Mazatrol Fusion 640MT-Pro - Integrex-100 400MkIII Series

Applications Training
for
Integrex-100~400MkIII Series
Mazatrol Fusion 640MT-Pro
Publication # C373AT1000E
3/2005
CAUTION
This Manual is published to assist experienced personnel on the operation, maintenance

and/or programming of Mazak machine tools.
All Mazak machine tools are engineered with a number of safety devices to protect
personnel and equipment from injury or damage. Operators should not, however, rely
solely upon these safety devices, but should operate the machine only after fully
understanding what special precautions to take by reading the following documentation
thoroughly.
Do not attempt to operate or perform maintenance / repair on the machine without a
thorough understanding of the actions about to be taken. If any question exists, contact
the nearest Mazak service center for assistance.
Certain covers, doors or safety guards may be open or removed to more clearly show
machine components. These items must be in place before operating the machine.
Failure to comply with this instruction may result in serious personal injury or damage to
the machine tool.
This manual was considered complete and accurate at the time of publication, however,
due to our desire to constantly improve the quality and specification of all Mazak
products, it is subject to change or modification.
Notes:
INTEGREX-100~400MkIII APPLICATIONS TRAINING

CONTENTS
SAFETY PRECAUTIONS .................................................................................................................. S1
LOCKOUT PROCEDURE .................................................................................................................. S1
INSTALLATION PRECAUTIONS.......................................................................................................S4
WARNINGS........................................................................................................................................ S5
DOOR INTERLOCK SAFETY SPECIFICATION ............................................................................... S11
SWITCH PANEL DIAGRAM............................................................................................................... S12
1 INTEGREX-100~400MkIII MANUAL ATC OPERATION .............................................................. 1-1
Updating the Current Tool in the Turret Pocket........................................................... 1-8
2 UPPER TURRET ALIGNMENT..................................................................................................... 2-1
3 LOWER TURRET ALIGNMENT.................................................................................................... 3-1
4 FIRST & SECOND SPINDLE ALIGNMENT.................................................................................. 4-1
4-1 Outline of the 1st Spindle & 2nd Spindle.......................................................................... 4-1
4-2 Alignment of the First Spindle........................................................................................ 4-1
4-3 Concentricity Adjustment Between the First and Second Spindle ................................ 4-5
5 RENISHAW TOUCH PROBE ADJUSTMENT PROCEDURE ...................................................... 5-1
5-1 Touch Probe Adjustment Procedure............................................................................... 5-1
6 TURRET CENTER OF ROTATION ADJUSTMENT PROCEDURE (Parameter B234) .............. 6-1
7 TOOL EYE CALIBRATION PROCEDURE ................................................................................... 7-1
7-1 Integrex-100~400ST Tool Eye Parallelism Adjustment................................................. 7-1
7-2 Tool Eye Parameters ..................................................................................................... 7-3
7-3 Parameter Screen Selection .......................................................................................... 7-4
7-4 Tool Eye Calibration Procedure.....................................................................................7-5
8 TURRET SIDE ATC POSITION ADJUSTMENT ........................................................................... 8-1
9 TOOL FUNCTIONS ....................................................................................................................... 9-1
9-1 Tool Function (4 Digit T-Code) ......................................................................................9-1
9-2 Tool Function (6 Digit T-Code_......................................................................................9-2
9-3 Next Tool Automatic Selection....................................................................................... 9-2
10 EIA/ISO PROGRAMMING EXAMPLE ........................................................................................ 10-1
11 COORDINATE SYSTEM SETTING.............................................................................................11-1
11-1 G125 Coordinate System Setting Macro .....................................................................11-1
11-2 G128.8 Coordinate System Setting Macro ..................................................................11-4
APPENDIX
PLC ALARMS .............................................................................................................. APP-1
ADDITIONAL PLC ALARMS........................................................................................ APP-1
M CODE TABLE ..........................................................................................................APP-15
LOWER TURRET M-CODES .................................................................................. APP-26
INTEGREX-MkIII STROKE DIAGRAMS ..................................................................... APP-29
INTEGREX-100MkIII............................................................................................... APP-29
INTEGREX-200MkIII............................................................................................... APP-35
INTEGREX-300/400MkIII........................................................................................ APP-43
Notes:
SAFETY PRECAUTIONS
6) Do not deface, scratch or remove any caution
plate. Should it become illegible or missing,
order another caution plate from the supplier,
specifying the part number shown at the lower
right corner of the plate.
BEFORE POWERING UP
DANGER:
Cables, cords or electric wires whose insulation
is damaged can produce current leaks and
electric shocks.
Before using, check their
condition.
WARNING:
1) Be sure the instruction manual and the
programming manual are fully understood
before operating the machine. Every function
and operating procedure should be completely
clear.
2) Use approved oil resistant safety shoes, safety
goggles with side covers, safe clothes, and
other safety protection required.
3) Close all NC unit, operating panel, electric
control panel doors and covers.
CAUTION:
1) The power cable from the factory feeder switch
to the machine main circuit breaker should
have a sufficient sectional area to handle the
electric power used.
2) Cables which must be laid on the floor must be
protected from hot chips, by using rigid or
other approved conduit, so that short-circuits
will not occur.
3) Before first time operation of the machine after
unpacking it or from being idle for a long period
of time (several days or more), each sliding
part must be sufficiently lubricated. To do so,
push and release the pump button several
times until the oil seeps out on the sliding
parts. The pump button has a return spring, so
do not force it to return.
4) Oil reservoirs should be filled to indicated
levels. Check and add oil, if needed.
5) For lubrication points, oil specification and
appropriate levels, see the various instruction
plates.
6) Switches and levers should operate smoothly.
Check that they do.
7) When powering the machine on, turn on the
switches in the following order: first the factory
feeder switch, then the machine main circuit
breaker, and then the control power on switch
located on the operating panel.
8) Check the coolant level, and add coolant, if
needed.
The machine is provided with a number of safety

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

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

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

2) Check motors, gear boxes and other parts for
abnormal noises.
3) Check the motor lubrication, and sliding parts
for evidence of proper lubrication.
4) Check safety covers and safety devices for
proper operation.
5) Check belt tensions. Replace any set of belts
that have become stretched with a fresh
matching set.
OPERATION
WARNING:
1) Do not work with long hair that can be caught
by the machine. Tie it back, out of the way.
2) Do not operate switches with gloves on. This
could cause mis-operation.
3) Whenever a heavy workpiece must be moved,
if there is any risk involved, two or more people
should work together.
4) Only trained, qualified workers should operate
forklift trucks, cranes or similar equipment and
apply slings.
5) Whenever operating a forklift truck, crane or
similar equipment, special care should be taken
to prevent collisions and damage to the
surroundings.
6) Wire ropes or slings should be strong enough
to handle the loads to be lifted and should
conform to the mandatory provisions.
7) Grip workpieces securely.
8) Stop the machine before adjusting the coolant
nozzle at the tip.
9) Never touch a turning workpiece in the spindle
with bare hands, or in any other way.
10) To remove a workpiece from the machine other
than by a pallet changer, stop the tool and
provide plenty of distance between the
workpiece and the tool (for M/C).
11) While a workpiece or tool is turning, do not
wipe it off or remove chips with a cloth or by
hand. Always stop the machine first and then
use a brush and a sweeper.
12) Do not operate the machine with the chuck and
front safety covers removed (For T/M).
13) Use a brush to remove chips from the tool tip,
do not use bare hands .
14) Stop the machine whenever installing or
removing a tool.
15) Whenever machining magnesium alloy parts,
wear a protective mask.
WARM UP
CAUTION:
1) Warm up the machine, especially the spindle
and feed shaft, by running the machine for 10
to 20 minutes at about one-half or one-third the
maximum speed in the automatic operation
mode.
2) The automatic operation program should cause
each machine component to operate. At the
same time, check their operations.
3) Be particularly careful to warm up the spindle
which can turn above 4000 rpm.
If the machine is used for actual machining
immediately after being started up following a
long idle period, the sliding parts may be worn
due to the lack of oil. Also, thermal expansion
of the machine components can jeopardize
machining accuracy. To prevent this condition,
always make sure that the machine is warmed
up.
PREPARATIONS
WARNING:
1) Tooling should conform to the machine
specifications, dimensions and types.
2) Replace all seriously worn tools with new ones
to prevent injuries.
3) The work area should be adequately lighted to
facilitate safety checks.
S-2
CAUTION:
1) Thoroughly read and understand the safety
precautions in the instruction manual.
2) Thoroughly read the whole maintenance
manual and fully understand the principles,
construction and precautions involved.
MAINTENANCE OPERATION
DANGER:
1) Those not engaged in the maintenance work
should not operate the main circuit breaker or
the control power "ON" switch on the
operating panel. For this purpose, "Do not
Touch the Switch, Maintenance Operation in
Progress!" or similar warning should be
indicated on such switches and at any other
appropriate locations. Such indication should
be secured by a semi-permanent means in the
reading direction.
2) With the machine turned on, any maintenance
operation can be dangerous. In principle, the
main circuit breaker should be turned off
throughout the maintenance operation.
WARNING:
1) The electrical maintenance should be done by
a qualified person or by others competent to do
the job.
Keep close contact with the
responsible person. Do not proceed alone.
2) Overtravel limit and proximity switches and
interlock mechanisms including functional parts
should not be removed or modified.
3) When working at a height, use steps or ladders
which are maintained and controlled daily for
safety.
4) Fuses, cables, etc. made by qualified
manufacturers should be employed.
BEFORE OPERATION & MAINTENANCE BEGINS
WARNING:
1) Arrange things in order around the section to
receive the maintenance, including working
environments. Wipe water and oil off parts and
provide safe working environments.
2) All parts and waste oils should be removed by
the operator and placed far enough away from
the machine to be safe.
CAUTION:
1) The maintenance person should check that the
machine operates safely.
2) Maintenance and inspection data should be
recorded and kept for reference.
CAUTION:
1) During automatic operation, never open the
machine door. Machines equipped with the
door interlock will set the program to single
step.
2) When performing heavy-duty machining,
carefully prevent chips from being accumulated
since hot chips from certain materials can
cause a fire.
TO INTERRUPT MACHINING
WARNING:
When leaving the machine temporarily after
completing a job, turn off the power switch on
the operation panel, and also the main circuit
breaker.
COMPLETING A JOB
CAUTION:
1) Always clean the machine or equipment.
Remove and dispose of chips and clean cover
windows, etc.
2) Make sure the machine has stopped running,
before cleaning.
3) Return each machine component to its initial
condition.
4) Check the wipers for breakage.
Replace
broken wipers.
5) Check the coolant, hydraulic oils and lubricants
for contamination. Change them if they are
seriously contaminated.
6) Check the coolant, hydraulic oil and lubricant
levels. Add if necessary.
7) Clean the oil pan filter.
8) Before leaving the machine at the end of the
shift, turn off the power switch on the operating
panel, machine main circuit breaker and factory
feeder switch in that order.
SAFETY DEVICES
1) Front cover, rear cover and coolant cover.
2) Chuck barrier, tail barrier and tool barrier (NC
software).
3) Stored stroke limit (NC software).
4) Emergency stop pushbutton switch.
MAINTENANCE OPERATION PREPARATIONS
1) Do not proceed to do any maintenance
operation unless instructed to do so by the
foreman.
2) Replacement parts, consumables (packing, oil
seals, O rings, bearing, oil and grease, etc.)
Should be arranged in advance.
3) Prepare preventive maintenance and record
maintenance programs.
000X717-KY 11/98
S-3
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WARNING
ALWAYS TURN THE MAIN CIRCUIT BREAKER TO THE OFF POSITION & USE AN APPROVED
LOCKOUT DEVICE WHEN COMPLETING MAINTENANCE OR REPAIRS.
THE LOCKOUT PROCEDURE THAT FOLLOWS IS INTENDED TO SAFEGUARD PERSONNEL &
EQUIPMENT DURING MAINTENANCE OPERATIONS, AND, REPRESENTS THE MINIMUM
REQUIREMENTS. ANY ACTION SHOULD BE PRECEDED BY A HAZARD ANALYSIS TO DETERMINE
ANY ADDITIONAL SAFETY PRECAUTIONS THAT MAY BE NECESSARY TO ENSURE THE SAFETY OF
PERSONNEL AND EQUIPMENT.
NOTE: USE OF THE FOLLOWING LOCKOUT PROCEDURE IS MANDATORY WHEN COMPLETING

MAINTENANCE OR REPAIRS.
LOCKOUT PROCEDURE
1)
THE LOCKOUT PROCESS MUST BE PERFORMED BY AUTHORIZED PERSONNEL ONLY.
2)
INFORM ALL EFFECTED PERSONNEL OF YOUR INTENT TO LOCKOUT AND SERVICE THE
SPECIFIED MACHINE.
3)
SHUT OFF MACHINE POWER USING NORMAL SHUT DOWN PROCEDURES.
4)
TURN OFF THE MACHINE AND INDIVIDUAL BUILDING CIRCUIT BREAKERS. MAKE SURE ALL
STORED ELECTRICAL ENERGY IS RELIEVED. (EG: SPINDLE & AXIS SERVO CONTROLLERS)
5)
CONNECT THE LOCKOUT DEVICE AS SHOWN IN FIGURE 1, AND ATTACH THE APPROPRIATE
TAG AT THE MACHINE CIRCUIT BREAKER. THE TAG MUST IDENTIFY THE PERSON
RESPONSIBLE FOR THE LOCKOUT. THIS WILL ENSURE THAT POWER CANNOT BE
RESTORED BY ANYONE ELSE.
6)
TEST THE MACHINE TO VERIFY THAT MACHINE SYSTEMS DO NOT OPERATE IN ANY WAY.
ONCE TESTING IS COMPLETE, MAKE SURE ALL SWITCHES ARE IN THE OFF POSITION.
CONFIRM THAT THE LOCKOUT DEVICES REMAIN PROPERLY INSTALLED.
7)
COMPLETE THE REQUIRED MAINTENANCE OPERATIONS.
8)
MAKE SURE ALL PERSONNEL ARE CLEAR OF THE MACHINE.
9)
REMOVE THE LOCKOUT DEVICE. MAKE SURE ALL PERSONNEL ARE AT A SAFE LOCATION
BEFORE RESTORING MACHINE POWER.
PADLOCK
FIGURE
S-4
INSTALLATION PRECAUTIONS
The following subjects outline the items that
directly affect the machine installation and startup. To ensure an efficient and timely installation,
please follow these recommendations before
calling to schedule a service engineer.
6)
ENVIRONMENTAL REQUIREMENTS
Avoid the following places for installing the
machine:
1) Avoid exposure to direct sunlight and/or near a
heat source, etc. Ambient temperature during
operation: 0 thru 45C (32F to 113F).
2) Avoid areas where the humidity fluctuates
greatly and/or if high humidity is present;
normally 75% and below in relative humidity. A
higher humidity deteriorates insulation and
might accelerate the deterioration of parts.
3) Avoid areas that are especially dusty and/or
where acid fumes, corrosive gases and salt are
present.
4) Avoid areas of high vibration.
5) Avoid soft or weak ground (minimum load
bearing capacity of 1025 lbs./ft2)
In pouring grout, fasten the leveling block

base plates with the collar retaining screws
to prevent the base plates from dropping.
When the grout has completely hardened,
level the machine properly, and tighten M24
nuts to secure the machine to the
foundation.
Note:
The machine must be anchored to the
foundation with J-bolts, expansion bolts or
other suitable method.
The machine accuracy and alignment
specifications quoted by Mazak can usually
be obtained when the minimum foundation
requirements are met. However, production
of close tolerance parts requires the use of an
appropriate certified foundation. Foundations
that do not meet certified specifications may
require more frequent machine re-leveling and
re-alignment, which can not be provided
under terms of warranty.
If any of these conditions cannot be met,
contact the nearest Mazak service office
immediately.
FOUNDATION REQUIREMENTS
For high machining accuracy, the foundation
must be firm and rigid.
This is typically
accomplished by securely fastening the
machine to the foundation with anchor bolts. In
addition, the depth of concrete should be as
deep as possible (minimum 6 - 8 inches). Note
the following:
1) There can be no cracks in the foundation
concrete or surrounding area.
2) Vibration proofing material (such as asphalt)
should be put all around the concrete pad.
3) Form a cone in the foundation for J-bolt
anchors, or use expansion anchors.
4) With the foundation anchor bolt holes open
pour the primary concrete at a minimum
thickness of 6 - 8 inches. Typically, the
concrete must have a minimum compression
rating of 2500 lbs. @ 250 lbs. compression
and strengthened with reinforcing rods. When
the concrete has cured, rough level the
machine, and install the J-bolts, leveling blocks,
etc., and pour grout into foundation bolt holes.
5) Mix an anti-shrinkage agent such as Denka
CSA with concrete, or use Embeco grout to fill
the foundation bolt holes.
S-5
WIRING
1) Use
only
electrical
conductors
with
performance ratings equivalent or superior.
2) Do not connect any power cables for devices
which can cause line noise to the power
distribution panel, such as arc welders and high
frequency machinery.
3) Arrange for a qualified electrician to connect
the power lines.
4) Incoming supply voltage should not deviate
more than 10% of specified supply voltage.
5) Source frequency should be2 Hz of nominal
frequency.
Desirable Independent Grounding:
NC
Machine
Earth resistance:
Less than 100 ohms
Common Grounds:
Resistance to ground
= 100 the number of
devices connected to
the grounding (ohms)
[ CAUTION ]
VERIFY THE ACTUAL MACHINE ELECTRICAL

Note: Never ground equipment as shown below:
POWER REQUIREMENT AND THE MAIN

TRANSFORMER RATING (IF APPLICABLE), AS
WELL AS THE LOCAL ELECTRICAL CODE
BEFORE SIZING AND INSTALLING THE
INCOMING POWER WIRING.
PLEASE SEE THE ADDITIONAL CAUTIONS ON
THE FOLLOWING PAGE.
GROUNDING
1) An isolated earth ground with a resistance to
ground of less than 100 ohms is required.
Typically, a 5/8 copper rod, 8 feet long, and
no more than 5 feet from the machine, is
sufficient.
Building grounds or multiple
machines grounded to the same ground rod,
are not acceptable.
2) The wire size should be greater than AWG
(American Wire Gauge) No. 5 and SWG
(British Legal Standard Wire Gauge) No. 6.
000X713-KY 11/98
S-6
CAUTION
A step-down transformer is optional on some machine models. Be certain to

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

MACHINE. IF ANY QUESTION EXISTS, CONTACT THE NEAREST MAZAK SERVICE
CENTER FOR ASSISTANCE.
S-7
WARNING
MAZATROL CNC CONTROLLERS PROVIDE PARAMETER SETTINGS TO LIMIT SPINDLE

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

PROTECT PERSONNEL AND EQUIPMENT FROM INJURY AND DAMAGE.
DO NOT REMOVE, DISCONNECT, BYPASS OR MODIFY ANY LIMIT SWITCH, INTERLOCK,
COVER, OR OTHER SAFETY FEATURE IN ANY WAY, EITHER MECHANICALLY OR
ELECTRICALLY.
ASSISTANCE.
S-8
WARNING
MAZAK MACHINES ARE ENGINEERED WITH A NUMBER OF SAFETY DEVICES TO

PROTECT PERSONNEL AND EQUIPMENT FROM INJURY AND DAMAGE.
MACHINE OPERATOR DOORS AND COVERS ARE DESIGNED TO WITHSTAND
ACCIDENTAL IMPACT OF A BROKEN INSERT WHERE A MAXIMUM WEIGHT INSERT AT
MAXIMUM TOOL DIAMETER IS RUNNING AT MAXIMUM SPINDLE RPM
NEVER USE A CUTTING TOOL OR TOOL INSERT THAT EXCEEDS MACHINE
SPECIFICATIONS OR THAT OF A SPECIFIC TOOL HOLDER ITSELF, WHICHEVER IS LESS.
THIS RESTRICTION APPLIES TO DIAMETER, WEIGHT, MAXIMUM SPINDLE RPM,
MAXIMUM CUTTING TOOL ROTATION SPEED, ETC.
FOR COMPLETE SPECIFICATIONS, MAKE SURE TO REFERENCE OPERATION,
MAINTENANCE AND DETAIL SPECIFICATION DOCUMENTATION SUPPLIED WITH THE
MACHINE AND BY THE TOOLING MANUFACTURER.
NOTE: THE MAXIMUM INSERT WEIGHT FOR MAZAK MACHINES IS 20 gf. (0.04 lbs.).
ASSISTANCE.
S-9
WARNING
BEFORE STARTING OPERATION, CHECK THAT THE WORKPIECE IS SECURELY MOUNTED

IN A VISE OR A SUITABLE FIXTURE. BE CERTAIN THAT THE MOUNTING IS SUFFICIENT
TO WITHSTAND CUTTING FORCES DURING WORKPIECE MACHINING.
ASSISTANCE.
WARNING
CONFIRM PROPER WORKPIECE FIXTURING/CLAMPING, TOOL SETUP AND THAT THE

MACHINE DOOR IS SECURELY CLOSED BEFORE THE START OF MACHINING.
VERIFY ALL SAFETY PRECAUTIONS OUTLINED IN THIS MANUAL BEFORE USING THE
FOLLOWING CUTTING CONDITIONS:
-
CUTTING CONDITIONS THAT ARE THE RESULT OF THE MAZATROL FUSION 640
AUTOMATIC CUTTING DETERMINATION FUNCTION
CUTTING CONDITIONS SUGGESTED BY THE MACHINING NAVAGATION FUNCTION
CUTTING CONDITIONS FOR TOOLS THAT ARE SUGGESTED TO BE USED BY THE

MACHINING NAVAGATION FUNCTION

ASSISTANCE.
S-10
CENGDB0551E
DOOR INTERLOCK SAFTY SPEC.
Determined by YMW Eng. H.Q. 99/9/1

Revised by YMC Prod. Eng. 99.10.28
MACHINING CENTER
DOOR
MODE
OPEN
MANUAL
AUTO
CLOSE
I
V
OPEN
MANUAL
Prohibit
Prohibit
Prohibit
Prohibit
Prohibit
I (ON)
Limit the rapid override. Max is 12%.
Prohibit to run chip spiral conveyor.
Can run spindle JOG.
Can run spindle Orient.
Can operate manual ATC.
to move axis.
to start spindle running.
to operate manual ATC.
to operate manual Pallet Changer.
to run chip spiral conveyor.
Prohibit cycle start.


Door is always locked. Door lock can be released by pushing DOOR UNLOCK SW on operator panel.
But, it can not release in operating ATC/Pallet changer/Axis/Spindle.
Prohibit
Prohibit
Prohibit
Prohibit
Prohibit
AUTO
CLOSE
SET UP SWITCH
O (OFF)
Limit the rapid override. Max is 12%.

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

MANUAL
No Limitation.
No Limitation.
AUTO
No Limitation.
Can not run auto operation.
TURNING CENTER
SET UP SWITCH
DOOR
MODE
O (OFF)
I (ON)
Can operate CHUCK, TAILSLEEVE ,

STEADY REST for Loading workpiece.

Can NOT operate Spindle, Axis, Turret,

MANUAL Coolant, ToolEye, Partscatcher,
Chip Conveyor.
Can not operate Spindle running, but

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

Can not run Auto-operation.

MANUAL Can not open the front door in Spindle running, Axis moving, Auto-running( Cycle start, Feed hold ) due to
&
Mechanical locking system. (Except Single Block Stop or M00 program stop or M01 optional stop)
AUTO
But, if release the lock by note(*1), Alarm will occur then stop the all motion.
MANUAL No Limitation.
CLOSE
AUTO
No Limitation.
No Limitation.
*1 : Door lock mechanism can not be released in machine stop by NC power OFF.
If it is necessary to release the lock such as emergencies, the lock can be released by operating the
supplementary lock release mechanism of the main body of the safety door lock switch.
*2 : Override Limitation of Rapid speed of AXIS
Machining Center : 12%. Turning Center : 10%.
*3 : Chip Conveyor and Coolant should stop in the door open.
PED-EDS-001
S-11
CENGDB0551E
APPENDIX
SWITCH PANEL for M640M (Machining Center)
MACHINE SET UP
SWITCH
SWITCH PANEL for M640MT/T (Turning Center)
PED-EDS-001
S-12
DOOR UNLOCK
SWITCH
1 INTEGREX-100~400MkIII MANUAL ATC OPERATION
Set the B-axis at zero degrees.

Press the POSITION menu key.
Press the C-AX Connect menu key with the MFI auxiliary key.
Place the TOOL SELECT switch to F/H/0 and press.
Note: If a 256 TOOL ROTATION INHIBIT alarm occurs, place the TOOL SELECT switch to
R/V/2 and press.
Press the HOME key and move the axes to home position as shown below:
Move X-axis to home position.
Move Y-axis to home position.
Move Z-axis to home position.
1-1
Press the MDI key.

The MDI window will open:
Key in: M601S__ (where S__ is the desired tool number) to index the tool magazine to the
desired tool number.

Press the MACHINE key to display the ATC menu screen.
Turn MDI off by pressing any manual operation key.

Press the ATC MAINTE. menu key.
Press the TOOL LOAD menu key.
1-2
Verify that that the MILL 0 ORIENT key is highlighted.
If it is not, press the MILLAXIS UNCLAMP key, then the MILL 0 ORIENT key to orient the mill
spindle. Next press the MILLAXIS CLAMP key to re-clamp the mill spindle.
Press the AXIS ATC POS key to position the Y axis to the ATC position.
Press the Display Select Menu soft key (Left end of menu keys).
Press the ATC MENU key.
1-3
Verify that the shifter is at the ATC side. Move to the ATC side if currently at the Magazine side.
Press the Menu Select soft key (Right end of menu keys.)
Press the ATC ARM SWING menu key.
Turn the TOOL CLAMP/UNCLAMP key switch to the UNCLAMP position
1-4
Press the ATC ARM CHG POS key.
Turn the TOOL CLAMP/UNCLAMP key switch to CLAMP.
Press the ATC ARM HOME POS key.
1-5
Press the HOME key.
Move the Y-axis to the home position.
Press MDI menu key.
The MDI window will open:
Key in M602 S___ (Where S___ is the proper next tool number.)
Key in M601 S___ (Where S___ is the proper magazine position.)
1-6
Press the Menu Select menu soft key (Left end of menu keys).
Press the ATC MAINTE menu key.
Press the TOOL UNLOAD menu key.
1-7
Updating The Current Tool In the Turret Pocket

When the tool has been replaced by the ATC unit manually, set the number of the tool being mounted
on the turret on the TURRET TOOL window of the DIAGNOSTIC display.
When TNo 5 is mounted as shown above, perform operation following the procedure described below:
(1) Open the TURRET TOOL window and move the cursor to the first line of Tno. using the cursor keys
1-8
Press the MDI key.
-The MDI window will open on the monitor.
Input MDI data: M65 (ATC TOOL No. MEMORY CLEAR)

Do a tool change. (Eg: T01000.0001)
If you get an alarm, Tool Number Mismatch you forgot the M65.
NOTE: If you get a Not in ATC Position alarm, make sure the shifter is at the magazine side and
issue a M602S0, this will set the Next Tool display to zero.
1-9
Notes:
1-10
2 UPPER TURRET ALIGNMENT
1.Turret adjustment
Mount a test bar to the mill spindle.
2. Measure parallelism between X-axis and the turret.

Tolerance: 0.01mm (0.0004 in.) or less per L=100mm (4 in.)
3. If the turret is off center, mount a test bar as shown in the photo
and loosen all six turret mounting bolts.
(The photo shows the turret in H direction, but it will be easier to
do this with the turret in V direction.)
2-1
4. Place the turret in V direction, loosen all six mounting bolts,

and fit an indicator to a side face of a test bar. While tapping a
turret box (arrow) with a soft hammer, adjust parallelism between
the X-axis and the turret so that it will be within tolerance. Some
old machines used a taper pin, but current machines do not (as of
November 2000).
5. Tolerance: 0.01mm (0.0004 in.) or less per L=100mm (4 in.)

After the turret mounting bolts are tightened, measure parallelism
between X-axis and the turret again.
2-2
Note:
The INTEGREX-100MKIII series only uses a set
screw for adjustment.
It will not move even if it is tapped with a soft
hammer.
Adjust by pushing or pulling a set screw (2 places,

arrow) in the two photos.
2-3
Notes:
2-4
3 LOWER TURRET ALIGNMENT

Note:
The concentric adjustment between the main & 2nd spindles must be completed before starting this adjustment.
1. Rotational Alignment
Select the turret No. 2 and place it toward the secondary
spindle. Then mount a magnet stand to the upper turret.
Mount a dial indicator as shown to measure parallelism
of the grooves for installing a boring bar holder.
Loosen the eight bolts for mounting a turret coupling.
Using a plastic hammer, tap the turret in a

rotational direction for parallel adjustment of the grooves
for a boring bar holder.
<Tolerance>
L = 5/1000 mm or less per 40 mm
(L = 0.0002 inch or less per 1.575 inch)
When the adjustment is completed, tighten the eight
turret coupling mounting bolts that have been loosened
before, and check the parallelism again.
3-1
2. Lower Turret Alignment
Mount a boring bar holder to the turret No. 2

and measure the center of the main spindle
and that of the lower turret.
Align the centers so that a runout (up/down)
becomes "0" in the X direction.
Also, find a place where a runout (right/left)
is the minimum in the Y direction.
Measure a difference between the center of the main

spindle and that of the secondary spindle.
With the X2-axis stationary, move the boring bar holder
toward the secondary spindle side and measure a
difference between the center of the secondary spindle
and that of the lower turret.
Take out a shim (indicated by a red arrow) from the

carriage base of the lower turret. Grind the shim so that the
turrets of the main and secondary spindles will be in a
range of tolerance in the X and Y directions.
<Tolerance>
Measure at the main spindle and at the secondary spindle. Tolerance must be 2/100 mm (0.0008inch) or less.
3-2
3. Parallel adjustment of the lower turret
Mount a millimess indicator to the upper surface of the

turret and measure parallelism by moving the Z2-axis.
Loosen the lower turret & linear guide mounting bolts

(M8 x 30) and check parallelism on the upper surface of
the turret using the adjusting bolts (M6 x 20) indicated by
a red arrow.
Tolerance: 5/1000 mm (0.0002inch) or less

Refer to the illustration below (the right photo is not good
for viewing).
3-3
4. Final alignment & checking

There are four adjusting bolts only at the main spindle side.
3-4
4 FIRST & SECOND SPINDLE ALIGNMENT

4.1
Outline of the 1st Spindle & 2nd Spindle
1st spindle (standard specifications): 22kw/350N.m and dia. 76 bore in 0.0001-deg. C-axis encoder
2nd spindle (standard specifications): 18.5kw/326N.m and dia. 76 bore in 0.001-deg. PLG encoder Secondary
spindle (optional specifications): 18.5kw/326N.m and dia. 76 bore in 0.0001-deg. C-axis encoder.
4.2
Alignment of the First Spindle
1. Check the current vertical alignment (spindle centerline parallelism to Z1 axis movement)
Mount a test bar to the 1st spindle and mount a millimess indicator on the test bar as shown below.
Note: The indicator is mounted on the top of test bar for this measurement.
4-1
2. Center height adjustment of the first spindle.
Lift the 1st. spindle using a crane, and remove the shims
(4 places) to grind.
Note:
Viewed from the chuck cylinder side and at the left side
of the 1st spindle.
The positioning pin (indicated by a red arrow) is located
between the spindle mounting bolts. Remove the pin
using an M6 pin puller and lift the spindle. After the shims
are ground, remember to put the positioning pin back.
Re-install the shims and hand-tighten the 1st spindle

mounting bolts. Re-check the spindle centerline
parallelism to Z axis movement.
<Tolerance>
L = 300 mm (11.811 inch)

A = 1/100 mm (0.0004 inch) or less
B = 5/1000 mm (0.0002 inch) or less.
4-2
3. Check the current horizontal alignment (spindle centerline parallelism to Z1 axis movement)
Mount a test bar in the 1st spindle and a millimess dial indicator to the side of the test bar as shown.
Note: The indicator is on the back of test bar for this measurement.
4-3
4. Center horizontal adjustment of 1st spindle.
Adjust the parallelism in the horizontal direction using

the adjusting bolts on the block indicated by the red
arrow.
The adjusting bolt A is a pull bolt while adjusting bolt B is

a push bolt.
<Tolerance>
L = 300 mm (11.811 inch) A = 1/100 mm (0.0004 inch) or less B = 5/1000 mm (0.0002 inch) or less
Tighten the 1st. spindle mounting bolts firmly and check parallelism both in the height direction and in the
horizontal direction again.
5. Center horizontal adjustment of the 1st spindle
Put a workpiece in the chuck for a test cut. Using a micrometer, measure the outer diameter at each end to check
for taper. Re-adjust as shown above to remove any taper.
<Tolerance>
0.0003 inch or less
Note:
Adjust in the following order:
X & Yt axis home position
X & Yt ATC position
Tool Eye parameter adjustment
Tailstock alignment or concentricity adjustment between the first & second spindle
4-4
4.3
Concentricity Adjustment Between the First and Second Spindle
NOTE: Make this adjustment after the 1st. spindle alignment is completed.
1. Check the current alignments
Mount a jig with reference to the 1st spindle, and

measure the outer diameter of the 2nd spindle to check
whether any variance exists.
Mount a test bar to the 2nd spindle and a millimess dial

indicator to the test bar to check the parallelism in the
height direction.
4-5
2. Center height adjustment of 2nd spindle
Based on the data obtained in step 1, remove the shims

for grinding. Loosen the mounting bolts (6 places) on the
2nd spindle.
Lift the 2nd spindle using a crane, and remove the shims
(4 places) to grind.
Re-install the shims that have been ground and

hand-tighten the mounting bolts on the 2nd spindle.
Re-check the parallelism in the height direction.
<Tolerance>
L = 300 mm (11.811 inch)

A = 1/100 mm (0.0004 inch) or less
B = 5/1000 mm (0.0002 inch) or less concentricity adjustment between the 1st & 2nd spindle
Make this adjustment after the 1st. spindle alignment is completed.
4-6
3. Concentricity adjustment between the 1st & 2nd spindle

Note: Make this adjustment after the1st spindle alignment has been completed.
Touch the dial indicator (A) attached to the 1st spindle to

the side of the test bar mounted to the 2nd spindle.
Touch the millimess dial indicator (B) attached to the
upper turret to the other side of the test bar.
Unlike the 1st spindle, the 2nd spindle does not have a
positioning pin. Therefore, adjust both spindles by using
the two measuring instruments as described above.
To fit the1st spindle, adjust the 2nd spindle in the right/left

direction using the adjusting bolts on the adjusting blocks
(2 places) indicated by a red arrow.
Tolerance = 1/100 mm (0.0004 inch) or less
4-7
3. Concentricity Adjustment Between the 1st. & 2nd. Spindle (Contd)

Note: Make this adjustment after the 1st spindle alignment has been completed.
Touch the dial indicator (A) attached to the 1st spindle to

the upper surface of the test bar mounted to the 2nd
spindle.
Touch the millimess dial indicator (B) attached to the
upper turret to the side face of the test bar, then tighten
the mounting bolts on the 2nd spindle.
Tighten the bolts little by little while checking the dial
indicator (A) and the millimess dial indicator (B).
4. Checking concentricity after adjustment.

Remove the test bar from the 2nd spindle and measure
the outer diameter as shown.
<Tolerance>
Tolerance = 1/100 mm (0.0004 inch) or less
4-8
5 RENISHAW TOUCH PROBE ADJUSTMENT PROCEDURE

Mount a touch probe to the milling spindle and apply a lever type dial indicator to the tool edge.
While turning the tool, adjust runout at the edge of the tool while rotating the spindle manually.
5-1
Descriptions of touch probe
5-2
5.1
Touch Probe Adjustment Procedure
As shown in the illustration below, the tool shank has four adjusting screws. Unscrew all the lock screws
and make an adjustment with the adjusting screws.
As shown in the picture below, set a lever indicator to the edge of the stylus and tighten or loosen the four adjusting
screws while turning the tool. With the four adjusting screws tightened, the runout of the lever indicator must be
within 0.02 mm (0.0008 in.) or less. After the adjustment is completed, tighten all the lock screws firmly.
5-3
Notes:
5-4
Turret Center of Rotation Adjustment Procedure (Parameter B234)

A
W- Axis Stroke
Reference
workpiece
origin
Turret center of rotation
100mm
A8
B234
A = The full W-axis stroke between head 1 & head 2.

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

(See the adjustment procedure on the following page.)
Parameters:
A8 = The distance from the turret face to the reference workpiece origin.
B234 = The distance from the turret center of rotation to the reference workpiece origin.
Reference workpiece origin = 100mm from the chuck face.
6-1
Turret Center of Rotation Adjustment Procedure (Parameter B234)

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

d) Add this value to the gauge block or feeler gauge dimension to determine variable B.
e) Repeat steps a ~ d for head 2 as shown below to determine variable C.
f) Add B to C and subtract from the Z1 axis stroke value A to determine the turret rotation diameter.
g) Divide by 2 for value R.
2) Add value R to the value of parameter A8.
3) Enter this value into parameter B234.
Formula:
B234 = A8 + R
R = [ A - (B +C) ] / 2
6-2
7 TOOL EYE CALIBRATION PROCEDURE

7.1
Integrex-100~400ST MkIII Tool Eye Parallelism Adjustment
Parallelism measurement between the tool eye sensors is taken with respect to points A and B as indicated by the
red arrows in the photo below.
It is unnecessary to check parallelism between the sensors between the upper turret and the lower turret.
7-1
1) Upper turret tool eye parallelism adjustment

Attach a magnetic stand with a millimess dial
indicator to the upper turret as shown.
Set the indicator to the outer point A and take a
reading to the lower point A.
Adjust as described in step (3).
2) Lower turret tool eye parallelism adjustment

Attach a magnetic stand with a millimess dial
indicator to the upper turret as shown.
Set the indicator to the outer point B and take a
reading to the lower point B.
Adjust as described in step (3).
3) Loosen the 4 tool eye mounting bolts and adjust

with a wrench as shown.
<Tolerance>
Parallelism must be 1/100mm (0.0004 inch) or
less.
7-2
7.2
Tool Eye Parameters
The upper turret parameters are shown in blue and the lower turret are in red.
Note:
Tool eye parameters must be adjusted whenever a home position confirmation sensor is replaced or accuracy
needs to be assured after a collision.
The address names and adjusting procedure are the same as for earlier Integrex machines.
For parameters B61 & B62, the measured value is entered. For parameter B63, one half of the measured value is
entered.
The input unit is 0.001mm (metric only). These parameters become valid immediately after the setting change.
7-3
7.3
Parameter screen selection
The parameter drawing on the previous page shows the same parameter address names for the upper and lower
turrets. Use the [TURRET SELECT] switch as shown below to select the parameter page for the desired turret.
7-4
8 TURRET SIDE ATC POSITION ADJUSTMENT

Using the ATC alignment tools shown below, adjust the tool change position at the turret side and the X-axis and
Yt-axis positions.
Note: Make sure no tools are in the turret or ATC arm.

From the ATC menu, select the INTERLOCK NEG. menu key.
CAUTION: Interlocks will be ignored, perform the following operation with extreme care.
Note: Make sure the X-axis and Yt-axis are in a position where no interference occurs before performing
the ATC arm swing-in operation.
Press the ATC ARM SWING menu key to swing in the ATC arm
as shown.
Mount the alignment tool B to the arm No. 1 and the alignment tool
C to the mill spindle respectively.
Move the X-axis and Yt-axis close to the ATC arm with the manual
hand wheel, and find a position where alignment tool A passes
through the alignment tools B and C smoothly.
Make note of the machine position value for input into parameter
data.
Remove the alignment tool A, and press the
ATC ARM HOME POS menu key to return the arm.
Remove the alignment tools B and C.
From the ATC menu, select the INTERLOCK NEG. menu key to
cancel the interlock neglect function.
8-1
Parameter Change
Input the values of the machine position noted above for X-axis and Yt-axis to the following parameters:
RL-16 (tool change position for Yt-axis)
RL-17 (tool change position for X-axis)
Note: Unlike previous M640, the parameter input unit of M640 MT-Pro is changed from 1/1000 to 1/10000.
8-2
9 TOOL FUNCTIONS
9-1 Tool Function (4-Digit T-Code)
Tool function, also referred to as T-code function, is used to designate the tool number and offset
number. Of a four-digit integer at address T, upper and lower two digits are respectively used to
specify the tool number and offset number.
T !!"". ;
Tool ID code
Application direction
Tool offset number
Tool number
Use two digits after the decimal point to specify the application direction of the tool in accordance
with the registration on the TOOL DATA display.
0, 2, 4, 6, 8
1, 3, 5, 7, 9
11
13
14
15
DIRECTION
Note 1: The directions shown above may not all apply to some machine models.
Note 2: The reverse-display directions refer to a milling spindle orientation of 180 degrees, and
can be used for the application of a turning tool with the tip reversely directed.
In addition to the application direction, the ID code (A to Z) of the tool can also be designated in
accordance with the registration on the TOOL DATA display on condition that the bit 6 of the
parameter P111 is set to 1.
11
12
13
ID code
14
15
16
17
18
19
21
22
23
24
25
26
ID code
Note 3: An alarm will result if no corresponding tool for the specified direction and ID code is
registered on the TOOL DATA display.
Note 4: Depending on the number of the decimal places, the T-code is processed as follows:
1) A designation of a single or two decimal places is always processed as that of the
application direction. It is not possible, therefore, to merely designate the ID code.
2) The T-code with three or five and more decimal places causes an alarm.
3) The default attribute of the T-code is of
direction without ID code.
Only one T-code can be included in a block, and the available range of T-codes depends on the
machine specifications. For further details, especially on how to number the actual tools to be
used, refer to the operating manual of the relevant machine.
The T-code can be given with any other commands in one block, and the T-code given together
with an axis motion command is executed, depending upon the machine specifications, in one of
the following two timings:
- The T-code is not executed till completion of the motion command, or
- The T-code is executed simultaneously with the motion command.
9-1
9-2 Tool Function (6-Digit T-Code)

This function is also used to designate the tool number and offset number. Of a six-digit integer
at address T, upper and lower three digits are respectively used to specify the tool number and
offset number. See the above description of the 4-digit T-code for the meaning of the decimal
fractions.
The available range of T-codes depends on the machine specifications. For further details, refer
to the operating manual of the relevant machine.
Only one T-code can be included in a block.
T !!!""". ;
Tool ID code
Tool offset number
Tool number
Set bit 4 of parameter P10 to 0 or 1 respectively to use 4-digit or 6-digit T-codes.
9-3 Next Tool Automatic Selection

You can designate return tool and a next tool for the machine provided with ATC function by
commanding T-code in the format shown below. The return tool refers to an unnecessary tool
returned to load another tool to be used. The assigned return tool is accomodated in the
magazine. The next tool refers to a tool used for the next machining, which can be assigned
when it is now accomodated in the magazine. The next tool in the magazine can be indexed at
ATC position beforehand by commanding the next tool, thus permitting reduced ATC time.
See Section 11-1 for the details of the application direction and ID code.
T !!!""". A B ;
Next tool
Return tool
Tool ID code
9-2
10 EIA/ISO PROGRAMMING EXAMPLE
10-1
O00000001 (Integrex-200S
Programming Example)
#500=30. (SUB SHIFT )

N1(Edge Face)
G53 (T32 MODE)
M202
G28 U0 Y0
T0101.9 B2
G96 S250 M03
M08
G00 Z.1
G00 X10.
G00 X3.1 Z0
G99
G01 X-.0625 F.005
G00 Z.08 X2.6 Z.05
G01 Z-.995 X3.1
G00 X3.2 Z.05 X2.2
G01 Z-.995 X2.6
G00 Z.05 X1.8575
G01 X1.9017 Z-.0092 X2.04 Z-.0783 Z-.995 X2.2
G00 Z.0474 X1.7486
G01 X1.8617 Z-.0092 X2. Z-.0783 Z-1. X2.9375 X3.0975
G28 U0 Y0 M05
N2(Mill Hex on Face HD1)

G53
M302 M201
T0202.8 B3
G97 S2000 M203
G28 U0 Y0
M212
G0 C0
M211
G98 G00 Z1.
G17 UV
G12.1
G00 X1.6495 Y-.375 M08
Z.1
Z-1. F20.
G41 G01 X1. Y0
X.5 Y-.866
X-.5
X-1. Y0
X-.5 Y.866
X.5
X1. Y0
Z1. F100.
G40 X1.6495 Y.375
G13.1
M212
G28 U0
M302 M201
T0202.8 B3
G97 S2000 M203
G28 U0 Y0
M212 G0 C0
10-2
M211
M153
M250
B45.
M251
G125 X1. Y0 Z-1. R1
G17 UV
G00 Z.5
X0 Y1.616
G01 Z0 F20.
G41 G01 X1. Y.866 F10.
Y-.866
G40 Y-1.616 F10.
G0 Z.5
M212
M205
G69.5
N3(Drill 1/8" hole 45 degree Face)

G53
M302 M201
T0303.8 B11
G97 S2000 M203
G28 U0 Y0
M212
G0 C0
M211
M153
M250
B45.
M251
G125 X1. Y0 Z-1. R1 S#500
G17 UV
G98 G00 X.25 Y.3 M08
Z.1
G83 Z-.25 F2.
Y0
Y-.3
Z1. M09
G80
G69.5
M212
M154
G28 U0
T0303.8
10-3
N4 ( TRANSFER )
G28 U0 Y0
M202
M05 M305 G110
Z2 M306 G00 Z-#500 ( TRANSFER POSITION )
M544
M508 G98
G31 W-.1 F20.
M307
M06
G28 W0
G111
M545
M509 G50 W-#500 ( SUB SHIFT )
M300
N5(Edge Face HD2)

G53
G28 U0 Y0
G50 S3000
T1111.9 B12
G96 S250 M03
M08
G50 W-#500 (SUB SHIFT )
G00 Z.1
G00 X10.
G00 X3.1 Z-.9325
G99 Z-4.
G01 X-.0625 F.005
G00 Z-4.08
(Rough OD turn HD2)
X2.6 Z-4.05
G01 Z-3.005
X3.1
G00 X3.2
Z-4.05
X2.2
G01 Z-3.005
X2.6
G00 Z-4.05
X1.8575
G01 X1.9017 Z-3.9908
X2.0017 Z-3.9408
X2.04 Z-3.9217
Z-3.005
X2.2
(Finish OD Turn HD2)
G00 X3.1
Z-4.0474
X1.7486
G01 X1.8617 Z-3.9908
X2. Z-3.9217
Z-3.
X2.9375
X3.0975
G69.5
G28 U0 Y0 M05
10-4
N6(Mill 45 degree Face)

G53
M300 M201
G112 M19 S0
T1212.8 B13
G97 G112 S2000 M203
M212
G0 C0
M211
G28 U0 Y0
M153
M250
G00 B135.
M251
G125 X1. Y0 Z-3. R1 S#500
G98 G00
Z1.
G17 UV
G00 X0 Y-1.616 M08
Z.5
Z0 F20.
G01 G41 Y-.866 F10.
Y.866
Y1.616 F10.
G40
G00 Z.5
M205 M212
G69.5
M154
N7(Drill 1/8" hole 45 degree Face HD2)

G53
M302 M201
T1313.8 B1
G97 S2000 M203
G28 U0 Y0
M212
G0 C0
M211
M250
B135.
M251
G125 X1. Y0 Z0 R1 S#500
G17 UV
G00 Z.1
G98 G00 X-.25 Y.3 M08
G83 Z-1. F2.
Y0
T-.3
G0 Z5. M09
M205 M212
G80
G69.5
G28 U0 Y0
M30
10-5
Notes:
10-6
11 COORDINATE SYSTEM SETTING

11.1 G125 Coordinate System Setting Macro
Program position coordinate system rotation
1. Outline
This command is used to determine a new coordinate system through the translation of the origin of the currently
active workpiece coordinate system and the rotation on an axis of coordinate. Use this command to specify freely
a plane in space which is convenient for programming.
2. Programming format
G125 Xx 0 Zz0 Yy0 Rr Ss ;
Program coordinate system rotation ON
G69.5 ;
Program coordinate system rotation OFF

Xx0 Zz0 Yy0 :
Coordinates of the center of rotation

Specify in absolute dimensions the translation of the workpiece origin.
Rr : Designation of plane rotation (1: valid, 0: invalid)
After the selection of the G17 (X-Y) plane, the workpiece origin is shifted to the point
(X, Z, Y) = (1, 2, 0) and the plane is rotated by 30 degrees on the Y-axis. The new coordinate system (X, Y, Z)
has thus been established. The sub spindle shift is zero.
-The cancel command G69.5 will set again the coordinate system subjected to the translation and rotation by the
preceding G125 command.
-In the G125 mode all the dimensions must be entered in radius values.
11-1
3. G125 Macro Program Example
O00000001 (sample 1)
N1(Mill Slot)
G53 ( T32 MODE )
M201
T0101.8 B2
G97 S2000 M203
G28 U0
M250
G00 B30.
M251
G17
G125 X2.5 Y0 Z-2. R1 S0.
G98 G00 C0
Z1.
G0 X4. Y0M08
Z.1
M211
G01 Z-.25 F20.
X-4. F10.
M212
G00 Z1.0
M205
G69.5
G28 U0Y0
11-2
G125 Macro Program Example (Contd)
N2(Drill .5" hole Solid Carbide)

G53 ( T32 MODE )
M201
T0202.8 B1
G97 S2000 M203
G28 U0 Y0
M250
B30.
M251
G17 G125 X2.5 Y0 Z-2. R1 S0.
G98 G00 X2. C0 M08
M211
Z1.0
Y-1.0
G01 Z.1 F20.
G01 Z-1. F7.5
G01 Z.1 F400.
G00 Y1.0
G01 Z-1. F7.5
G01 Z.1 F400.
M212
M09
M205
G69.5
G28 U0 Y0
M30
11-3
11.2 G128.8 Coordinate System Setting Macro

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

(If Xx. Yy or Zz omitted 0 is the default)
Xx0 Zz0 Yy0 :
Coordinates of the center of rotation

Designation of plane rotation (1; valid, 0: invalid)
Rr :
Designation of plane rotation (1: valid, 0: invalid)
Ss;
Designation of Z2 axis shifter for transfer of HD2 (amount Z2 moved)
Q**
Calculating point
0:
Tip of tool
1.0:
Center of ball nose (for mold machining)
2.0:
Center of turret (for B axis contouring)
(Data Q is not necessary to command if choosing tip of tool for calculating point)
11-4
G128.8 Program position coordinate system rotation (Contd)

1)
2)
3)
4)
5)
Y axis must be at home position before commanding the macro program.

B axis must be positioned to programming point before commanding the macro program.
X and Z axis do not require home position return before commanding the macro program.
Workpiece coordinate created by this macro program will be canceled by G53.5 or next tool change.
The following data is required in the TOOL DATA and SET UP SCREEN:
(TOOL DATA SCREEN)
Tool Name
Actual Tool Diameter
Tool Set X
Tool Set Z
6)
(SET UP SCREEN)
Z Offset
Make sure parameters B234 and B263 are set properly.
11-5
Notes:
11-6
INTEGREX-100~400MkIII
PLC
ALARM
LISTS
! As shown below, the alarm message in the DIAGNOSIS display varies between models
INTEGREX 300/400-III/IIIT and INTEGREX 300/400-IIIS/IIIST.
CAUTION
D135W0049E
1.
INTEGREX 300/400-III
Neither SP1 nor SP2 is displayed on the display.
2.
INTEGREX 300/400-IIIS/IIIST
SP1 or SP2 is displayed on the display. The alarm message related to the secondary
spindle or W-axis is displayed with SP2.
Example:
3.
250 SPINDLE START MISOPERATION

( , , )SP1
An alarm message related to the main spindle. SP1 is replaced with SP2 for an
alarm of the same message but related to the secondary spindle.
INTEGREX 300/400-IIIT
TR1 or TR2 is displayed on the display. The alarm message related to the lower turret is
displayed with TR2. (Only SP1/SP2 is used for IIIST.)
Example:
256 TURRET ROTATION PROHIBITED

( , , )TR1
An alarm message related to the upper turret (milling head). TR1 is replaced
with TR2 for an alarm of the same message but related to the lower turret.
Remark: Alarms shown in Section 2-1 Alarm List for the INTEGREX 300/400III/IIIT/IIIS/IIIST are all displayed with SP1 in the INTEGREX 300/400-IIIS.
H374S5B012E
APP-1
Alarm List for the INTEGREX 300/400-II

II
Alarm No. and message
Description
Check and remedy
Address
200: THERMAL TRIP

Thermal relay for the hydraulic unit has
(EMERGENCY STOP) tripped.
Check that the hydraulic unit motor is

normal, and then turn the power off and on.
X2
201: BREAKER TRIP
Power line on/off circuit breaker QF2, QP3,

QF4, QF81, or QF82 has tripped.
Check the circuit breakers within the control

panel and then reset the circuit breaker that
has tripped.
X3 X4
202: HYDRAULIC
PRESSURE DOWN
An oil pressure decrease below the

required level has activated the pressure
switch.
Check the hydraulic unit and piping for

abnormalities.
X447
203: AIR PRESSURE

DOWN
An air pressure decrease below the

required level has activated the pressure
switch SP30.
Check the air supply port and piping for

abnormalities.
X446
204: SPINDLE
CONTROLLER
MALFUNCTION
An alarm occurred at spindle controller.
Turn off the main circuit breaker and then

turn it back on.
If the alarm is not released, please contact
your MAZAK service representative.
205: MILLING
CONTROLLER
MALFUNCTION
An alarm occurred at milling spindle

controller.

turn it back on.
206: OPEN FRONT DOOR

(EMERGENCY
STOP)
Coolant cover (front door) is opened during

automatic operation.
Close the coolant cover (front door) and

start the machine in automatic operation
mode.
211: NOT OPERATED MCODE SIMULTA.
M-codes which must not be used in

combination were selected at the same
time.
Correct the program.
212: CHUCK
OPEN/CLOSE
SWITCH MALF.
The signal from the chuck open/close foot

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

circuit
213: ILLEGAL
DESIGNATED TOOL
No.
T code that does not exist in the

specification is assigned.
215: CHUCK SYSTEM

MALFUNCTION
An erroneous chucking action was detected

during chucking operation.
The chuck unit has failed to grip the

material.
XA
X44E
(X44F)
The chuck open/close end sensor

(SQ2/SQ3) is abnormal or faulty.
218: CHUCKING TYPE
NOT SELECTED
Type of chucking (inner/outer) of spindle

chuck is not selected.
Select the type of chucking.
220: TURRET POSITION

SENSOR MALF.
The milling head positioning /B-axis sensor

(encoder) signal has become invalid.
The milling head positioning /B-axis sensor

(encoder) is in trouble.
The milling head index /B-axis motor is

malfunctioning.

turn it back on.
X440/
X441
221: TURRET CLAMP

SENSOR
MALFUNCTION
In spite of the fact that the milling head is

The clamping confirmation sensor is
actually clamped, the clamping confirmation abnormal or faulty.
sensor (SQ18) does not turn on.
In spite of the fact that the milling head is
actually unclamped, the clamping
confirmation sensor (SQ18) does not turn
off.
X460
224: CHUCK SENSOR

MALFUNCTION
The chuck open or close confirmation

sensor fails in function, or both of the
sensors are ON simultaneously.
X440/
X441
APP-2
The chuck open or close confirmation

sensor (SQ2/SQ3) is abnormal or faulty.
Description
Check and remedy
Address
225: FRONT DOOR

SENSOR
MALFUNCTION
For the machine with an optional automatic

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

sensor (SQ2/SQ3) is abnormal or faulty.
231: TOOL EYE

POSITION SENSOR
MALF.
The TOOL EYE extension or retraction

confirmation sensor (SQ7/SQ8) does not
turn on, or both of the sensors are ON
simultaneously.
The TOOL EYE arm is likely to be

obstructed in the middle of its operation.
234: TOOL CLAMP

SENSOR
MALFUNCTION
The tool clamp check sensor fails to

function.
Adjust the setting of the TIM12 timer.
236: PARTS-CATCHER
SENSOR MALF.

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

confirmation sensors are faulty or
malfunctioning.
243: MEASURING
CONTROLLER
MALF.
An error occurred at the workpiece

measurement controller (option).
Check the cause of error at the workpiece

measurement controller.
245: BAR-FEEDER
CONTROLLER
MALF.
An error occurred at the bar feeder

controller.
Check the cause of error at the bar feeder

controller.
248: EXTERNAL
CONTROLLER (No.1)
MALF.
Failure of controller of a peripheral unit

(option)
Check the cause of error at the controller of

a peripheral unit (option).
250: SPINDLE START

MISOPERATION
1. A spindle rotation command was given

during mis-chucking. (Chuck sensor
provided.)
1. Close the chuck and start operation

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

even though the chuck was not closed.
2. After closing the chuck using the chuck

clamp command, designate the spindle
rotation command.

together with an orient command.
3. Take steps so that the commands are

not given together.
4. The M3, M4, M16, M17, M18 or M19

command was given in the milling mode.
4. 1) Program error Correct the

program.
Or the corresponding sensor is faulty.
X14/
XA
X444/
X445
X440/
X441
2) Switch to the turning mode and

then designate the command.
without the TOOL EYE at the backward
end.
5. Retract the TOOL EYE. Also, check the

backward end sensor.
X445

with the door not closed when the door
interlock switch was set to AUTO.
6. Close the door and start the spindle

rotation.
X15
7. Alarm 297 CHUCK PRESSURE DOWN

or 296 TAIL SLEEVE PRESSURE
DOWN is displayed.
7. Clear the alarm 297 or 296.
X442
X443
X480
APP-3
XA
Description
Check and remedy
251: MILLING MOTOR

ROTATION PROHIB.
1. A milling spindle rotation command was

given even though the chuck was not
closed.
1. After closing the chuck using the chuck

clamp command, designate the milling
spindle rotation command.

given even though the milling tool was
not clamped.
2. After clamping the milling tool,

designate the milling spindle rotation
command.

given even though the milling head (Baxis) was not clamped.
3. After clamping the milling head (Baxis), designate the milling spindle
rotation command and check the
milling head clamp sensor.
4. The M203, M204 or M219 command

was given in the turning mode.
4. 1) Program error Correct the

program.
Address
X460
2) Switch to the milling mode and

then designate the command.
252: AXIS MOVE

MISOPERATION

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

spindle rotation.
X15
XA

or 296 TAIL SLEEVE PRESSURE
DOWN is displayed.
6. Clear the alarm 297 or 296.
X442
X443
X480
7. The touch sensor for workpiece

measurement is mounted on the milling
head.
7. Change the touch sensor for a rotating

tool in the MDI or automatic mode.
8. The milling tool rotation command is

given though the TOOL EYE is not
placed at the backward end.
8. Retract the TOOL EYE. Also check the

backward end sensor.
X445
An attempt was made to execute an axis

movement under the axis movement
interdiction.
1. First close the magazine cover and

then execute the axis movement.
XD
1. An attempt was made to execute an axis

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

following states:
1) When the milling head is not
clamped.
2) When the tool is not clamped.
3) When the milling head is not
positioned at the indexing position.
4) When the arm is positioned
somewhere between the stand-by
position and the swinging-in
position.
5) When the magazine cover is
opened.
Note:
When states 1) to 5) occur, an axis
movement can be executed by the
manual pulse handle and the [ATC
MENU] [INTERLOCK NEG.] menu
key operation. (Refer to PART 2.)
6) When the steady rest is connected.
7) When the tailstock body is
connected.
APP-4
X460
XD

252: AXIS MOVE
MISOPERATION
Description
Check and remedy

movement along the Z-axis with the Zaxis interlock activated.
Address
3. Z-axis interlock is activated in the

following states:
1) Same as states 1) to 7) for the
X-axis interlock.
Note: An axis movement can be

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

following states: When the C-axis is
clamped.
253: OVERLOAD
DETECTION
An overload has been detected in a

machine having an overload detection
option.
Check the overload detection level.
256: TURRET ROTATION

PROHIBITED
This alarm display lights when an attempt

has been made to turn the milling head or
when the conditions were unstable.
Reduce the cutting load.
1. Set the arm to the stand-by position by

using the ATC menu. (Refer to PART
2.)
2. The turning tool or milling tool has been

unclamped.
2. Clamp the tool using the clamp switch.
257: ILLEGAL M-CODE
An illegal M code has been specified.
258: TNo. MISMATCH
Since ATC has been aborted by pressing

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

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

IMPOSSIBLE
The rapid feed mode or zero point return

mode switch on the operating panel has
been pressed during tool nose
measurement with the TOOL EYE.
The rapid feed or zero point return mode

cannot be selected during tool nose
measurement.
260: SLIDEWAY
LUBRICATION
ALARM
The pressure switch for slideway lubrication

(SP67) does not turn on within a fixed time.
Check the lubricating grease amount, and

replenish grease if required.
X465
261: HEAD LUBRICATION

ALARM
The pressure switch (SP25, SP26, SP27) in

the spindle cooling unit has worked.
Check the coolant level.
X485
264: THERMAL TRIP

(SINGLE BLOCK)
Thermal relay F13 for the coolant motor has

tripped.
Check the regarding unit (e.g. chip

conveyor for clogging with chips) and then
reset the thermal relay.
X5
1. When the arm is at the milling head side

or at a swinging-in position between
stand-by and the milling head side.
In the automatic/manual mode:
Thermal relay F14 for the chip conveyor

has tripped.
267: BALL SCREW
LUBRICATION
ALARM
The pressure switch (SP7) for ball screw

and C-axis gear lubrication does not turn on
or off within a fixed time.
Check the lubrication oil level, and

replenish lubricating oil if required.
The float switch (SL1) has turned off.
X6
X44C
X44D
270: SPINDLE ORIENT

EXCEED TIME
Although a spindle orientation command is

given, the orientation confirmation signal
does not turn on within a predetermined
time.
The spindle motor detector/controller is

abnormal.
272: TURRET INDEX

EXCEED TIME
Although a milling head indexing command

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

detector/controller is abnormal.
APP-5
Description
Check and remedy
275: ROBOT SERVICE

EXCEED TIME
For machines with an optional robot,

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

robot controller to examine the cause).
276: ATC CYCLE

EXCEED TIME
Although 120 seconds have passed since

the issuance of the ATC command, the
operation complete signal does not turn on.
Reset the ATC unit using either of the

following methods:
Address
(1) Cancel the ATC command by pressing

the emergency stop button.
(2) Release the emergency stop status by
pressing the RESET key.
(3) Execute the ATC reset function of the

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

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

confirmation sensor are faulty or
malfunctioning.
282: CHUCK CLAMP

EXCEED TIME
Although a chuck open/close command is

given, the confirmation signal does not turn
on within a predetermined time.
Adjust the chuck open/close end sensor.

Or the sensor is in trouble.
286: FRONT DOOR

EXCEED TIME
For machines with an optional automatic

door, although a door open/close command
is given, the confirmation signal does not
turn on within a predetermined time.
X440/
X441
The hydraulic system is abnormal.
Adjust the front door open/close end

sensor.
The pneumatic system is abnormal.
292: SENSOR
MALFUNCTION No. 3
The correction value has exceeded the limit

set in the thermal displacement
compensation.
Check that the thermal sensor is correctly

wiring.
R1, R2,
R3
293: SENSOR
MALFUNCTION No. 4
The correction value has changed largely

than the previous one in the thermal
displacement compensation.
Check that the thermal sensor is correctly

wiring.
R1, R2,
R3
297: CHUCK PRESSURE

DOWN
The spindle chuck pressure remains

reduced in a machine having a spindle
chuck pressure guarantee option.
Check the spindle chuck pressure.
X442/
X443
300: START COND. ERR.

(DOOR OPEN)
The cycle start button was pressed while

the front cover (front door) was opened.
Close the front cover.
XA

(TUR UNCLAMP)

the milling head was unclamped.
Clamp the milling head.
X460

(EXT RESET)

the external reset signal was ON.
Check the controller of the external unit.

(EXT FEED HOLD)
The start button was pressed while the

external feed hold signal was ON.
Check the controller of the external unit.
308: C/S ERROR (TOOL

EYE EXTEND)
The cycle start button has been pressed

with the TOOL EYE arm placed in a
measurement position.
Retract (restore) the TOOL EYE arm into

position.
310: C/S ERROR

(TNo.MISMATCH)
During the restart of operation after manual

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

was valid before interruption.
311: C/S ERROR (TAIL

STOCK QUILL)

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

advance end.
APP-6
X445
Description
Check and remedy
Address
312: C/S ERROR (PTCATCHER EXTEND)

with the parts catcher (workpiece unloader)
extended.
Retract (restore) the parts catcher into the

position.
313: C/S ERROR (C/S

QUILL COMMAND)
A tailstock advance/retract command was

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

switch at the neutral position.
320: TOOL UNCLAMP

IMP. (M-SP ROT.)
A milling head unclamping command has

been given during rotation of the milling
spindle motor.
After the milling spindle motor has stopped,

perform the operations described at left.
321: MODE CHANGE

IMPOSSIBLE
(DURING ATC
CYCLE)
Mode changing has been attempted during

the ATC cycle.
The operation mode cannot be changed

during ATC. To change the mode, wait until
ATC has been completed.
322: RAPID MODE IMP.

(ORIGIN RET UNF)
The rapid feed mode was selected without

carrying out the zero point return operation
after the power supply had been turned on.
Carry out the zero-point return operation.
324: DIFF. MODE (ORIGIN

RET UNFIN.)
The automatic operation mode was

selected without carrying out the zero-point
return operation after the power supply had
been turned on.
Carry out the zero-point return operation.
325: TL. EYE EXT. IMP.
A TOOL EYE extend/retract command has

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

I. Or close the front door.
X11C/
XA
326: T/S QUILL EXT. IMP.
The tail spindle has advanced with the

TOOL EYE arm extended.
Retract the TOOL EYE arm.
X444
The tail spindle has advanced/retracted

during the spindle rotation.
Stop the spindle.
The tail spindle has advanced/retracted

during the milling spindle rotation.
Stop the milling spindle.
The condition to perform ATC is not

appropriate. The details are described at
the left. See D200/D201.
90
(D201)
The machine is under locking

state. After releasing the
machine lock, press the cycle
start button. The ATC will be
executed.
91
(D201)
The tailstock is in the connection

state. After releasing the
connection of the tailstock,
perform the ATC.
97
(D201)
When the loading tool is

specified in the ATC, the shifter
is not placed at the ATC side.
Move the shifter manually on the
ATC side.
98
(D201)
The magazine cannot be rotated

because the specified tool is
different from the loading tool
and the shifter is not placed on
the ATC side. Move the shifter to
the ATC side manually.
327: NOT IN ATC START

POSITION
APP-7

327: NOT IN ATC START
POSITION
329: CHUCKING
SELECTION
PROHIBITED
340: CONDITION No.1

MISSING
Description
Check and remedy
The condition to perform ATC is not

appropriate. The details are described at
the left. See D200/D201.
99
(D201)
The shifter is not placed in the

magazine side without the
loading tool when commanding
the ATC.
Move the shifter to the magazine
side/retract position manually.
9800
(D200)
The tool command is given

incorrectly. Perform again.
9900
(D200)
The ATC arm is not at the

reference point position. Move
the ATC arm to the reference
point position manually. Then
perform again the ATC.
The inside/outside chucking selection is

performed with the chuck not opened.
Open the chuck (and remove the

workpiece.)
The inside/outside chucking selection is

performed when the spindle or milling
spindle is not stopped.
Stop the spindle or milling spindle.
Address
In a machine having a warming-up option

- the warming-up program number is not
registered.
Register the warming-up program number

(1 9999) in the MACHINE PARAMETER
display.
R18
- the front cover (front door) is open.
Close the front cover (front door).
XA
- The axis had not yet been initialized

when the NC unit was turned off.
To warm up the machine, return all axes to

their zero points before turning off the NC
unit.
341: CONDITION No.2

MISSING
The M-code command for milling spindle

through air blowout has been issued during
coolant injection.
361: TAIL ALARM
The tailstock amplifier has detected an

overload or too great an error.
If the alarm is not cleared, please contact

The tailstock has moved during spindle

rotation.
365 CARRIER
CONTROLER
MALFUNCTION
An alarm signal has been sent from the

carrier-use amplifier to the NC unit.
After turning NC power off, turn the main

circuit breaker off and then turn it back on.
366: SHIFTER
CONTROLER
MALFUNCTION
An alarm signal has been sent from the

shifter-use amplifier to the NC unit.
374: OPERATING
SWITCH FAULT
A control (switch) on the operation panel

was ON upon turning-on.
The control is faulty unless it has been

inadvertently turned on.
375: MOTOR & SERVO

TURNING OFF ERR.
Since the electromagnetic switch OFF

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

376: MAIN POWER

TURNING OFF
MALFUNCTION
When the front door of a CE specifications

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

377: COOLANT LEVEL

LOW
The coolant level in the coolant unit of a

machine of the high-pressure coolant
specifications has decreased.
Check the coolant level in the coolant unit

and add coolant.

APP-8
X10

X11

X492
Description
Check and remedy
Address
378: HIGH PRESSURE

PUMP THERMAL
TRIP
The thermal relays in the coolant unit of a

specifications have become tripped.
Check the thermal relays of the coolant

unit.
X490
379: TANK PRESSURE

LOW
The pressure in the coolant unit tank of a

specifications has decreased.
Check and adjust the coolant unit tank

pressure.
X491
381: CONDITION
MISSING (SET UP
SWITCH)
The cycle start button has been pressed in

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

to I and then press the cycle start button.
Single-block automatic operation will be
activated.
For a machine of the front door lock pin

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

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

MALF.
An error signal has been sent from the

coolant unit of a machine of the highpressure coolant specifications.
Check the coolant unit for alarms.
383: ATC ALM:

CARRIER&SHIFT.
POS. MALF.
In a machine of the 80/120-tool magazine

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

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

(Z-AXIS POS.)
Under 20- or 40-tool magazine

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

relative to its zero point before opening the
ATC cover.
When the [ATC STOP] menu key in the

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

[ATC STOP] menu key in the machine
menu.
390: TOOL ON INTERFER

ALARM
An attempt has been made to return the tool

to a magazine pocket containing another
tool.
Check the tool number of the tool to be

returned and that of the tool stored within
the magazine pocket.
391: LD/ULD/ACHG
CONDITION ALARM
During ATC, although returning the tool was

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

ATC arm.
Check the magazine pocket tool
confirmation sensor for normal operation.
X475
392: MAGAZINE MANUAL

INTERR.
Under 20- or 40-tool magazine

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

interruption switch to OFF.
X1C
394: ATC CONTROLLER

MALF.
An alarm signal has been received from the

ATC amplifier.
After turning NC power off, turn off the main

circuit breaker and then turn if back on.
386: ATC STOP
APP-9
X493

395: CHECK SENSOR
MALF. (SEE D199)
Description
Check and remedy
The operational check sensors at both ends

of the stroke have turned on.
The positions of the operational check

sensors or watchdogs are not correct or the
sensors themselves are malfunctioning.
After the command has been issued, no

sensors did not turn on within the required
time.
Address
Confirm the value of D199 on the

DIAGNOSIS display and examine the
sensor causing the alarm.
D199
Corresponding sensor
Normal
The X470 limit switch at the ATC

side of the shifter has not turned
on 20 seconds after the Y4F0
command for moving the shifter
to the ATC side has been issued.
The X471 limit switch at the
magazine side of the shifter has
not turned on 20 seconds after
the Y4F1 command for moving
the shifter to the magazine side
has been issued.
X470
X471

extending side of the shifter has
the Y4F2 command for extending
the shifter has been issued.
retracting side of the shifter has
the Y4F3 command for retracting
the shifter has been issued.
X472
X473
The chuck-clamping pressure

switch (X442) and the chuckunclamping pressure switch
(X443) are both on.
X442
X443
12
The top door open end sensor

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

INTERLOCK
The magazine door has been opened

during issuance of the tool change
command or the magazine rotation
command.
Close the magazine door.
XD
398: MAGAZINE COVER

OPEN
The magazine cover is open.
Close the magazine cover.
The machine of the CE specifications has

its magazine setup switch remaining set to
ON.
Change the setting of the magazine setup

switch to OFF.
XD
X1C
399: MAINTE./ADJUST
PARAM. ON
The maintenance/adjustment parameters

are validated.
After turning NC power off, turn off the main

circuit breaker and then turn it back on.
APP-10
Alarm List for the INTEGREX 300/400-III

III
204: SPINDLE
CONTROLLER
MALFUNCTION
S/III
IIIST
(Addition)
III
Description
Check and remedy
Address
An alarm occurred at secondary spindle

controller.

turn it back on.
An erroneous chucking action was detected

during chucking operation on secondary
spindle.
The chuck unit on secondary spindle has

failed to grip the material.
SP2
215: CHUCK SYSTEM
MALFUNCTION
SP2
The chuck open/close end sensor on

secondary spindle (SQ62/SQ63) is
abnormal or faulty.
X483/
X484
Type of chucking (inner/outer) of secondary

spindle chuck is not selected.
Select the type of chucking.
The secondary spindle chuck open or

close confirmation sensor (SQ62/SQ63) is
abnormal or faulty.
X483/
X484
SP2
The secondary spindle chuck open or close

confirmation sensor fails in function, or both
of the sensors are ON simultaneously.
1. Close the chuck and start operation

with the workpiece gripped.
Alternatively, the chuck open/close
check sensor may be improperly
adjusted.
Check the sensor.
X483/
X484
SP2
1. A secondary spindle rotation command

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

even though the chuck of secondary
spindle was not closed.
2. After closing the chuck of secondary

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

without the TOOL EYE placed at the
backward end.
3. Retract the TOOL EYE. Also, check

the backward end sensor.
X445
4. A secondary spindle rotation command

was given without the door closed.
4. Close the door and start the

secondary spindle rotation.
XA

is displayed.
5. Clear the alarm 297.
X448
X449
218: CHUCKING TYPE

NOT SELECTED
SP2
224: CHUCK SENSOR
MALFUNCTION
250: SPINDLE START
MISOPERATION
252: AXIS MOVE

MISOPERATION
SP2
An attempt was made to execute an axis

movement under the axis movement
interdiction.
movement along the W-axis (secondary
spindle traveling axis) without the X- and
Y-axes placed at the zero point.
1.
Perform the X- and Y-axes zero point

return operation.

movement along the X-, Z- (milling head
traveling axis) and Y-axes without the Waxis (secondary spindle traveling axis)
placed at the zero point.
2.
Perform the W-axis zero point return

operation.
3. Though the W-axis zero point return is

not completed after power on, an attempt
was made to execute a movement along
the W-axis in direction at rapid feed
without the TOOL EYE placed at the
backward end.
3.
Retract the TOOL EYE. Also, check

the backward end sensor.
4 An attempt was made to execute a

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

secondary spindle.
APP-11
X445

270: SPINDLE ORIENT
EXCEED TIME
SP2
282: CHUCK CLAMP
EXCEED TIME
SP2
329: CHUCKING
SELECTION
PROHIBITED
SP2
Description
Check and remedy
Although a secondary spindle orientation

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

detector/controller is abnormal.
Although a chuck open/close command for

secondary spindle was given, the
confirmation signal does not turn on within a
predetermined time.
Adjust the chuck open/close end sensor.

The hydraulic system is abnormal.
The inside/outside chucking selection was

performed without the chuck of secondary
spindle opened.
Open the chuck of secndary spindle (and

remove the workpiece).
The inside/outside chucking selection was

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

spindle.
APP-12
Address
X483/
X484
Alarm List for the INTEGREX 300/400-III

IIIT/III
(Addition)
III IIIST
III
221: TURRET CLAMP
SENSOR
MALFUNCTION
TR2/SP2
256: TURRET ROTATION
PROHIBITED
TR2/SP2
258: TNo. MISMATCH

TR2/SP2
272: TURRET INDEX

EXCEED TIME
TR2/SP2
(TUR UNCLAMP)
Description
Check and remedy
In spite of the fact that the (lower) turret is

The clamping confirmation sensor is
actually clamped, the clamping confirmation abnormal or faulty.
sensor (SQ39) does not turn on.
In spite of the fact that the (lower) turret is
actually unclamped, the clamping
confirmation sensor (SQ39) does not turn off.
Address
X52
A turret indexing command was given during

tool nose measurement with the TOOL EYE.
Cancel the measurement mode.
A turret indexing command was given with

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

to I. Or close the front door.
For resuming automatic operation after a

manual interruption, the indexed face of the
turret is different from the face indexed
before the interruption.
Index the turret for the same face to

continue the automatic operation.
Although a turret indexing command is

given, the index confirmation signal does not
turn on within a predetermined time.
The detector/controller of the turret

indexing motor is abnormal.
The cycle start button was pressed while the

turet was unclamped.
Clamp the (lower) turret.
For resuming automatic operation after a

manual interruption, the number of the tool
in use differs from the number before the
interruption.
Use a tool of the same number to continue

the automatic operation.
X198
X1F8
X52
TR2/SP2
310: C/S ERROR
(TNo.MISMATCH)
TR2/SP2
APP-13
- NOTE -
APP-14
M-CODE TABLE
Miscellaneous Function (M-Code) for the INTEGREX 300/400-III
III/I
III III
T/IIIIS/IIIIST
!: Standard
": Optional
: Special order
M-codes
Description
Category
Remarks
M00
Program stop
M01
Optional stop
M02
Program end
M03
Spindle normal rotation
M04
Spindle reverse rotation
M05
Spindle stop
M06
Chuck unclamp (releasing workpiece)
"
M07
Chuck clamp (holding workpiece)
"
M08
Flood coolant ON
M09
Coolant OFF
Milling spindle mode cancel (Turning mode selection)
M13
Milling tool normal rotation
M14
Milling tool reverse rotation
M15
Milling tool stop
M16
Spindle orientation 0 (for AJC)
M17
M18
M19
Spindle orientation position (for the robot to insert a workpiece)
"
M20
Robot service call
"
M21
Robot service call
"
M22
Robot service call
"
M23
Robot service call
"
M24
Robot service call
"
M25
Robot service call
"
M26
Robot service call
"
M27
Robot service call
"
M28
Robot service call
"
M29
Robot service call
"
M30
Reset & tape rewind
M31
Tail spindle & tailstock body advance
for 300/400-III/IIIT
M10
M11
M12
M32
Tail spindle & tailstock body retract
M33
Low chuck pressure
M34
High chuck pressure
M35
M36
M37
M38
M39
M40
H374S5C010E
APP-15
M-codes
Description
Category
M41
M42
M43
M44
M45
Air coolant blow ON (coolant stop: M09)
"
M48
Parts catcher advance
"
M49
Parts catcher retract
"
M51
Error detect OFF
M52
Error detect ON
M53
Chamfering OFF
M54
Chamfering ON
M55
Piece count
M56
Front door open
"
M57
Front door close
"
M58
Chuck air blast
"
C-axis unclamp
M66
C-axis clamp
M67
C-axis brake (for machining by G01)
M68
Cycle bar feeder call 1
M69
Cycle bar feeder call 2
M72
Inside chuck clamp
M73
Outside chuck clamp
M74
Steady rest - milling head connection mode release
M75
Steady rest - milling head connection mode start
Workpiece measurement start
"
M82
Workpiece measurement end
"
M83
Tool measurement start
"
M84
Tool measurement end
"
M86
Steady rest 1 unclamp
"
M87
Steady rest 1 clamp
"
M46
M47
M50
M59
M60
M61
M62
M63
M64
M65
M70
M71
M76
M77
M78
M79
M80
M81
M85
APP-16
Remarks
M-codes
Description
Category
Remarks
M88
Steady rest 2 unclamp
M89
Steady rest 2 clamp
User macro interruption, valid
M97
User macro interruption, invalid
M98
EIA EIA Subprogram call
M99
EIA EIA Return to main EIA program
M100
Workpiece measurement DIA start
"
M101
Workpiece measurement DIA end
"
M102
Workpiece measurement STP start
"
M103
Workpiece measurement STP end
"
M104
Workpiece measurement GRV start
"
M105
Workpiece measurement GRV end
"
M106
Workpiece measurement WID start
"
M107
Workpiece measurement WID end
"
M108
Workpiece measurement DIS start (chuck barrier release)
"
M109
Workpiece measurement DIS end
"
M110
Tool tip measurement TOL start
M111
Tool tip measurement TOL end
M112
External tool compensation EXT start
"
M113
External tool compensation EXT end
"
M114
Z-axis offset measurement ZOF start
"
M115
Z-axis offset measurement ZOF end
"
M116
C-axis offset measurement COF start
"
M117
C-axis offset measurement COF end
"
Measurement data print out
"
M150
Workpiece unload demand to robot
M151
Milling spindle through air blow ON
Only for turning tools
M152
Milling spindle through air blow OFF
Only for turning tools
M153
Milling spindle through coolant ON
M154
Milling spindle through coolant OFF
M155
Chuck coolant ON (composed movement)
"
M156
Chuck coolant OFF (composed movement)
"
M157
Spindle through coolant blow ON (OFF: M159)
"
M158
Spindle through air blow ON (OFF: M159)
"
M159
M157, M158 OFF
"
M160
Shower coolant ON/chuck stopper extend
"
M90
M91
M92
M93
M94
M95
M96
M118
M119
M120
M121
M149
APP-17
M-codes
Description
Category
Remarks
M161
Shower coolant OFF/chuck stopper retract
"
M162
Workpiece rechucking (for a piece delivered by robot)
"
M163
Tail spindle thrust
low pressure
"
M164
Tail spindle thrust
high pressure
"
35K, 70K high pressure coolant ON (OFF: M9, M154)
"
M172
Index 0(KOUYOU)
M173
Index 90(KOUYOU)
M174
Index 180(KOUYOU)
M175
Index 270(KOUYOU)
M176
Index 270(KOUYOU)
M177
Index 270(KOUYOU)
M178
Index 270(KOUYOU)
M179
Index 270(KOUYOU)
M198
EIA MAZATROL program call
"
M199
EIA MAZATROL program end
"
M200
Milling point machining start
M201
Milling line machining start
M202
Turning mode
M203
Milling tool normal rotation
M204
Milling tool reverse rotation
M205
Milling tool stop
M207
M208, M209 mode cancel
M208
ATC prohibition mode during finishing, coolant ON
M209
ATC prohibition mode during finishing, coolant OFF
M210
C-axis clamp (for milling)
M211
C-axis brake (for milling)
M212
C-axis unclamp (for milling)
M213
C-axis brake only (brake by M211)
M214
C-axis unclamp only (unclamp by M212)
M215
M213, M214 and M216 mode cancel
M216
C-axis unclamp neglect mode (cancel:
M165
M166
M167
M168
M169
M170
M171
M180
M197
M206
M215)
M217
M218
M219
Milling tool orient
M220
M229
APP-18
M-codes
Description
Category
M230
Grinding mode ON
"
M231
Grinding speed setting
"
M236
C-axis servo gain normal
M237
C-axis servo gain low
M238
C-axis servo gain middle
M239
C-axis servo gain high
M248
Spindle speed check (for interlocking the start of cutting)
M249
Milling head selection preparation
M250
Milling head/B-axis unclamp
M251
B-axis clamp
M252
Milling spindle unclamp
M253
Milling spindle clamp
M254
Milling head/B-axis clamp
Milling head air blow
M260
Polygon mode ON
"
M261
Polygon mode OFF
"
M274
Steady rest coolant ON
M275
Steady rest coolant OFF
M331
Spindle coil change fixed to high speed
M332
Spindle coil change, valid
M348
Yt-axis selection
M349
Y-axis selection
M232
M233
M234
M235
M240
M241
M242
M243
M244
M245
M246
M247
M255
M256
M257
M258
M259
M262
M273
M276
M330
M333
M347
APP-19
Remarks
M-codes
Description
Category
M350
M351
M352 cancel
M352
Spindle speed arrival signal check, valid
M353
M369
M370
Axis load detection, invalid
"
M371
Axis load detection, valid
"
M372
Axis load detection, temporarily invalid
"
M373
Axis load detection, re-start
"
M374
NC feed holding on overload detection
"
M375
NC feed holding & spindle stop on overload detection
"
M376
Overload detection level % setting
"
M377
Overload detection time setting (unit: 0.1 sec)
"
M378
Overload detection peak %/detection frequency setting
"
M379
Overload detection table No. registration
"
M390
M391 cancel
"
M391
Spindle mis-chucking cancel (M3/M4 completed with chuck open)
"
M394
TOOL EYE extension possible during chuck close (when robot valid)
M395
M394 cancel
Magazine tool rotation
M731
Tail thrust 1 selection
M732
M733
M734
M735
M736
M737
M738
M739
M740
M741
Positioning tailstock to Position 1
M742
Positioning tailstock to Position 2
M743
Positioning tailstock to Retract
M380
M389
M392
M393
M396
M600
M601
M602
M730
APP-20
Remarks
M-codes
Description
Category
M744
M927
M928
Y-axis zero point return
Yt-axis moving to ATC position
M929
M930
M931
M999
APP-21
Remarks
Miscellaneous Function (M-Code) for the INTEGREX 300/400-IIII

(Addition)
S/IIIIST
!: Standard
": Optional
: Special order
M-codes
M300
Description
Category
Remarks
Secondary spindle selection
System M-code
Main spindle selection
System M-code
M303
Secondary spindle normal rotation
M304
Secondary spindle reverse rotation
M305
Secondary spindle stop
M306
Secondary spindle chuck unclamp (releasing workpiece)
M307
Secondary spindle chuck clamp (holding workpiece)
Secondary spindle orientation
"
M321
Increase of main spindle torque for synchronous rotation
"
M322
Cancellation of M321
"
M333
Torque limit of main spindle to 1/2
M334
Torque limit of main spindle
M335
Keeping of nominal torque of main spindle
M336
M337
Torque limit of main spindle only at the starting and stopping
M351
M352
Spindle speed arrival signal check
M357
Secondary spindle chuck air blast start
"
M358
Secondary spindle chuck air blast stop
"
M359
"
M360
Secondary spindle orientation clamp mode
"
M361
"
M362
Simultaneous chuck operation on main and secondary spindles in TRSCHK mode
"
M363
"
M364
Immediate completion of spindle/milling spindle start commands (Mcode) in TRS mode
"
M380
Spindle synchronous rotation mode
M381
Spindle synchronous rotation mode cancel
Release of chuck open/close interlock during spindle rotation
M301
M302
M319
M320
M350
M500
M501
M502
Main/secondary spindle synchronous rotation (Cross mode)
"
M503
APP-22
System M-code
M-codes
Description
Category
Remarks
M504
M505
"
System M-code
M506
Master spindle chuck open after slave spindle chuck close
System M-code
M507
The slave spindle chuck open after master spindle chuck close
System M-code
M508
Pressing start
M509
M511
Start of synchronous action of two spindles
System M-code
M512
System M-code
M518
Interlock release during chucking of a bar workpiece by both spindles
M519
Spindle orientation
"
M527
Check for workpiece chucked in the spindle
"
M528
Modal workpiece check in TRS mode
"
M540
TRS-CHK mode start
System M-code
M541
Cancellation of TRS-CHK mode
System M-code
M542
TRS-BAR mode start
System M-code
M510
M543
Cancellation of TRS-BAR mode
System M-code
M544
Cross-machining start
"
System M-code
M545
Cancellation of cross-machining
"
System M-code
M546
TRS-MOV mode start
System M-code
M547
Cancellation of TRS-MOV mode
System M-code
APP-23
Miscellaneous Function (M-Code) for the INTEGREX 300/400-IIII

(Addition)
T/IIIIST
For the upper turret

!: Standard
": Optional
: Special order
M-codes
Description
Category
M560
Spindle control and Constant cutting speed control for the upper turret
M561
Spindle control and Constant cutting speed control for the lower turret
M562
Axis movement synchronization
M563
Cancellation of axis movement synchronization
M950
Stand-by M-code
M951
Stand-by M-code
M952
Stand-by M-code
M953
Stand-by M-code
M954
Stand-by M-code
M955
Stand-by M-code
M956
Stand-by M-code
M957
Stand-by M-code
M958
Stand-by M-code
M959
Stand-by M-code
M960
Stand-by M-code
M961
Stand-by M-code
M962
Stand-by M-code
M963
Stand-by M-code
M964
Stand-by M-code
M965
Stand-by M-code
M966
Stand-by M-code
M967
Stand-by M-code
M968
Stand-by M-code
M969
Stand-by M-code
M970
Stand-by M-code
M971
Stand-by M-code
M972
Stand-by M-code
M973
Stand-by M-code
M974
Stand-by M-code
M975
Stand-by M-code
M976
Stand-by M-code
M977
Stand-by M-code
M978
Stand-by M-code
M979
Stand-by M-code
M980
Stand-by M-code
M981
Stand-by M-code
M982
Stand-by M-code
M949
APP-24
Remarks
M-codes
Description
Category
M983
Stand-by M-code
M984
Stand-by M-code
M985
Stand-by M-code
M986
Stand-by M-code
M987
Stand-by M-code
M988
Stand-by M-code
M989
Stand-by M-code
M990
Stand-by M-code
M991
Stand-by M-code
M992
Stand-by M-code
M993
Stand-by M-code
M994
Stand-by M-code
M995
Stand-by M-code
M996
Stand-by M-code
M997
Stand-by M-code
APP-25
Remarks
Integrex-100~400MkIII Lower Turret M-Codes

!: Standard
": Optional
: Special order
M-codes
Description
Category
M00
Program stop
M01
Optional stop
M02
Program end
M03
Secondary spindle normal rotation (for ST)
M04
Secondary spindle reverse rotation (for ST)
M05
Secondary spindle stop (for ST)
M08
Coolant ON
M09
Coolant OFF
M30
Reset & tape rewind
M51
Error detect OFF
M52
Error detect ON
M53
Chamfering OFF
M54
Chamfering ON
M58
Secondary spindle chuck air blast
"
M300
Main spindle mode
M302
Secondary spindle mode
M303
Main spindle normal rotation
M304
Main spindle reverse rotation
M305
Main spindle stop
M358
Main spindle chuck air blast
"
M560
Spindle control and Constant cutting speed control for the upper turret
M561
Spindle control and Constant cutting speed control for the lower turret
M562
Axis movement synchronization
M563
Cancellation of axis movement synchronization
M950
Stand-by M-code
M951
Stand-by M-code
M952
Stand-by M-code
M953
Stand-by M-code
M954
Stand-by M-code
M301
M949
APP-26
Remarks
M-codes
Description
Category
M955
Stand-by M-code
M956
Stand-by M-code
M957
Stand-by M-code
M958
Stand-by M-code
M959
Stand-by M-code
M960
Stand-by M-code
M961
Stand-by M-code
M962
Stand-by M-code
M963
Stand-by M-code
M964
Stand-by M-code
M965
Stand-by M-code
M966
Stand-by M-code
M967
Stand-by M-code
M968
Stand-by M-code
M969
Stand-by M-code
M970
Stand-by M-code
M971
Stand-by M-code
M972
Stand-by M-code
M973
Stand-by M-code
M974
Stand-by M-code
M975
Stand-by M-code
M976
Stand-by M-code
M977
Stand-by M-code
M978
Stand-by M-code
M979
Stand-by M-code
M980
Stand-by M-code
M981
Stand-by M-code
M982
Stand-by M-code
M983
Stand-by M-code
M984
Stand-by M-code
M985
Stand-by M-code
M986
Stand-by M-code
M987
Stand-by M-code
M988
Stand-by M-code
M989
Stand-by M-code
M990
Stand-by M-code
M991
Stand-by M-code
M992
Stand-by M-code
M993
Stand-by M-code
M994
Stand-by M-code
M995
Stand-by M-code
M996
Stand-by M-code
M997
Stand-by M-code
APP-27
Remarks
- NOTE-
APP-28
Notes:
Stroke diagram (INTEGREX 100- - Metric -)
APP-29
Drawing No.
1372ST00012
Unit: mm
1.
1. If B = 90, the tool lengths that can be
measured using the TOOL EYE are
limited.
2. If B = 0, when a special chuck or long
jaws are mounted the tool lengths that
can be measured using the TOOL EYE
may be limited.
3.
BT40 spec.
Stroke Diagram
INTEGREX 100-
(Metric)
Stroke diagram (INTEGREX 100- - Inch -)
APP-30
Notes:
Drawing No.
1372ST00041
Unit: in. (mm)

limited.
may be limited.
3.
BT40 spec.
INTEGREX 100-
(Inch)
Stroke diagram (INTEGREX 100-S - Metric -)
APP-31
Notes:
Drawing No.
1372ST00022
Unit: mm

limited.
may be limited.
3.
BT40 spec.
INTEGREX 100-
S
(Metric)
Stroke diagram (INTEGREX 100-S - Inch -)
APP-32
Notes:
Drawing No.
1372ST00051
Unit: in. (mm)

limited.
may be limited.
3.
BT40 spec.
INTEGREX 100-
S
(Inch)
Stroke diagram (INTEGREX 100-ST - Metric -)
APP-33
Notes:
Drawing No.
1372ST00032
Unit: mm

limited.
may be limited.
3.
BT40 spec.
INTEGREX 100-
ST
(Metric)
Stroke diagram (INTEGREX 100-ST - Inch -)
APP-34
Notes:
Drawing No.
1372ST00062
Unit: in. (mm)

limited.
may be limited.
3.
BT40 spec.
INTEGREX 100-
ST
(Inch)
Stroke diagram (INTEGREX 200-III)
APP-35
Drawing No.
DOM./EX.
Main spindle
Hollow chuck of 8"
1373PGD0011
Unit: mm (in.)
Note: For BT Spec *1: 165 mm (6.5")

*2: 40 mm (1.57")
Stroke Diagram
INTEGREX 200-III
III
Stroke diagram (INTEGREX 200-IIIS)
APP-36
Drawing No.
DOM./EX.
Main spindle
Hollow chuck of 8"
Secondary spindle
Hollow chuck of 8"
1373PGD0021
Unit: mm (in.)

*2: 40 mm (1.57")
INTEGREX 200-II
III
IIIS
Stroke diagram (INTEGREX 200-IIIT)
APP-37
Drawing No.
DOM./EX.
Main spindle
Hollow chuck of 8"
1373PGD0031
Unit: mm (in.)

*2: 40 mm (1.57")
INTEGREX 200-II
III
IIIT
Stroke diagram (INTEGREX 200-IIIST)
APP-38
Drawing No.
DOM./EX.
Main spindle
Hollow chuck of 8"
Secondary spindle
Hollow chuck of 8"
1373PGD0041
Unit: mm (in.)

*2: 40 mm (1.57")
INTEGREX 200-II
III
IIIST
Stroke diagram (INTEGREX 200-III) - with work rest -
APP-39
Drawing No.
1373PGD0110
Unit: mm (in.)
DOM./EX.
Main spindle
Hollow chuck of 8"
Work rest spec.: SLU2Z/SMW

*2: 40 mm (1.57")
INTEGREX 200-III
III (with work rest)
Stroke diagram (INTEGREX 200-IIIS) - with work rest -
APP-40
Drawing No.
1373PGD0120
Unit: mm (in.)
DOM./EX.
Main spindle
Hollow chuck of 8"
Secondary spindle
Hollow chuck of 8"
Work rest spec.: SLU2Z/SMW

*2: 40 mm (1.57")
INTEGREX 200-III
IIIS
III (with work rest)
Stroke diagram (INTEGREX 200-IIIT) - for Lower turret with milling capability -
APP-41
1373PGD0050
Drawing No.
Unit: mm (in.)
DOM./EX.
Main spindle
Hollow chuck of 8"

*2: 40 mm (1.57")
INTEGREX 200-III
IIIT
III (for Lower turret with milling capability)
Stroke diagram (INTEGREX 200-IIIST) - for Lower turret with milling capability -
APP-42
Drawing No.
DOM./EX.
Main spindle
Hollow chuck of 8"
Secondary spindle
Hollow chuck of 8"
1373PGD0060
Unit: mm (in.)

*2: 40 mm (1.57")
INTEGREX 200-III
IIIST
(for Lower turret with milling capability)
III
Stroke diagram (INTEGREX 300- [1000U, 10" hollow chuck])
APP-43
Drawing No.
MAIN SPINDLE
DOM./EX.
1374PGD0020
10" CHUCK
(THROUGH HOLE)
Unit: mm (in.)
Note:BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")
Stroke Diagram
INTEGREX 300-
(1000U, 10" hollow chuck)
Stroke diagram (INTEGREX 300-S [1000U, 10" hollow chuck])
APP-44
Drawing No.
MAIN SPINDLE
1374PGD0050
10" CHUCK
(THROUGH HOLE)
10" CHUCK
SECONDARY SPINDLE (THROUGH HOLE)
DOM./EX.
Unit: mm (in.)
*1: 165 mm (6.50")

*2: 40 mm (1.57")
INTEGREX 300-
S
APP-45
Drawing No.
MAIN SPINDLE
DOM./EX.
1374PGD0040
12" CHUCK
(THROUGH HOLE)
Unit: mm (in.)
Note:BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")
INTEGREX 400-
APP-46
Drawing No.
MAIN SPINDLE
1374PGD0060
10" CHUCK
(THROUGH HOLE)
10" CHUCK
DOM./EX.
Unit: mm (in.)
*1: 165 mm (6.50")

*2: 40 mm (1.57")
INTEGREX 400-
S
APP-47
Drawing No.
MAIN SPINDLE
DOM./EX.
1374PGD0140
10" CHUCK
(THROUGH HOLE)
Unit: mm (in.)
Note:BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")
INTEGREX 300-
APP-48
Unit: mm (in.)
Drawing No.
MAIN SPINDLE
1374PGD0170
10" CHUCK
(THROUGH HOLE)
10" CHUCK
SECONDARY SPINDLE
(THROUGH HOLE)
DOM./EX.
Note:BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")
INTEGREX 300-II
II
IS (1500U, 10" hollow chuck)
Fig. 1-13 Stroke diagram (INTEGREX 300-T [1500U, 10" hollow chuck])
APP-49
Drawing No.
MAIN SPINDLE
DOM./EX.
1374PGD0200
10" CHUCK
(THROUGH HOLE)
Unit: mm (in.)
Note:BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")
INTEGREX 300-II
II
IT (1500U, 10" hollow chuck)
Stroke diagram (INTEGREX 300-ST [1500U, 10" hollow chuck])
APP-50
Unit: mm (in.)
Drawing No.
MAIN SPINDLE
1374PGD0230
10" CHUCK
(THROUGH HOLE)
10" CHUCK
DOM./EX.
Note:BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")
INTEGREX 300-II
II
IST (1500U, 10" hollow chuck)
APP-51
Drawing No.
MAIN SPINDLE
DOM./EX.
1374PGD0160
12" CHUCK
(THROUGH HOLE)
Unit: mm (in.)
Note:BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")
INTEGREX 400-
APP-52
Unit: mm (in.)
Drawing No.
MAIN SPINDLE
1374PGD0180
12" CHUCK
(THROUGH HOLE)
10" CHUCK
SECONDARY SPINDLE
(THROUGH HOLE)
DOM./EX.
Note:BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")
INTEGREX 400-II
II
I S (1500U, 12" hollow chuck)
Stroke diagram (INTEGREX 400-T [1500U, 12" hollow chuck])
APP-53
Drawing No.
MAIN SPINDLE
DOM./EX.
1374PGD0220
12" CHUCK
(THROUGH HOLE)
Unit: mm (in.)
Note:BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")
INTEGREX 400-II
II
IT (1500U, 12" hollow chuck)
Stroke diagram (INTEGREX 400-ST [1500U, 12" hollow chuck])
APP-54
Unit: mm (in.)
Drawing No.
MAIN SPINDLE
1374PGD0240
12" CHUCK
(THROUGH HOLE)
10" CHUCK
SECONDARY SPINDLE
(THROUGH HOLE)
DOM./EX.
Note:BT spec.
*1: 165 mm (6.50")
*2: 40 mm (1.57")
INTEGREX 400-II
II
IST (1500U, 12" hollow chuck)

Mazatrol Fusion 640MT-Pro - Integrex-100 400MkIII Series

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Mazatrol Fusion 640MT-Pro - Integrex-100 400MkIII Series

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Applications Training

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

INTEGREX-100~400MkIII APPLICATIONS TRAINING

The machine is provided with a number of safety

AFTER CONTROL POWER IS TURNED ON

4) Tools and other items around the machine or

1) Check pressure gages for proper readings.

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

THE LOCKOUT PROCESS MUST BE PERFORMED BY AUTHORIZED PERSONNEL ONLY.

SHUT OFF MACHINE POWER USING NORMAL SHUT DOWN PROCEDURES.

COMPLETE THE REQUIRED MAINTENANCE OPERATIONS.

MAKE SURE ALL PERSONNEL ARE CLEAR OF THE MACHINE.

In pouring grout, fasten the leveling block

Desirable Independent Grounding:

VERIFY THE ACTUAL MACHINE ELECTRICAL

POWER REQUIREMENT AND THE MAIN

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

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

MAZATROL CNC CONTROLLERS PROVIDE PARAMETER SETTINGS TO LIMIT SPINDLE

MAZAK MACHINES ARE ENGINEERED WITH A NUMBER OF SAFETY DEVICES TO

MAZAK MACHINES ARE ENGINEERED WITH A NUMBER OF SAFETY DEVICES TO

BEFORE STARTING OPERATION, CHECK THAT THE WORKPIECE IS SECURELY MOUNTED

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

CUTTING CONDITIONS SUGGESTED BY THE MACHINING NAVAGATION FUNCTION

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

FAILURE TO COMPLY WITH THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO

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

Prohibit cycle start.

Prohibit cycle start.

Limit the rapid override. Max is 12%.

Prohibit cycle start.

Can not run auto operation.

Can operate CHUCK, TAILSLEEVE ,

Can operate CHUCK, TAILSLEEVE ,

Can NOT operate Spindle, Axis, Turret,

Can not operate Spindle running, but

Can operate CHUCK, TAILSLEEVE ,

Can operate CHUCK, TAILSLEEVE ,

Can not run Auto-operation.

1 INTEGREX-100~400MkIII MANUAL ATC OPERATION

Set the B-axis at zero degrees.

R/V/2 and press.

Press the MDI key.

desired tool number.

Turn MDI off by pressing any manual operation key.

Press the TOOL LOAD menu key.

Verify that that the MILL 0 ORIENT key is highlighted.

Press the ATC MENU key.

Press the ATC ARM SWING menu key.

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

Press the ATC ARM CHG POS key.

Turn the TOOL CLAMP/UNCLAMP key switch to CLAMP.

Press the ATC ARM HOME POS key.

Press the HOME key.

Move the Y-axis to the home position.

Press MDI menu key.

The MDI window will open:

Press the ATC MAINTE menu key.

Press the TOOL UNLOAD menu key.

Updating The Current Tool In the Turret Pocket

Press the MDI key.

-The MDI window will open on the monitor.