Address
MTR-LU1 Lubrication Unit (Bijur) Y18 528-AC2 G06MBL00410 TM-1

MTR-LU Spindle Cooling Unit Y17 U2-V2-W2 G04ZZ001220 KSP-MA27J-100WCL

MTR-MG Magazine Forward Y02 520-AC2

MTR-MG Magazine Reverse Y03 522-AC2

MTR-CO Coolant pump Y19 U3-V3-W3

MTR-CH Chip conveyor Y20 U41-V41-

W41

4-8
ELECTRICAL DEVICE LISTS - VTC-20C & 30C
Device List: Solenoid (YVS)

Diagnostics
Device # Description Wire # Mazak Part # Vendor Part #
Address
513 Tool Unclamp Y10 513 G50SV007410 VFS3420-1D-02

514 Tool Clamp Y11 514 G50SV007410 VFS3420-1D-02

516 Work Air Blast Y16 516 G50SV005950 VP542-1D-02A-B

523 Magazine #1 Y00 523 G20SV014610 DZ323-1D-03

Extend Decel

524 Magazine #1 Y01 524 G20SV014610 DZ323-1D-03

Retract Decel

525 Magazine #1 Extend Y12 525 G50SV007420 VFS3220-1D-03

526 Magazine #1 Retract Y14 526 G50SV007420 VFS3220-1D-03

1016 Magazine #1 Cover Open Y1B 1844 G50SV006390 VFS1220-1D-01

1018 Magazine #1 Cover Close Y1C 1848 G50SV006390 VFS1220-1D-01

573 Magazine #2 Y30 573 G20SV014610 DZ323-1D-03

Extend Decel

574 Magazine #2 Y31 574 G20SV014610 DZ323-1D-03

Retract Decel
575 Magazine #2 Extend Y32 575 G50SV007420 VFS3220-1D-03

576 Magazine #2 Retract Y34 576 G50SV007420 VFS3220-1D-03

1066 Magazine #2 Cover Open Y39 1066 G50SV006390 VFS1220-1D-01

1068 Magazine #2 Cover Close Y3A 1068 G50SV006390 VFS1220-1D-01

AEX Measuring Arm Extend Y2C AEX

2504 Main Air --- AC1

4-9
4-3 PROXIMITY SWITCH ADJUSTMENT & SPECIFICATION
The distance between the detection surface of the proximity switch and object is set at

1 mm (0.04 in.). This gap can be adjusted by loosening the nuts on either side of the
mounting plate. Take care not to overtighten after adjusting the gap.

4-4 #1 HOME POSITION GRID ADJUSTMENT PROCEDURE (Zero Return Limit

Switch)
Each time machine power is turned on, the zero point return procedure must be carried
out to establish the machine coordinate system. (See section 3-5-1 INITIAL MACHINE

POWER ON & ZERO RETURN PROCEDURE on page 3-19).

#1 home position is preset and typically does not need to be adjusted, however, use the

following procedure if adjustment is necessary due to a change in the machine units.

(Eg.: home position dog, limit switch, ball screw, etc.)

1) Make note of the current machine constant parameter values for parameter N11.

[ NOTE ]

Make sure to write down the current value of any parameter before making

any changes so that the original value can be reentered if necessary.

2) Enter a new value of “0” for the X, Y & Z axes for parameter N11.

3) Turn NC power off, then restart and complete the zero point return procedure.
(The rapid approach feedrate can be altered with machine constant parameter M2.)

4 - 10
4) Using a gauge block (Z axis) or dial indicator (X & Y axis) move the axis from the
current #1 home position to the actual mechanical home position reference points

shown below.

X Axis Machine
Home Position
X Axis Stroke Values:
VTC-16A 22.00” (560 mm)
VTC-16B 44.00” (1120mm)
VTC-20B 44.00” (1120mm)
X Stroke VTC-20C 65.35” (1660mm)
VTC-30C 65.35” (1660mm)

Each axis mechanical #1 home position reference points:

X Axis home position: 170mm (6.6929”) from the edge of the table.

Y Axis home position: 205mm (8.0708”) from the center of the table.

Z Axis home position: 110mm (4.3307”) from the table. (-Z stroke end)

5) Make note of the axis position shown on the COMMAND display.

6) Adjust parameter N11 for actual X, Y & Z home position.

Example: If the distance from the edge of the table to the center T-slot (Y) is off

by .0630”, adjust parameter N11 (Y) to a value of 630.

4 - 11
 7) Turn NC power off, then restart and complete the zero point return procedure.

8) Make sure that the distance from the electrical home position to the point where

the home position limit switch first contacts the positioning dog is 0.197" (±0.098).
If not, adjust the dog and repeat steps 1 - 8.

9) Turn NC power off, then restart and complete the zero point return procedure.

10) Repeat step 4 to verify #1 home position accuracy.

( M2 )

( N11 )

[Stroke]

Stroke values: VTC-16A VTC-16B VTC-20B VTC-20C

X Axis: 22.00” (560 mm) 44.00” (1120mm) 4.00” (1120mm) 65.35” (1660mm)
Y Axis 16.14” (410 mm) 16.14” (410 mm) 20.79” (510 mm) 20.79” (510 mm)
Z Axis 20.79” (510 mm) 20.79” (510 mm) 20.79” (510 mm) 20.79” (510 mm)

Zero Return Sequence Diagram

4 - 12
4-5 #2 HOME POSITION ADJUSTMENT PROCEDURE (Tool change position)
4-5-1 X AXIS #2 HOME POSITION ADJUSTMENT

1) Manually place a tool in the magazine. Use a tool with a long shank, such as an

end mill holder.

2) Set a dial indicator on the shank of the tool in the magazine. Set the indicator to

"0".

3) Take the tool out of the magazine by firmly gripping the tool and pulling it out of the

magazine fingers.

4) Manually load this tool into the spindle:

a) Press the SPINDLE ORIENT menu key.

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MAGAZINE MAGAZINE MAGAZINE MAGAZINE SPINDLE ATC COVR ATC COVR TOOL UN-
EXTEND RETRACT FORWARD REVERSE ORIENT OPEN CLOSE CLAMP OK

b) When the spindle orient is completed, load the tool using the TOOL
UNCLAMP key switch.

4) Move the Y & Z axes to the #2 home position:

Press the #2 HOME POSITION key and manually move the Y & Z axes to
the #2 home position with the AXIS MOVEMENT pushbuttons.

5) Press the MAGAZINE EXTEND menu key to move the magazine to the spindle.
Make sure the headstock does not interfere with the magazine.

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EXTEND RETRACT FORWARD REVERSE ORIENT OPEN CLOSE CLAMP OK

6) Move the X axis in the + direction into the magazine fingers. Move by handle

pulse generator until dial indicator in magazine read 0, ± .008”.

7) Read the position value on the position page and note this value.

4 - 13
 8) Press the MAGAZINE RETRACT menu key to move to its home position.

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EXTEND RETRACT FORWARD REVERSE ORIENT OPEN CLOSE CLAMP OK

9) Set the value on the position page for X into parameter M5.

10) Recheck the X axis #2 home position values.

a) Press the #1 HOME POSITION key and manually move the X axis to

the #1 home position with the AXIS MOVEMENT pushbuttons.

b) Press the #2 HOME POSITION key and manually move the X axis to

the #2 home position with the AXIS MOVEMENT pushbuttons.

4-5-2 Y AXIS #2 HOME POSITION ADJUSTMENT

1) Press the MAGAZINE FORWARD or MAGAZINE REVERSE menu key until a tool is
in the tool changing position.

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EXTEND RETRACT FORWARD REVERSE ORIENT OPEN CLOSE CLAMP OK

2) Press the SPINDLE ORIENT menu key.

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EXTEND RETRACT FORWARD REVERSE ORIENT OPEN CLOSE CLAMP OK

4 - 14
 3) Press the MAGAZINE EXTEND menu key to move the magazine to the spindle.
Make sure the headstock does not interfere with the magazine.

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EXTEND RETRACT FORWARD REVERSE ORIENT OPEN CLOSE CLAMP OK

4) Move the Y & Z axes to the #2 home position:

Press the #2 HOME POSITION key and manually move the Y & Z axes to
the #2 home position with the AXIS MOVEMENT pushbuttons.

5) Move X axis towards magazine by handle pulse mode. When in position relative to

the tool in the magazine, measure the gap between the spindle key and the key

slot on the tool. Adjust the Y axis with handle mode until the gap is even on both
sides.

6) Read the position value on the position screen for Y axis.

7) Set the position value in parameter

8) Recheck the Y axis #2 home position values.

a) Press the #1 HOME POSITION key and manually move the Y axis to
the #1 home position with the AXIS MOVEMENT pushbuttons.

b) Press the #2 HOME POSITION key and manually move the Y axis to
the #2 home position with the AXIS MOVEMENT pushbuttons.

c) Recheck dimensions by repeating steps 2-7.

4 - 15
4-5-3 Z AXIS #2 HOME POSITION ADJUSTMENT

1) Press the #1 HOME POSITION key and manually move the Z axis to the #1

home position with the AXIS MOVEMENT pushbuttons.

2) Press the #2 HOME POSITION key and manually move the X & Y axes to
the #2 home position with the AXIS MOVEMENT pushbuttons.

3) Press the MAGAZINE EXTEND menu key to move the magazine to the spindle.
Make sure the headstock does not interfere with the magazine.

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EXTEND RETRACT FORWARD REVERSE ORIENT OPEN CLOSE CLAMP OK

4) Measure the distance from spindle face to the retention stud. (Distance A)

5) Calculate the distance from machine home position to #2 home position.

B = A + 3.33” (84.582 mm)

6) Set value (B) for Z axis into parameter M5.

8) Press the MAGAZINE RETRACT menu key to move to its home position.

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4 - 16
4-6 LUBRICATION SYSTEM (Sliding surfaces & ballscrews)
Sliding surfaces, ball screws and nuts for each axis are centrally lubricated by an

automatic lubrication system. The amount of oil supplied to each lubrication point
is maintained constant by a metering valve.

4-6-1 LUBRICATION UNIT DESCRIPTION

The centralized lubrication unit is mounted at the rear of the machine, behind the
electrical panel. Lubricating oil is supplied by metering valves to four points on the linear

guides and one point on the ballscrew nut for each axis. System operation is monitored
by a pressure switch mounted on a manifold to the right of the lube unit. An alarm will

show on the NC CRT in the event of a system failure.

4-6-2 LUBRICATION SYSTEM MAINTENANCE

With the exception of monitoring the lubricant level, the Bijur TMD-5 centralized
lubrication system requires little daily maintenance. However, the filter disc and line filter

should be cleaned at least once per year. If the amount of oil discharged should
decrease, check and replace the filters.

4-6-3 LUBRICATION SCHEMATIC

4 - 17
4-6-4 LUBRICATION PUMP COMPONENT PARTS

Bijur TMD-5

No. Description Part No.

1
1 Motor G06USA00340
2 Float switch G06USA00360
7 8
3 Reservoir G06USA00320
4 Spring clip G06USA00290
3 5 Filter disc G06USA00300
6 Filter screen G06USA00310

7 Bijur lube unit G06USA00280

8 Filler screen G06USA00330

4 5 6

4-6-5 LUBRICATION SYSTEM TROUBLESHOOTING

Problem Cause Remedy

No oil is supplied °Oil level in tank low. °Add the same brand and grade of oil
or “LUBE °Motor turns in wrong direction. °Check the motor wiring
PRESSURE °Clogged suction filter. °Clean or replace the filter. Change the oil.
ERROR“ shows on °Incorrect pump discharge amount. °Adjust pump discharge amount.
CRT alarm screen. °Pump tubing is damaged.(bent, °Tighten connections or replace tubing
crushed or loose) section.
°Viscosity is too high. °Examine oil, replace with suitable oil.
°Air is in the distribution system. °Bleed the system of air.
°Foreign substance in the system. °Clean system and replace metering valves.
°Check valve stuck. °Clean or replace.
°Defective pressure switch or wiring. °Check wiring or replace pressure switch.
Pressure in the °No oil is supplied for reasons above. °Correct conditions as described.
main distribution °Pump piston O-ring damaged. °Replace O-ring
tubing does not °Air in oil supply tubing. °Check system as shown in #4 below and
increase operate the pump to bleed the system.
°Oil leaks at tubing connections. °Tighten to or install new tubing.
°Damaged tubing section. °Replace damaged tubing section.
Oil leakage °Pump packing damaged °Replace seal.
°Pump mounting loose °Tighten bolts.
°Oil gauge loose or damaged °Tighten gauge or replace.
°Drain plug loose °Tighten plug.
Air in the system °Oil level low. (air entered through the °Add the same brand and grade of oil
intake port)
°Improper pipe connection at the °Tighten or replace fittings.
suction block.
°Pipe damaged. °Replace damaged pipe sections.

4 - 18
4-7 PNEUMATIC SYSTEM
4-7-1 PNEUMATIC SYSTEM SCHEMATIC

4 - 19
4-7-2 PNEUMATIC SYSTEM COMPONENT PARTS

Item No. Qty. Description Vendor Part No. Mazak Part No.
1 1 Air filter/regulator AW4000-04BDG G48SV001010
2 1 Solenoid valve VFS3420-1D-02 G50SV007410
3 1 Pressure switch IS1000-01-X201 G23MSV00210
4 3 Speed controller AS3000F G54SV000690
5 1 Solenoid valve VX2130-02-1D-B G50SV005950
6 1 Air cylinder CM2C20-130A-C73 G20SV014610
2 Reed switch (for air cylinder) C-73 G20SV01461A
7 1 Solenoid valve VFS1220-1D-01 G50SV006390
8 2 Metering valve ASN2-01 G54SV000750
9 1 Air cylinder CDA1FN63-250-A57L G20SV016240
2 Reed switch (for air cylinder) C-A57L R27SV000140
10 1 Solenoid valve VFS3220-1D-03-X1 G50SV007420
11 8 Silencer AN303-03 G51SV001040
12 2 Decelerator DZ323-1D-03 G50SV007431
13 2 Speed controller AS3210F-03-10 G54SV001350
14 1 Lubricator AL4000-04 G46MSV00270
15 1 Speed contoller AS2210-02 G54SV001550
16 2 Air operate valve VZA214-1-01 G50MSV00610
17 3 Silencer AN103-01 G51SV001000
18 1 Booster valve VBA1110-02GN G63MSV00590
19 1 Solenoid valve VXD2130-03 G50SV004890

4-7-3 PNEUMATIC SYSTEM TROUBLESHOOTING

Problem Cause Remedy

Decrease in air °Air filter/regulator clogged °Clean unit and replace filter element.
flow
Water drops °Excess water in system. °Drain water.
appear in tubing. °Check incoming air system & water trap.
Unable to regulate °Regulator mounted backwards. °Remount unit.
air pressure. °Regulator spring broken. °Replace spring.
°Valve stuck. °Clean unit.
°Diaphragm or seal is torn. °Replace diaphragm or seal.
Air leaking from °Diaphragm is torn. °Replace diaphragm.
filter/regulator.

4 - 20
4-7-4 AIR FILTER / REGULATOR ADJUSTMENT

Pressure adjustment knob

Regulator “Orange” mark

Pressure gauge

Air lubricator

Air
Inlet

Filter

1) Pull the adjustment knob once to release the lock. The adjusting knob can be

turned when the “Orange” mark appears.

2) Turn the adjustment knob to set the secondary air pressure. The pressure
increases as the knob is turned clockwise. Standard pressure setting is 71.1 PSI.

3) Press the adjustment knob to lock.

[ CAUTION ]

If the incoming air supply contains water, the pneumatic

components used in the machine may be subject to abnormal

deterioration and failure. An air dryer system should be used

and maintained to prevent such damage.

4 - 21
4-8 COOLANT CIRCUIT

Drain

Chip pan

Filter
(mesh 30 SUS)
Coolant pump VBV-44F
G07MGP0050

Coolant tank capacity: 37 gallons

4 - 22
4-9 MECHANICAL ASSEMBLIES
4-9-1 COLUMN & SPINDLE

4-9-1a SPINDLE HEAD CONSTRUCTION

The spindle head is composed of a motor, cartridge assembly and pneumatic tool
clamp/unclamp components. The AC spindle motor is direct coupled to the cartridge.

The spindle cartridge incorporates the drawbar and belleville springs (tool clamp
assembly) as well as the main spindle bearings and housing. The spindle bearings are

permanently lubricated with a specified amount of grease as follows:

Recommended grease: Isoflex NBU-15

Amount: 2-2.5 cc distributed evenly to each of the four bearings.

Tool Clamp / Unclamp Piston

Spindle Motor

Belleville Springs

Spindle cartridge

4 - 23
4-9-1b TOOL CLAMP ADJUSTMENT

The tool retention stud pushing allowance is adjusted so that the drawbar pushes the

tool out 0.016” to 0.020” (0.4 to 0.5 mm) when the tool is unclamped. Adjust as
follows:

1) Remove the headstock cover.

2) Loosen the locknut.

3) Turn the stopper to adjust the pushing allowance to the specified value. Turn

counter clockwise to increase, clockwise to decrease. One turn is equal to

0.06” (1.5 mm).

4) Adjust the proximity switches for a 0.02” to 0.04” (0.5 to 1.0 mm) gap.

5) Tighten locknut and install the headstock cover.

Stopper

Locknut

4 - 24
4-9-1c SPINDLE COOLING UNIT

The spindle cooling unit consists of a trochoid pump, heat exchanger with filter and fluid

reservoir built into the machine column.

Cooling fluid is circulated through the spindle cartridge casting to control heat and
thermal expansion.

Rear View of Machine

Heat Exchanger
Trochoid Pump & Air Filter

Machine Column

Cooling Fluid Inlet

(Mobil Velocite # 3)

(Reservoir capacity=4 gallons)

Reservoir Drain
Coolant Filter

Note: Cooling fluid

must be above the
end of the inlet pipe.

Typically, the air filter should be cleaned every six months, or if it becomes clogged.

The reservoir should be cleaned and cooling fluid replaced once per year. The coolant

filter should be replaced every six months.

Fluid level should be maintained by adding Mobil Velocite No. 3 at the coolant inlet
shown above.

4 - 25
Spindle Cooling Unit Troubleshooting

Problem Cause Remedy

Insufficient cooling. °Insufficient pump pressure. °Replace pump.
°Cooling fan has failed. °Replace cooling fan.
°Air filter clogged °Clean or replace filter.
Coolant leakage °Broken tubing, hose or fitting. °Check piping and repair or replace.
°Loose fitting. °Tighten fitting.
Insufficient pump °Damaged trochoid pump °Replace pump.
pressure. °Clogged filter or hose °Clean system and replace filter and fluid.

[ WARNING ]

Do not attempt to service the spindle cooling unit with the machine

in operation. Failure to comply could result in serious personal

injury.

Notes:

4 - 26
4-9-2 TOOL STORAGE MAGAZINE & CHANGER (ATC)

4-9-2a TOOL STORAGE MAGAZINE ASSEMBLY

The tool storage magazine assembly consists of a rotary tool storage drum, index

mechanism and body shuttle (ATC) . The assembly is mounted to a bracket

attached to the machine bed.

Tool in magazine sensor

Magazine home position

Proximity switch

Rotary tool
storage drum

Barrel cam

Induction motor Tool “in position”

Proximity switch

Magazine body shuttle

pneumatic cylinder

Linear guides

Machine bed

Mounting bracket

4 - 27
 Tools are indexed by an induction motor and barrel cam, with position and tool
number recognized by an “in position”and a “magazine home position” proximity

switch.

The automatic tool change operation is performed by the magazine body shuttle

mechanism, where the tool storage and index assembly is moved on linear guides
in the X minus direction by a pneumatic cylinder.

4-9-2b TOOL STORAGE MAGAZINE & ATC TROUBLESHOOTING

Problem Cause Remedy

Magazine rotation °Bevel gear key missing. °Replace the gear key.
is slow or °Barrel cam groove damaged. °Replace barrel cam.
intermittent
Magazine is noisy °Cam follower damaged. °Replace or grease cam follower.
when rotating. °Barrel cam damaged. °Replace or grease barrel cam.
°Damage to bevel gears. °Replace or grease bevel gears.
Magazine rotates, °Defective “in position” proximity °Adjust or replace switch.
but does not stop. switch
Magazine stops on °Defective “in position” proximity °Replace switch.
wrong tool. switch.
°Defective home position proximity °Replace switch.
switch.
Magazine stroke °Nut on air cylinder is loose. °Tighten nut and adjust X axis #2 zero point.
end position varies. °Linear guide problem. °Inspect linear guides.
Backlash in °Cam follower damaged. °Replace or grease cam follower.
magazine. °Barrel cam damaged. °Replace or grease barrel cam.
°Damage to bevel gears. °Replace or grease bevel gears.
Magazine is noisy °Linear guide problem. °Inspect linear guides.
when shuttling
(ATC)
Problem in loading °Inadequate grease in tool storage °Grease the tool storage drum.
or unloading a tool drum.
into tool storage °Tool holder worn. °Replace tool holder.
drum.
Attempts are made °The “tool in magazine” photo switch °Adjust the tool in magazine photo switch.
to put a tool in the is improperly adjusted.
magazine where a °Damaged or defective “tool in °Replace the photo switch.
tool already exists magazine ”photo switch

4 - 28
5. PREVENTATIVE MAINTENANCE
5-1 MAINTENANCE CONSIDERATIONS
An effective program of regularly performed preventative maintenance will

guarantee more productive “uptime” than a machine run until a failure

occurs. Break downs like these always seem to occur when the machine is

needed most. By taking the time to have maintenance personnel create a

custom tailored preventative maintenance schedule from that which follows,

a program can be implemented that will extend the life expectancy of a

machine and decrease down time associated with untimely break downs.

Keep a maintenance record of all work done for future reference.

Maintenance considerations:

• Use only the hydraulic oils or lubricants specified in the

maintenance manual or machine tag. The use of substitute fluids of

an equivalent grade is not recommended.

• Do not use compressed air when cleaning the machine or other

elements. Dust, lint or other foreign matter may contaminate

machine units such as bearings and slide ways.

• Keeping the machine clean is a very important factor in preventative

maintenance. Dust, humidity and other contaminates may

accelerate corrosion of electrical components leading to intermittent

failure.

• Keep electrical enclosure doors tightly closed when the machine is

in daily operation.

Notes:

5-1
5-2 PERIDODIC MAINTENANCE SCHEDULE

The following 12 month preventative maintenance schedule represents a

general approach based on 8 hours operation per day.

PREVENTATIVE MAINTENANCE SCHEDULE VTC-16/20

(Based on 8 hours operation per day)

3 6 12 Date Completed
Maintenance Operation Daily Weekly Monthly
Month Month Month

MACHINE UNITS

Inspect spindle & tool holders O

Remove any chips or debris

Take off the spindle nose cover

(bearing retainer) & remove any
chips or debris. O
Note: Make sure the drain hole
is clear of obstructions.
Re-torque all bolts evenly.

Clean slide way covers O

Inspect linear guides and ways O

Inspect way wipers O

Inspect/lubricate motor bearings O

Check machine level O

Check alignments & backlash O

PNEUMATIC SYSTEM
Check incoming air supply O

Check filter / regulator O

Clean filter / regulator O

Check air lubricator oil level O

5-2
 PREVENTATIVE MAINTENANCE SCHEDULE VTC-16/20
(Based on 8 hours operation per day)

3 6 12 Date Completed
Maintenance Operation Daily Weekly Monthly
Month Month Month

HEADSTOCK COOLING UNIT

Check fluid level O

Check system for leakage O

Inspect hoses & piping O

Check system pressure O

Clean the strainer O

Clean reservoir & change fluid O

LUBRICATION SYSTEM

Check lubricant level O

Verify oil flow to ways O

Check operation interval O

Check system pressure O

Check system for leakage O

Verify spindle lubrication O

ELECTRICAL COMPONENTS
Clean enclosure filters O

Verify cooling fan operation O

Inspect switches for debris O

Check safety interlocks O

Inspect wiring, relays & timers O

Inspect enclosure components O

Verify indicator lights operation O

Check incoming power source O

Re-tighten terminal strips O

COOLANT SYSTEM

Check coolant level O

Clean / replace coolant filter O

Drain coolant O

5-3
Notes:

5-4
6. INTRODUCTION TO MAZATROL PROGRAMMING
6-1 COMPONENTS OF A MAZATROL PROGRAM
A MAZATROL program requires the following four units:

1. Common Unit

The common unit refers to the necessary data entered in the program head. It

specifies the common data in a program such as material type, initial linear axis
positioning points the multiple part machining, etc.

2. Basic Coordinate System Unit (WPC)

Used to specify the workpiece coordinate zero point (basic coordinates) in the

machine coordinate system.

3. Machining Unit

Used to specify data concerning the machining method and the machining form.

The machining unit is available in the following three types:

Point machining unit

$ Drilling
$ RGH CBOR machining
$ RGH BCB machining
$ Reaming
$ Tapping
$ Boring – Boring of through hole
– Back boring – Boring of stepped through hole
– Circular milling – Boring of non-through hole
– Counterbore-tapping – Boring of stepped non-through hole

Line machining unit Face machining unit

– Central linear machining – Face milling
– Right-hand linear machining – End milling-Top
– Left-hand linear machining – End milling-Step
– Outside linear machining – Pocket milling
– Inside linear machining – Pocket milling-Mountain
– Right-hand chamfering – Pocket milling-Valley
– Left-hand chamfering – End milling-Slot
– Outside chamfering – 3-D (option)
– Inside chamfering

6>1
 Necessary data in a machining unit is specified in the following two sequences:

Tool sequence: Used to specify a tool and the movement of the tool.

Shape sequence: Used to specify data related to the machining dimensions.

4. End Unit
Unit adjusted at the end of program.

The following units are entered as needed:

5. Auxiliary Coordinates System Unit

Used to specify the auxiliary coordinates system (OFFSET).

6. Special Mode Unit

Used to specify a machine function or movement other than machining.

(Units marked with an asterisk (*) represent option that may not be available on
certain machine models.)

M code . . . . . . . . . . . Output of an M code

Sub-program . . . . . . . Calling up a sub-program

Drum changing* . . . . . Changing of a tool drum

Pallet changing* . . . . . Changing of pallet

Index* . . . . . . . . . . . . Use to specify the angle of the indexing table.

Process end ....... Stops the process in priority function for the same
tool.

7. Manual Program Mode Unit

This unit is entered for establishing a program corresponding to the EIA/ISO

program using the G and M codes which permits performing minute movement or

a movement other than machining. (Please refer to the Mazatrol EIA/ISO

Programming manual for detailed information.)

8. MMS Unit

Automatic measurement of the basic coordinates system (WPC). The MMS unit

requires the Renishaw or equivalent probe option.

6>2
6-2 COORDINATE SYSTEMS
A system of coordinates is used for introducing the position and form of the machining

in program preparation.

The system of coordinates consists of three axes, each crossing the reference zero
point at right angles.

An arbitrary point found in this coordinate system can be defined by the value of the
coordinates in the 3 axes (X,Y and Z).

There are two types of coordinate systems:

- Machine coordinates system

- Workpiece coordinates system

Z axis

X axis Reference point zero

Y axis

Fig. 6-1 Coordinates system M3P001

6-2-1 MACHINE COORDINATES SYSTEM

The machine actually moves in its own system of coordinates called the machine

coordinates system. A point of reference in this system of coordinates is known as

machine zero point.

Generally, the machine coordinates system has the machining zone on the side of the
minus (negative) direction from the machine zone point.

6>3
 +Z

+Y +X
Machining zone Machining zero point
(Machine coordinates system) (X0, Y0, Z0)

-Z
Axis of Z
Axis of X coordinate -Y
coordinate
Axis of Y
-X coordinate

Table

Fig. 6-2 Machine coordinates system NM210-00510

6-2-2 WORKPIECE COORDINATES SYSTEM

If the program is prepared on the basis of the machine coordinates system, the entering

of the machining position and of the form of machining is very complex, tedious and

inflexible.

Consequently, a temporary reference point is established in the machine coodinates

system for the program.

This point is called the workpiece zero point, and the system of coordinates taking this
point as reference is called the workpiece coordinates system.

Example:

Plan view of the workpiece

P3 P2
<
R5 M8 tapped holes
(4 places)
100
95 10-mm diameter
60 z50 drilled hole
R5
20 5 =
aa
a

P1
aa

5
aa
a

50
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a
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a
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a
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a
aaaaaaa a
aaaaaaaa

Zero point of
a
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the workpiece 100

a
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a

145
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a

to be taken
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150
a
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aaa
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aaaa a
a
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a

Fig. 6-3 Workpiece layout drawing M3P002

a
a
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a
a
a

6>4
 When the dimensions are entered of the configuration on the basis of the above
plan of the workpiece, the bottom left hand corner is taken as the workpiece zero

point. Coordinate values are shown below:

Workpiece zero point = (0, 0, 0)

P1 = (150, 0, 0)

P2 = (150, 100, 0)

P3 = (0, 100, 0)

The adoption of the workpiece zero point facilitates the entering of the machining
dimensions and therefore the programming.

6-2-3 MACHINE COORDINATES SYSTEM AND WORKPIECE COORDINATES SYSTEM

The relationship between the machine coordinates system and workpiece coordinates
system when workpiece has been mounted on the table of a machine is shown below.

Machine coordinates systems

Machine coordinates system

Workpiece coordinates
system

<Model V, types VQC and AJV> NM210-00511 NM210-00512

<Model V, type VTC>

Machine coordinates system

aa
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aaa a
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Workpiece coordinates system

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aaaa a
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aa

<Model H> NM210-00513

aaa
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Fig. 6-4 Machine coordinates system and workpiece coordinates system

6>5
6-2-4 BASIC COORDINATES

The machine moves in the machine coordinates system while the program is prepared

depending on the workpiece coordinates system.

It is necessary to enter into the program, the position relationship between the machine
coordinates system and the workpiece coordinates system.

This is done in the basic coordinates unit.

The basic coordinates are entered as the workpiece zero point values in the machine

coordinates system.

The basic coordinates unit data is entered by utilizing the coordinates measurement

function after the workpiece is placed on the machine.

Basic Machine zero point

coordinate Z
Machine coordinates system

Basic coordinate Y
Basic
coordinate X

-Y
-Z
-X

+Z
+Y +X

Workpiece coordinates system

Workpiece zero point

Fig. 6-5 Basic coordinates NM210-00514

6>6
 Example of entering of the basic coordinates unit:

UNO UNIT X Y k Z 4
1 WPC-0 –500. –300. 0. –200. 0.

Basic coordinates unit Coordinate or

angle of 4th
No. of basic coordinates axis, if there
unit
is one.

Basic coordinate X Basic coordinate Z

(Example: –500) (Example: –200)

Basic coordinate Y (Example: –300)

Angle formed by the axes X and Y of the
machine coordinates system and the axes X and
Y of the workpiece coordinates system.

6-2-5 AUXILIARY COORDINATES (Offsets)

Auxiliary coordinates are used to offset the workpiece zero point to any position
necessary in the preparation of a program.

The auxiliary coordinates unit (OFFSET) is entered as an offset value from the
workpiece zero point.

1. Example of auxiliary coordinates entry:

+y0

P2
20
P1
30°
R0
+x0
50
70
Workpiece zero point M3P003

In this example, data entry of the position of hole P1 requires the following
calculation:
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a
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a
aa
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aa
a
aa
a

1
aa
aaaa

aa
aa

|3
aa
aa
a

aa
aa

P1 = (70 + 50× , 50 × )
aa
a

aa
aa

,2
aa
a
aa

aa
aa

2
a
a
a

a
a

6>7
 However, the use of auxiliary coordinates permits performing this entry
easily.

+y1
+x1
P2
20
P1
30°
R1
R0
50

70 Zero point offset in auxiliary

coordinates mode M3P004

As this figure shows, positions P1 and P2 are entered as follows by offsetting

the workpiece zero point to R1.

P1 = (50, 0)

P2 = (50, 20)

In this case, the auxiliary coordinates unit to be programmed is as

follows:

UNO UNIT U (X) V (Y) D (k) W (Z)

2 OFFSET 70. 0. 30. 0.

Offsetting on Z axis
Auxiliary coordinates unit
Angle with relation
Offsetting on X axis to workpiece
coordinates system

Offsetting on Y axis

2. Cancellation of auxiliary coordinates

The auxiliary coordinate offsets are voided in the following cases:

A) The system of auxiliary coordinates specified in a sub-program is voided

at the time of the return on the main program.

When the main program contains a system of auxiliary coordinates, the

return is made to this system of auxiliary coordinates.

6>8
 B. The system of auxiliary coordinates is voided when a new system of
basic coordinates is introduced. In this case, the state without a system

of auxiliary coordinates is assumed. (When the system of basic

coordinates was specified in the sub-program as shown in Figure 6-5,

the return to the main program has the effect of voiding the system of
auxiliary coordinates of the main program.)

Main program

WPC-1
Sub program
Machining —

Subprogram WPC-2

Machining “

WPC is a code that signifies the basic coordinates sytem.

Machining “ is performed under the coordinates system of WPC-2.

Fig. 6-6 Basic coordinates system after execution of subprogram M3P005

6>9
6-3 PREPARING FOR MACHINING
6-3-1 MACHINING PREPARATION FLOWCHART

The following flowchart shows the general procedure to be followed in preparation for

machining.

Preparation of part drawings

Reflection of the mounting workpiece

TOOL FILE display WK. PROGRAM display

Recording of tools Preparation of machining

available in the workshop program
FIGURE CHECK display

Verification of the program-

med form
TOOL DATA display TOOL LAYOUT display

Verification of the tools Recording of a tool to be

mounted on the tool drums mounted on the tool drum

TOOL PATH display

Verification of path of tool

Note: The tool path can be
monitored even if the tool is
not recorded in the tool data,
Installation of tool however, automatic operation
can not be performed.
(The path of the tool is laid
out by taking the diameter of
TOOL DATA display
the tool = the nominal
Measurement of length of diameter and the length of the
tool tool = 0).

Installation of workpiece

WK. PROGRAM display

Measurement of basic
coordinates

Automatic operation

Fig. 6-7 Machining Preparation Flowchart M3P006

6>10
6-3-2 PART DRAWINGS AND STOCK MATERIAL

The following shows the part drawing for which a program is to be created using this

manual.

<
R5 M8 tapped holes
(4 places)
z50

100 95 10-mm diameter

drilled hole
60
R5
20 =

5 10

50 20

100 Material: Carbon steel

Finish-machining surface: (π, ππ)
145
150

Fig. 6-8 Part drawing example M3P007

Held by a vise, the part to be machined is shown below.

Fig. 6-9 Part in workholding vise NM210-00516

6>11
 Machining of this part consists of the following four processes:

— Milling the top face of the workpiece. “ End-milling the edges of the workpiece.

CW

NM210-00517 NM210-00518

” Drilling a 10-mm diameter through-hole. ‘ Drilling four M8 tapped holes.

Fig. 6-10 NM210-00519 NM210-00520

6>12
6-4 REGISTRATION OF TOOLS
First, turn MAZATROL NC power ON and perform the zero point return procedure.

(Refer to section for detailed information.)

Next, turn the Program Edit Enable key switch to the ENABLE position.

Turn

Fig. 6-11 Program edit enable switch NM210-00521

Before creating the program, information on the tools to be used must be registered in
a tool file. Unregistered tools cannot be used for programming or automatic operation.

6-4-1 DISPLAYING THE TOOL FILE SCREEN

Display the TOOL FILE screen by first pressing the Display Selector menu key and

then the Tool File menu key.

*** POSITION *** MAZATROL ( )

POSITION COMMAND TRACE PROGRAM TOOL TOOL TOOL PAR DATA

FILE DATA LAYOUT I/O

Fig. 6-12 M3P008

6>13
 The TOOL FILE will be displayed as shown below.

NO. TOOL NOM-z MAT. DEPTH NO. NO. TOOL NOM-z MAT. DEPTH NO.
1 17
2 18
3 19
4 20
5 21
6 22
7 23
8 24
9 25
10 26
11 27
12 28
13 29
14 30
15 31
16 32
PAGE 1/2

*** TOOL FILE (ENDMILL) *** ( )

ENDMILL FACEMILL CHAMF BALL ALL PROGRAM NEXT

CUTTER ENDMILL ERASE PAGE

M3P009

Register tools in the TOOL FILE display as follows:

End mill Face mill Chamfering cutter Ball-end mill

NM210-00522 NM210-00523 NM210-00524 NM210-00525

Fig. 6-13

Tools other than these four types do not require registration. Tool selection is

automatically made by the NC unit during programming.

6>14
 In this example, registration is done using the two types of tools shown below.

Tool material: Tool material:

Cemented carbide Cemented carbide
Number of teeth: 2 Number of teeth: 6
5

30

10 80

End mill NM210-00522 Face mill NM210-00523

Fig. 6-14 Registered tools example

6-4-2 REGISTERING AN END MILL

Using the NEXT PAGE menu key, search the display for the tool indicated as “E-
MILL 10.A”.

Up to 64 tools can be registered. If the tool is found, this indicates that the tool
has been registered. Once this is done, proceed to the procedure described in

“Registering the face mill” on page 6-17.

A] Press the CURSOR key and position the cursor on an unregistered tool

number.

NO. TOOL NOM-z MAT. DEPTH NO. NO. TOOL NOM- z MAT. DEPTH NO.
aaaaaaaa

1 17
2 18
3 19
4 20
5 21

The message REGISTER OF TOOL <INPUT>? will then be

displayed in the message display area.

B] Press the INPUT key to register the tool.

The message NOMINAL DIAMETER? will be displayed.

C] Input an approximate tool-diameter value (in this example, input 10 by

pressing numeric keys and and then pressing the INPUT key

).

The message TOOL ID CODE <MENU>? will be displayed.

6>15
 D] Input a specific code that identifies the particular tool (in this example, input
“A” by pressing the A menu key) .

*** TOOL FILE (END MILL) *** TOOL ID CODE <MENU>?

A B C D E F G H J

The message TOOL MATERIAL <MENU>? will be displayed.

E] Select as a tool material either HSS (high-speed steel) or CARBIDE

(cemented carbide) (in this example, select the latter by pressing the
CARBIDE menu key).

The message MAX DEPTH OF CUT? will be displayed.

F] Input the maximum depth to which the workpiece can be cut in the axial

direction by one cutting operation (in this example, input “30” by pressing
numeric keys and and then pressing the INPUT key ).

The message NUMBER OF TEETH? will be displayed.

G] Input the number of teeth of the tool (in this example, input “2” by pressing
numeric key and then pressing the INPUT key ).

Registration of the 10-mm diameter end mill will be completed as shown

below.

NO. TOOL NOM-z MAT. DEPTH NO. NO. TOOL NOM-z MAT. DEPTH NO.
1 E-MILL 10. A CBD 30. 2 17
2 18
3 19
4 20
5 21
6 22
7 23
8 24
9 25
10 26
11 27
12 28
13 29
14 30
15 31
16 32
PAGE 1/2

*** TOOL FILE (ENDMILL) *** REGISTER TOOL <INPUT>? ( )

ENDMILL FACEMILL CHAMF BALL ALL PROGRAM NEXT

CUTTER ENDMILL ERASE PAGE

M3P010

6>16
6-4-3 REGISTERING THE FACE MILL

The operations to be carried out are similar to those required for registering the 10-mm

diameter end mill.

A] Press the FACE MILL menu key.

Check if the tool indicated as F-MILL 80.A is included in the display. If the

tool is found, then this indicates that the tool has been registered.

B] (Position the cursor on an unregistered tool number.)

C] TOOL REGISTRATION <INPUT>?

D] NOMINAL DIAMETER?

E] TOOL ID CODE <MENU>? [A]

F] TOOL MATERIAL <MENU>? [ CARBIDE ]

G] MAX DEPTH OF CUT?

H] NUMBER OF TEETH?
Æ This completes registration of the 80-mm diameter face mill as shown
below.

NO. TOOL NOM-z MAT. DEPTH NO. NO. TOOL NOM-z MAT. DEPTH NO.
1 F-MILL 80. A CBD 5. 6 17
2 18
3 19
4 20
5 21
6 22
7 23
8 24
9 25
10 26
11 27
12 28
13 29
14 30
15 31
16 32
PAGE 1/2

*** TOOL FILE (FACEMILL) *** REGISTER TOOL <INPUT>? ( )

ENDMILL FACEMILL CHAMF BALL ALL PROGRAM NEXT

CUTTER ENDMILL ERASE PAGE
aaa
a
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a
aaaa a

M3P011
a
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6>17
Notes:

6>18
6-5 CREATING SIMPLE PROGRAMS
6-5-1 PROGRAM STRUCTURE

The structure of a MAZATROL program is described before creating a program. Each

MAZATROL program is made up of PROGRAM UNITS. The name of each part of a

program is described below using part of the program to be created.

UNO MAT INITIAL-Z ATC MODE MULTI MODE MULTI FLAG PITCH-X PITCH-Y
0 CBN STL 20. 1 OFF ! ! ! —
UNO UNIT X Y k Z 4
1 WPC-1 -300. -200. 0. -100. 0. “
UNO UNIT DEPTH SRV-Z SRV-R BTM WAL FIN-Z FIN-R
2 F-MILL 0. 3. ! 2 ! 0. ! ”
SNO TOOL NOM-z NO APRCH-X APRCH-Y TYPE ZFD DEP-Z WID-R C-SP FR M M
R1 F-MILL 80. A ? ? XBI ! 3. 56. 121 1.079 a)
FIG PTN P1X/CX P1Y/CY P3X/R P3Y CN1 CN2 CN3 CN4 b)
1 SQR 0. 0. 150. 100.

UNO UNIT CONTI. NUMBER

6 END 0 0 ‘

Fig. 6-15 Program structure M3P012

— Common unit

Basic data related to the entire program, such as the material of the workpiece, is
to be input to this unit.

“ Basic coordinates system unit

The coordinate values of the workpiece zero point in the machine coordinates

system are to be inputted to this unit.

” Machining units

Various types of machining units are provided. Data related to the selection of a

machining method and to machining dimensions are to be entered into these units.

a) Tool sequence Consists of data related to the operation of a tool.

b) Shape sequence Consists of data related to part machining shape.

6>19
 ‘ End unit

Denotes the end of a program (i.e., the completion of machining).

6-5-2 CALLING UP THE WK. PROGRAM DISPLAY

First, the WK. PROGRAM display is to be presented as previously done when

displaying the TOOL FILE display:

1] Press the DISPLAY SELECTOR key.

2] Press the PROGRAM menu key.

The WK. PROGRAM display will be presented then as shown below.

*** WK. PROGRAM NO. 1234 *** ( )

WORK NO. SEARCH PROGRAM ≠ Ø TOOL PROGRAM WPC MSR DETAILED

EDIT ≠ Ø PATH FILE INFORM.

M3P013

Note:

The actual display is identical in both the *** WK. PROGRAM NO. *** display and the

menu display.

The display status shown above is referred to as the listing mode.

The listing mode is a program-contents check.

6>20
6-5-3 ASSIGNING WORKPIECE NUMBERS

Number the individual programs to be created. These numbers identify the individual

programs just as part number in a part drawing identify the individual parts. These
numbers are referred to as workpiece numbers, and the desired number from 1 to 9999

can be selected for each program. Here, workpiece No. 1234 is to be set.

1] Press the WORK NO. menu key

2] WORK PIECE PROGRAM NUMBER?

The message NEW PROGRAM <PROGRAM>? will be displayed.

If either one of the two displays (1) and (2) shown below is displayed instead

of this message, then this indicates that workpiece No. 1234 has already
been used. In that case, input a different workpiece number.

(1) MAZATROL program

UNO MAT INITIAL-Z ATC MODE MULTI MODE MULTI FLAG PITCH-X PITCH-Y
0 CBN STL 20. 1 OFF ! ! !
UNO UNIT X Y k Z 4
1 WPC-1 -300. -200. 0. -100. 0.
UNO UNIT DEPTH SRV-Z SRV-R BTM WAL FIN-Z FIN-R
2 F-MILL 0. 3. ! 2 ! 0. !
SNO TOOL NOM>z NO APRCH-X APRCH-Y TYPE ZFD DEP-Z WID-R C-SP FR M M
R1 F-MILL 80.A ? ? XBI ! 3. 56. 121 0.176
FIG PTN P1X / CX P1Y / CY P3X / P P3Y CN1 CN2 CN3 CN4
1 SQR 0. 0. 150. 100.
UNO UNIT DEPTH SRV-Z SRV-R RGH CHMF FIN-Z FIN-R
3 LINE OUT 10. 10. 5. 3 ! 0. 0.
SNO TOOL NOM>z NO APRCH-X APRCH-Y TYPE ZFD DEP-Z WID-R C-SP FR M M
R1 E-MILL 10.A ? ? CW G01 10. ! 54 0.027

*** WK. PROGRAM NO. 1234 *** ( )

WORK NO. SEARCH PROGRAM ≠ Ø TOOL PROGRAM WPC MSR DETAILED

EDIT ≠ Ø PATH FILE INFORM.

M3P014

6>21
 (2) EIA/ISO program

N001 G91 G80 S800 T01 M03; N016 M06 T01;

N002 G92 X0 Y0 Z0; N017 G00 X-25.0 Y-25.0;
N003 M06 T00; N018 S1000 M03;
N004 G00 X-50.0 Y-25.0; N019 G00 G45 Z-48.0 H02;

aa
aa
a
aaa
a
a
aaaa
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a
aaa
aaaa
N005 G45 Z-48.0 H01; N020 G99 X0!Y0 Z-31.0 R0 Q3000 F100;

aa
a
aa
a
aaa
aa
aa
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aa
a
a
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a
a
a
a
N006 G01 Z-4.0 F60; N021 X-25.0 X-50.0;
aaa
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aaa
aaaa a
a
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a

N007 Y-130.0 F85;

a
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a

N008 G02 X-20.0 Y-20.0 I-10.0 J0;

N009 G01 X-150.0;
N010 G03 X-30.0 Y30.0 I-30.0 J0;
N011 G01 Y50.0;
N012 X80.0 Y60.0;
N013 G02 X30.0 Y10.0 I 30.0 J-40.0;
N014 G01 X90.0 T02;
N015 G28 Z0;

*** WK. PROGRAM NO. 1234 *** ( )

WORK NO. SEARCH PROGRAM ≠ Ø TOOL PROGRAM WPC MSR DETAILED

EDIT ≠ Ø PATH FILE INFORM.

M3P015

Note:

In Mazatrol, two different programs can be created. The program (1) above is
referred to as a MAZATROL program, and the one (2), as an EIA/ISO program.

6-5-4 CREATING A PROGRAM

1] While the message NEW PROGRAM <PROGRAM>? is displayed, press the

PROGRAM EDIT menu key.

The display shown in Figure 6-16 will appear. This status is referred to as

the creating mode.

If the EIA/ISO program (option) is provided in the system, the message

MAZATROL, EIA/ISO <MENU>? will be displayed in succession and the

menu will be changed as follows.

aaa
aaa
aaaaaaaaa a
aaaaaaaaa a
aaaaaaaaa a
a
aaa
a
aaaaaaaaaa a
aaaaaaaaaa a
aaaaaaaaaa a
aaaaaaaaaa a
aa
aa
a
a
a
a
aa
a
a
a
a
a

EIA / ISO MAZATROL

aa
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PROGRAM PROGRAM
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6>22
 2] Press the MAZATROL PROGRAM menu key.

The following screen will be displayed.

UNO MAT INITIAL-Z ATC MODE MULTI MODE MULTI FLAG PITCH-X PITCH-Y
aa
0 aaaa
a
a
a

*** WK. PROGRAM NO. 1234 *** MATERIAL <MENU>? ( )

CAST IRN DUCTILE CARBON ALLOY STAINLES ALUMINUM COPPER OTHER

CAST IRN STEEL STEEL STEEL ALLOY

Fig. 6-16 WK. PROGRAM display (creating mode) M3P016

6-5-5 CREATING THE COMMON UNIT

The common unit is the program unit that must be created in the header of any

program. Basic data on the entire program is entered in this unit.

The DETAILED INFORM. display is described here before the creation of common unit.
Prior to input of data in the unit, full details of the data to be entered can be displayed

on the screen for ease of programming. This display is referred to as the DETAILED

INFORM. display.

Carry out the following operations to display the DETAILED INFORM. screen:

1] If the DETAILED INFORM menu key. is not on the display, press the MENU

SELECTOR key.

2] Press the DETAILED INFORM menu key.

3] Press the MENU SELECTOR key to resume the original menu.

6>23
 The following DETAILED INFORM. screen will be displayed.

UNO MAT INITIAL-Z ATC MODE MULTI MODE MULTI FLAG PITCH-X PITCH-Y

aaaa
aaaa
0

aa
a
a 5*2 MODE OFFSET TYPE

aa aa
aa
aa a
6 7 8 9 10

a
INITIAL-Z
PITCH-Y OFS-3

1 2 3 4 5 OFS-2
a
a
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a

PITCH-X FLAG OFS-1

10 9 8 7 6 5 4 3 2 1
# # # # # # # # # WPC
:WPC ZERO POINT
(# : 1 YES)
(# : 0 NO)

*** WK. PROGRAM NO. 1234 *** MATERIAL <MENU>? ( )

CAST IRN DUCTILE CARBON ALLOY STAINLES ALUMINUM COPPER OTHER

CAST IRN STEEL STEEL STEEL ALLOY

M3P017

Now, start creating the common unit. The data for the article MAT, INITIAL-Z and

ATC MODE will be specified here.

MAT Specify the material of the workpiece.

INITIAL-Z Specify the initial height of the tool where it comes close to the

workpiece for machining purposes.

From this level up, the tool

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is kept clear of the workpiece

a

or jigs.
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b
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Initial point
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Workpiece
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a

zero point
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a
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a
a
a
a
a
a
a
a
a
a
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a
a
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a
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a
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a
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a
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a
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a
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a
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a
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Fig. 6-17 Tool path M3P018

6>24
 ATC MODE Specify the manner in which the tool is to be returned to the ATC
position for tool change.

MULTI MODE Use this function only when multiple workpieces of the same type
are arranged on the table for successive machining.

4] MATEIRAL <MENU>? [ CARBON STEEL ]

5] INITIAL POINT-Z <CLEARANCE>?

6] SHELTER WAY <AXIS:0,SIM.:1>?

7] MULTI MODE <MENU>? [ MULTI OFF ]

The common unit will be created as shown below.

When the unit is created, the DETAILED INFORM. display will be deleted and the
program will await data input to the next unit.

UNO MAT INITIAL-Z ATC MODE MULTI MODE MULTI FLAG PITCH-X PITCH-Y
0 CBN STL 20. 1 OFF ! ! !
UNO UNIT
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*** WK. PROGRAM NO. 1234 *** MACHINING UNIT <MENU>? ( )

POINT LINE FACE MANUAL OTHER WPC OFFSET END SHAPE

MACH-ING MACH-ING MACH-ING PROGRAM CHECK

M3P019

6>25
6-5-6 CREATING THE BASIC COORDINATES SYSTEM UNIT

Set the basic coordinates (the coordinate values of the workpiece zero point in a

machine coordinate system). This data is entered using the coordinates measuring
function after a workpiece is mounted on the machine.

Machine zero point

-300 (Basic coordinate y)

-Z -Y
-X
-300
-300 (Basic
(Basic coordinate x)
coordinate z)

Workpiece zero point

Fig. 6-18 Workpiece mounting position NM210-00526

1] When the MACHINING UNIT <MENU>? message is displayed, press the WPC

menu key. (“WPC” is the abbreviation for workpiece coordinates.)

2] Press the DETAILED INFORM menu key.

The DETAILED INFORM. screen on the following page will be displayed.

UNO UNIT X Y k Z 4
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0 WPC> 0

X
WPC-Z WPC-4
X’
Y’ WPC>k
QUILL AXIS

WPC-Y
WPC-X WPC-4
Z
Y WPC ZERO
MACHINE ZERO
X
POINT

*** WK. PROGRAM NO.1234 *** WPC NUMBER? ( )

DETAILED
INFORM.

M3P020

6>26
 3] WPC NUMBER? < 1 > <INPUT >

4] WORK PIECE COORDINATE, WPC-X? < - 300 > <INPUT >

5] WORK PIECE COORDINATE, WPC-Y? < - 200 > <INPUT >

6] WORK PIECE COORDINATE, WPC-k? < 0 > <INPUT >

7] WORK PIECE COORDINATE, WPC-Z? < - 100 > <INPUT >

8] WORK PIECE COORDINATE, WPC-4? < 0 > <INPUT >

The basic coordinates unit system will be created as shown below.

When the unit is created, the DETAILED INFORM. display will be deleted and the
program will await data input to the next unit.

UNO UNIT X Y k Z 4
1 WPC-1 -300. -200. 0. -100. 0.
UNO UNIT
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*** WK. PROGRAM NO. 1234 *** MACHINING UNIT <MENU>? ( )

POINT LINE FACE MANUAL OTHER WPC OFFSET END SHAPE

MACH-ING MACH-ING MACH-ING PROGRAM CHECK

M3P021

6>27
6-5-7 CREATING A FACE MACHINING UNIT

The following programed unit mills the top face of a part. This machining unit is referred

to as a face milling unit.

NM210-00517

1. Creating the face machining unit

A] While the message MACHINING UNIT <MENU>? is displayed, press the

FACE MACH-IN menu key .

B] MACHINING UNIT <MENU>? FACE MILL

C] Press the DETAILED INFORM. menu key.

The following DETAILED INFORM. screen is displayed.

UNO UNIT DEPTH SRV-Z SRV-R BTM WAL FIN-Z FIN-R

2 FACE MIL ! ! !
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DEPTH

SRV-Z

FIN-Z

*** WK. PROGRAM NO. 1234 *** DIST: WPC·Z=0 TO FIN. SURFACE? ( )

DETAILED
INFORM.

M3P022

6>28
Now, start creating the face machining unit. The data for items DEPTH, SRV-Z,
BTM, and FIN-Z will be specified here.

DEPTH Input the distance from the workpiece zero point of the Z axis to
the surface to be finished.

The depth is 0 because the workpiece zero point is on the

finishing surface.

+Z

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Chamfering area

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a
a
Workpiece zero point

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Allowance Z
(SRV-Z)
Position of +X
WPC > Z=0
Surface to be
finished

Fig. 6-19 DEPTH and SRV-Z M3P023

SRV-Z Input the chamfering thickness of the workpiece. An approximate

value may be input because the workpiece surface is not plane.

BTM Input an appropriate finishing code that designates the roughness of the

workpiece surface to be finished.

FIN-Z Input the finish milling thickness. This data will be automatically set if

the roughness of the bottom is specified using a finishing code of the

menu.

D] DIST: WPC-Z = 0 TO FIN. SURFACE? <0> < INPUT >

E] Z AXIS STOCK REMOVAL? < 3 > < INPUT >

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F] BOTTOM ROUGHNESS <MENU>? π

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2
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a

G] FINISH ALLOWANCE-Z?

(When the bottom roughness is input, the FIN-Z value will be set
automatically. Thus, the operator can proceed directly to the next data item

using the appropriate cursor key.)

6>29
 A machining unit such as that shown below is now completed. Usually, a tool
appropriate for the particular tool sequence is automatically selected on the

basis of the data of the machining unit. Here, a face mill has been selected.

UNO UNIT DEPTH SRV-Z SRV-R BTM WAL FIN-Z FIN-R

2 FACE MIL 0. 3. ! 2 ! 0. !
SNO TOOL NOM>z NO APPCH-X APPCH-Y TYPE ZFD DEP-Z DEP-R C-SP FR
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a MM
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R1 F-MILL //!
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*** WK. PROGRAM NO. 1234 *** WHICH TYPE OF TOOL<MENU>? ( )

ENDMILL FACEMILL CHAMF BALL

CUTTER ENDMILL

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M3P024

2. Creating the tool sequence

A] When the message WHICH TYPE OF TOOL <MENU>? is displayed,

press the CURSOR key .

B] Press the TOOL FILE menu key to call the TOOL FILE display on the screen,
and check that the previously registered tool is included in the display.

The TOOL FILE (FACEMILL) display on the following page shows that

the 80 mm diameter face mill is registered.

6>30
NO. TOOL NOM-z MAT. DEPTH NO. NO. TOOL NOM-z MAT. DEPTH NO.
1 F-MILL 80.A CBD 5. 6 17
2 18
3 19
4 20
5 21
6 22
7 23
8 24
9 25
10 26
11 27
12 28
13 29
14 30
15 31
16 32
PAGE 1/2

*** TOOL FILE (FACEMILL) *** ( )

ENDMILL FACEMILL CHAMF BALL ALL PROGRAM NEXT

CUTTER ENDMILL ERASE PAGE

M3P025

C] Press the PROGRAM menu key to return to the WK. PROGRAM display and
continue programming.

D] NOMINAL DIAMETER? < 80 ><INPUT >

E] TOOL FILE CODE <MENU>? [A]

F] MACHINING PRIORITY No.?

(Skip to the next item since the identical-tool priority function is not used
here. Refer to the Part II, Chapter 5).
G] APPROACH POINT X, AUTO Æ <MENU>? [ AUTO SET ]
H] APPROACH POINT Y, AUTO Æ <MENU>? [ AUTO SET ]
I] CUTTING DIRECTION <MENU>? [ X BI-DIR ]
The possible directions of cutting are shown below.

Cutting feed
Rapid feed

(BI-DIR) (UNI-DIR) (BI-DIR SHORT)

M3P026

6>31
 J] DEPTH OF CUT, AUTO Æ <MENU>? [ AUTO SET ]
K] WIDTH OF CUT, AUTO Æ <MENU>? [ AUTO SET ]
L] CUTTING SPEED, AUTO Æ <MENU>? [ AUTO SET ]
M] FEED RATE, AUTO Æ <MENU>? [ AUTO SET ]

N] M CODE?

O] M CODE?

The tool sequence such as that shown below is now completed. For most of
the data items, optimal values are set by pressing the AUTO SET menu key.

Items APRCH-X & APRCH-Y, however, remains a question mark [ ? ]

because the necessary data is automatically set upon completion of the tool

path check.

UNO MAT INITIAL-Z ATC MODE MULTI MODE MULTI FLAG PITCH-X PITCH-Y
0 CBN-STL 20. 1 OFF ! ! !
UNO UNIT X Y k Z 4
1 WPC-1 -300. -200. 0. -100. 0.
UNO UNIT DEPTH SRV-Z SRV-R BTM WAL FIN-Z FIN-R
2 FACE MIL 0. 3. ! 2 ! 0. !
SNO TOOL NOM-z NO APRCH-X APRCH-Y TYPE ZFD DEP-Z WID-R C-SP FR M M
R1 F-MILL 80.A ? ? XBI ! 3. 56. 121 1.079
FIG PTN P1X/CX P1Y/CY R3X/R P3Y CN1 CN2 CN3 CN4
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aaa

*** WK. PROGRAM NO. 1234 ***

PATTERN OF FIGURE<MENU>? ( )
SQUARE CIRCLE ARBITRY
SHAPE CHECK
END

M3P027

3. Cutting parameters

The following describes the cutting parameters automatically set in steps [ L ] and
[ M ] shown on the previous page. The speed at which a tool revolves around a

part (circumferential speed) and the related axis feedrates are referred to as
cutting parameters.

6>32
 Circumferential speed (C-SP):

Speed (m/min) at which a tool moves on the outer circumference. The

relationship between the revolutions per minute and circumferential speed is

given by the following equation.

Circumferential = Tool diameter (mm)×Revolutions per minute (rpm)×3.14

speed (m/min) 1000

Feed rate (FR):

The distance (mm/rev) through which workpiece is cut during one revolution
of the tool. This feed rate is called synchronous feed rate.

Cutting speed

Feedrate

NM210-00527

4. Creating the shape sequence

Obtain the necessary data regarding the machining area from the part drawing and

input the coordinate values necessary for the machining shape. For face milling,
the top face of the workpiece is to be machined.

Input the dimensions of a shape as that shown below.

150 (X coordinate of diagonal point)

Diagonal point

Corner 2 Corner 3

100
(Y coordinate of
diagonal point)

Corner 1 Corner 4

Starting point

M3P028

Note: The X- and Y-coordinates of the start point become the workpiece zero point.

6>33
 Creating the shape sequence (Cont’d)

A] PATTERN OF FIGURE <MENU>? [ SQUARE ]

B] STARTING POINT X? <0><INPUT>

C] STARTING POINT Y? <0><INPUT>

D] CORNER 3 COORDINATE X? <150><INPUT>

E] CORNER 3 COORDINATE Y ? <100><INPUT>

F] CORNER 1 CHAMFER?
G] PATTERN OF FIGURE <MENU>? [ SHAPE END ]

A shape sequence such as that shown below is now completed.

UNO MAT INITIAL-Z ATC MODE MULTI MODE MULTI FLAG PITCH-X PITCH-Y
0 CBN-STL 20. 1 OFF ! ! !
UNO UNIT X Y k Z 4
1 WPC-1 -300. -200. 0. -100. 0.
UNO UNIT DEPTH SRV-Z SRV-R BTM WAL FIN-Z FIN-R
2 FACE MIL 0. 3. ! 2 ! 0. !
SNO TOOL NOM-z NO APRCH-X APRCH-Y TYPE ZFD DEP-Z WID-R C-SP FR M M
R1 F-MILL 80.A ? ? XBI ! 3. 56. 121 1.079
FIG PTN P1X/CX P1Y/CY R3X/R P3Y CN1 CN2 CN3 CN4
1 SQR 0. 0. 150. 100.
UNO UNIT
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*** WK. PROGRAM NO. 1234 ***

MACHINING UNIT <MENU>? ( )

POINT LINE FACE MANUAL OTHER WPC OFFSET END SHAPE

MACH-ING MACH-ING MACH-ING PROGRAM CHECK
M3P029

6>34
 5. Shape check

Of the various functions available with the SHAPE CHECK display, only those for

continuous display of shapes, for erasure of shapes, and for step display of
shapes are described here.

A] Press the SHAPE CHECK menu key.

The following SHAPE CHECK screen will be displayed.

-83.5 X 0.
Y 0.
Z 0.
WNO.1234 (!!!)
UNO. 0

0 37.1
-216.4
-318.7 -131.2
X

*** SHAPE CHECK ***

( )

SHAPE SHAPE SHAPE SHAPE STORE PLANE SCALE PROGRAM

CONTINUE UNIT STEP ERASE SELECT
M3P030

B] Press the SHAPE CONTINUE menu key to display shapes continuously.

Shapes will be displayed continuously. The shapes displayed on the

screen will be those of the portions which are chamfered by machining.

C] Press the SHAPE ERASE menu key to erase the shape.

D] Repeatedly press the SHAPE STEP menu key to show the shape step by

step on the screen.

The menu reverse display state will be cleared when the final group of

shapes is displayed.

6>35
 -83.5 X -225.
Y -200.
Z -100.
WNO.1234 (!!!)
UNO. 2

0 37.1
-216.4
-318.7 -131.2
X

*** SHAPE CHECK ***

( )

SHAPE SHAPE SHAPE SHAPE STORE PLANE SCALE PROGRAM

CONTINUE UNIT STEP ERASE SELECT

M3P031

-83.5 X -300.
Y -100.
Z -100.
WNO.1234 (!!!)
UNO. 2

0 37.1
-216.4
-318.7 -131.2

*** SHAPE CHECK ***

( )

SHAPE SHAPE SHAPE SHAPE STORE PLANE SCALE PROGRAM

CONTINUE UNIT STEP ERASE SELECT

M3P032

E] Press the PROGRAM menu key to resume the WK. PROGRAM display.

6>36
6-5-8 LINE MACHINING UNIT

The machining unit that steps the edges of a material by contour machining is referred

to as outside linear machining.

NM210-00518

1. Creating the line machining unit

A] While the message MACHINING UNIT <MENU>? is displayed, press the

LINE MACH-ING menu key.

B] MACHINING UNIT <MENU>? LINE OUT

C] Press the DETAILED INFORM. menu key.

The DETAILED INFORM. display will be presented.

UNO UNIT DEPTH SRV-Z SRV-R RGH CHMF FIN-Z FIN-R

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aaa

3 LINE OUT !

DEPTH

SRV-Z
FIN-R
FIN-Z

SRV-R

*** WK. PROGRAM NO. 1234 ***

DIST: WPC-Z = 0 TO FIN. SURFACE? ( )

DETAILED
INFORM.

M3P033

6>37
 Now, start creating the line machining unit. The data for items DEPTH, SRV-
Z, SRV-R and RGH will be specified here.

DEPTH Input a depth value of 10.

SRV-Z Input the wall thickness of the workpiece through which it is to be

chamfered in a Z axial direction from the face milled surface.

SRV-R Input the wall thickness of the workpiece through which it is to be

chamfered in a radial direction.

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aa a
z

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a

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x

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a
y

Depth=
Allowance Z
(SRV-Z) Allowance R (SRV-R)

Fig. 6-20 SRV-Z and SRV-R M3P034

D] DIST: WPC-Z = 0 TO FIN. SURFACE? <100><INPUT>

E] Z AXIS STOCK REMOVAL? <100><INPUT>

F] Y AXIS STOCK REMOVAL? <5><INPUT>

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a
ππ
G] SURFACE ROUGHNESS <MENU>? 3

H] FINISH ALLOWANCE-Z?

I] FINISH ALLOWANCE-R?

6>38
 A line machining unit such as that shown below is now completed. This display
shows that an end mill has been automatically selected for the particular tool

sequence that is to be programmed.

UNO UNIT DEPTH SRV-Z SRV-R RGH CHMF FIN-Z FIN-R

3 LINE OUT 10. 10. 5. 3 ! 0. 0.
SNO TOOL NOM-z NO APRCH-X APRCH-Y TYPE ZFD DEP-Z WID-R C-SP FR M M
R1 F-MILL G01 !

*** WK. PROGRAM NO. 1234 ***

WHICH TYPE OF TOOL <MENU>? ( )

ENDMILL FACE MILL CHAMF BALL

CUTTER ENDMILL

M3P035

2. Creating tool sequence

A] While the message WHICH TYPE OF TOOL <MENU>? is displayed,

press the CURSOR key .

B] Press the TOOL FILE menu key to display the TOOL FILE on the screen,
and check that the previously registered tools are included.

The following TOOL FILE (END MILL) display shows that the 10-mm
diameter end mill is registered.

NO. TOOL NOM-z MAT. DEPTH NO. NO. TOOL NOM-z MAT. DEPTH NO.
1 E-MILL 10.A CBD 30. 2. 17
2 18

C] Press the PROGRAM menu key to return to the WK. PROGRAM display and
continue programming.

6>39
 D] NOMINAL DIAMETER? <100> <INPUT>

E] TOOL FILE CODE <MENU>? [A]

F] MACHINING PRIORITY No.?

(Skip to the next article since the priority function for the same tool is not
to be used here. See Part II, Chapter 5.)

G] APPROACH POINT X, AUTO Æ <MENU>? [ AUTO SET ]

H] APPROACH POINT Y, AUTO Æ<MENU>? [ AUTO SET ]

I] CUTTING DIRECTION <MENU>? [ CW CUT ]
(Specify the direction in which the circumference is to be cut, that is either
clockwise (CW) or counterclockwise (CCW).)

CCW
CW

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NM210-00528

J] FEED RATE-Z, <MENU> OR <DATA>?

K] DEPTH OF CUT, AUTO Æ <MENU>? [ AUTO SET ]

L] CUTTING SPEED, AUTO Æ <MENU>? [ AUTO SET ]
M] FEED RATE, AUTO Æ <MENU>? [ AUTO SET ]

N] M CODE?

O] M CODE?

6>40
 A tool sequence such as that shown below is now completed.

UNO UNIT DEPTH SRV-Z SRV-R RGH CHMF FIN-Z FIN-R

3 FACE MIL 10. 10. 5. 3 ! 0. 0.
SNO TOOL NOM-z NO APRCH-X APRCH-Y TYPE ZFD DEP-Z WID-R C-SP FR M M
R1 E-MILL 10.A ? ? CW G01 10. ! 54 0.027
FIG PTNaa P1X/CX P1Y/CY R3X/R P3Y CN1 CN2 CN3 CN4
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1
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a

*** WK. PROGRAM NO. 1234 ***

PATTERN OF FIGURE<MENU>? ( )
SQUARE CIRCLE ARBITRY
SHAPE CHECK
END

M3P036

3. Creating the shape sequence

For outside linear machining, the edges of a part to be machined. Set the
dimensions of a shape as shown below.

145 (X coordinate of diagonal point)

Corner 2

R5 Corner 3
95
(Y coordinate of
diagonal point)

(Y coordinate
of the starting R5
Corner 1
point)
5
Corner 4
5 (X coordinate of the starting point)
M3P037

6>41
 A] While the message PATTERN OF FIGURE <MENU>? is displayed, press
the SQUARE menu key.

B] STARTING POINT X? < 5 ><INPUT>

C] STARTING POINT Y? < 5 ><INPUT>

D] CORNER 3 COORDINATE X? < 145 ><INPUT>

E] CORNER 3 COORDINATE Y? < 95 ><INPUT>

F] CORNER 1 CHAMFER?

G] CORNER 2 CHAMFER? < 5 ><INPUT>

H] CORNER 3 CHAMFER?

I] CORNER 4 CHAMFER? < 5 ><INPUT>

J] PATTERN OF FIGURE <MENU>? [ SHAPE END ]

A shape sequence such as that shown below is now completed.

UNO UNIT DEPTH SRV-Z SRV-R RGH CHMF FIN-Z FIN-R

3 LINE OUT 10. 10. 5. 3 ! 0. 0.
SNO TOOL NOM-z NO APRCH-X APRCH-Y TYPE ZFD DEP-Z WID-R C-SP FR M M
R1 E-MILL 10.A ? ? CW G01 10. ! 54 0.027
FIG PTN P1X/CX P1Y/CY R3X/R P3Y CN1 CN2 CN3 CN4
1 SQR 5. 5. 145. 95. R5. R5.
UNO UNIT
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aaa

*** WK. PROGRAM NO. 1234 ***

MACHINING UNIT <MENU>? ( )

POINT LINE FACE MANUAL OTHER WPC OFFSET END SHAPE

MACH-ING MACH-ING MACH-ING PROGRAM CHECK

M3P038

6>42
 4. Shape check

Call the SHAPE CHECK display on the screen.

A] Press the SHAPE CHECK menu key to call the SHAPE CHECK display.

B] Press the SHAPE CONTINUE menu key.

-83.5 X -225.
Y -195.
Z -110.
WNO.1234 (!!!)
UNO. 3

0 37.1
-216.4
-318.7 -131.2

*** SHAPE CHECK ***

MACHINING UNIT <MENU>? ( )

SHAPE SHAPE SHAPE SHAPE STORE PLANE SCALE PROGRAM

CONTINUE UNIT STEP ERASE SELECT

M3P039

6>43
 The PLANE SELECT function is described here. The shape being displayed
in procedural step [2] is that of the workpiece as seen from above. With this

function, it becomes possible to display shapes as seen from the side or

from an oblique angle.

The selectable plane is one of the four types shown below. It is also possible
to display one of two plane pairs (either XY-XZ (XY plane and XZ plane) or

XY-YZ (XY plane and YZ plane)) at the same time. See section 6-5-3 SHAPE
CHECK display of the Operating manual for NC unit for the details.

XY plane

XZ plane

Orthographic
view

YZ plane

Fig. 6-21 Plane selection M3P040

Display shapes of various planes

XY-XZ plane

C] Press the PLANE SELECT menu key.

D] Press the XY-XZ menu key

Shapes as seen from above and from the side are selected.

6>44
 E] Press the SHAPE CONTINUE menu key to display shapes continuously.

As shown below, a shape as seen from above (XY plane) and a shape

as seen from the side (XZ plane) are displayed at the same time.

-87.4 X -225.
Y -195.
Z -110.
WNO.1234 (!!!)
UNO. 3
Y

- 212.5
- 70.3

Z 0 53.4
-136.6
-360. -89.9

*** SHAPE CHECK ***

( )

SHAPE SHAPE SHAPE SHAPE STORE PLANE SCALE PROGRAM

CONTINUE UNIT STEP ERASE SELECT

M3P041

6-5-9 POINT MACHINING UNIT (1)

This section will create a program unit used to drill a 10-mm diameter through hole.

This machining unit is referred to as a drilling unit.

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NM210-00519
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6>45
 1. Creation of point machining unit (1)

A] While message MACHINING UNIT <MENU>? is displayed, press the

POINT MACH-ING menu key.

B] MACHINING UNIT <MENU>? DRILLING

C] Press the DETAILED INFORM menu key.

The following DETAILED INFORM. screen will be displayed.

UNO UNIT DIA DEPTH CHMF

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4 DRILLING
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a
a

DIA

>
CHMF
DEPTH

*** WK. PROGRAM NO. 1234 ***

HOLE DIAMETER? ( )

DETAILED
INFORM.

M3P043

Now, start creating the point machining unit. The data for the item DIA,

DEPTH and CHMF will be specified here.

D] HOLE DIAMETER? < 10 > <INPUT >

E] HOLE DEPTH? < 20 > <INPUT >

F] CHAMFER WIDTH? < 0 > <INPUT >

6>46
 A machining program unit such as that shown below is now completed.
This shows that a spot and a drill have been automatically selected for

the tool sequence that is to be programmed.

UNO UNIT DIA DEPTH CHMF

4 DRILLING 10. 20. 0.

SNO TOOL NOM-z NO HOLE-z HOLE-DEP PRE-DIA PRE-DEP RGH DEPTH C-SP FR M M
1 CTR-DR 20. 10. ! ! ! 90° !
2 DRILL 10. 10. 20 ! ! DRIL T5.

*** WK. PROGRAM NO. 1234 ***

WHICH TYPE OF TOOL<MENU>? ( )

CENTER DRILL CHAMF ENDMILL BACKSPOT REAMER TAP BORING BACK

DRILL CUTTER FACER BAR BOR. BAR

M3P044

2. Creating the tool sequence

For the point machining unit, it is necessary just to set the cutting parameters

(circumferential speed and feed rate) since most of the tool sequence data are set

automatically.

A] While the message WHICH TYPE OF TOOL <MENU>? is displayed,

move the cursor to the position under the article C-SP by pressing the cursor

key six times in succession.

B] CUTTING SPEED, Æ AUTO <MENU>? [ HSS AUTO ]

C] FEED RATE, AUTO Æ<MENU>? [ HSS AUTO ]

D] M CODE?

E] M CODE?
F] Press the cursor key eight times in succession to
move the cursor to the position under item C-SP.

6>47
 G] CUTTING SPEED, AUTO Æ<MENU>? [ HSS AUTO ]
H] FEED RATE, AUTO Æ<MENU>? [ HSS AUTO ]

I] M CODE?

J] M CODE?

A tool sequence such as that shown below is now completed.

UNO UNIT DIA DEPTH CHMF

4 DRILLING 10. 20. 0.
SNO TOOL NOM-z NO HOLE-z HOLE-DEP PRE-DIA PRE-DEP RGH DEPTH C-SP FR M M
1 CTR-DR 20. 10. ! ! ! 90° ! 20 0.2
2 DRILL 10. 10. 20. ! ! DRIL T5. 25 0.132

FIG PTN Z X Y AN1 AN2 T1 T2 F M N P Q R

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*** WK. PROGRAM NO. 1234 *** POINT CUTTING PATTERN <MENU>? ( )
POINT LINE SQUARE GRID CIRCLE ARC CHORD
SHAPE CHECK

END

M3P045

3. Creating the shape sequence

Next, create a shape sequence. For drilling, input the coordinates of the hole

center as shown below.

(Y coordinate of
20
hole center)

100

(X coordinate of hole center)

M3P046

6>48
 A] While the message POINT CUTTING PATTERN <MENU>? is displayed,
press the menu key POINT.

B] Z VALUE OF WORK SURFACE? < 0 > <INPUT >

C] HOLE POSITION X? < 100 > <INPUT >

D] HOLE POSITION Y? < 20 > <INPUT >

E] PATH <Y:0, YÆX:1, XÆY:2>? < 0 > <INPUT >

(The tool path to the next hole is to be selected from the three types shown

below. If, however, the hole to which the tool is to be fed does not exist,
input 0 since the selected function is unavailable.)
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y y y

x x x

If 0, both the X and Y axes If 1, the X axis starts moving If 2, the Y axis starts moving
move simultaneously. after the Y axis has moved. after the X axis has moved.

Fig. 6-12 Tool path M3P047

F] OMIT SPT MACHINING <Y:1, N:0>? < 0 > <INPUT >

(If 0, drilling occurs. If 1, positioning only occurs.)

G] RETURN POSITION <INT:0, R:1>? < 0 > <INPUT >

(The height of the tool path to the next hole is to be selected from the two

types shown below. If however, the hole to which the tool is to be fed does
not exist, input 0 since the selected function is unavailable.)

6>49
 a
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“ ’ Initial point R point
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Initial point
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R point ’

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Cutting in program

a
a

a
Movement in program
If 0, the tool moves to the next hole If 1, the tool moves to the next hole
at the height of initial point. at the height of R point.

Fig. 6-23 Return position M3P048

H] POINT CUTTING PATTERN <MENU>? SHAPE END

A shape sequence such as that shown below is now completed. Call the
SHAPE CHECK display to check the shapes.

UNO UNIT DIA DEPTH CHMF

4 DRILLING 10. 20. 0.
SNO TOOL NOM-z NO HOLE-z HOLE-DEP PRE-DIA PRE-DEP RGH DEPTH C-SP FR M M
1 CTR-DR 20. 10. ! ! ! 90° ! 20 0.2
2 DRILL 10. 10. 20. ! ! DRIL T5. 25 0.132

FIG PTN Z X Y AN1 AN2 T1 T2 F M N P Q R

1 PT 0. 100. 20. ! ! ! ! ! ! ! 0 0 0

UNO UNIT
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*** WK. PROGRAM NO. 1234 ***

MACHINING UNIT <MENU>? ( )

POINT LINE FACE MANUAL OTHER WPC OFFSET END SHAPE

MACH-ING MACH-ING MACH-ING PROGRAM CHECK

M3P049

6>50
 4. Shape check

Call the SHAPE CHECK display on the screen.

A] Press the SHAPE CHECK menu key to call the SHAPE CHECK display.

B] Press the SHAPE CONTINUE menu key.

-83.5 X -200.
Y -100.
Z -100.
WNO.1234 (!!!)
UNO. 4

0 37.1
-216.4
-318.7 -131.2
X

*** SHAPE CHECK ***

( )

SHAPE SHAPE SHAPE SHAPE STORE PLANE SCALE PROGRAM

CONTINUE UNIT STEP ERASE SELECT

M3P050

The SCALE function is explained here. This function allows enlargement/reduction

of shapes, as well as changing of the shape display position.

Enlargement of shapes

Let us display a 10 mm diameter hole in enlarged form using the SCALE function.

C] Press the SCALE menu key.

D] Using the cursor keys , place the cursor on the 10 mm diameter

hole position as shown on the following page.

E] SCALE <INPUT>? < 20 ><INPUT>

(The size of the shape is changed so that the line on the lower right corner
of the screen becomes 20 mm in length.)

6>51
 -83.5 X -200.
Y -100.
Z -100.
WNO.1234 (!!!)
UNO. 4

aa
a
aaa
aa
a
0 37.1
-216.4
-318.7 -131.2
X

*** SHAPE CHECK ***

( )

SHAPE SHAPE SHAPE SHAPE STORE PLANE SCALE PROGRAM

CONTINUE UNIT STEP ERASE SELECT

M3P051

F] Press the SHAPE CONTINUE menu key.

As shown below, the shape has been enlarged with its center in the 10

mm diameter hole position.

-147.6 X -200.
Y -100.
Z -100.
WNO.1234 (!!!)
UNO. 4

0 20.
-219.2
-251.7 -150.7
X

*** SHAPE CHECK ***

( )

SHAPE SHAPE SHAPE SHAPE STORE PLANE SCALE PROGRAM

CONTINUE UNIT STEP ERASE SELECT

M3P052

6>52
 Reduction of shapes

G] Press the SCALE menu key.

H] SCALE <INPUT>? < 100 > <INPUT >

(The size of the shape is changed so that the line on the lower right corner

of the screen becomes 100 mm in length.)

I] Press the SHAPE CONTINUE menu key.

As shown below, the shape has been reduced in size.

-4.4 X -200.
Y -100.
Z -100.
WNO.1234 (!!!)
UNO. 4

0 100.
-362.4
-453.7 51.2
X

*** SHAPE CHECK ***

( )

SHAPE SHAPE SHAPE SHAPE STORE PLANE SCALE PROGRAM

CONTINUE UNIT STEP ERASE SELECT

M3P053

J] Press the PROGRAM menu key to resume the WK. PROGRAM display.

6>53
6-5-10 POINT MACHINING UNIT (2)

Create a unit that is used to drill four M8 tapped through-holes. This machining program

unit is referred to as a tapping unit.

Fig. 6-24 Point machining NM210-00520

1. Creating the point machining unit (2)

A] While the message MACHINING UNIT <MENU>? is displayed, press the

POINT MACH-ING menu key.

B] MACHINING UNIT <MENU>? TAPPING

C] Press the MENU SELECTOR key.

D] Press the DETAILED INFORM. menu key.

UNO UNIT NOM- MAJOR-z PITCH TAP-DEP CHMF CHP

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5 TAPPING 0

MAJOR-z

CHMF
TAP-DEP
PITCH

*** WK. PROGRAM NO. 1234 ***

TAP TYPE <MENU>? ( )

PROGRAM SEARCH LINE ERASE SHAPE UNIT PROGRAM DETAILED

END INSERT COPY COPY COPY INFORM.

M3P054

6>54
 E] Press the MENU SELECTOR key to return to the original menu.

Begin creating the point machining unit. The data for the items NOM-, TAP-

DEP will be specified here.

F] TAP TYPE <MENU>? [ METRIC THRD (M) ]

G] NOMINAL DIAMETER? < 8 > <INPUT >

(Setting of the nominal diameter causes automatic setting of the outer
diameter, the pitch and the amount of chamfering.)

H] TAPPING DEPTH? < 20 > <INPUT >

I] CHAMFER WIDTH?

J] CHIPS VAC. CLEANER <Y:1, N:0>?

A point machining unit such as that shown below is now completed. This

shows that after the data inputted for the point machining unit, a spot, a drill
and a tap have been automatically selected for the tool sequence that is to

be programmed.

UNO UNIT NOM- MAJOR-z PITCH TAP-DEP CHMF CHP

5 TAPPING M8. 8. 1.25 20. 0.6 0

SNO TOOL NOM-z NO HOLE-z HOLE-DEP PRE-DIA PRE-DEP RGH DEPTH C-SP FR M M
1 CTR-DR 20. 8.117 ! ! ! 90° !
2 DRILL 6.9 6.9 27.25 ! ! PCK1 T3.45
3 TAP M8. 8. 20. ! ! FIX P1.25 1.25

*** WK. PROGRAM NO. 1234 ***

WHICH TYPE OF TOOL<MENU>? ( )

CENTER DRILL CHAMF ENDMILL BACKSPOT REAMER TAP BORING BACK

DRILL CUTTER FACER BAR BOR. BAR

M3P055

6>55
2. Creating the tool sequence

A] Press the CURSOR key six times in succession to move the cursor to

the position under item C-SP.

B] CUTTING SPEED, AUTO Æ <MENU>? [ HSS AUTO ]

C] FEED RATE, AUTO Æ <MENU>? [ HSS AUTO ]

D] M CODE?

E] M CODE?

F] Press the CURSOR key eight times in succession to move the

cursor to the position under the article C-SP.
G] CUTTING SPEED, AUTO Æ<MENU>? [ HSS AUTO ]
H] FEED RATE, AUTO Æ<MENU>? [ HSS AUTO ]

I] M CODE?

J] M CODE?

K] Press the cursor key eight times in succession to move the cursor to

the position under the article C-SP.

L] CUTTING SPEED, AUTOÆ <MENU>? [ HSS AUTO ]

M] FEED RATE, AUTO Æ <MENU>? [ HSS AUTO ]

N] M CODE?

O] M CODE?

A tool sequence such as that shown on the following page is now completed.

6>56
UNO UNIT NOM- MAJOR-z PITCH TAP-DEP CHMF CHP

5 TAPPING M8. 8. 1.25 20. 0.6 0

SNO TOOL NOM-z NO HOLE-z HOLE-DEP PRE-DIA PRE-DEP RGH DEPTH C-SP FR M M
1 CTR-DR 20. 8.117 ! ! ! 90° ! 20 0.2
2 DRILL 6.9 6.9 27.25 ! ! PCK1 T3.45 22 0.005
3 TAP M8. 8. 20. ! ! FIX P1.25 8 1.25

FIG PTN Z X Y AN1 AN2 T1 T2 F M N P Q R

*** WK. PROGRAM NO. 1234 *** POINT CUTTING PATTERN <MENU>? ( )
POINT LINE SQUARE GRID CIRCLE ARC CHORD
SHAPE CHECK

END

M3P056

3. Creating the shape sequence

Next, create a shape sequence. For tapping, four holes are to be drilled. These

holes are to be set as one shape, as shown below.

25 (Radius of circle-R)

Start point
60
(Y coordinate of
circle center)

50

Fig. 6-25 (X coordinate of circle center) M3P057

A] While the message POINT CUTTING PATTERN <MENU>? is displayed,

press the CIRCLE menu key.

6>57
B] Z VALUE OF WORK SURFACE? < 0 > <INPUT>

C] CIRCLE CENTER X? < 50 > <INPUT>

D] CIRCLE CENTER Y? < 60 > <INPUT>

E] ANG OF START PT FROM X AXIS? < 0 > <INPUT>

(Input the angle of the line connecting the center of the circle and the first

hole to be drilled with respect to the X-axis.)

Example 1 Example 2

Start point
Center
Center
45°
0° 0°
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270° -90°

Start point
Fig. 6-26 M3P058

F] CIRCLE RADIUS R < 25 > <INPUT>

G] NUMBER OF HOLES? < 4 > <INPUT>

H] RETURN POSITION <INIT:0, R:1>? < 1 > <INPUT>

I] POINT CUTTING PATTERN <MENU>? [ SHAPE END ]

A shape sequence such as that shown on the top of the following page is
now completed.

6>58
UNO UNIT NOM- MAJOR-z PITCH TAP-DEP CHMF CHP

5 TAPPING M8. 8. 1.25 20. 0.6 0

SNO TOOL NOM-z NO HOLE-z HOLE-DEP PRE-DIA PRE-DEP RGH DEPTH C-SP FR M M

1 CTR-DR 20. 8.117 ! ! ! 90° ! 20 0.2

2 DRILL 6.9 6.9 27.25 ! ! PCK1 T3.45 22 0.005
3 TAP M8. 8. 20. ! ! FIX P1.25 8 1.25

FIG PTN Z X Y AN1 AN2 T1 T2 F M N P Q R

1 CIR 0. 50. 60. 0. ! 25. ! ! 4 ! ! ! 1

UNO UNIT
6

*** WK. PROGRAM NO. 1234 ***

MACHINING UNIT <MENU>? ( )

POINT LINE FACE MANUAL OTHER WPC OFFSET END SHAPE

MACH-ING MACH-ING MACH-ING PROGRAM CHECK

M3P059

4. Shape check

A] Press the SHAPE CHECK menu key.

B] Press the SHAPE CONTINUE menu key.

-4.4 X -250.
Y -165.
Z -100.
WNO.1234 (!!!)
UNO. 5

0 100.
-362.4
-453.7 51.2
X
*** SHAPE CHECK ***
( )

SHAPE SHAPE SHAPE SHAPE STORE PLANE SCALE PROGRAM

CONTINUE UNIT STEP ERASE SELECT

M3P060

6>59
 C] Press the SHAPE ERASE menu key to erase the shape.

D] Press the SHAPE UNIT menu key several times to display shapes on a unit

basis.

The reverse-display status of SHAPE UNIT is cleared when the final shape
has been displayed.

The following display shows the unit number 4 shape of point machining unit
(A).

-4.4 X -200.
Y -100.
Z -100.
WNO.1234 (!!!)
UNO. 4

0 100.
-362.4
-453.7 51.2
X
*** SHAPE CHECK ***
( )

SHAPE SHAPE SHAPE SHAPE STORE PLANE SCALE PROGRAM

CONTINUE UNIT STEP ERASE SELECT

M3P061

E] Press the PROGRAM menu key to resume the WK. PROGRAM display.

This completes a point machining (tapping) unit.

6>60
6-5-11 END UNIT

Create an end unit that indicates the end of the program.

1] While the message MACHINING UNIT <MENU>? is displayed, press the

END menu key.

2] CONTINUE <Y:1, N:0>? < 0 > <INPUT >

(Specify whether or not the machining program is to be repeated. If 0, the
program ends with the particular step. If 1, the program returns to its
beginning and returns to machine the next workpiece.)

3] PARTS COUNTER <Y:1 N:0>? < 0 > <INPUT >

(Specify whether or not the number of times that the machining operation

has been repeated is to be counted. If 0, counting does not occur. If 1,

counting occurs and the results are displayed on the COMMAND display of
the screen.)

An end unit such as that shown below is now completed, which means that the

creation of the program is to be ended.

UNO UNIT NOM MAJOR-z PITCH TAP-DEP CHMF CHP

5 TAPPING M8. 8. 1.25 20. 0.6 0

SNO TOOL NOM-z NO HOLE-z HOLE-DEP PRE-DIA PRE-DEP RGH DEPTH C-SP FR M M
1 CTR-DR 20. 8.117 ! ! ! 90° ! 20 0.2
2 DRILL 6.9 6.9 27.25 ! ! PCK1 T3.45 22 0.005
3 TAP M8. 8. 20. ! ! FIX P1.25 8 1.25

FIG PTN Z X Y AN1 AN2 T1 T2 F M N P Q R

1 CIR 0. 50. 60. 0. ! 25. ! ! 4 ! ! ! 1
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UNO UNIT CONTI. NUMBER

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a
a
a
a
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a
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6 END 0 0
a
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a
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a
a
a
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a
a
a

*** WK. PROGRAM NO. 1234 ***

MACHINING UNIT <MENU>? ( )

POINT LINE FACE MANUAL OTHER WPC OFFSET END SHAPE

MACH-ING MACH-ING MACH-ING PROGRAM CHECK

M3P062

6>61
6-5-12 END OF THE PROGRAM

1] Press the MENU SELECTOR key.

2] Press the PROGRAM END menu key.

Displaying the newly created program by pressing the CURSOR keys

repeatedly to scroll the screen up or forward continuously.

UNO MAT INITIAL-Z ACT MODE MULTI MODE MULTI FLAG PITCH-X PITCH-Y
0 CST IRN 20. 1 OFF ! ! !

UNO UNIT X Y k Z 4
1 WPC-1 -300. -200. 0. -100. 0.

UNO UNIT DEPTH SRV-Z SRV-R BTM WAL FIN-Z FIN-R

2 FACE MIL 0. 3. ! 2 ! 0. !

SNO TOOL NOM-z NO APRCH-X APRCH-Y TYPE ZFD DEP-Z WID-R C-SP FR M M
R1 F-MILL 80.A ? ? XBI ! 3. 56. 121 1.079

FIG PTN P1X / CX P1Y / CY P3X / R P3Y CN1 CN2 CN3 CN4
1 SQR 0. 0. 150. 100.

UNO UNIT DEPTH SRV-Z SRV-R RGH CHMF FIN>Z FIN>R

3 LINE OUT 10. 10. 5. 3 ! 0. 0.

SNO TOOL NOM-z NO APRCH-X APRCH-Y TYPE ZFD DEP-Z WID-R C-SP FR M M
R1 E-MILL 10.A ? ? CW G01 10. ! 54 0.027

FIG PTN P1X / CX P1Y / CY P3X / R P3Y CN1 CN2 CN3 CN4
1 SQR 5. 5. 145. 95. R5. R5.

UNO UNIT HOLE-z HOLE-DEP. CHMF

4 DRILLING 10. 20. 0.

SNO TOOL NOM-z NO HOLE-z HOLE-DEP PRE-DIA PRE-DEP RGH DEPTH C-SP FR M M
1 CTR-DR 20. 10. ! ! ! 90° ! 20 0.2
2 DRILL 10. 10. 20. ! ! DRIL T5. 25 0.132

FIG PTN Z X Y AN1 AN2 T1 T2 F M N P Q R

1 PT 0. 100. 20. ! ! ! ! ! ! ! 0 0 0
UNO UNIT NOM- MAJOR-z PITCH TAP-DEP CHMF CHP

5 TAPPING M8 8 1.25 20. 0.6 0

SNO TOOL NOM-z NO HOLE-z HOLE-DEP PRE-DIA PRE-DEP RGH DEPTH C-SP FR M M
1 CTR-DR 20. 8.117 ! ! ! 90° ! 20 0.2
2 DRILL 6.9 6.9 27.25 ! ! PCK1 T3.45 22 0.005
3 TAP M8. 8. 20. ! ! FIX P1.25 8 1.25

FIG PTN Z X Y AN1 AN2 T1 T2 F M N P Q R

1 CIR 0. 50. 60. 0. ! 25. ! ! 4 ! ! ! 1

UNO UNIT CONTI. NUMBER

6 END 0 0
Fig. 6-27 Sample program M3P063

6>62
6-6 REGISTRATION OF TOOLS IN THE TOOL DATA FILE
When creating a program, the names and nominal diameters of the tools required for

machining should have already been inputted. To machine a workpiece by automatic

run, those tools must be mounted in a tool magazine in advance. In addition, the tools

to be mounted in a tool magazine must be registered in a tool data file. Registration of

tools in a tool data file is referred to as assignment of pocket numbers to the tools.

6-6-1 POCKET NUMBERS AND TOOL NUMBERS

The pocket number refers to the number inscribed on the side face of the pocket of a
tool magazine. The tool that has been mounted in the pocket is specified by the pocket

number. The identification number of the pocket which accommodates a tool is called

tool number.

Tool magazine (Vertical machines) Tool magazine (Horizontal machines)

This tool is referred

to as the tool having
tool No. 4.

These numbers are

referred to as pocket
numbers.

Fig. 6-28 NM210-00529

Note: The design of the tool magazine slightly differs according to the type of
machine to be used.

6>63
6-6-2 TOOL DATA DISPLAY

Carry out the following key operations to call the TOOL DATA display:

1] Press the DISPLAY SELECTOR key.

2] Press the TOOL DATA menu key.

The TOOL DATA display will then be presented as shown below.

Function of the TOOL DATA display

The TOOL DATA display shows that types of tools mounted in the tool magazine.
The types of tools are displayed in order of pocket number; the pocket numbers

being displayed on the left end of the screen.

If no tool types are being displayed on the screen, this indicates that no tools are

mounted in the tool magazine. The pocket numbers on the TOOL DATA display
correspond to the pocket numbers of the tool magazine. The relationship between

these two types of pocket numbers can be represented as shown below.

PKNO. TOOL NOM-z ACT-z LENGTH COMP. AUXIL. THR. HP LIFE(M) TIME(M)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

* * * TOOL DATA * * * (!!!!!)

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a
a
aaaaaa a
aaaaaaa
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aaaaaa
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aa
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aaaaaa a
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aa
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a
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a
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DRUM NO. TEACH T-DATA INCR. TOOL TOOL PREVIOUS NEXT

a
a
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aaa
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MOVE ASSIGN SEARCH PAGE PAGE

a
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NM210-00530

Fig. 6-29 Tool pocket numbers M3P064

6>64
6-6-3 TOOL LAYOUT DISPLAY

Carry out the following key operation to call the TOOL LAYOUT display:

1] Press the DISPLAY SELECTOR key.

2] Press the TOOL LAYOUT menu key.

The following TOOL LAYOUT screen will be displayed.

CURRENT NEXT!!!WORK NO.

PKNO. TOOL NOM-z PKNO. TOOL NOM-z PKNO. TOOL NOM-z PKNO. TOOL NOM-z
1 17
2 18
3 19
4 20
5 21
6 22
7 23
8 24
9 25
10 26
11 27
12 28
13 29
14 30
15
16
PAGE 1/1 PAGE /

*** TOOL LAYOUT *** WORK PIECE PROGRAM NUMBER ? ( )

WORK NO. DRUM NO. SPARE T PK NO. PK NO. PK NO. SPARE T LAYOUT NEXT
ERASE CLEAR SHIFT ASSIGN ADDITION FINISH PAGE

M3P065

Function of the TOOL LAYOUT display

The TOOL LAYOUT display shows the tools that have been set on the program

are to be registered in a tool data file. This display consists of two sections:

The ”NEXT” display on the right side, and the “CURRENT” display on the left
side. On the CURRENT display, tool names and pocket numbers are indicated in

the same state as that of the TOOL DATA display. The NEXT display is used to

carry out setup operations such as display of the tools that have been set on the
program and assignment of pocket numbers to them. When the setup operations

are completed, the tools on the NEXT display will be registered on the CURRENT
display (tool data).

The diagram on the following pages show the relationship between the WK.
PROGRAM display, TOOL DATA display and TOOL LAYOUT display.

6>65
PKNO. TOOL NOM-z ACT-z LENGTH COMP. AUXIL. THR. HP LIFE (M) TIME (M)
1 F-MILL 80.A 80. 0. ! ! 0 0 0
2 E-MILL 10.A 10. 0. 0 0 0 0
3 CTR-DR 20. ! 0. ! ! ! 0 0
4 DRILL 10. ! 0. ! 0 0 0 0
5 DRILL 6.9 ! 0. ! 0 0 0 0
6 TAP M8. 8. 0. 0 ! ! 0 0
7
8
9
10
11
12
13
14
15
16
PAGE!1/2

*** TOOL DATA * * * (!!!!!)

DRUM NO. TEACH T-DATA INCR. TOOL TOOL PREVIOUS NEXT

MOVE ASSIGN SEARCH PAGE PAGE

The CURRENT display and the TOOL DATA

3
display always possess the same contents.
Thus, the tool data also changes when new tools
3
have been registered on the CURRENT display.

CURRENT
PKNO. TOOL NOM-z PKNO. TOOL
1 F-MILL 80.A 17
2 E-MILL 10.A 18
3 CTR-DR 20. 19
4 DRILL 10. 20
5 DRILL 6.9 21
6 TAP M8. 22
7 23
8 24
9 25
10 26
11 27
12 28
13 29
14 30
15 PAGE
16

*** TOOL LAYOUT ***

WORK NO. DRUM NO. SPARE T PK NO.

ERASE CLEAR

6>66
 UNO MAT INITIAL-Z ACT MODE MULTI MODE MULTI FLAG PITCH-X PITCH-Y
0 CST IRN 20. 1 OFF ! ! !
UNO UNIT X Y k Z 4
1 WPC-1 -300. -200. 0. –100. 0.
UNO UNIT DEPTH SRV-Z SRV-R BTM WAL FIN-Z FIN-R
2 FACE MIL 0. 3. ! 2 ! 0. !
SNO TOOL NOM-z NO APRCH-X APRCH-Y TYPE ZFD DEP-Z WID-R C-SP FR M M
R1 F-MILL 80.A -50. 16. XBI ! 3. 56. 121 0.176
FIG PTN P1X / CX P1Y / CY P3X / R P3Y CN1 CN2 CN3 CN4
1 SQR 0. 0. 150. 100.
UNO UNIT DEPTH SRV-Z SRV-R RGH CHMF FIN-Z FIN-R
3 LINE OUT 10. 10. 5. 3 ! 0. 0.
SNO TOOL NOM-z NO APRCH-X APRCH-Y TYPE ZFD DEP-Z WID-R C-SP FR M M
R1 E-MILL 10.A 0. -10. CW G01 10. ! 54 0.027

*** WK. PROGRAM NO. 1234 ***

( !!!!! )

WORK NO. SEARCH PROGRAM ≠ Ø TOOL PROGRAM WPC MSR DETAILED

EDIT ≠ Ø PATH FILE INFORM.

Registration of new tools

The tools that have been
set on the program are displayed.
2 1

NEXT WORK NO. 1234

NOM-z PKNO. TOOL NOM-z PKNO. TOOL NOM-z
1 F-MILL 80.A
2 E-MILL 10.A
3 CTR-DR 20.
4 DRILL 10.
5 DRILL 6.9
6 TAP M8.

1/1 PAGE!1/1

PKNO. SHIFT OR ASSIGN <MENU>? ( ! ! ! ! ! )

PK NO. PK NO. SPARE T LAYOUT NEXT

SHIFT ASSIGN ADDITION FINISH PAGE

M3P066

6>67
6-6-4 REGISTRATION OF TOOLS

The display of menu data WORK NO. is reversed, and the message WORKPIECE

PROGRAM NUMBER? is displayed on the TOOL LAYOUT display. Input the work
number of the program which has been previously created in section 4-4.

See section 4-7 TOOL LAYOUT Display in the Mazatrol Operating manual for detailed

information.

A) WORKPIECE PROGRAM NUMBER? < 1 2 3 4 > <INPUT >

CURRENT NEXT!!!WORK NO. 1234

PKNO. TOOL NOM-z PKNO. TOOL NOM-z PKNO. TOOL NOM-z PKNO. TOOL NOM-z
1 17 0 F-MILL 80.A
2 18 0 E-MILL 10.A
3 19 0 CTR-DR 20.
4 20 0 DRILL 10.
5 21 0 DRILL 6.9
6 22 0 TAP M8.
7 23
8 24
9 25
10 26
11 27
12 28
13 29
14 30
15
16
PAGE 1/1 PAGE 1/1

*** TOOL LAYOUT ***

PKNO. SHIFT OR ASSIGN <MENU>? ( )

WORK NO. DRUM NO. SPARE T PK NO. PK NO. PK NO. SPARE T LAYOUT NEXT
ERASE CLEAR SHIFT ASSIGN ADDITION FINISH PAGE

M3P067

The tools that have been set on the program having work No. 1234 will then be
displayed as shown on the NEXT display.

Assign pocket numbers to the displayed tools.

Three modes are available for assigning pocket numbers: automatic, manual, and shift.

Automatic assignment, the simplest of these three modes, is described.

Note: If automatic assignment is performed, data of the registered tools will be

erased entirely. To prevent this data erasure, either the manual assignment

mode or the shift mode must be used.

6>68
 B] PKNo. SHIFT OR ASSIGN <MENU>? [ PKNO. ASSIGN ]

C] POCKET NUMBER ASSIGN <INPUT>? < INPUT >

Pocket numbers will then be assigned to the tools as shown below.

CURRENT NEXT!!!WORK NO. 1234

PKNO. TOOL NOM-z PKNO. TOOL NOM-z PKNO. TOOL NOM-z PKNO. TOOL NOM-z
1 17 1 F-MILL 80.A
2 18 2 E-MILL 10.A
3 19 3 CTR-DR 20.
4 20 4 DRILL 10.
5 21 5 DRILL 6.9
6 22 6 TAP M8.
7 23
8 24
9 25
10 26
11 27
12 28
13 29
14 30
15
16
PAGE 1/1 PAGE 1/1

*** TOOL LAYOUT ***

LAYOUT FINISH <MENU>? ( )

WORK NO. DRUM NO. SPARE T PK NO. PK NO. PK NO. SPARE T LAYOUT NEXT
ERASE CLEAR SHIFT ASSIGN ADDITION FINISH PAGE

M3P068

Next, carry out the following key operations to register the tools on the NEXT
display onto the CURRENT display.

D] LAYOUT FINISH <MENU>? [ LAYOUT FINISH ]

E] LAYOUT FINISH <INPUT>? < INPUT >

6>69
 F] LAYOUT FINISH?

The tools will be registered on the CURRENT display as shown below.

Recall the TOOL DATA display on the screen.

CURRENT NEXT!!!WORK NO. 1234

PKNO. TOOL NOM-z PKNO. TOOL NOM-z PKNO. TOOL NOM-z PKNO. TOOL NOM-z
1 F-MILL 80.A 17 1 F-MILL 80.A
2 E-MILL 10.A 18 2 E-MILL 10.A
3 CTR-DR 20. 19 3 CTR-DR 20.
4 DRILL 10. 20 4 DRILL 10.
5 DRILL 6.9 21 5 DRILL 6.9
6 TAP M8. 22 6 TAP M8.
7 23
8 24
9 25
10 26
11 27
12 28
13 29
14 30
15
16
PAGE 1/1 PAGE 1/1

*** TOOL LAYOUT ***

LAYOUT FINISH ( )

WORK NO. DRUM NO. SPARE T PK NO. PK NO. PK NO. SPARE T LAYOUT NEXT
ERASE CLEAR SHIFT ASSIGN ADDITION FINISH PAGE

M3P069

G] Press the DISPLAY SELECTOR key.

6>70
 H] Press the TOOL DATA menu key.

The tools that have been registered in the TOOL LAYOUT display will

be shown in the TOOL DATA display, as shown below.

PKNO. TOOL NOM-z ACT-z LENGTH COMP. AUXIL. THR. HP LIFE(M) TIME(M)
1 F-MILL 80.A 80. 0. ! ! 0 0 0
2 E-MILL 10.A 10. 0. 0 0 0 0
3 CTR-DR 20. ! 0. ! ! ! 0 0
4 DRILL 10. ! 0. ! 0 0 0 0
5 DRILL 6.9 ! 0. ! 0 0 0 0
6 TAP M8. 8. 0. 0 ! ! 0 0
7
8
9
10
11
12
13
14
15
16

PAGE 1/2

*** TOOL DATA ***

( )

WORK NO. DRUM NO. SPARE T PK NO. PK NO. PK NO. SPARE T LAYOUT NEXT
ERASE CLEAR SHIFT ASSIGN ADDITION FINISH PAGE

M3P070

6-7 CHECKING THE MACHINING PATH

Return the WK. PROGRAM display as follows:

1] Press the DISPLAY SELECTOR key.

2] Press the PROGRAM menu key.

The program with work No. 1234 will be displayed as shown below. Next, call

the PATH CHECK display on the screen and check the machining path on
that display. See section 4-4-1 PATH CHECK display in the Mazatrol

Operating manual for details.

6>71
UNO MAT INITIAL-Z ATC MODE MULTI MODE MULTI FLAG PITCH-X PITCH-Y
0 CBN STL 20. 1 OFF ! ! !
UNO UNIT X Y k Z 4
1 WPC-1 -300. -200. 0. -100.
UNO UNIT DEPTH SRV-Z SRV-R RGH CHMF FIN-Z FIN-R
2 LINE OUT 0. 3. ! 2. ! 0. !
SNO TOOL NOM-z NO APRCH-X APRCH-Y TYPE ZFD DEP-Z WID-R C-SP FR M M
R1 F-MILL 80.A -50. 16. XBI ! 3. 56. 121 0.176

FIG PTN P1X / CX P1Y / CY P3X / R P3Y CN1 CN2 CN3 CN4
1 SQR 0. 0. 150. 100.
UNO UNIT DEPTH SRV-Z SRV-R RGH CHMF FIN-Z FIN-R
3 LINE OUT 10. 10. 5. 3 ! 0. 0.
SNO TOOL NOM-z NO APRCH-X APRCH-Y TYPE ZFD DEP-Z WID-R C-SP FR M M
R1 F-MILL 10.A 0. -10. CW G01 10. ! 54 0.027

*** WK. PROGRAM NO. 1234 ***

( )

WORK NO. SEARCH PROGRAM ≠ Ø TOOL PROGRAM WPC MSR DETAILED

EDIT ≠ Ø PATH FILE INFORM.

M3P071

3] Press theTOOL PATH menu key .

The following PATH CHECK screen will be displayed.

-4.4 X 0.
Y 0.
Z 0.

WNO.1234 (!!!)

UNO. 0

TNO. 0
Y

CUTTING TIME
0:9’12”

0 100.
-362.4
-453.7 51.2
X
*** PATH CHECK ***
( )

PATH PATH SHAPE SHAPE PATH PROGRAM STORE PLANE SCALE

CONTINUE UNIT CONTINUE ERASE ERASE SELECT

M3P072

6>72
 4] Press the SHAPE CONTINUE menu key to display shapes continuously.

X -350.
-4.4
Y -116.
Z -100.

WNO.1234 (!!!)

UNO. 2 FACE MIL

TNO. 1 F-MILL

Y
CUTTING TIME
0:6’55”

-362.4
-453.7 51.2 0 100.

*** PATH CHECK ***

( )

PATH PATH SHAPE SHAPE PATH PROGRAM STORE PLANE SCALE

CONTINUE STEP CONTINUE ERASE ERASE SELECT

M3P074

5] Next, press the PATH CONTINUE menu key to display the machining path of

the tool through to the end.

-4.4 X 0.
Y 0.
Z 0.

WNO.1234 (!!!)

UNO. 6 END

TNO. 0

CUTTING TIME
0:43’14”

0 100.
-362.4
-453.7 51.2
X
*** PATH CHECK ***
( )

PATH PATH SHAPE SHAPE PATH PROGRAM STORE PLANE SCALE

CONTINUE STEP CONTINUE ERASE ERASE SELECT

M3P073

6>73
6] Press the PATH ERASE menu key to erase the machining path of the tool.

7] Press the PATH CONTINUE menu key several times to display the machining

path in steps. The reverse-display state of the menu continues until the
entire machining path appears.

8] To check the machining path in further details, use the PLANE SELECT

function (see section 6-5-8) or the SCALE function (see section 6-5-9).

9] When the all operation has been completed, press the DISPLAY SELECTOR

key to resume the POSITION display.

6>74
6-8 PROGRAMMING EXAMPLE
Work No. 1234

6>75
Notes:

6>76
MAZATROL Program Work No. 1234

6>77
MAZATROL Program Work No. 1234 (Cont’d)

6>78
APPENDIX
Machining Center PLC Alarm List (200 - 400 Series)

200 HYDRAULIC UNIT PRESSURE DOWN ( , , ) 203 SPINDLE OIL PRESSURE DOWN ( , , )

Cause Type of Cause Type of

error error
Insufficient hydraulic system pressure. Insufficient spindle lubrication pressure.
F F

Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Check the hydraulic unit, filter and Check the spindle lube pump and
N N
pressure switch for proper operation. pressure switch for proper operation.
Check the hydraulic unit for proper oil Check the resevoir for proper oil level with
level with the specified fluid. Display the specified fluid. Display

201 CHILLER MALFUNCTION ( , , ) 204 SPINDLE OIL INSUFFICIENT ( , , )

Cause Type of Cause Type of

error error
Hydraulic chiller unit fault. Insufficient spindle lubrication oil level.
F F

Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Check the chiller unit fault status. Check the fluid level and fill with the
N N
recommended oil.
Check the oil level switch.
Display Display

202 AIR PRESSURE DOWN ( , , ) 205 SPINDLE OIL OVERFLOW ( , , )

Cause Type of Cause Type of

error error
The incoming system air pressure has Spindle lubrication oil level too high.
F F
dropped or the air pressure switch has
failed.
Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Check the incoming air supply and Check the fluid level.
N N
pressure switch. Check the oil level switch.

Display Display

APPX - 1
206 SPINDLE LUB. CHILLER MALFUNC. ( , , ) 209 SLIDEWAY OIL CONSTANT ( , , )

Cause Type of Cause Type of

error error
Spindle chller unit malfunction. Way lubrication pressure is low or oil level
F is insufficient. F

Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Check spindle lubricating fluid level and fill Verify that the lubrication unit is filled with
N N
with the specified oil. the approved oil.
Check the fault status indicators and Check the lube pressure switch and
contact the nearest Mazak service center Display replace if necessary. Display
for assistance. Check the lube tubing and fittings for
leaks.

207 SLIDEWAY OIL PRESSURE CONSTANT ( , , ) 210 TAP COOLANT INSUFFICIENT ( , , )

Cause Type of Cause Type of

error error
Low oil level in the way lubrication unit.
F F

Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Verify that the lubrication unit is filled with
N N
the approved oil.
Check the lube unit float (level) switch
and replace if necessary. Display Display

208 SLIDEWAY OIL INSUFFICIENT ( , , ) 211 SPINDLE DRIVER MALFUNCTION ( , , )

Cause Type of Cause Type of

error error
Way lubrication pressure , flow rate or oil Spindle controller fault.
F D
level is insufficient.
Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Verify that the lubrication unit is filled with Check the spindle controller fault status
N N
the approved oil. indicators and contact the nearest Mazak
Check the lube pressure switch and service center for assistance.
replace if necessary. Display Display
Check the lube tubing and fittings for
leaks.

APPX - 2
212 MAGAZINE DRIVER MALFUNCTION ( , , ) 215 ( , , )

Cause Type of Cause Type of

error error
Magazine controller or drive malfunction.
F

Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure
Check the fault status indicators and
contact the nearest Mazak service center N
for assistance.
Display Display

213 INDEX TABLE DRIVER MALFUNC. ( , , ) 216 ( , , )

Cause Type of Cause Type of

error error
Index table controller or drive malfunction.
C

Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure
Check the fault status indicators and
contact the nearest Mazak service center N
for assistance.
Display Display

214 ILLEGAL TOOL DESIGNATED ( , , ) 217 THERMAL TRIP ( , , )

Cause Type of Cause Type of

error error
An invalid tool was specified. A thermal overload has tripped in the
B machine electrical cabinet. F

Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Check the tool data for accuracy. Press the reset button on the thermal
S overload or replace the unit. N
If the problem persists, check for
Display abnormal current draw by protected AC Display
motor and take appropriate action.

APPX - 3
218 CONVEYOR THERMAL TRIP ( , , ) 221 MACHINE +24v MALFUNCTION ( , , )

Cause Type of Cause Type of

error error
The chip conveyor motor thermal +24v power supply fault.
overload has tripped in the machine F F
electrical cabinet.
Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Press the reset button on the thermal Check the+24v power supply and fuse in
overload or replace the unit. N the machine electrical cabinet. N
If the problem persists, check for
abnormal current draw by protected AC Display Display
motor and take appropriate action.

219 MAIN TRANSFORMER OVERHEAT ( , , ) 222 AFC OVERLOAD ( , , )

Cause Type of Cause Type of

error error
The main power transformer temperature The spindle and Z axis load has not
exceeds 120° C F dropped within 5 seconds of applying the C
AFC function feed override.
Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Allow the transformer to cool. Reduce the load and repeat operation.
Check for air flow obstruction around the N N
transformer.
If problem recurrs, contact the nearest Display Display
Mazak service center for assistance.

220 ( , , ) 223 IMPOS. S. AUTO TOOL ( , , )

Cause Type of Cause (IN M. UNIT) Type of

error error

Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure

Display Display

APPX - 4
224 UNSUITABLE TL FOR TL LGTH MSMT ( , , ) 227 NOT OPERATED M CODE SIMULAT. ( , , )

Cause Type of Cause Type of

error error
Tool measurement was attempted with a M code error.
touch sensor (Renishaw probe) or an B B
invalid tool type (backboring, chamfering,
face milling or special tools). Stopped Stopped
status status

I I

Action Clearing Action Clearing

procedure procedure
Correct the tool measurement program or Correct the program.
tool data for the correct tools. Q Q

Display Display

225 TOOL LIFE OVER ( , , ) 228 ILLEGAL M CODE ( , , )

Cause Type of Cause Type of

error error
A tool was called for in the program that An invalid M code was programed.
has exceeded its established tool life and B B
no spare tool was specified.
Stopped Stopped
status status

J I

Action Clearing Action Clearing

procedure procedure
Replace the affected tool and/or correct Correct the program.
tool data. N Q
Press the [Link] CLEAR key and restart
operation by pressing CYCLE START. Display Display

226 TOOL BREAKAGE ( , , ) 229 IMPOSSIBLE SCREEN CYCLE START ( , , )

Cause Type of Cause Type of

error error
A broken tool was detected (M35 An attempt was made to start a
command) or a broken tool was mounted B MEMORY or TAPE operation from other B
into the spindle. than the POSITION, COMMAND,
Stopped TRACE or MODAL INFO. displays. Stopped
status status

J I

Action Clearing Action Clearing

procedure procedure
Check the tool condition, replace and Go the the correct display and retry.
correct tool data. N S

Display Display

APPX - 5
230 ILLEGAL MMS UNIT ( , , ) 233 MACHINE DOOR INTERLOCK ( , , )

Cause [MMS UNIT MALFUNCTION] Type of Cause Type of

error error
Mazak measuring system error. A machine door was opened during
F automatic cycle. F

Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Check the MMS unit in the machine With the door interlock key at AUTO:
electrical panel or contact the nearest N close the door, press the RESET key and N
Mazak service center for assistance. press CYCLE START.
With the door interlock key at TEST:
Display close the door, press the [Link] CLEAR Display
key and press CYCLE START.

231 EXTERNAL CONTROLLER ALARM ( , , ) 234 PALLET CHANGER DOOR INTERLOCK ( , , )

Cause Type of Cause Type of

error error
The contoller fault occurred for a vendor A pallet changer door was opened during
supplied option . F automatic cycle. F

Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Check the contoller fault status indicators. With the door interlock key at AUTO:
Contact the component manufacturer or N close the door, press the RESET key and N
the nearest Mazak service center for press CYCLE START.
assistance. With the door interlock key at TEST:
Display close the door, press the [Link] CLEAR Display
key and press CYCLE START.

232 MACHINE DOOR INTERLOCK ( , , ) 235 MAGAZINE MANUAL INTERRUPT ( , , )

Cause Type of Cause Type of

error error
A machine door was opened during
automatic cycle. F F

Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
With the door interlock key at AUTO:
close the door, press the RESET key and N N
press CYCLE START.
With the door interlock key at TEST:
close the door, press the [Link] CLEAR Display Display
key and press CYCLE START.

APPX - 6
236 HOLD PALLET CHANGE ( , , ) 239 ( , , )

Cause Type of Cause Type of

error error
The area shift command was issued in
automatic mode with the 1 cycle switch in
the off position.
Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure
Press the 1 cycle switch and cycle start.

Display Display

237 MAGAZINE DOOR OPEN ( , , ) 240 RESTART OPERATION UNFINISHED ( , , )

Cause Type of Cause Type of

error error
An attempt was made to start operation
without completing the EIA restart A
operation.
Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure

Display Display

238 ATC STOP ( , , ) 241 SPINDLE OVERLOAD ( , , )

Cause Type of Cause (SPINDLE RPM MALF.) Type of

error error
The ATC STOP menu key way pressed. Spindle controller fault.
A The zero speed signal remained ON. D

Stopped Stopped
status status

K I

Action Clearing Action Clearing

procedure procedure
Turn the ATC STOP key off and press Check the spindle controller fault status
CYCLE START to resume automatic tool S indicators and contact the nearest Mazak N
change. service center for assistance.
Display Display

APPX - 7
242 SPINDLE ORIENT TIME OVER ( , , ) 245 ( , , )

Cause Type of Cause Type of

error error
Spindle controller fault.
The orient check signal did not come ON D
10 seconds after the spindle orient
command. Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure
Check the spindle controller fault status
indicators and contact the nearest Mazak Q
service center for assistance.
Display Display

243 SPINDLE ORIENT CANCEL OVER ( , , ) 246 ( , , )

Cause Type of Cause Type of

error error
Spindle controller fault.
The orient command signal remained ON D
1 second after the Off orient command.
Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure
Check the spindle controller fault status
indicators and contact the nearest Mazak Q
service center for assistance.
Display Display

244 SPINDLE ORI. ZERO SIGNAL OFF ( , , ) 247 ( , , )

Cause Type of Cause Type of

error error
Spindle controller fault.
The spindle zero speed check is OFF D
while the orient check signal is ON.
Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure
Check the spindle controller fault status
indicators and contact the nearest Mazak Q
service center for assistance.
Display Display

APPX - 8
248 ( , , ) 251 TOOL LENGTH RETRACT SENSOR MAL. ( , , )

Cause Type of Cause Type of

error error
A tool length measurement stand retract
command was given but no confirmation F
was received.
Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure
Check the tool measurement stand for
proper operation and the confirmation N
proximity switch.
Display Display

249 ( , , ) 252 DECELERATION SENSOR MALF. ( , , )

Cause Type of Cause Type of

error error
During tool length measurement, the SKIP
signal was generated without the F
DECELERATION signal first.
Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure
Check the tool measurement stand for
proper operation and the confirmation N
proximity switches.
Display Display

250 TOOL LENGTH EXTEND SENSOR MAL. ( , , ) 253 SKIP SENSOR MALF. ( , , )

Cause Type of Cause Type of

error error
A tool length measurement stand extend During tool length measurement, the
command was given but no confirmation F DECELERATION signal was generated F
was received. although the SKIP signal was not.
Stopped Stopped
status status

I K

Action Clearing Action Clearing

procedure procedure
Check the tool measurement stand for Check the tool measurement stand for
proper operation and the confirmation N proper operation and the confirmation N
proximity switch. proximity switches.
Display Display

APPX - 9
254 SPINDLE DETECTOR SENSOR MALF. ( , , ) 257 TOOL UN-CLAMP SENSOR MALF. ( , , )

Cause Type of Cause Type of

error error
A tool was detected in the spindle Tool unclamp confirmation was not
although the CRT display indicates no D received within 5 seconds after the F
active tool. unclamp command was given.
Stopped Stopped
status status

I K

Action Clearing Action Clearing

procedure procedure
Manually remove the tool from the spindle Check the tool unclamp proximity switch
or use to tool no. set procedure to correct N for proper adjustment. N
the CRT display. Replace if necessary.
Check the spindle tool detector sensor for Display Display
proper adjustment.
Replace if necessary.

255 MGZN TOOL DETECTOR SENSOR MALF. ( , , ) 258 ATC COVER SENSOR (OPEN) MALF. ( , , )

Cause Type of Cause Type of

error error
An attempt was made to place a tool in ATC cover open confirmation was not
the magazine at a location where a tool F received within 5 seconds after the cover F
already exists. open command was given.
Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Move the tool to a different magazine Check the ATC cover open proximity
pocket and/or update tool data. N switch for proper adjustment. N
Check the magazine tool detector sensor Replace if necessary.
for proper adjustment. Display Display
Replace if necessary.

256 TOOL CLAMP SENSOR MALFUNCTION ( , , ) 259 ATC COVER SENSOR (CLOSE) MALF. ( , , )

Cause Type of Cause Type of

error error
Tool clamp confirmation was not received ATC cover closed confirmation was not
within 5 seconds after the clamp F received within 5 seconds after the cover F
command was given. close command was given.
Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Check the tool clamp proximity switch for Check the ATC cover open proximity
proper adjustment. N switch for proper adjustment. N
Replace if necessary. Replace if necessary.
Display Display

APPX - 10
260 ATC ARM EXTEND SENSOR MALF. ( , , ) 263 GEAR SENSOR (MIDDLE SPEED) MALF. ( , , )

Cause Type of Cause Type of

error error
ATC arm extend confirmation was not Middle speed gear confirmation was not
received within 5 seconds after the F received within 5 seconds after the gear F
extend command was given. shift command was given.
Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Check the proximity switch for proper Check the middle speed proximity switch
adjustment. N for proper adjustment. N
Replace if necessary. Replace if necessary.
Display Display

261 ATC ARM RETRACT SENSOR MALF. ( , , ) 264 GEAR SENSOR (LOW SPEED) MALF. ( , , )

Cause Type of Cause Type of

error error
ATC arm retract confirmation was not Low speed gear confirmation was not
received within 5 seconds after the retract F received within 5 seconds after the gear F
command was given. shift command was given.
Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Check the proximity switch for proper Check the low speed proximity switch for
adjustment. N proper adjustment. N
Replace if necessary. Replace if necessary.
Display Display

262 GEAR SENSOR (HIGH SPEED) MALF. ( , , ) 265 NEUTRAL SENSOR MALFUNCTION ( , , )

Cause Type of Cause Type of

error error
High speed gear confirmation was not Neutral speed confirmation was not
received within 5 seconds after the gear F received within 5 seconds after the gear F
shift command was given. shift command was given.
Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Check the high speed proximity switch for Check the neutral position proximity
proper adjustment. N switch for proper adjustment. N
Replace if necessary. Replace if necessary.
Display Display

APPX - 11
266 PALLET CLAMP SENSOR MALF. ( , , ) 269 MAGAZINE STOP PIN MALF. ( , , )

Cause Type of Cause Type of

error error
Pallet clamp confirmation was not Magazine stop pin confirmation was not
received within 5 seconds after the clamp F received within 5 minutes after the F
command was given. magazine rotate command was given.
Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Check the pallet clamp proximity switch Check the magazine stop pin proximity
for proper adjustment. N switch for proper adjustment. N
Replace if necessary. Replace if necessary.
Display Display

267 PALLET UN-CLAMP SENSOR MALF. ( , , ) 270 X AXIS ORGIN RETURN UNFINISHED ( , , )

Cause Type of Cause Type of

error error
Pallet unclamp confirmation was not An attempt was made to do a tool
received within 5 seconds after the F change, tool length measurement, pallet
unclamp command was given. change, etc, without first completing the
Stopped zero point return procedure. Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Check the pallet unclamp proximity switch Perform the zero point return procedure.
for proper adjustment. N N
Replace if necessary.
Display Display

268 MAGAZINE INPOSI. SENSOR MALF. ( , , ) 271 Y AXIS ORGIN RETURN UNFINISHED ( , , )

Cause Type of Cause Type of

error error
Magazine in position confirmation was not An attempt was made to do a tool
received within 5 minutes after the F change, tool length measurement, pallet F
magazine rotate command was given. change, etc, without first completing the
Stopped zero point return procedure. Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Check the magazine in position proximity Perform the zero point return procedure.
switch for proper adjustment. N N
Replace if necessary.
Check the magazine assembly for proper
Display Display
positioning.

APPX - 12
272 Z AXIS ORGIN RETURN UNFINISHED ( , , ) 275 SPINDLE IMPOS. (SPECIAL TOOL) ( , , )

Cause Type of Cause Type of

error error
An attempt was made to do a tool A spindle rotation command was given
change, tool length measurement, pallet F with a touch sensor (Renishaw probe), A
change, etc, without first completing the chip removal tool or other special tool in
zero point return procedure. Stopped the spindle. Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Perform the zero point return procedure. Remove the tool or put the correct tool in
N the spindle. N

Display Display

273 4 AXIS ORGIN RETURN UNFINISHED ( , , ) 276 SPINDLE IMPOS. (NOT FIT ATC ARM) ( , , )

Cause Type of Cause Type of

error error
An attempt was made to do a tool
change, tool length measurement, pallet F F
change, etc, without first completing the
zero point return procedure. Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Perform the zero point return procedure.
N N

Display Display

274 SPINDLE IMPOS. (NOT TOOL CLAMP) ( , , ) 277 GEAR SHIFT IMPOS. (NO TOOL CLAMP) ( , , )

Cause Type of Cause Type of

error error
A spindle rotation command was given A gear shift command was given without
without tool clamp confirmation. F tool clamp confirmation.

Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure
Check the tool clamp proximity switch for Check the tool clamp proximity switch for
proper adjustment. N proper adjustment.
Replace if necessary. Replace if necessary.
Verify that the manual tool unclamp Verify that the manual tool unclamp
Display Display
switch is in the tool clamp position. switch is in the tool clamp position.

APPX - 13
278 GEAR SHIFT IMPOS. (SPECIAL TOOL) ( , , ) 281 SPDL ORIENT IMP. (SPECIAL TOOL) ( , , )

Cause Type of Cause Type of

error error
A gear shift command was given with a The spindle orient command was given
touch sensor (Renishaw probe), chip F with a touch sensor (Renishaw probe), A
removal tool or other special tool in the chip removal tool or other special tool in
spindle. Stopped the spindle. Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Remove the tool or put the correct tool in Remove the tool or put the correct tool in
the spindle. N the spindle. N

Display Display

279 GEAR SHIFT IMPOS. (NOT FIT ATC ARM) ( , , ) 282 ORIENT IMP. (NOT FIT ATC) ( , , )

Cause Type of Cause Type of

error error

F F

Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure

N N

Display Display

280 SPDL ORIENT IMP. (NOT TOOL CLAMP) ( , , ) 283 UNCLAMP IMP. (NOT STOP SPINDLE) ( , , )

Cause Type of Cause Type of

error error
The spindle orient command was given The tool unclamp key switch was turned
without tool clamp confirmation. F ON while the spindle was turning or in jog F
mode.
Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Check the tool clamp proximity switch for Stop all spindle operations.
proper adjustment. N N
Replace if necessary.
Verify that the manual tool unclamp
Display Display
switch is in the tool clamp position.

APPX - 14
284 UNCLAMP IMP. (SPNDL ORI. UNFI.) ( , , ) 287 AUTO MODE IMP. (MGZN MANUAL) ( , , )

Cause Type of Cause Type of

error error
The tool unclamp key switch was turned An attempt was made to change to the
ON before the spindle orient was A auto mode while the magazine manual A
completed. switch was ON.
Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Complete the spindle orient and retry. Turn the magazine manual switch OFF.
N N

Display Display

285 UNCLAMP IMP. (NOT MANUAL MODE) ( , , ) 288 TOOL LOAD IMP. (TOOL IN ARM) ( , , )

Cause Type of Cause Type of

error error
The tool unclamp key switch was turned A tool load command was made although
ON although the machine was not in A the current spindle tool does not equal 0. A
manual mode. A tool unload command was made
Stopped although a tool was detected in the Stopped
status magazine. status

K K

Action Clearing Action Clearing

procedure procedure
Place the machine in manual mode and Correct the spindle tool data and retry.
retry. N N

Display Display

286 AUTO MODE IMP. (TOOL UNCLAMP) ( , , ) 289 TOOL LOAD IMP. (NOT FIT ARM. SFT) ( , , )

Cause Type of Cause Type of

error error
An attempt was made to change to the
auto mode while the tool unclamp key A A
switch was ON.
Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Turn the tool unclamp key switch OFF.
N N

Display Display

APPX - 15
290 TOOL LOAD IMP. (NOT FIT MGZN) ( , , ) 293 UNLOAD IMP. (TOOL IN MAGAZINE) ( , , )

Cause Type of Cause Type of

error error
An attempt was made to load a tool An attempt was made to unload a tool
although the magazine in position signal in F although the magazine in position signal in F
not ON. not ON.
Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Wait until the magazine is in position. Wait until the magazine is in position.
Check the magazine in position proximity N Check the magazine in position proximity N
switch for proper adjustment. switch for proper adjustment.
Replace if necessary. Replace if necessary.
Display Check the magazine assembly for proper Display
Check the magazine assembly for proper
positioning. positioning.

291 UNLOAD IMP. (TOOL IN MAGAZINE) ( , , ) 294 TOOL SELECT IMP. ([Link]) ( , , )

Cause Type of Cause Type of

error error
An attempt was made to unload a tool in
the magazine at a location where a tool F F
already exists.
Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Move the tool to a different magazine
pocket and/or update tool data. N N
Check the magazine tool detector sensor
for proper adjustment. Display Display
Replace if necessary.

292 UNLOAD IMP. (NOT FIT ARM. SHIFT) ( , , ) 295 TOOL SELECT MISS OPERATION ( , , )

Cause Type of Cause Type of

error error

F A

Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure

N N

Display Display

APPX - 16
296 MAGAZINE EXTEND ALARM ( , , ) 299 ( , , )

Cause Type of Cause Type of

error error
Magazine extended confirmation was not
received within 5 seconds after the extend F
command was given.
Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure
Check the magazine extended proximity
switch for proper adjustment. N
Replace if necessary.
Display Display

297 MAGAZINE RETRACT ALARM ( , , ) 300 TOOL SELECT MISS OPERATION 1 ( , , )

Cause Type of Cause Type of

error error
Magazine retracted confirmation was not A wrong tool was selected.
received within 5 seconds after the retract F A
command was given.
Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Check the magazine retracted proximity Check tool data for accuracy.
switch for proper adjustment. N N
Replace if necessary.
Display Display

298 MAGAZINE NOT ZERO RETURN ( , , ) 301 TOOL SELECT MISS OPERATION 2 ( , , )

Cause Type of Cause Type of

error error
The magazine was not fully retracted
F (home position). A

Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Manually jog the magazine to home
N position. N
Chcek the magazine home position
Display proximity switch and replace if necessary. Display

APPX - 17
302 MAGAZINE EXTEND ALARM ( , , ) 305 TOOL HOLDER DOWN SENSOR MALF. ( , , )

Cause Type of Cause Type of

error error
Magazine extended confirmation was not Tool holder down confirmation was not
received within 5 seconds after the extend F received within 5 seconds after the F
command was given. command was given.
Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Check the magazine extended proximity Check the tool holder down proximity
switch for proper adjustment. N switch for proper adjustment. N
Replace if necessary. Replace if necessary.
Display Display

303 MAGAZINE RETRACT ALARM ( , , ) 306 NC TABLE UNCLAMP SENSOR MALF. ( , , )

Cause Type of Cause Type of

error error
Magazine retracted confirmation was not NC rotary table unclamp confirmation was
received within 5 seconds after the retract F not received within 5 seconds after the F
command was given. unclamp command was given.
Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Check the magazine retracted proximity Check the NC table unclamp proximity
switch for proper adjustment. N switch for proper adjustment. N
Replace if necessary. Replace if necessary.
Display Display

304 MAGAZINE NOT ZERO RETURN ( , , ) 307 5 AXIS UNCLAMP SENSOR MALF. ( , , )

Cause Type of Cause Type of

error error
5th axis unclamp confirmation was not
F received within 5 seconds after the F
unclamp command was given.
Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Check the 5th axis unclamp proximity
N switch for proper adjustment. N
Replace if necessary.
Display Display

APPX - 18
308 5 AXIS ORIGIN RETURN UNFINISHED ( , , ) 311 ( , , )

Cause Type of Cause Type of

error error
An attempt was made to do a tool
change, tool length measurement, pallet F
change, etc., without first completing the
zero point return procedure. Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure
Perform the zero point return procedure.
N

Display Display

309 MMS SKIP SIGNAL MALF. ( , , ) 312 CAN’T ATC (M. LOCK OR Z. NG.) ( , , )

Cause Type of Cause Type of

error error
The SKIP signal was received while an An ATC command was given while the
axis was moving in rapid traverse. F MACHINE LOCK or Z AXIS CANCEL F
menu was active.
Stopped Stopped
status status

H K

Action Clearing Action Clearing

procedure procedure
Check the touch sensor (Renishaw probe) Turn off the MACHINE LOCK or Z AXIS
for looseness or damage. N CANCEL menu and press CYCLE N
If the problem repeats, check the MMS START to continue.
unit in the machine electrical panel. Display Display

310 ( , , ) 313 ( , , )

Cause Type of Cause Type of

error error

Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure

Display Display

APPX - 19
314 ( , , ) 317 CAN’T PLUS MOTION ( , , )

Cause Type of Cause Type of

error error
After first turning machine power ON, an
attempt was made to move an axis in the A
plus direction before moving in the minus
Stopped direction. Stopped
status (During the zero return procedure) status

Action Clearing Action Clearing

procedure procedure
Move the axis a short distance minus
before attempting a plus direction move. N

Display Display

315 ( , , ) 318 SET UP SWITCH WAS SELECTED ( , , )

Cause Type of Cause Type of

error error
An attempt was made to run the machine
in automatic with the Set Up selector F
switch ON.
Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure
Turn OFF the Set Up switch located on
the front operation panel and retry. N

Display Display

316 DOOR INTERLOCK (SINGLE BLOCK) ( , , ) 319 PALLET-HYD. PRESSUR TOO LOW ( , , )

Cause Type of Cause Type of

error error
A machine door was opened while in the
TEST mode of automatic operation. The F F
machine will continue to run single block.
Stopped Stopped
status status

J K

Action Clearing Action Clearing

procedure procedure
Close the machine door or run in single
block. N N

Display Display

APPX - 20
320 PALLET #1 SELECT SENSOR MALF. ( , , ) 323 PALLET DOOR CLOSE SENSOR MALF. ( , , )

Cause Type of Cause Type of

error error

F F

Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure

N N

Display Display

321 PALLET #2 SELECT SENSOR MALF. ( , , ) 324 PALLET LOAD SENSOR MALF. ( , , )

Cause Type of Cause Type of

error error

F F

Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure

N N

Display Display

322 PALLET DOOR OPEN SENSOR MALF. ( , , ) 325 PALLET UNLOAD SENSOR MALF. ( , , )

Cause Type of Cause Type of

error error

F F

Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure

N N

Display Display

APPX - 21
326 PALLET LOAD DEC. SENSOR MALF. ( , , ) ( , , )

Cause Type of Cause Type of

error error

Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure

Display Display

327 PALLET UNLOAD DEC. SENSOR MALF. ( , , ) ( , , )

Cause Type of Cause Type of

error error

Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure

Display Display

( , , ) ( , , )

Cause Type of Cause Type of

error error

Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure

Display Display

APPX - 22
 ( , , ) ( , , )

Cause Type of Cause Type of

error error

Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure

Display Display

( , , ) ( , , )

Cause Type of Cause Type of

error error

Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure

Display Display

( , , ) 349 Z AXIS AIR BLOW LS MALF. ( , , )

Cause Type of Cause Type of

error error

Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure

Display Display

APPX - 23
350 DOOR INTERLOCK (ATC) ( , , ) 353 MAGAZINE RETRACT MISSOPERATION ( , ,
)
Cause Type of Cause [MAGAZINE WILL NOTINSERT] Type of
error error
A machine door was opened during A magazine retract command was made
automatic tool change operation. F with the machine units out of position. A

Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Close the door, press the RESET key and Properly position the machine units:
press CYCLE START. N 1) Make sure the tool is clamped N
2) Move the X & Y axes to #2 home
3) Move Z axis to #1 or #2 home
Display Display

351 RESTART (CYCLE START PB.) ( , , ) 354 ATC COVER CLOSE MISSOPERATION ( , , )

Cause [REOPEN (CYCLE START)] Type of Cause [ATC COVER WILL NOT OPEN] Type of
error error
An attempt to start ATC with a machine An attempt was made to close the ATC
door open. (Door interlock) A cover while the magazine was not fully A
retracted.
Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Restart operation using the CYCLE Check the magazine assembly and the
START pushbutton after closing the N retracted proximity switch for proper N
machine door and clearing alarms 232 & adjustment.
350. Replace if necessary.
Display Display

352 MAGAZINE EXTEND MISSOPERATION ( , , ) 355 MAGAZINE ROTATION MISSOPERATION ( , , )

Cause [MAGAZINE WILL NOT EJECT] Type of Cause [MAGAZINE WILL NOT TURN] Type of
error error
A magazine extend command was made A magazine rotation command was made
with the machine units out of position. A with the machine units out of position. A

Stopped Stopped
status status

K K

Action Clearing Action Clearing

procedure procedure
Properly position the machine units: Properly position the machine units:
1) Close the ATC cover N 1) Fully retract the magazine N
2) Move the X & Y axes to #2 home OR
3) Move Z axis to #1 home when the 2) The Z axis is positioned at #1 home
magazine has a tool. (Tool load) Display Display
and the active spindle tool is “0“
Move Z axis to #2 home when the
magazine does not have a tool. (Unload)

APPX - 24
356 NO CYCLE START ( , , ) ( , , )

Cause (X AXIS POSITION) Type of Cause Type of

error error
The table is partitioned and a spindle tool
number between 25 to 48 is used for
work in area 1 (right) or a spindle tool
number between 1 to 24 is used for work Stopped Stopped
in area 2 (left) status status

Action Clearing Action Clearing

procedure procedure
Correct the work area/spindle tool number
relationship.

Display Display

( , , ) ( , , )

Cause Type of Cause Type of

error error

Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure

Display Display

( , , ) ( , , )

Cause Type of Cause Type of

error error

Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure

Display Display

APPX - 25
 ( , , ) ( , , )

Cause Type of Cause Type of

error error

Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure

Display Display

( , , ) ( , , )

Cause Type of Cause Type of

error error

Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure

Display Display

( , , ) ( , , )

Cause Type of Cause Type of

error error

Stopped Stopped
status status

Action Clearing Action Clearing

procedure procedure

Display Display

APPX - 26
7-2 LIST OF M CODES
The following list shows the general M codes used in the machining centers. It must be noted
however, that certain codes cannot be used in certain machines and that other codes can be
ordered. For details, refer to the Operating Manual for the machine.

M code Function

0 Programmed stop

1 Optional stop

2 End of program (EIA/ISO)

3 Rotation of spindle (to the right)

4 Rotation of spindle (to the left)

5 Stop of the spindle

6 Changing of tool (EIA/ISO)

7 Mist spray during operation

8 Liquid spray during operation

9 Stop of all spray and compressed air

10 Clamping of tool in the spindle

11 Unclamping of tool in the spindle

15 Magazine cover closed

16 Magazine cover open

19 Orientation of spindle

23 Error detection valid

24 Error detection invalid

30 End of program and rewinding of strip (EIA/ISO)

33 Tool length measurement unit feed

34 Tool length measurement unit withdrawal

35 Detection of tool rupture

36 Selection of spindle speed range (Low)

EIA/ISO: valid in EIA/ISO program

MAZATROL: valid in MAZATROL program

APPX-27
M code Function

37 Selection of spindle speed range (Low/Medium low)

38 Selection of spindle speed range (Low/Medium/Medium high)

39 Selection of spindle speed range (High)

40 Selection of spindle speed range (Neutral)

42 Inverted rotation of indexing table

43 External command of M code 3

44 External command of M code 4

45 External command of M code 5

48 Spindle speed correction—Valid

49 Spindle speed correction—Invalid

50 Air blast in operation

51 Spraying crossing the spindle in operation

52 Spraying for tapping in operation

58 Check of tool life

64 Closing of pallet door

65 Opening of pallet door

68 Clamping of pallet

69 Unclamping of pallet

70 Pallet unload

71 Selection of pallet No. 1

72 Selection of pallet No. 2

73 Selection of pallet No. 3

74 Selection of pallet No. 4

75 Selection of pallet No. 5

76 Selection of pallet No. 6

EIA/ISO: valid in EIA/ISO program

MAZATROL: valid in MAZATROL program

APPX-28
M code Function

90 Cancellation of symmetrical image (MAZATROL)

91 Symmetrical image WPC-X—Valid (MAZATROL)

92 Symmetrical image WPC-Y—Valid (MAZATROL)

93 Symmetrical image WPC-4—Valid (MAZATROL)

98 Call-up of subprogram (EIA/ISO)

99 End of subprogram (EIA/ISO)

100 External command of M code 1

101 External command of M code 2

122 Play takeup device—Valid

123 Play takeup device—Invalid

130 Niagara spraying in operation

132 Compressed air crossing the spindle in operation

EIA/ISO: valid in EIA/ISO program

MAZATROL: valid in MAZATROL program

APPX-29
7-3 CNC MISOPERATION RECOVERY REFERENCE

1. A wrong numeric key has been pressed.

2. Wrong data has been input (data change).

3. Wrong data has been input (data erasure).

4. The display selector key or the menu selector key has been pressed

inadvertently.

5. How to add a unit(s).

6. How to erase unit(s).

7. How to add a tool sequence(s).

8. How to erase a tool sequence(s).

APPX-30
1. Wrong numeric key has been pressed.
Operate as follows: Wrong data
!!!!!!!!!
(!!101)

[1] Press the clear key to erase the data in the data selection area.
The wrong data has been erased.
!!!
(!!!)

[2] Press the correct numeric key(s).

2. Wrong data has been input (data change).

Operate as follows:

SNo. TOOL NOM-z No. APRCH-X APRCH-Y

R1 E-MILL 10.A ? ?
FIG PTN P1X / CX P1Y / CY P3X / R P3Y
1 SQR 5. 5. 140. 95.

This data is to be changed to 145.

[1] Position the cursor on the wrong data using the cursor keys ( ).

P1Y / CY P3X / R P3Y

5. 14 0 95.

[2] Input correct data. In this case, press in this order.

SNo. TOOL NOM-z No. APRCH-X APRCH-Y

R1 E-MILL 10.A ? ?
FIG PTN P1X / CX P1Y / CY P3X / R P3Y
1 SQR 5. 5. 145. 95.

The wrong data has been changed to a correct one.

APPX-31
3. Wrong data has been input (data erasure).
Operate as follows:
This data is to be erased.

P1X / CX P1Y / CY P3X / R CN1

5. 5. 140. R5.

[1] Position the cursor on the wrong data using the cursor keys ( ).

P3Y CN1

95. R 5

aa
a
aaaa
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CAN

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[2] Press the data cancellation key .

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P1X / CX P1Y / CY P3X / R P3Y CN1
5. 5. 145. 95. __

The wrong data has been erased.

4. The display selector key or the menu selector key has been
pressed inadvertently.
Pressing of the menu selector key causes the original menu to be resumed.

5. How to add a unit(s).

Refer to Part 2, Subsection 2-2-3, “1. Insertion of the unit.”

6. How to erase a unit(s).

Refer to Part 2, Subsection 2-2-4, “1. Deletion of the unit.”

7. How to add a tool sequence(s).

Refer to Part 2, Subsection 2-2-3, “2. Insertion of the tool sequence.”

8. How to erase a tool sequence(s).

Refer to Part 2, Subsection 2-2-4, “2. Deletion of the tool sequence.”

APPX-32