uuu mul MAZATECH t-800 IAZATRMazak INSTALLATION PRECAUTIONS To ensure the safe operation of the NC machine, note the following during installation: 1. Wiring 1) Be sure to use electrical conductors with performance ratings equivalent or superior to those described in the ‘Maintenance Manual 2) Do not connect to the power distribution panel any power cablos for devices which can cause ine noise, such 2s are welders and high frequency quenching machines. 3) Arrange for a qualified engineer to connect the power lines. 2. Grounding Use a grounding wire with a cross section of more than 14 min and a resistance to ground of less than 100 ohms. This wire size should be greater than AWG (American Wire Gauge) No. 5 and SWG (British Legal Standard Wire Gauge) No. 6. Generally, the NC machine should be grounded to a separate ‘grounding rod. If an independent ground ean not be pro- vided for the machine, propare the ground connection as follows: 1) Connect a single conductor to its own grounding termi- ral, This will avoid possible serious accidents resulting from ground currents which might otherwise flow in the NC machine if a peripheral device should malfunction. 2) Be careful when using concrete reinforcing rods as ‘grounding points. These reinforcing rods often are used to ground equipment because they usually offer a resis tance to ground of less than 100 ohms. In doing so, make the connection as follows: This also applies to connecting ground wites to regular ‘grounding terminals. a, Do not use the same grounding reinforcing rod oF ‘grounding terminal for other davieas since this could lead to line noise such as produced electric welders and high frequency quenching machines. Bb. Use 8 grounding terminal with an adequate electrical performance rating and which is durable. 8) A separate grounding wire should be used, one whose length is as shon as possible. 4) Check the resistanée ta ground by actual, measurement. ‘This should measure less than 100 ohms if the single device is connected to its own grounding rod. Desirabl Independent Ground Earth resistance: Less than 100 ohms ‘ground = 100/the ‘umber of dovicos Resistance to connected to the grounding (9) Never ground equipment as shown in the following 3. Environmental Conditions Generally, the machine will be installed on the following conditions. However, these may change over a period of time or in response to seasonal changes. af {85% to 110% of nominal Supply voltage 1: £2 Hz of nominal frequency FOC to 48°C (32°F 10 113°F) Less than 90% ‘Temperature changes should not cause condensation 1) Supply voltage 2) Source frequency 3) Ambient temperature 4) Relative Humiity Free from excessive dust, acid fumes corrosive gases and salt 6) It should be avoided to expose the machine to direct, ‘sunlight or heat rays which can change the environmental temperature. 7) Avoid exposing the NC machine to abnormal vibration. 5) Atmosphere If it is difficult to observe meet these conditions, contact us immodiatoly. (900x713 121083, 3600 ©Mazak INTRODUCTION This manual has been prepared for the operators of this procedures for the machina so it can pertorm satistactorily. peetne ‘Tho precautions relating to safely, moreover, are also relerred ‘might result in injury or Both those who have not yet operated numerically controlled 10 prevent possible accidents wh lathes and those who have already done so, are requested death or damage to the machine. to become familiar with the correct methods and operating + Discrepencies may atise occasionally between the because the latter may have been modified without notice. present operation manual and the actual machine CONTENTS Page 4. SAFETY PRECAUTIONS ......nccummne 1 * WARMUP 4 2. MACHINE SPECIFICATION .. 5 24 Overall View .. saat 5 22 Machine Body Specification (Standard). 6 2.9 Stroke Diagram oe 8 2-4 Spindle R.PM-Power-Torque Diagram ... 8 OPERATING PANEL DESIGNATIONS 9 SH Panel Mlustralion nace 9 3:2 NC Operating Panel " 3.3 Description of Operation Buttons at Lower Portion of NC Contol Panel sans 13 3-4 Description of Controis on Pallet Changer Operating Panel .. veers 1) 3-4-1 Pallet changer operating panel .. a 13 ‘3-4-2 Funetional description of controls on pallet changer operating panel 13 3-4-3 Reinslaling the machine when it stops while in pallet change operation .... 6 8 Designation of Control Buttons on Control Panels of Magazine 18 36 Functional Description of Control Buttons, etc. other than these on Control Panels 16 3:7 Manipulating Buttons on the Hand Pulse Control Box 7 4 Manual pulse operator panel view 7 2 Functions of the manual control keys and switches .. 7 OPERATION 8 444 Operating Procedure (Steps pricr to Machining) 16 42 Outline of Display .... 7 8 43. Checking for Operations prior to Starting this Machine .. 8 4-4 Machine Switch ON .. inn 19 48 Status and Inepection aller Switching tho Machino ON 19 48 Procedure for Switching POWER OFF 19 4-7 Inspection and Cleaning alter Operation 19 48 Procedure for Manual Tool Change aan . 19 49 Procedure for Mounting a Tool onto the Spindle .. ean 20 4-40 Procedure for Removing a Too! from the Spindle ... 20 4-11 Switching the Machine ON 20 4-42 Tool Setting Precautions ... 20 4-13 ATC Operation .. 20 4-14 Description of Coolant Gireull Operations 23 5. APPENDIX alata 28 541 Spindle Speed Changing and Spinate Tursing Spaed 26 5:2 Relations between Mechanical Movement and Coordination Axes 24 53 Precautions during the ATC Cycle .. 24 5-4 Palle Dimensions 26 4368023,1 SAFETY PRECAUTIONS ‘This machine is provided with a number of safety devices to ratect personnel and equipment from injury and damage. Operators should not, however, rely solely upon these safety devices but should operate the machine after fully under standing what special precautions to take by reading the following remarks thoroughly. Operating Practices 1) Some controt panels, transformers, motors, junction boxes and ether parts have high-voltage terminals, these should not be touched, or a severe electric shock will be sustained. 2) Do not touch a switch with wet hands. This, too, can produce an electric shock. WARNING: 1) The emergency stop push-button switch location should be well known so that it can be operated at any time without having to look for it 2) Before replacing a fuse, switch off the machine. 3) Provide sufficient working space to avoid hazardous falls. 4) Water or oil can make floors slippery and hazardous. To prevent accidents all floors should be dry and clean, 5) Before operating switches, always check that they are the right ones, 6) Never touch a switch accidentally. 7) Work benches near the machine must be strong enough to prevent accidents. Articles should be prevented from slipping off the bench surface. 8) Itajob is to be done by two or more persons, coordinat- ing signals should be given at each step of the operation. Unless a signal is given and acknowledged, the next step should not be taken. CAUTION: 1) In the event of power failure, turn off the main circuit breaker immediately. 2) Use the recommended hydraulic oils, lubricants and ‘grease or acceptable equivalents. 3) Replacement fuses should have the proper current rat- ings. 4) Protect the NC unit, operating panel, electric control panel, etc. from shocks, since this could cause a failure ‘or maifunetion 5) Donot change parameters, volumes and other electrical settings unnecessarily. If such changes are unavoidable, record the values prior to the change so that they cen be returned to their original settings if necessary. 6) Donot soll, scratch or remove the caution plate. Should become illegible or be 3, order another caution plate from the supplier specifying the part number shown at the lower right of the plate. (2) Before Switching On: DANGE! Cables, cords or electric wires whose insulation is damaged ‘can produce current leaks and electric shacks. Before using these, check their condition, WARNING: 1) Be sure the instruction manual and the programming ‘manual are fully understood. Every function and operat- ing procedure should completely clear. 2) Use safety shoes which are not damaged by oll, safety ‘goggles with side covers, safe clothes and other safety protection, 3}, Close all NC unit, operating panel and electric control panel doors and covers. CAUTION: 1) The power cable from the factory feeder switch to the machine main circuit breaker should have a sufficiont sectional area to handle the electric power used. 2). Cables which must be laid on the floor must be protected against chips so that short-circuits will not occur. 8} Before first operating the machine after unpacking or keeping the machine idle for 2 long pariod (several or more), each sliding part must be freshly lubricated. For the lubricating and so forth, keep lubricating oil pump ‘working until oil oozes out from wiper. Contact our Ser- vice Station in connection with whet procedure should be taken since it depends on the type of machine. 4) Oil reservoirs should be filled to indicated levels. Check and add oil, if necessary. 8) For lubricating points, oil brands and appropriate levels, see the various instruction plates. 6) Switches and levers should operate smoothly. Check that they do. 7). When switching the machine on, put the factory feeder ‘switch, the machine main circuit breaker and the power switch on the operating panel to the ON position in the order. 8) Check the cootant level, and add coolant, if necessary. (3) After Control Power Switch Has been Turned On CAUTION: When the power switch on the operating panel is ON es described in 7 above, the READY lamp should also be on; ccheck that it is. (4) Routine Inspections WARNING: When checking bett tensions, do not get your fingers ceught between the belt and pulley. CAUTION: 1) Check pressure gages for proper readings. 2) Check motors, gear boxes and other parts for abnormat 3) Check’ the motor lubrication, and sliding parts for evi- dence of proper lubrication. 4). Check safety covers and safety devices for proper opera tion 5) Check belt tensions. Replace any set of bells that has become stretched with a fresh matching set (for L/M), (3) Warm Up CAUTION: 1) Warm up the machine, espacially the spindle and feed shaft by running them for 10 to 20 minutes at about half oF one-third the maximum speed in the automatic opera- tion mode,2) Thi automatic operation program should cause each machine component te operate. At the same time, check their operations. 3) Be particularly careful to watm up the spindle which can turn above 4000 rpms. Ifthe machine is used for actual machining immediately after being started, following a long idle period, sliding pans may tbe worn due to lack of oil. Also, thermal expansion of the machine components can jeopardize machining accuracy. To prevent this condition, always warm the machine up. (8) Preparations WARNING: 1) Tooling should conform to the mack dimensions and types. 2). Seriously worn tools can cause injuries. Replace all such tools with new ones beforehand. 3) The wotk area should be adequately safety checks. 4) Tools and other items around the machine or equipment should be stored to ensure good footing and clear aisles. 15). Tools or any items must not be placed on the headstock, turcet, cover and similar places (for L/M). 6) Ifthe center holes of heavy cylindrical workpiece are too small, the workpieces can jump out when loaded. Be careful about center holes and angles (for L/M). cauUTION: 1) Too lengths should be within spe event interference. 2) Alter installing @ tool, make a trial run, (2) Operatic WARNING: 1) Do not work with long hale that can be caught by the machine. Tie it up at the back, out of the way. 2) Do not operate switches with gloves on. This could cause malfunctions, ete. 3) Whenever a heavy workpiece must be moved, two or ‘more persons should always work together there is any risk involved. 4) Only trained, qualified workers should operate forklift trucks, cranes or similar equipment and apply stings. 5) Whenever operating a forklift truck, crane or similar equipment, special care should be taken to prevent colli sions and damage to surroundings. 6) Wire ropes or slings should be strong enough to handle the loads to be lifted and should conform to the manda tory provisions. 7) Grip workpieces securely. 8) Stop the machine before adjusting the coolant nozzle at the tip. 9) Never touch a turning workpiece or spindle with bare hhands or in any other way. 10) To remove a workpiece from the machine other than by a pallet changer, stop the tool and provide plenty of distance between the workpiece and the tool (for M/C). 11) While a workpiece is turning, do not wipe it off or re- move chips with a cloth or by hand. Always stop the ‘machine frst and then use a brush and a sweeper (for M 70), specitications, hted to facilitate d tolerances 10 12) Do not operate the machine with safety front and chuck covers removed (for L/M) 43) Use a hrush to remove chips (rom the tool tip-not bare hands (for L/ #4) 14) Stop the machine whenever installing of removing stool {ior L/1™) 415)Whenever machining magnesium alloy parts, wear 2 protective mask (for L/ A). cauTION: 1) During automatic operation, never open the machine door 2) When petforming heavy-duty machining, careully pro- vent chips from Being accumulated sines hot chips can catch fre {8) To Interrupt Machining WARNING: ‘When leaving the machine temporarily after completing a job, turn off the power switch on the operation panel, and the main circuit breaker. (9) Completing a Job cauTiot 1) Always clean the machine or equipment. Remove and dispose of chips and clean cover windows, etc. 2) Do not clean the machine or equipment, befor stopped. 3) Return each machine component to its initial condition. 4) Check wipers for breakage. Replace broken wipers. 5) Check coolants, hydraulic oils and lubricants for con- tamination, Change them if they are seriously contami- nated, 8) Check coolant, hydraulic oll and lubricant levels. Add, if necessary. 7) Clean the oil pan filter. 8) Before leaving the machine at the end of the shift, turn off the power switch on the oporating panel, machine main circuit breaker and factory feeder switch in thet order. it has (10) Safety Devices 1) Front cover. rear cover and coolant cover, 2}, Over travel limit switches 3) Chuck barrier, tall barrier and tool bar 4) Stored stroke limit (NC software) 5) Emergency stop push-button switch (11) Maintenance Opera’ 1) Do not proceed to any maintenance operation unless instructed to do so by the foreman. 2) Replacement parts, consumables (packing, oll seals, O- rings, bearing, oil and grease etc.) should be arranged in advance. 3) Prepare to record preventive and corrective maintenance operations. ‘CAUTION: 1) Thoroughly read and understand the safety precautions, In the instruction manual. 2) Thoroughly read the whole maintenance manual and fully understand the principles, constuction and pre- cautions involved.(12) Maintenance Operation DANGER: 1) Those not engaged in the maintenance work should hot operate the main circuit breaker or the control power ON switch on the operating panel. For this purpose, “Do not Touch the Switch, Maintenance Operation in Progress!" or similar wording should be indicated on such switches and at any other appropri ates locations. Such indication should be secured by ‘a semi-permanent means in the teading direction. 2) With the machine turned on, any maintenance oper tion ean be dangerous. In principle, the main circuit breaker should be turned off throughout the opera- tion. WARNING: 1) The electrical maintenance should be done by 2 qual- sd person or by others competent to do the job. Keep close contact with the responsible person. Do not decide by yourseif. 2) Overtravel limit and proximity switches and interiock mechanisms including functional parts should not be removed or modited. 3) When working at a height, use steps or ladders which ‘arg maintained and controlled daily for safety. 4) Fuses, cables, otc. made by qualified manufacturers should be employed. (13)_Until Opere Maintenance ion is Begun after WARNING: 1}, Arrange things in order around the section to receive the maintenance, including working environments. Wipe weter and oil off parts and provide safe working environments. 2) All parts and waste oils should be removed by the ‘operator and placed far enough away from the ma- chine to be safe. CAUTION: 1) The maintenance person should check that the ma- chine operates safaly. 2) Maintenance and inspection data should be recorded and kept for reference.+ WARM-UP Putting the machine into a major cutting operation immediately after a protonged shutdown may result in an abnormal abrasion from insufficient lubrication, which can cause the workpiece to be machined inaccurately due 10 thermal expansion of the machine component paris. A warm- ‘up, however, wil prevent such problems as abrasion of slicing Mazak surfaces, stick-slipping, ete. Fully warming up the machine, moreover, will stabilize its, thermal expansion and permit a workpiece to be machined uniformly and with high accuracy. Before starting a dally job, theretore, always warm-up the machine. This fs especially important in cold-weather. HINTS OF WARMING UP 1.800 (thru 22 to 4500 rpm) (Warm-up time ‘Approx. 80 min. (2) Spindle speed 600 @) Travel stroke 1 — 1,000 tpi — 9500 cpm — Max, speed Full stoke on every axis NOTE: While warming up the machine, check every part for operation, lubrication, ete.Mazak 2. MACHINE SPECIFICATION 244 Overall ViewMazak tem Unit Feature Maximum diamotor of toot ai ise madated in the ine (with adjacent pocket | inch 10.24 ‘Maximum tool weight 9 7 replaceable’ (including shunk ‘2nd pullstud) tbs 58 Maximum tool lengih mn 500 replaceable (Irom taper : telerence surface) al ad “Teo! clamping force 9 2500 tbs 5500 ‘umber of tools accommodated | pes. 40 “Tool selection systort Random Machining capacity (equivalent to S45) H800 © Maximum Milling Capacity 700 ecimin @® Maximum Driltng Capacity 260 mm (02.84 *) @ Maximum Tapping Capacity MB2 x PS © Maximum End Mill Capacity ‘540 cefmin Electrle Speciticati Frequency: 0160 Hz., #1 Hz. Voltages: 2001220V,'3 phase Voitage Regulation: within + 10 4 Gross Load Capacity: 632 kVA (Standard) Cable Required (Standard, with 2 PCs at 4.500 rpm) Primary Service Cable: 100 mm? Grounding Cable: 80 mm? ‘but ambient temperature: 30°C and below, input voltage: ‘AG 200 V, 8 phase metal duct wiring ‘The diameter of a primary service cable and that of a grounding cable may depend on machine ‘specifications. Consult the nearest MAZAK technical center A grounding work with a ground resistance of 1008 and below Is required. -2:2 Machine Body Specification (standard) Mazak tem ait Feature Table lateral traveling stroke, | mmimin 1,250 Xaxis inch “4921 Head vertical traveling stroke, mm 4,000 : Yeaxis inet 3037 Head horizontal traveling mm 50 stroke, Z-axis inch 33.45 Distance from the center of min ‘50 ~ 1,050 spindle to the top surface of ~ the pallet inch 197 ~ 4134 Distance from spindle end to mm 250 ~ 1,100 the center of pallet inch 984 — 4331 Machine weight ‘9 20/000 bs 44,000 ‘Overall machine height (rom mm 3,183 the bottom of the base) inch 72531 Floor space required mm Ba70 x 5510 : inch 12874 x 21699 Main drive motor HP 25 (rated continuous operation) 35 (rated 80 minute operation) ‘Shape of spindio nd 1SO #50 ‘Spindle speed, standard rpm) (22 ~ 4500 Dimension of pallet mm ‘800 = 600 ‘configuration inch 315 x 315 ‘Waximum weight to be loaded kg 2,200) on the pallet Tbs 4540 Rapid feedrate, X-axis Tamim. 78000 inchimin. 70866 Cutting Teedrate, X-axis ‘ammimin, 8000 inchvmin. 315 a Rapid feedraie, Y-axis ‘mmimin, 78000 inchvinin. 70866 ‘ulling feedrate, Y-axis ‘mm/min, 8000 inchvmin. 315 Rapid feedrate, Z-axis ‘m/min. 76,000 inchimin. 70866 Cutting feedrate, Z- ‘mm/min. 8000, inchvmin. 315 Maximum tool diameter mm 2260 replaceable inch 210.24 Maximum diameter of tool mm 2130 accommodated in the magazine inch 05.12Mazak 2:3 Stroke Diagram 7 Unit: mm (inch) 2508.24) 850(89.40)_) Z=0 CTN x 5,250 (49.21) Kd 1.260(68.61) 1,900(89.37) « Doct stoke ijt 5011.97) 2-4 Spindle R.P.M - POWER - Torque Diagram Spindle speed: 4,500 rpm (option) AG spindle motor: 26 KW (@5HPY‘90 min, rating Kg-m + KW. tn tH rorquel-]Power 25 Ka H } GHP) | Il 108.6 kg. 792 Wt 10 |-Hi0 58, jaa Ton A (32 we 288 a7 kg. H ea tb) 55 kg.m FT 68 tt. tbe) Lit "90.29%, | | 708 1000 2147 400" [rpmMazak 3. OPERATING PANEL DESIGNATIONS 3-1 Panel illustration a MAZATROL M-32 ° Power On button LLY Power OFF bution ELS Cnr screen evigriness Menu keys scsi knob) Serer oe (111 Menu tatoo ney . °o Reprograming swicn _| | see toenarged view om tho nen Page. oor ick swten_| Star.button + - Feed hold button} ‘Axls-movernent buttons |Spindte contr buttons! Emergency stop bution ‘Alanis zero-point return buttonEnlarged view of the operating panel Fst zero-point return indicator lamps Cutting feed override Kays Manval pulse feed key —_—_—eceve Second zoo pn stun ince lamps TP5 key Data conection key Machi Indicator ta VEC ey re eee in sta ncatr tmp | | — a eeeceeeeeee eYet mor | J Rare eae noon 7 Fame f=) Eel [fe le fo} No.5 vsror | [© Yio. Lai | Ve [o—\(e c OF cles ey if” ale la elais|ie. Fouchsersorstaus [FOS Display erasure key |} indicator lamps Oo} 1} 2i3 Input key oe Auitay boy : om OE 3 Spine speed dplay rea ST Sono 8 (O\fRrn z i aes 1 [Peet — octet cies key tne dopey ao __& & sa Coolant menu key 9 Mom * [IC x 1% [°. Poa. ATC ae =H =e | DD | [fees |S benatind ee 1% Ae e—\6 ee ase Po intenance dstoy Fnsfiwn fle fie) | [fae tr aaldall Fes sep] | “Tepe wn key return key. Memory tun key + Function selector keys. — Second zero-point MOI run key J for utomatc un mode = Shinde over hee ‘au key a Rapid feed Indias lamps Casting feed key N Papiteed rate changing Keys api fee toy 2) Function selector keys for inanval mode(2) Manual pulse operating panel Mazak cooLant NozzLe sop LEFT RIGHT SPIRAL CONVEYOR ‘STOP REVERSE FORWARD:OFF on, © cover cooLanT @ (9) Display of Too! No. and index Table O ® Index Table Positon (ee 41) “Tool No” display The indicated too! is ready for ATC operation. 2) “Index table position” display This indicates the table turning angle, 1 x 960 Index table specification (Tool No. and Index table position par oO | drawing) 4) “Tool No” display The indicated too! is ready for ATC operation. NC rotary table specification (Toot No. panel drawing) 3-2 NC Operating Panel ()) ATC MENU key Pressing this key in the manual made causes the following ‘menus to be displayed and allows ATC-related operations to Description ARM CHANGE: Spindle tool and toolshitter tool are interchanged. TOOL LOAD: Tool is loaded from magazine into too! shifter. TOOL UNLOAI magazine, SPINDLE ORIENT: Spindle oriontation is porformed. ATC COVA OPEN: ATC cover is opened. ATC COVA CLOSE: ATC cover is closed. TFUNCLAMP OKI: When this key is pressed, the tool will b= tunclamped by the tool unciamp switch even if tis notin the ‘orient spindte. ‘To relurn the ATC menu display to the normal display, press the ATC MENU key once again. (2) COOLANT MENU key ‘When this key is pressed, menu key becomes as follows and COOLANT ON/OFF is performed. On other than AUTO ON/OFF, character light goes on and off when key Is pressed ‘once and once more. Tool is returned from tool shifter into COOLANT AUTO: even if M08 command is given, coolant does not appear unioss this key lights. NIAGARA AUTO: even if M130 command is given, NIAGARA coolant does not appear unless this key glows. MIST AUTO: even if MO7 command is given, mist coolant does not appear unless this key glows, AIR BLST AUTO: even if MEQ command is given, air blast does not appear unless this key illuminates. THR COOL AUTO: even if M51 command is given, spindle through coolant does not appear unless this key becomes bright. YAP COOL AUTO: even it M52 command is given, tap coolant does not appear unless this key glows. JET COOL AUTO: even it M131 command is given, jot coolant does not appear unless this key lights. THRU AIR AUTO: even if M132 command is given, spindle through air does not appear unless this key glows. ALL COOL AUTO ON: when this key is pressed, all AA 4 ‘AUTO keys put fight on. -n-ALL COOL AUTO OFF: when this key is pressed, all 0.4.4 ‘AUTO keys put light off. COOLANT MANUAL: Coolant appé switched on. NIAGARA MANUAL: NIAGARA coolant appears when this key Is switched on. MIST MANUAL: Mist coolant appears when this key is switched on. AIR BLST MANUAL: Alr blast appears when this key is switched on. when is key Is THR COOL MANUAL: Spindle through coolant appears . when this key is switched on. ‘TAP COOL MANUAL: ‘Tap coolant appears when this key is switched on. JET COOL MANUAL: Jet coolant appears when this Key is ‘uitched on. THRU AIR MANUAL: Through air appears when this key is switched on. AUTO keys “1 glow on power supply by parameter (R2101 bit 4. 7 ‘Bo select between single-screen-paue display and double- screen-page display, press the green menu key on the right ‘side. Press COOLANT MENU key once more for the return from COOLANT menu to ordinary menu. (@) PALLET MENU key Pressing this key In the manual mode causes the following menus to be displayed and allows pallet-changing related operations to be carried out: Description PALLET 1 LOAD: The pallet on No. 1 stand is moved onto the table on the machine side. PALLET 1 UNLOAD: The palleton the table on the machine side is returned.onto No. 1 stand. PALLET 2 LOAD: The pallet on No. 2 stand is moved onto the table on the machine side. PALLET 2 UNLOAD: The pallet on the table on the machine side is returned onto No. 2 stand. ‘The requirements for loading or unloading operation by menu ‘manipulations are as follows +) Menu command is valld forthe status of pallets on the table ‘and each stand, (Example: When there is no pallet on No. 1 stand and there Is one each on No. 2 sland and the table, only PALLET 1 UNLOAD Is possible, 2) Pallat No. displayed on the CAT represents the actual state of the case. (Example: When there is no pallet on No. 1 stand and there is one each on No. 2 stand and the table, PALLET NO. 1. In other words, pallet No. denotes the ‘number of the pallet which is on the table.) 3) The table on.or from which the pallet is to be loaded or unloaded is at the zero point (0° rotation). 4) Tho X-axis is at No. 1 or No. 2 zero point (on the loading oF unloading side). 5) The Z-axis is at No. 1 of No. 2 zero point. 6) The table is al the zero point (0° rotation). 7) The measuring arm Is in ON status. 8) The position of the hook on the loading or unloading side is valid for the menu command. In other words, the hook {and pallet) must be at the end of the stand when loading and at the end of the table when unloading. Mazak DOOR OPEN: The pallet door opens. Even if the key is released trom pressing In the course of opening, the door will ‘ot stop opening unti it finishes opening. DOOR CLOSE: The pallet door closes. Evan if the Key is ‘released from pressing in the course of closing, the door will fot stop closing uni! it finishes closing, But if either No. 1 ‘or No. 2 hook is halfway (a position either at the end of stand ror at the end of table), it will not close. PC READY: To loed or unload by menu manipulations, the requirements described in 1) through @) above are prerequisite. However, f PC READY is ON, the requirements «will be invalid as far as those of items 4) through 6) above are concerned. Also, it can be used for EXTEND and RETRACT operations bby means of manual switching. {tis provided with an alternate function which repeats ON and OFF alternately each time the menu key is pressed. It will bbe OFF automatically when the menu picture is switched to another or loading or unloading operation is finished. Mote: Use this function only in an emergency such as when ‘an abnormal operation, etc., has occurred. PALLET CLAMP: The table on the machine side is turned to the pallet clamp status. PALLET UNCLAMP: ‘The table on the machine side is tuned to the pallet unclamp status. However, it cannot be done when the table is in the unclamp status. ‘To return the pailet-change menus to normal menus, press the PALLET MENU key once again. () Ft key ‘To turn onfolf the MACHINE LOCK, Z AXIS CANCEL, MST LOCK, or DRY RUN menu keys, press the FI Key and the corresponding menu key together. The menu display wil take a reverse display status when the selected menu function becomes valid ©) FO key ‘Simultaneous pressing of the FO and Ft keys places the equipment In the manual changer mode. See subsection 4.19(6) for details (©) MNT key Pressing this key causes the interface diagnostic display to appear. See Maintenance manual for detais (@ DOOR INTERLOGK switch (some machines aro not equipped with this function) This switch is used to interrupt machine DOOR INTERLOCK side operation lor preventing danger when [eB] _ mastte sce doors openes Auto Test Oy 12+Machine side operation on door opening is divided as follows. LEFT BGGRITER] can [actin epoto] Aaron endnote tron FF ene wrne, |e) 2, —_ prohibit, magazinal (arogram cannot eee [be continued). a eer Press [Z| or ES : Mee ror boud ter ea puat rest | amo | seq tos seo |Site ice aon eet rat, (cycle start eh, Tae aap = Mechanism Is provided to prevent door opening while machine is operating in automatic operation mode with this ‘switch AUTO. Yo temporally leave the door open, first set the DOOR INTERLOCK sutich to the TEST position, then select the single-black operation mode fom the displayed menu, and - when the single-block operation ends, open the door. For the ‘operation rasuming procedure, see the description of TEST ‘Auto above. Aller operation, set the DOOR INTERLOCK switch to the AUTO position. For keys or switches other than those numbered (1) through @)on the main operating panel, refer to the MAZATROL N32 Operating Manual, (cycle start) lamp flickers In some cases when ‘not accomplished (too! loadfunload, fnext time's tool select) although tool change command ‘operation is completed on the end or temporary stop of program-or on the stop of singla block operation or feed hold. (On other than emergency, be sure to carry out RESET, EMERGENCY STOP or POWER OFF after switching off lamp. 3-3 Description of the Operation Buttons at Lower Portion of NC Control Panel (t) COVER COOLANT cover cooLanT With this switch “ON, coolant will be elected trom the rear of the base to flush away cutting chips. If this function is not needed, this switch should be “OFF*, oFF Note: Ifthe switch of cover coolant is turned on in condition that the chips tay on the cover and the base alter a long ‘operation of the machine without using cover coolant, it may ccause the leak of coolant over the floor. The cover coolant Is expected to be used during the operation or alter removing the chips on the cover and the base. Mazak (2. SPIRAL coNvEVOR SPIRAL ESVEVOR Ths etch changes he direction tne aia reverse ‘forwanoconveyor tums. With this itch put in the “FORWARD” position, cating chips are ejected into the chip conainen, Note: Always use the spiral conveyor in clockwise rotation. 41 the machine is run long with the spiral conveyor stopped, chips will collect on the conveyor. Starting the conveyor in such condition will result in an overload of the motor thus causing its alarm stop. Avoid using the spiral conveyor in the counterclockwise rotation unless it is required for maintenance. (3) COOLANT NOZZLE (Optional) COOLANT NOZZLE Using this switch will permit a direction of STOP the remote control nozzle (optional) to be rion selected. ‘The switch Is of selt-return type. Normally, Its positioned at STOP. Therefore, throw it to the RIGHT of LEFT position as requiced. Releasing the switch will throw it {o the STOP position, 3-4 Description of Controls on Pallet Chang Operating Panel (Reter to a separate MAZATROL FMS pallet changer ‘operating manual for a machine equipped with MAZATROL FMS) 3-4-1 Pallet changer operating panel oO oO SNe emenaene sor 2@ © var eer nO. ore = oo noe Oo oO Pallet changer operating panel 3-4-2 Functional description of controls on pallet changer operating panel The céntrols are used to return the pallet changer to the reference zero when the operation can not be continued due to any trouble In an automatic operation mode, or for maintenance inspection and workpiece exchange. (1) EMERGENCY STOP EMERGENCY STOP This pushbutlon is used to stop tho pallet changer operation it any abnormal stale such as malfunction, noise and collision of the pallet changer occurs. The machine wil stop immediately after pressing this pushbutton. Mio. scugsee oFen(2) ONE CYCLE SWITCH ONE CYCLE SWITCH This function prevents the machined 2 1 workplece from being re-machined. ° 2 8 +), When the workpiece is set up on pallet, pressing the ONE. CYCLE switch button turns the lamp on. Pressing the ‘button again will turn the lamp oft 2) While the lamp ison, the auto pallet move command ("M71, (M72) becomes effective and the No.1 (or No.2) pallet can * bbe moved o Vie machine end the No2 (cr No.) paet can returned to the palit stand. @ Suppose machining of the workpiece on pallet No. 1 'bin process (in his case the lamp of ONE CYCLE SWITCH. is ON). @ To machine the workploce on pallet No.2 after finishing machining the one described in @ above, tun ONE GYOLE SWITCH 2 ON. @ Cémmand 872 wil turn the No.t pallet tothe original position and, at the same time, move the No.2 pallet to the NC machine, “MT7I: Pallet No.t setection M72: Pallet No2 selection ‘Simultaneously with completion of the return of pallet No. 1, the lamp of ONE CYCLE SWITCH 1 will be OFF @ Even if 71 is commanded again when the lamp is OFF, the NC call is invalid and the move of pallet No, 1 onto the machine wil not be exocuted. 9) Alter the workpiece is setup, the pallet can be moved to the machine by urning on ONE CYCLE lamp and pressing ‘CYCLE START on the NC control panel. Workpiece moves, to the main machine and the machining program wil sta. 4) Even if the lamp of ONE CYCLE SWITCH 1 or 2is OFF, M70 command (return ot paliet No. 1 oF No. 2 trom the machine to the pallet stand) will be executed. 5) When this funetion Is invalidates by parameter, the lamp willbe turned on regardless of the switching operation. This, ates thatthe pallet can be moved to the machine (@) PALLET DOOR PALLET DOOR This switch is used to open or close the OFF. automatic door Set to OPEN position to OPEN open the automatic door, and set to CLOSE Position to close the door since this switch restores automatically. Once itis put lo ON, this switch is activated as long as the operation continues. (4) PALLET CHANGE HOLD PALLET CHANGE HOLD close It PALLET CHANGE HOLD is switched ON when not in automatic pallet change operation mode, pallet change ‘operation will not be carried out even a pallet vauio Oo oFF / on outputted from the NC unit, Therefore, pallet change operation by automatic ‘operation will not be performed when setting a workpiece on the remaining pallet, thus ensuring prevention of doing harm tothe operator. Al this time, VALID lamp on the control panel is ON together with the display of pallet change hold underway change command is’ “4 Mazak fon the CAT. ‘Various switches for manual operation (rmanuall pallet change, manual pallet door operation) will be valid. I the switch is turned ON while in automatic operation, PALLET CHANGE HOLD will not be valid until the operation underway ends. ‘Switching OFF will make PALLET CHANGE HOLD invalid and the lamp and display will be OFF. ‘pallet change command (M70, M71 or M72) outputted from. the NC unit while PALLET CHANGE HOLD is valid wit! be invalid and the pallet change hold status will continue. tn this ‘case, just switching OFF will not cancel pallet change hold. Press CYCLE START pushbutton switch after turning PALLET ‘CHANGE HOLD switch OFF. The hold staus willbe cancelled, the lamp and display will be OFF, and the command to the standby pallet will be executed. (6) PALLET SELECT NO. 1 and NO. 2 This switch is used to select either pallet No. 1 or No. 2 to NEUTRAL, ‘move the pallet manually using No.2 No.1 PALLET HOOK EXTENO/ REVERSE switch described below. Since this switch Is automatic return type, removing the finger from the switch will return the knob to NEUTRAL position to stop the operation. (6) PALLET HOOK EXTEND/RETRACT ‘The pallet is moved using this ‘switch and PALLET SELECT NO. 1INo, 2 switch described above, PALLET SELECT PALLET HOOK exreno S70? RETRACT will move the pallet to the machine side and 10 RETRACT to the stand side. “The speed is high for both and will not be decelerated even reaching the decelerating point. ‘This switch functions regardless of ON or OFF of ONE CYCLE SWITCH. ‘Since this switch is automatic return type, removing the fingor from the switch will stop the operation. ‘The operation requirements for both EXTEND and RETRACT are as follows: 1) Pallet door is at opening end. 2) Table on machine side is in pallet unclamp status, 8) Pallet stand No. 1 or No. 2 (moving side) is at zero point (0°). 4) Xeaxis is at No. 1 oF No. 2 (moving side) zero point. 5) Zaxis is at No. 1 or No. 2 zero point. 6) Table Is at zero point (0°) 7) Measuring arm is in ON status. Ihe requirements for each axis cannot be satistied because itis in course of restoration after an emergency stop, etc. press PC READY key of pallet menu key ON (see pages 13), and only the requirements described in 4) through 6) will be lnvali(7) PALLET TURN NO. 1/NO. 2 PALLET TURN This witch is used to extract the turn. NO.2_NO.1 lock pin of the pallet stand and valid only when the following requirements are met: 4) The pallet change command is OFF or the inteflock is in effect because of alarm, or 2) The PALLET CHANGE HOLD switch In ON (even the VALD lamp is not ON, this function will be effective as long as the PALLET CHANGE HOLD switch is On). ‘Turing this switch to NO. t or NO. 2 will extract the turning lock pin of pallet stand No. 1 or No. 2, respectively, and the table may be freely turned by hand. The turn can be locked at every 90°. To lock, place the knob of PALLET TURN switch in halfway position. The lock pin wit be extracted. Note: Unless the palletis located at 0° position, pallet change cyele Is not accomplished. Example of manipulation: To load (move onto machine) pallet No. 1 which is on the stand side. 1) Set the mode of the control panel on the machine side to MANUAL. 2) Move the X-axis to No. 1 2670 point and the Z-axis to No. 1 or No. 2 zero point. '3) Conficm that the measuring arm is ON. 4) Confirm that pallet stand No. 11s at zero point (0° turn). not, set it to zero point using PALLET TURN NO. /NO. 2 switch mentioned above (7). 5) Confirm that the table is at zero point (0°). 8) Confirm that Z-axis is at No. 1 or No. 2 2er0 point. 7) Set the table in pallet unciamp status. 8) Press PALLET CHANGE HOLD switch on the pallet ‘changer operating panel ON and confirm that VALID lamp is ON. 9) Open the pallet door. 10) Turn PALLET HOOK switch to EXTEND side with PALLET SELECT switch turned to NO. 1 side, The pallet hook will extend until it reaches the extend end (on the table). 11) Release the switch when the pallet stops at the extend end, and set the fable in pallet clamp status. Note 1: ‘The NC unit confirms movements of the pallet and memorizes whether the pallet on the table is No. 1 or No. 2 ‘oF none. However, a manual extension or retraction does not change the memory. Therefore, after moving or returning a pallet manually, reinstate it manually or correct patlot No. (data contents of 1967 register) displayed on the CRT to what it should be. In the example cited above, correct PALLET NO. 0 10 PALLET NO. 1. Otherwise, commanding an automatic pallet change afterward will result in ALARM NO. 352-PALLET NO. MEMORY NG. Note2:Only to move from the end of the stand to that ofthe table and vice versa, load/unioad manipulation using menu switch is simpler to handle and requires less trouble than the method described in Note t above. 3-4-3 Reinstating the machine when it stops white in pallet change operation. (1) Ifthe hook stops halfway between the extend and retract ends: : Mazak Extend or retract the pallet by manual operation using PALLET CHANGE HOLD. (2) ifthe X-axis stops halfway between No, 1 and No, 2zero points: This can be Ignored if the ook position is not halfway. If automatic pallet change is commanded again, the X-axis will automatically move 10 @ proper zero point. (@) Both the hook and X-axis stop naltway: ‘When the table is in pallet unclamp status, set it in clamp status by menu manipulation. To do so, press the PALLET ‘CLAMP menu key alter displaying the PC menu and pressing the PC READY menu key. Then roturn the X-axis to No.1 or No.2 zero paint (on the side of the pallet which stops halfway). Finally, advance or retract the pallet oy manual operation using PALLET CHANGE HOLD. 3-6 Designation of Control Buttons on Control Panels of Magazine [Foor SELECT] AUTO. MANUAL 10 EMERGENCY STOP Oo) () TOOL SELECT : Use this switeh to determina the method of selecting a tool! {athe manual modo, the swiich lamp Iights up when MANUAL is selected. For automatic made of operation, see item (4), Manually Letting the Magazife Interrupt” (2) FORWARD REVERSE This button Is used to select the particular tool in the ‘magazine. Continue to press the button to turn the magazine until the too! number just before the one to be selected appears, then releas However, this. button conditions: @ Tho TOOL SELECT switch is sel to MANUAL. @ The MANUAL lamp is lt or blinking, © Tho magazine door is closed. (3) EMERGENCY STOP ‘This pushbutton is used whenever any abnormal status such {as a machino malfunction, abnormal noise or colsion occurs during operation. Pressing this pushbutton wil stop the hydraulic pressure and operation immediately stops. The NC ower, however, remains turned on. (@) Manually Letting the Magazine Interrupt With the machine running in the automatic ope valid only under the following lon mode, 18.itis possible to manually turn the magazine. With the MANUAL mode solected in selecting @ tool, itis possible to swing the magazine by means of the FORWARD or REVERSE switch as long es the MANUAL Lamp is ilyminated, Ever ifthe MANUAL mode is selected during the [ATC or while the magazine Is turning under a program, the amp will not come on, The lamp lights up after comptetion ‘of ATC or magazine turning operations. Ifthe MAGAZINE TURN command is issued in the ATC or In a program while the lamp is illuminated, moreover, it wil start blinking and the ATC or magazine will be ready to turn. . Under this conditions, it is possible to manually turn the magazine, To restart the machine, select the AUTO in selecting atool and press the, (CYCLE START) button, {@) Magazine Door Interlock (Some machines aren't equip- ped with this function) ‘With the magazine door let open, itis impossible to periorm ‘an ATC operation orto turn the magazine either automaticaly ‘or manually Should the door be opened during’ the ATC or while the magazine 1 turning, the machine will stop operating tentatively. Close the door and press the it, (CYCLE START) button after pressing firstly M. FAIL LEAR key on the machine operation panel and the machine will restart operating. 3-6 Functional Description of Contro! Buttons, etc. other than those on Control Panels DOOR INTERLOCK BYPASS. selector switch POWER DISCONNECT switch 16+ Mazak () POWER DISCONNECT switch (Non-tuse breaker) Before starting an operation, first turn this switch ON. Upon completion of the operation, turn it OFF last. (2) DOOR INTERLOCK BYPASS selector switch This switch is provided for the personnel in charge of maintenance. Normally keep it in OFF position, ‘With the switch OFF, the door switch will function to break the main power ‘supply clrcult when the control panel door is accidentally opened. With this switch ON, be careful, because the main power supply ci disconnected even with the door open. (9) MT 0° SEARCH switch Normally keep it at OFF position. When the MIT controller or battery ‘on the controller was aM replaced, turn this ‘switch OW first, then turn the POWER switch ON. “To turn the table for the first time, position it in the commanded OFF © place via 0° position. Than, keep the M/T 0° SEARCH switch at the OFF position. MIT 0° Search(4) AUTO POWER OFF switch (lor Factory Automation) ‘Turning the AUTO POWER OFF “OFFION’ switch ON will tip the CBI main breaker on the machine and intereupt the machine power after exceeding the time the APOFT timer fon the electrical control panel was set (standard setting: 180 seconds) if the program end, MO2 (resel) or M30 (reset & rewind) command is given. ‘At the beginning of the shift, urn the CBI main breaker OFF ‘and back ON to switch on the power to the machine. Turning this switch ON breaker after the APOFT timer setting time has ben exceeded when M02 or M30 is given from the tape or memory. AUTO POWER OFF (8) Chip conveyor (Optional) * Chip conveyor belt will move forward (removing the chip) with the operation of FORWARD switch fon the chip conveyor. °Chip conveyor belt will move reverse with the operation of REVERSE switch. © Chip conveyor will stop moving with, the operation of STOP switch. Note: Ifa large amount of chips are layed inside the conveyor, remove the chips making the conveyor belt move reverse ata time when the machining is not executed for one to three times a day. will trip the CBI main 17. Mazak 3-7 Manipulating Buttons on the Hand Pulse Contro! Box 3-7-1 Manual pulse operator panel view ——— Mazalk enencency stor oO x HAND “PULSE @ x10 o x100 fy poise " sneer 7 ‘The manual pulse control box is to be used when it is unavoidably necessary to work outside of the machine or apat from the control panel. 3-7-2 Functions of the manual control keys and switches () Too. By turning the switch toward CLAMP, a tool will be clamped land by turning toward UNCLAME, it will be unclamped. ‘Changeover of this switch will enable the toot to be changed manually, {the machine is shified to the automatic mode with this switch turned toward UNCLAMP, “misoperation” display will be indicated. (@ EMERGENCY stop ‘This switch is tobe used when some unusual condition such ‘as malfunction, abnormal noise, etc., of the machine has ‘occurred during the operation. ‘Touse the machine after releasing the emergency stop, turn the push button type switch clockwis @ AXIS SELECT ‘This switch is to be used for axis selection for the manual ‘operation using hand pulse. Turn the switch to the desired axis (X, Y, Z oF 4) (8) Magnification: ‘This denotes the feedrate per pulse when the machine fs ‘manually operated using hand pulse. The axis will be moved 1,001 mm (0.00004*) per pulse with “x1 *, 001 mm (00004") with “x107and 0.1 mm (0.004*) with *x100". (Magnification for the 4th axis is for the NC rotary (optional) snd *x100" magnification is not valid.) (8) HAND PULSE By turning this switch to ON, the hand pulse will be valid ‘egardiéss of the mode on the part of the machine. And the amp will light and manual operation can be done. Be sure to keep this switch turned to OFF to operate the machine ‘automatically. Automatic mode will net become valid if the ‘switch is turned to ON. By turning the pulse generator clockwise, every axis will move toward “+, and by turning counterclockwise, toward *—4. OPERATION 4-1 Operating Procedure (Steps prior to Machining) (PowER ON) DISPLAY IN USE ETURN TO NOt ZERO POINT (Except machine with absolute position detecting {all axes)) |POSITION display JCOMMAND display MANUAL OPERATION [OR MDI OPERATION. {as required) (REGISTER TOOLING] TOOL FILE display "UN TOOL FILE : (When tools ere newly loaded.) [PREPARE PROGRAY] WK.PROGRAM display PROGRAM FILE play CHECK display When the necessary data are available. RAM. ALLOCATE MAGAZINE | TOOL LAYOUT POCKET NUMBERS TO| display os MOUNT TOOLS ONTO MAGAZINE i MEASURE TOOLING —] TOOL DATA display LENGTH ANDO SET ‘TOOL COMPENSATING StnoKes ‘SET WORKPIECE POSITION display COORDINATE ZERO| —WK.PROGRAM POINTS display T PREPARE FOR AUTOMATIC OPERATION MACHINING 4-2 Outline of Display Machining is carried out by following the steps summarized ina table above. In this numerical control unit, a program can be easily prepared by depressing numerical values or menu keys (below the CRT) in response to questions given by the machine, ‘The following CRT displays are available, depending upon fa requirement and an objective: POSITION display: This displays the current status, position, spindle speed, feed, spindle and Z-axis load (96), work program ‘number, unit number, toot numb parts count. This shows position (machanical coordinate system), residual distance, offset. ‘and _ tool compensating stroke in addition to those displayed on the POSITION display. POSITION display COMMAND display COMMAND display: -18- Mazak This displays program tool path. This displays the position of a tool PATH CHECK display: TRACE display: (while a program is running). WK.PROGRAM NO. This is used to prepare andior edit a display: program or programs. PROGRAM ‘This disptays a volume of program FILE display: data. A program is erased or inputted and outputted through an external memory. These display a programmed machining shape and a programmed too! route. FIGURE CHECK, SECTIONAL CHECK and PLANE CHECK displays: TOOL FILE display: Thisis used toregistor tools (ond mil, faco mill and beveling cutter). TOOL LAYOUT isplaye: ‘This display Is used to set the number of a magazine pocket into which a programmed too! Is to be mounted, ‘This is used to set the tool length, tool compensation stroke and lite fime of a programmed toot. ‘These display parameters and is used to set parameters. This 1s used to input and output programs by CMT, DNC or tape. ‘This is used to ‘display and sot TOOL DATA display: PARAMETER displays: DATA IN OUT display: EIA/ISO Information cisplay: preparation data of EIA program. MODAL INFO. display: This displays modal informations. ALARM display: This displays maximum four alarms. PRC. CONTROL —This displays process control by isplay: same tool priority funetion. MAINTENANCE This displays the reason for an alarm isplay: and Is used to diagnose the NC. Press MNT key 10 change to this, display. Note: Refer to MAZATROL M2 operation manual for detailed information on the screen. 4-3 Checking for Operations prior to Starting this Machine Points to be checked before switching the machine on (@) Make certain that the NC unit and the electrical controt ‘cabinet doors are closed. (@) Make certain that the DOOR INTERLOCK selector switch ts OFF (@) Check satety covers, ete. or possibie absence. {@) Check oi gauge levels. (Check asterisked sections shown In the following figures.) (6) Make certain that he air source forthe aie pressure circuit is activated. Specified pressure: § kglom® (71.12 PS!)Continvous tap coolant lubrication uit (eptonay Centralized Iupeeation unit Lubsiation port, chiller unit tank 4-4 Machine Switch ON (1) iest urn OW the main Switch on the dlstbution board. (2 Turn ON the POWER DISCONNECT switch. () Prose the POWER ON [J] pustouton onthe NC operating pancl u CAUTION: When inal switching the machine oncght ater instaling it, check te points specified in the maintenance manual 4-5 Status and Irispection after Switching the Machine ON (0 Press the poweR oN [1] pushboton on the NC operating panel and the READY pilot lamp will come on, and (2) The hydraulic unit will start operating. Make certain that, the hydraulic pressure gage reads the specified pressure. ‘Specified pressure: 70 kgicm® (99561 PS) (with machine at pause) Lubrication port 43616082 ‘Toot wrench s19- Mazak 4-6 Procedure for Switching POWER OFF (1) Press the POWER OFF pushbutton on the NC operating panel. (2) Tum OFF the POWER DISCONNECT switch. (9) Turn OFF the Main Switch on the distribution board. This is all for the POWER OFF operation. 4-7 Inspection and Cleaning after Operation AAfier operation, clean the machine and at the sama time check the following: (1) Machine for possible rupture or abrasion, (2) Tools for possible disappearance or abrasion, (@) Sliding surface lubricant and hydraulic unit tanks for oil level, (4) Hydraulic piping for possible ol! leakage. 4-8 Procedure for Manual Tool Change Since tools are replaced by hand, care must be exercised when handling them. Tools weighing up to 27 kg (694 Ib) can be accomodated by the magazine. (Max. total too! weight is 600 kg (1820 1b.) ‘Arrange tools in the proper sequence and load them in the magazine. Magazine ant aa Lif] 3st coer Roten pin all (1) Procedure for loading tools in the magazine 1) Select the manual operation mode from the NC control panel. 2)Set the TOOL SELECT switch on the magazine control panel to the MANUAL position. (The lamp will be ‘Muminated.) {3)Rotate the magazine using the FORWARD or REVERSE switch on the magazine control panel. To insert the tool, leave off the switch when the tool pocket is in the proper position. 4)Align the toot holdar sockat key with the key groove in the tool, then insert the tool in the toot pocket. A steel ball Dull in the tool pocket enters into the groove on the toot shank and holds the tool.(2) Procedure for taking tools out of magazine 1) Select the manual operation mode from the NC operating panel. 2) Sel the TOOL SELECT switch on the magazine control panel to the MANUAL position. (The lamp will be itluminated.) 9) Rotate the magazine with the FORWARD or REVERSE, switch on the magazine control panel. Leave off the switch when the tool to be taken out is in the proper position. 4) The desired tool can be removed from the magazine by Inserting the tool wrench (housed as standard within the , tool box) into the gap between the toot and the tool pocket, as shown in previous page, and then pressing the wrench in the direction of the arrow. 4.9 Procedure for Mounting a Too! onto the Spindle (1) Stop the spindle at the orientation position. (2) Select a manual operation mode. (8) Cause the spindle to unclamp the tool, using the TOOL, CLAMPIUNCLAMP key on the hand puise control box. (4) Firmly insert the too! into the spindle. (6) Using the TOOL CLAMP/UNCLAMP key, cause the spindle to clamp the toot. 4-10 Procedure for Removing a Too! from the Spindle (1) Stop the spindle at the orientation position. @) Select a manual operation mode. {(B) Set the TOOL UNCLAMP switch to the ON position. ‘Cause the spindle to unclamp the tool, using the TOOL, CLAMP/UNCLAMP key on the hand pulse control box. (Hold the tool by hand in advance to prevent fall of the tool) (4) Remove the tool from the spindle. (6) Using the TOOL CLAMP/UNCLAMP key, cause the spindle to clamp the tool. CAUTION: With.the tool holder mounted on the spindle and too! (milling cutter, end mill ete) fitted, never use a wrench ‘or spanner to clamp. This is very dangerous. Normally, itis ‘dangerous to install and remove a tool in the spindle manually, £0 avold doing so. 41 Switching the Machine ON POWER ON. Depress the POWER ON [1] key. Alter a moment, the READY indicator lamp will turn on. The operating panel is the following condition: 1) The POSITION display appears, b) The machine is set to manual operation mode. (For machines having an all-axis absolute-position detect function (option), automatic operation mode) ©) The displayed spindle speed and feedrate represent the setting before the machine is switched on. [NO. 1 ZERO POINT RETURN ‘The data setting message (referred to as rnessage) goes with: ZERO RETURN? ‘Then, return to No. 1 zero point manually. After returning to No. 1 zero point, the No. 1 z2r0 point return LED on the ‘operating panel will turn on. Now, manual operation, automatic op available Note: Always return to No. 1 zero point alter switching the jon or MOI are Mazak ‘machine on. Normally, however, ist-zero point returning is not required for machines provided with an all-axis absolute-position detection function. Even when power is turned off, the state ‘existing at that time wil be resumed by turning the power back ‘on, unless itis left turnad off for a long time, 4.12 Tool Setting Precautions ‘When the tool must be shifted in axis directions (shilted away for the next cutting step) such as in back boring or fine boring methods, be careful for the directions in which the tool is shifted. This machine applied for the plus Y direction in which the magazine, be sure that the toot tip can be directed as showin in the following figure, except that the tools which do, ot require shifting in cutting cycle operations. “Too! atachidetach position Tip dirsetion ms 90° Magazirie key ‘Set the too! tip so 2s to form an angle of 90 degrees with the magazine key. Direction of shilting of bocing bat 4-13 ATC Operation (1) Emergency stop 4) In case of emergency stop When the machine is in operation, it must stop instantaneously. 2)When the emergency stop is released. The machine should not continue operation. ‘of the machine after the emergency stop is 'e magazine is turning (when the too! shitter i the original position) + Command magazine turning by the manual mode. + Repeat the operation of returning to the zero point ‘Command magazine turning by the MOI mode.(This is net tool change) = 20-@While loading or unioading a tool ‘= Press the TOOL LOAD or TOOL UNLOAD menu key by tne manual mode to have the operation continued. + For restoration by the manual changer mode, see lem ©. ‘@Wwhile in arm change operation For restoration by tho manual charger mode, see instructions for manual changer mode given in iter (6). ‘Aller the completion of restoration, check that the pocket ‘number of the tool mounted on the spindle, the pocket ‘number of the standby tool mounted on the arm, and the pocket number being displayed on the CRT sereen are the same. See precautions given in Item (8). (2) Reset stop 1) In case of reset stop When the machine is in operation, it must. stop instantaneously. 2) Restoration of the machine after the reset stop is released. @While the magazin is turning (when the ATC arm is in the original position) ‘= Command magazine turning by the manual mode. Command magazine turning by the MOI mod @White loading or unloading a tol structions for operation by the manual changer mode given in Item (6). ‘@White in arm change operation ‘= The arm can be returned to the original position by the ‘esioration operation by the manual changer mode. See instructions for operation by the manual changer mode sven in iter (6). Ater the completion of restoration, be sure to check that the packet number of the tool actually mounted on the spindle and that displayed on the CAT are the same. Sea pracautions given in Item (8). (3) Feedhold ‘1) When on the way back to the ATC zero point MW FEEDHOLD is commanded while an axis is on the way bback fo the ATC zero point, the FEEDHOLD lamp will light ‘and the axis will stop travelling instantaneously. ‘Accordingly, the ATC operation will not be performed since the Y- and Z-axis has not been back to the second zero point. However, spindle orientation also continues when the sifler grasps a too! and loads it onto the spindle. At this time the cycle start lamp changes from its It state 10 the blinking state, and goes out when the successive Operations are completed. To restart, press the CYCLE START button. 2) White in arm change operation Mt FEEDHOLD is commandad while in arm change ‘operation, the FEEDHOLD lamp will ight instantly, but a serles of ATC operation will continue until the last step Is finished. In other words, the TOOL, UNLOAD operation will continue, and the magazine turning and tool load ‘operations according to the next tool number willbe carried out. ‘At this time the eyclo start lamp changes from it lit stata to the blinking state, and goes out when the successive ‘operations are completed. ‘To restart, press the CYCLE STAAT button, (4) Manual interruption . When a series of ATC operation is underway, changeover 10 the manuel mode cannot be done. To change over to the Mazak ‘manual mode, suspend the successive operations by single- block stop, wait for ihe cycle start lamp 10 siop blinking and then to go out at completion of the successive operations, and make the mode changeover. (8) MOI Interruption It the MDI button is pressed while the CYCLE START lamp Is it during the automatic operation, the mode willbe switched fo the MDI mode as soon as the block in execution is completa. Also, pross the SINGLE BLOCK menu key to change to SINGLE BLOCK and after both the CYCLE START and FEEDHOLD lamps cut off, change to the MDI mode. To restart, switch to the automatic operation and push the CYCLE START button, {6) Manual changer operation The manual changer relurns the ATC arm or the tool shifter arin to the station manually. If the ATC arm stops at a position other than the station because of emergency siop or resetting during the ATC operation, or due to abnormal operation such as machine fault, trouble, etc., use this manual changer to feturn the ATC arm to the station. Since the manual changer is provided to return the ATC arm in an emergency, do not use it unnecessarily during the dally operation. ‘Aigo, use the manual changer with utmost care so that no accident, etc., may occur 1) How to set the manual changer mode @Change to the manual mode. @Fress the FO and F1 keys simultaneously. (The Ft key lamp will then light up.) @Make sure that the following menu display appears at the ‘bottom of the screen: First display Second display TT ‘To change over beiween the first display and the second display, press the green key located to the right of the menu keys. a) Display detail 1 ATC ARM RETRACT: The ATC arms move backward. ATC ARM EXTEND: The ATC arms move forward, ATC ARM 70°CW: The ATC arms rotate 70 degrees in a clockwise direction as seen from the front of the arms. ‘The ATC arms rotate 70 degrees in a counterclockwise direction as seen. from the tront of the arms. The ATC arms rotate 180 degrees in a clockwise direction as seen from the front of the arms. The ATC arms rotate 180 dagress in a counterclockwise direction as seen from the front of the arms. ‘This menu is used to unclamp the spincle when spindle orient cannot take place for some reason. ATC ARM 70°COW: ATC ARM 180°CW: ‘ATC ARM 180°CCW: PUNCLAMP OK I: ate(Procedure) @ Press FUNCLAMP OK ! menu key. © Next, sot the TOOL UNCLAMP key switch to the ON position. (At this time, ia tool is mounted on the spinal, hold the tool by hand to prevent its possible fall during tunetarmping.) © The TUNCLAMP LED lights when toot unclamping begins. © Aller dismounting the tool from the spindle, reset the TOOL UNCLAMP key switch to the OFF position and make sure that the TUNCLAMP LED goes out. @® Release of the manual changer mode is performed even when the TUNCLAMP OKlis lit on the display. (b) Display detail 2 SHIFTER RETRACT: The shifter arm moves backward, SHIFTER EXTEND: The shifter arm moves forward. SHIFTER MG. SIDE: The shifter arm moves toward the magazine. SHIFTER SP. SIDE: The shifter arm moves toward the . spindle. SHIFTER PARKED A: The shifter arm moves to standby position A. SHIFTER PARKED B: The shifter arm moves to standby position B. (6) Releasing the manual changer mode To release the manual changer mode and reset the display to anormal modo, pross the FO key once again. (The FO key amp will then go out) 2) If the tool shifier arm is out of position, the manual changer mode will apply to the tool shitter 3) ATC arm return procedure ‘Toreturn an ATC arm in the manuel! mode, obey the operation Inthe folowing procedure. ‘The way to change mode to manual too! change. Push the Mazak Concitions Go AIC cover s open. ATC arm's at ATG arm fetraciad end, al extended end ‘Tool is unclamped. —° Tools #1 arm is clamped. athe postion fnere too! is clamped. “#50 sm is atthe ATC cover + Ren oe postion where tool is _ open. famped «Wet the arm * ATC cover Ieoperated "is open. senoue) wing & forward, the Pay): | spindle ‘ortent rroure 4] OQ) a condition. “Too! ster is ta Note waiting positon, When the arm is “When the arm i norated ath retracting, the spindle 7° forwarding, oriont i in stop Ac cover condition. a Remarks * To unolamp a spindle, push “on” key, and’turn the TOOL key of pulse generator box to unclamp side. © Operate the machine in the above procedure fo return the ATC in the condition you can push the emergency button” whenever it is needed. * To release a tool change by manual, push FO or RESET key : 4) Tool shitter return procedure ‘Torelurn a too! shifter in the manual mode, obey the operation in the following procedure. The way to change mode to manual tool change. op] Push tne RESET RESET key = key. @Push the A Push the RESET key. eps oe RESeTiey Ss made to [rd fal [Pi Push one to change iyi Push one man, ey Gheet meas Te orihe tat fiw) 9 eye manual. ot} [5] [5] Keys © Fa Peer O Troi — @ FS] Pumoan @ Ae] The Foy fe] tne Fond [eo] temp wit, fe] the Fo and FI famp wil ight ma] Fors tg on a] keye tgether a Sj together ATC Shifter eperation operation cee becomes possible by posable by franval an Ase sea Sor Scena “come Ou PARKED A. mt ca | Baane i A 7 ; ee “ems 7 Sy -S pane 8 22+ SPINDLE SIDE