H747S40016E

Serial No.
289476
Original Instructions
OPERATING MANUAL
MAZATROL SmoothX
(for Machining Center) (for INTEGREX e series)
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(for INTEGREX i series) (for VORTEX i series)
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MAZATROL SmoothG
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(for Machining Center) (for INTEGREX j series)
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AUTOMATIC OPERATION
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Manual No.: H747S40016E
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Serial No.:
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Before using this machine and equipment, fully understand the contents of this
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manual to ensure proper operation. Should any questions arise, please ask the
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nearest Technical Center or Technology Center.

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IMPORTANT NOTICE
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1. Be sure to observe the safety precautions described in this manual and the contents of the
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safety plates on the machine and equipment. Failure may cause serious personal injury or
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material damage. Please replace any missing safety plates as soon as possible.
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2. No modifications are to be performed that will affect operation safety.

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3. For the purpose of explaining the operation of the machine and equipment, some illustrations
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may not include safety features such as covers, doors, etc. Before operation, make sure all
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such items are in place.

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4. This manual was considered complete and accurate at the time of publication, however, due to
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our desire to constantly improve the quality and specification of all our products, it is subject
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to change or modification. If you have any questions, please contact the nearest Technical
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Center or Technology Center.

5. Always keep this manual near the machinery for immediate use.
6. If a new manual is required, please order from the nearest Technical Center or Technology
Center with the manual No. or the machine name, serial No. and manual name.
7. The export of machining programs may be restricted to prevent them from being used for
military purposes. The machining programs you prepared are your property, so you should
manage them yourself in accordance with the law.
Issued by Manual Publication Section, YAMAZAKI MAZAK CORPORATION, Japan
01.2018
Copyright (C) 2017 YAMAZAKI MAZAK CORPORATION. All Rights Reserved.

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Serial No. 289476
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Serial No. 289476
PART 4
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AUTOMATIC OPERATION
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H747S40016E
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Serial No. 289476
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Serial No. 289476
SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
Preface
Safety precautions relating to the CNC unit (in the remainder of this manual, referred to simply as
the NC unit) that is provided in this machine are explained below. Not only the persons who
create programs, but also those who operate the machine must thoroughly understand the
contents of this manual to ensure safe operation of the machine.
Read all these safety precautions, even if your NC model does not have the corresponding
functions or optional units and a part of the precautions do not apply.
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Rule
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1. This section contains the precautions to be observed as to the working methods and states
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usually expected. Of course, however, unexpected operations and/or unexpected working
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states may take place at the user site.
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During daily operation of the machine, therefore, the user must pay extra careful attention to
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its own working safety as well as to observe the precautions described below.
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2. Although this manual contains as great an amount of information as it can, since it is not
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rare for the user to perform the operations that overstep the manufacturer-assumed ones,
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not all of “what the user cannot perform” or “what the user must not perform” can be fully
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covered in this manual with all such operations taken into consideration beforehand.
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It is to be understood, therefore, that functions not clearly written as “executable” are

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“inexecutable” functions.
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3. The meanings of our safety precautions to DANGER, WARNING, and CAUTION are as
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follows:
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: Failure to follow these instructions could result in loss of life.

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

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life or body.
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WARNING
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: Failure to observe these instructions could result in minor injuries or serious

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machine damage.
CAUTION
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HGENPA0102E S-1
Serial No. 289476
SAFETY PRECAUTIONS
Basics
 After turning power on, keep hands away from the keys, buttons, or switches of the
operating panel until an initial display has been made.
WARNING  Before proceeding to the next operations, fully check that correct data has been entered
and/or set. If the operator performs operations without being aware of data errors,
unexpected operation of the machine will result.
 Before machining workpieces, perform operational tests and make sure that the machine
operates correctly. No workpieces must be machined without confirmation of normal
operation. Closely check the accuracy of programs by executing override, single-block,
and other functions or by operating the machine at no load. Also, fully utilize tool path
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check, Virtual Machining, and other functions, if provided.
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 Make sure that the appropriate feed rate and rotational speed are designated for the
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particular machining requirements. Always understand that since the maximum usable
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feed rate and rotational speed are determined by the specifications of the tool to be used,
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those of the workpiece to be machined, and various other factors, actual capabilities differ
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from the machine specifications listed in this manual. If an inappropriate feed rate or
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rotational speed is designated, the workpiece or the tool may abruptly move out from the
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machine.
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 Before executing correction functions, fully check that the direction and amount of
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correction are correct. Unexpected operation of the machine will result if a correction
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function is executed without its thorough understanding.

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 Parameters are set to the optimum standard machining conditions prior to shipping of the
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machine from the factory. In principle, these settings should not be modified. If it becomes
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absolutely necessary to modify the settings, perform modifications only after thoroughly
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understanding the functions of the corresponding parameters. Modifications usually affect

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any program. Unexpected operation of the machine will result if the settings are modified
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without a thorough understanding.

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Remarks on the Cutting Conditions Recommended by the NC

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 Before using the following cutting conditions:

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• Cutting conditions that are the result of the MAZATROL Automatic Cutting Conditions
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Determination Function
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WARNING
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• Cutting conditions suggested by the Machining Navigation Function

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• Cutting conditions for tools that are suggested to be used by the Machining Navigation
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Function
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Confirm that every necessary precaution in regards to safe machine setup has been taken
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– especially for workpiece fixturing/clamping and tool setup.

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 Confirm that the machine door is securely closed before starting machining.
Failure to confirm safe machine setup may result in serious injury or death.
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Serial No. 289476
SAFETY PRECAUTIONS
Programming
 Fully check that the settings of the coordinate systems are correct. Even if the designated
program data is correct, errors in the system settings may cause the machine to operate
in unexpected places and the workpiece to abruptly move out from the machine in the
WARNING
event of contact with the tool.
 During surface velocity hold control, as the current workpiece coordinates of the surface
velocity hold control axes approach zeroes, the spindle speed increases significantly. For
the lathe, the workpiece may even come off if the chucking force decreases. Safety speed
limits must therefore be observed when designating spindle speeds.
 Even after inch/metric system selection, the units of the programs, tool information, or
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parameters that have been registered until that time are not converted. Fully check these
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data units before operating the machine. If the machine is operated without checks being
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performed, even existing correct programs may cause the machine to operate differently
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from the way it did before.
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 If a program is executed that includes the absolute data commands and relative data
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commands taken in the reverse of their original meaning, totally unexpected operation of
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the machine will result. Recheck the command scheme before executing programs.
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 If an incorrect plane selection command is issued for a machine action such as arc
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interpolation or fixed-cycle machining, the tool may collide with the workpiece or part of
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the machine since the motions of the control axes assumed and those of actual ones will
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be interchanged. (This precaution applies only to NC units provided with EIA/ISO

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functions.)
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 The mirror image, if made valid, changes subsequent machine actions significantly. Use
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the mirror image function only after thoroughly understanding the above. (This precaution
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applies only to NC units provided with EIA/ISO functions.)

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 If machine coordinate system commands or reference position returning commands are

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issued with a correction function remaining made valid, correction may become invalid
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temporarily. If this is not thoroughly understood, the machine may appear as if it would
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operate against the expectations of the operator. Execute the above commands only after
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making the corresponding correction function invalid. (This precaution applies only to NC
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units provided with EIA/ISO functions.)

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 The barrier function performs interference checks based on designated tool data. Enter
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the tool information that matches the tools to be actually used. Otherwise, the barrier
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function will not work correctly.

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 The system of G-code and M-code commands differs, especially for turning, between the
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machines of INTEGREX i/e-Series and the other turning machines.

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Issuance of the wrong G-code or M-code command results in totally non-intended

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machine operation. Thoroughly understand the system of G-code and M-code commands
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before using this system.
Sample program Machines of INTEGREX i/e-Series Turning machines

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S1000M3 The milling spindle rotates at 1000 min . The turning spindle rotates at 1000 min–1.
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S1000M203 The turning spindle rotates at 1000 min . The milling spindle rotates at 1000 min–1.
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Serial No. 289476
SAFETY PRECAUTIONS
 For the machines of INTEGREX i/e-Series, programmed coordinates can be rotated using
an index unit of the MAZATROL program and a G68 command (coordinate rotate com-
mand) of the EIA/ISO program. However, for example, when the B-axis is rotated through
WARNING
180 degrees around the Y-axis to implement machining with the turning spindle No. 2, the
plus side of the X-axis in the programmed coordinate system faces downward and if the
program is created ignoring this fact, the resulting movement of the tool to unexpected
positions may incite collisions.
To create the program with the plus side of the X-axis oriented in an upward direction, use
the mirror function of the WPC shift unit or the mirror imaging function of G-code
command (G50.1, G51.1).
 After modifying the tool data specified in the program, be sure to perform the tool path
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check function, the Virtual Machining function, and other functions, and confirm that the
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program operates properly. The modification of tool data may cause even a field-proven
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machining program to change in operational status.
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If the user operates the machine without being aware of any changes in program status,
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interference with the workpiece could arise from unexpected operation.
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For example, if the cutting edge of the tool during the start of automatic operation is
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present inside the clearance-including blank (unmachined workpiece) specified in the
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common unit of the MAZATROL program, care is required since the tool will directly move
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from that position to the approach point because of no obstructions being judged to be
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present on this path.
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For this reason, before starting automatic operation, make sure that the cutting edge of
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the tool during the start of automatic operation is present outside the clearance-including
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workpiece specified in the common unit of the MAZATROL program.

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 If axis-by-axis independent positioning is selected and simultaneously rapid feed selected

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for each axis, movements to the ending point will not usually become linear. Before using
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these functions, therefore, make sure that no obstructions are present on the path.
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CAUTION
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 Before starting the machining operation, be sure to confirm all contents of the program
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obtained by conversion. Imperfections in the program could lead to machine damage and
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operator injury.
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Serial No. 289476
SAFETY PRECAUTIONS
Operations
 Single-block, feed hold, and override functions can be made invalid using system
variables #3003 and #3004. Execution of this means the important modification that
makes the corresponding operations invalid. Before using these variables, therefore, give
WARNING
thorough notification to related persons. Also, the operator must check the settings of the
system variables before starting the above operations.
 If manual intervention during automatic operation, machine locking, the mirror image
function, or other functions are executed, the workpiece coordinate systems will usually be
shifted. When making machine restart after manual intervention, machine locking, the
mirror image function, or other functions, consider the resulting amounts of shift and take
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the appropriate measures. If operation is restarted without any appropriate measures
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being taken, collision with the tool or workpiece may occur.
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 Use the dry run function to check the machine for normal operation at no load. Since the
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feed rate at this time becomes a dry run rate different from the program-designated feed
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rate, the axes may move at a feed rate higher than the programmed value.
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 After operation has been stopped temporarily and insertion, deletion, updating, or other
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commands executed for the active program, unexpected operation of the machine may
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result if that program is restarted. No such commands should, in principle, be issued for
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the active program.
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 During manual operation, fully check the directions and speeds of axial movement.
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 For a machine that requires manual homing, perform manual homing operations after
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turning power on. Since the software-controlled stroke limits will remain ineffective until
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CAUTION
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manual homing is completed, the machine will not stop even if it oversteps the limit area.
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As a result, serious machine damage will result.

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 Do not designate an incorrect pulse multiplier when performing manual pulse handle feed
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operations. If the multiplier is set to 1000 times and the handle operated inadvertently,
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axial movement will become faster than that expected.

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S-5
Serial No. 289476
REQUEST TO THE USER
REQUEST TO THE USER
Request for Saving Data of Machining Programs

Machining programs saved on the local disk of the NC unit may not be read out in the event of
accidental local disk trouble. The user, therefore, is earnestly requested to back up and store
every machining program of importance at regular intervals onto an external memory (USB
memory, SD card, etc.).
 The procedure for data storage is detailed in the Operating Manual, Part 3
(OPERATING NC UNIT AND PREPARATION FOR AUTOMATIC
OPERATION), Chapter 10, (DISPLAYS RELATED TO DATA STORAGE).
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 Always use an initialized USB memory or SD card. The USB connector and
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the SD card slot are located on the right side of the machine operating panel.
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USB memory SD card
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 On machines with a random ATC feature, each actual ATC operation changes the tool
data (in pocket numbers). Be sure not to run the machine after loading the externally
stored data of the TOOL DATA display without having confirmed the data’s
CAUTION correspondence to the current tooling on the magazine. Otherwise the machine cannot be
be guaranteed to operate normally.
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Serial No. 289476
BEFORE USING THE NC UNIT
Limited Warranty
The warranty of the manufacturer does not cover any trouble arising if the NC unit is used for its
non-intended purpose. Take notice of this when operating the unit.
Examples of the trouble arising if the NC unit is used for its non-intended purpose are listed
below.
1. Trouble associated with and caused by the use of any commercially available software
products (including user-created ones)
2. Trouble associated with and caused by the use of any Windows operating systems
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3. Trouble associated with and caused by the use of any commercially available computer
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equipment
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Operating Environment
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1. Ambient temperature
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During machine operation: 0° to 50°C (32° to 122°F)
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2. Relative humidity
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During machine operation: 10 to 75% (without bedewing)
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Note : As humidity increases, insulation deteriorates causing electrical component parts to

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deteriorate quickly.
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Network Setting
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The NC unit operates using dedicated network adapters.

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Note 1: Do not change the settings of the following two network adapters. Any changes will
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prevent the NC unit from operating normally.

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 Ethernet_NC (IP address:192.168.100.2)

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 NC Trainer Virtual Network (IP address:192.168.202.10)

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Serial No. 289476
Note 2: Use “Ethernet_PC” to connect the NC to an intra-factory network and other systems.
Do not use, however, the following network addresses: “192.168.100.xxx” and
“192.168.202.xxx”
 If the setting of the network adapter “Ethernet_PC” is changed, other systems

connected to the network may not operate normally. So, be sure to check the
settings of the other systems on the network as well. Here are some
examples of systems connected to the network.
Other systems Sections describing how to configure network settings
Smooth PMC Operating Manual of the Smooth PMC
“Network Setting for the MAZATROL at the Machine”
TOOL HIVE Operating Manual & Maintenance Manual of the Extended
TOOL HIVE
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“How to Change Network Settings”
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Magazine display unit for Operating Manual of the Visual Tool ID/Data Management
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Tool ID (touch panel) “CONNECTING TO THE LOCAL AREA NETWORK”
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Note 3: If you configure network settings for the NC unit, using Internet Information Services
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(IIS) on Windows, do not use the following port numbers.
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
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 683
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 43816
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 55555
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
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55556 A

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57400
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Serial No. 289476
CONTENTS
1 AUTOMATIC OPERATION EXECUTION ............................................ 1-1
1-1 Automatic Operation Execution Procedure......................................................... 1-2
1-2 Types of Automatic Operation Mode .................................................................. 1-3
1-2-1 Automatic operation .............................................................................................. 1-4
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1-2-2 Restart operation/Smooth restart operation ........................................................... 1-8
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1-2-3 Single-process mode operation ........................................................................... 1-25
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1-2-4 MDI operation ..................................................................................................... 1-27
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2 SELECTING EXECUTION CONDITIONS ........................................... 2-1
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2-1 Optional Stop ...................................................................................................... 2-2
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2-1-1 Procedure ............................................................................................................. 2-2

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

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2-2 Dry Run .............................................................................................................. 2-3

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2-2-1 Selecting Dry Run function .................................................................................... 2-3

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2-2-2 Cancelling Dry Run function .................................................................................. 2-4

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2-3 Machine Lock ..................................................................................................... 2-5

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2-3-1 Procedure ............................................................................................................. 2-5

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2-3-2 Description ............................................................................................................ 2-5

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2-4 Work Light .......................................................................................................... 2-5

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2-4-1 Procedure ............................................................................................................. 2-5
2-5 Barrier Cancel Function ...................................................................................... 2-6
2-5-1 Procedure ............................................................................................................. 2-6
2-6 Barrier Cancel Teach.......................................................................................... 2-6
2-6-1 Procedure ............................................................................................................. 2-6
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Serial No. 289476
2-7 Block Skip........................................................................................................... 2-8
2-7-1 Procedure ............................................................................................................. 2-8
2-7-2 Description ............................................................................................................ 2-8
2-8 Single Block ........................................................................................................ 2-9
2-8-1 Procedure ............................................................................................................. 2-9
2-8-2 Description ............................................................................................................ 2-9
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2-9 Comparison Stop .............................................................................................. 2-10
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2-9-1 Setting procedure ................................................................................................ 2-10
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2-9-2 Description .......................................................................................................... 2-11
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2-10 Z-axis Cancel ................................................................................................... 2-13
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2-10-1 Procedure ........................................................................................................... 2-13
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2-10-2 Description .......................................................................................................... 2-13

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2-11 MST Lock ......................................................................................................... 2-14

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2-11-1 Procedure ........................................................................................................... 2-14

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2-11-2 Description .......................................................................................................... 2-14

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2-12 ATC Stop .......................................................................................................... 2-14

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2-13 Threading Position Teach (Optional) ................................................................ 2-15

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2-13-1 Procedure ........................................................................................................... 2-15

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

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3-1 Rapid Traverse Override .................................................................................... 3-1
3-1-1 Procedure ............................................................................................................. 3-1
3-2 Cutting Feed Override ........................................................................................ 3-2
3-2-1 Procedure ............................................................................................................. 3-2
3-2-2 Rate of feed during dry run .................................................................................... 3-2
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Serial No. 289476
3-3 Spindle Speed Override ..................................................................................... 3-3
3-3-1 Procedure ............................................................................................................. 3-3
3-4 VFC Function ..................................................................................................... 3-4
3-4-1 Procedure ............................................................................................................. 3-4
3-4-2 Description ............................................................................................................ 3-4
3-5 AFC Function ..................................................................................................... 3-8
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3-5-1 Setting the desired current load value ................................................................... 3-9
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3-5-2 Tools available with AFC and AFC supervisory modes ....................................... 3-10
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3-5-3 Functional operation ............................................................................................ 3-10
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3-6 Spindle Speed Waving Function (Optional) ...................................................... 3-12
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Procedure ........................................................................................................... 3-13
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3-6-2 Adjusting the spindle speed waving conditions .................................................... 3-16

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

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4-1 Emergency Stop ................................................................................................. 4-2

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4-1-1 Emergency stop .................................................................................................... 4-2

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

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4-2 Reset .................................................................................................................. 4-3

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

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

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4-5 Single-block Stop................................................................................................ 4-4
4-5-1 Single-block stop by changing within automatic operation modes ......................... 4-4
4-5-2 Single-block stop using the single block key.......................................................... 4-4
4-6 Program Stop ..................................................................................................... 4-4
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Serial No. 289476
4-7 Stopping by Turning the Power Off..................................................................... 4-4
5 MANUAL INTERRUPTION .................................................................. 5-1
5-1 TPS Function ...................................................................................................... 5-1
5-1-1 Storing the data of only the stop point of automatic operation ............................... 5-2
5-1-2 Storing the data of both the stop point of automatic operation and the
passage point(s) existing during manual interruption ............................................. 5-3
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5-1-3 Storing the data of only the passage point(s) existing during manual
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interruption ............................................................................................................ 5-4
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5-1-4 General remarks on TPS function ......................................................................... 5-4
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6 OPERATIONS POSSIBLE DURING AUTOMATIC OPERATION ........ 6-1
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6-1 Data Rewriting .................................................................................................... 6-1
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6-1-1 Data writing conditions .......................................................................................... 6-1

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7 COMPLETION OF OPERATION ......................................................... 7-1

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7-1 Procedure for Switching the Power OFF ............................................................ 7-1

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7-2 Cleaning and Inspections on Completion of Operation....................................... 7-2

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Serial No. 289476
AUTOMATIC OPERATION EXECUTION 1

1 AUTOMATIC OPERATION EXECUTION
Automatic operation of the machine according to previously created programs and data is
referred to as automatic operation.
Automatic operation becomes possible just by selecting the program to be executed and then
starting it, provided that errors are not present in the program or data. No other operations are
required.
During automatic operation, however, it is possible to stop the machine action, to change the
cutting conditions, or to generate hand interrupts.
This chapter describes automatic operation execution procedures.
 See PART 3 “OPERATING NC UNIT AND PREPARATION FOR AUTO-
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MATIC OPERATION” of the Operating Manual for the details of the operation
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on the NC screen.
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1-1
Serial No. 289476
1-1 Automatic Operation Execution Procedure

The description given below assumes that tooling, machine adjustment, programming, and
automatic operation data setting have already been completed. Here, general working proce-
dures to be used after completion of those operational setup jobs are described.
Calling up the program to be executed in the automatic operation mode
Selecting automatic operation execution conditions
.

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Single-block and optional-stop operation
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 Dry run and machine locking
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 Coolant injection
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
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Use of barrier release
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Adjusting the cutting conditions
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 Rapid feedrate overriding
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 Cutting feedrate overriding
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 Spindle speed overriding
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Mounting a workpiece
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Moving the tool away by tool offsetting

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 Setting on the TOOL DATA or TOOL OFFSET display

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Automatic operation (Test cutting)

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 Barrier cancel teach function

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Measuring the machined workpiece and editing the program

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 Editing the cutting conditions in the program

 Modifying the tool offset data
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Automatic operation (Mass production)

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Terminating operation
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Turning power off
Checking and cleaning
1-2
Serial No. 289476

1-2 Types of Automatic Operation Mode
Automatic operation can be executed using the programs registered within the NC unit or
EIA/ISO programs stored on paper tapes, microdisks, or other such external media.
The machine can also be made to automatically execute non-program data that the operator
may have set as required.
1. Memory operation mode
The memory operation mode is used to execute a program registered in the NC memory.
This mode is selected by pressing the key shown in the figure.
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Memory operation key
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2. Tape operation mode
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The tape operation mode is used if a registered EIA/ISO program within an external unit is
O
to be both loaded and executed at the same time.
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The tape operation mode will be selected when the lamp of the
A key shown in the
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figure is turned on by pressing this key.

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Tape operation key

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3. MDI mode
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The MDI mode is used to let the machine execute non-program data.
This mode is selected by pressing the key shown in the figure.
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MDI key
1-3
Serial No. 289476
1-2-1 Automatic operation
1. Memory operation mode (to execute the programs registered within the NC unit)
(1) Press the key.

(2) Select a program to be executed. (This operation is referred to as “work number search.”)
Carry out the following procedure.
(a) Call the POSITION display.
(b) Tap the [WORK No.] menu item.
 The WORK No. SELECT window will be displayed.
(c) Set the work number of the program to be executed.
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Example : To execute the program of work number 100:
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<Procedure 1>
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Tap WORK No. field of the WORK No. SELECT window and then 1 , 0 , 0
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and the [OK] button.
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<Procedure 2>
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Select the work No. 100 in the WORK No. SELECT window and then tap the [OK]
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.A
button.
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(3) Select automatic operation execution conditions.
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The menu that contains the menu items shown below is referred to as “execution conditions
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A
selection menu for automatic operation”. And the key shown below is referred to as
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“execution conditions selection key for automatic operation”.

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Selecting these items and key enables you to determine under what conditions the machine
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is to be operated in auto mode.

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 [OPTIONAL STOP]:
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If this item is selected, automatic operation can be stopped at M01 position within the
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program.
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 [DRYRUN]:
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If this item is selected together with the key, automatic operation can be started at
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a manually adjusted feedrate instead of the feedrate specified in the program.

A
 [MACHINE LOCK]:
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If this item is selected together with the key, automatic operation can be started
without actually performing any axis movements.
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 [WORK LIGHT]:
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If this item is selected, the illumination lamps mounted on the machine can be turned on.
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 [BLOCK SKIP]:
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If this item is selected, any block of the program can be skipped during program
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execution. This item is valid only if the program is an EIA/ISO program.

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 [BARRIER CANCEL]:
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If this item is selected, all barriers are cancelled, including tool barriers and chuck
barriers.
 [BARRIER CANCEL TEACH]
If this item is selected when a barrier alarm is raised during automatic operation,
automatic operation can be resumed from the alarm stop position.
 [ATC STOP]:
If this item is selected, the machine action will stop upon completion of the machining
with the tool currently used.
1-4
Serial No. 289476

 [Z AXIS CANCEL]:
If this item is selected together with the key, automatic operation can be
performed with no movement of the Z-axis.
 [MST LOCK]:
If this item is selected together with the key, automatic operation can be
performed with the M-, S-, T- and B-codes totally skipped.
During MST LOCK execution, M3 command is not output and the spindle does not rotate.
Select MST LOCK function together with the DRY RUN function. If the DRY RUN
function is not valid, the feed per revolution command causes the 133 STOP SPINDLE
alarm.
 If the key is pressed, the program can be executed in steps of one block.
d .
Remark 1: During automatic operation, it is possible to select or cancel the execution
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conditions.
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Remark 2: Some of the above menu items are not displayed until the [TEST] menu item
has been selected.
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 See Chapter 2, “SELECTING EXECUTION CONDITIONS”, for a detailed
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description of the usage of the above menu items and key.
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(4) Adjust the cutting conditions.
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 Perform the following procedure only when adjustments are to be made to the pro-
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grammed cutting conditions (rate of feed and surface speed of the spindle).
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 Adjust the rapid traverse speed using the rapid traverse override switch.
28
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Rapid traverse
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override switch
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D747S40001
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 Adjust the cutting feedrate using the cutting feed override switch.
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Cutting feed override

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switch
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D747S40002
1-5
Serial No. 289476
 Adjust the surface speed (number of revolutions) of the spindle using the spindle speed
override keys.
Spindle speed
override keys
D747S40003
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 The symbol-marked type of spindle whose data is to be overridden differs as follows:
s er
Symbol Spindle Symbol Spindle
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Turning spindle of the headstock 1 Milling spindle of the upper turret
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Turning spindle of the headstock 2 Milling spindle of the lower turret
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Remark 1: For a machine without headstock 2, the symbol only for the turning spindle of
N
the headstock 1 side is displayed.
O
Remark 2: For a machine without a lower turret, the symbol only for the milling spindle of
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the upper turret side is displayed. A

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 During automatic operation, the cutting conditions can be adjusted using the override
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switches and keys.

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 See Chapter 3, “CHANGING THE CUTTING CONDITIONS”, for a detailed

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description of the usage of the override switches and keys.

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Note 1: The cutting conditions specified in the program will remain unchanged even after
IM
they have been adjusted using the override switches and keys. Use the VFC
K
function if their overriding is required. See Section 3-4, “VFC Function” for details.
ZA
A
 See Section 3-4, “VFC Function” for a detailed description of the usage of the
M
VFC Function.
YA
3
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Note 2: The cutting feed override becomes 100% during threading or tapping. After these
)2
processes have been completed, the original, preadjusted value is restored auto-
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matically.
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Note 3: Separate override data are stored for automatic operation and manual operation.
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Note 4: The milling spindle override function for the lower turret will not be displayed if the
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lower turret is not installed or does not have milling-spindle function.

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(5) Press the key.
(6) Press the button.

 The automatic operation will start.
 The button stays lighting while automatic operation is in progress, and goes out
when automatic operation terminates.
Note : Before pressing the button, make sure that the key stays orange.
1-6
Serial No. 289476

2. Tape operation mode (to execute EIA/ISO programs stored on external media)
(1) Connect the external unit to the NC unit.
 For connection between the NC unit and the paper tape unit or microdisk unit
you are going to use, refer to the relevant Operating Manual for the external
unit.
(2) Press the key.

(3) Call the POSITION display.
 This display call is required for you to check the intended program and the operational
status of the machine.
.
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(4) Select automatic operation execution conditions.
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 The selection method is the same as that used when executing the programs registered
ser
within the NC unit.
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(5) Adjust the cutting conditions.
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 The adjustment method is the same as that used when executing the programs
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registered within the NC unit.
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(6) Call the starting part of the program.
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 The calling method is the same as that used when executing the programs registered
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within the NC unit.
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(7) Start automatic operation. A

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 The starting method is the same as that used when executing the programs registered
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within the NC unit.

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1-7
Serial No. 289476
1-2-2 Restart operation/Smooth restart operation

There are two different functions provided, as shown below, to resume, from the desired position
in the program, an automatic operation interrupted in an unusual way:
 Restart operation:
Operation can be resumed from an arbitrary position in the program.
 Smooth restart operation:
Operation can be resumed from a position which is automatically searched for on the basis of
the information, stored in the NC memory, on an interruption due to resetting or a power
failure.
Note : The function for Smooth restart operation may not be available depending upon the
.
specifications of the machine.
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The procedure up to activation of the restart operation is described below.
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The following description assumes that operations, such as a search for the work number of the
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program to be restarted, selection of execution conditions, etc. have already been completed.
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Restart from a position in a subprogram is limited to the following cases:
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 The case where both the main program and the subprogram come under the category of
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MAZATROL programs.
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 The case where both the main program and the subprogram come under the category of
N
O
EIA/ISO programs.
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For example, if the main program comes under the category of MAZATROL programs and the
A
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subprogram comes under the category of EIA/ISO programs, then it is not possible to restart
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from that subprogram.

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 See Subsection 1-2-1, “Automatic operation” for more details of operations

N
such as a search for the work number of the program you may wish to restart
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and selection of execution conditions.

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1-8
Serial No. 289476

1. Restart operation for a MAZATROL program
A. Basic procedure
(1) Press the key.

(2) Tap the [RESTART] menu item.
 The SELECT PROCESS window will be displayed.
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Remark 1: The icons shown below are displayed to the left of each process for which TPC
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relay points are specified.
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A
: Only approach relay points are specified.
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: Only escape relay points are specified.

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: Both approach and escape relay points are specified.

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Remark 2: The icon is displayed to the left of each process called by a subprogram
N
unit.
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Remark 3: The icon is displayed to the left of each process for which barrier cancel
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teach function is set.

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(3) Specify the machining process with which the restart operation is to begin.
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 Specify the desired process in the SELECT PROCESS window and tap the [OK] button.
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1-9
Serial No. 289476
 Selecting the process replaces the SELECT PROCESS window with the RESTART
(MAZATROL) window.
On condition that bit 4 of parameter F331 is set to one (1), a special RESTART
(MAZATROL) window as shown below is displayed for a point machining unit and C-axis
.
point machining unit in order that one of its shape sequences may be specified as restart
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position.
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Remark : The settings of TPC relay points, subprogram calls and barrier cancel teach
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are displayed in the RESTART (MAZATROL) window, as in the SELECT

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PROCESS window.
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(4) Perform settings as required for the NUMBER and REPEAT TIMES items. Depending upon
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the process selected in Step (3), these items are not to be specified, as is the case in the
A
example above with the NUMBER item whose field is displayed dull.
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 See Article B below for more information.

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 Specify the number of repetitions of the program execution in the REPEAT TIMES field.
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Example : For three time repetition in restart operation:

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Tap 3 to enter “3” in the REPEAT TIMES field.

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Irrespective of whether or not continuous execution is specified in the END unit of the
program in question, the programmed machining cycle will be repeated three times in a
succession of <from UNo. 4 Drilling with CTR-DR to END unit>, <from the beginning to
END unit> and <from the beginning to END unit>.
The program repetition, however, will be terminated properly when the target value of
the parts count (a data item on the POSITION display) has been reached, on condition
that the NUMBER item of the END unit is set to “1.”
1-10
Serial No. 289476

Note 1: The REPEAT TIMES setting is not necessary when the program section up to the
end is to be executed only once.
Note 2: To change the REPEAT TIMES setting, tap the REPEAT TIMES field to correct
the setting.
(5) Perform settings as required for the M CODE field.
 Set the M-codes to be executed preparatory to the restart operation.
Example : Setting M19 (Spindle orient)
Tap 1 and 9 to enter “19” in the M CODE field.
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Note 1: Up to six M-codes can be set for each restart operation.
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Note 2: Use the key as required to delete the M-code last specified.
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 The program execution will restart from the specified restart position.
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 The
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button will light up, the M-codes set in Step (5) will be executed in order, and
28
then machining operation will be restarted as specified.

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 The button will go out when program execution ends.

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Note 1: Restart operation cannot be started from within an EIA/ISO program which is called as
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a subprogram.
A
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Main program (WNo. 100)

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UNo. MAT TYPE

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0 CST IRN ONLY MILL.

A
UNo. UNIT
M
EIA/ISO subprogram (WNo. 101)

1 WPC
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UNo. UNIT DIA

G28XYZ
3
2 DRILLING 10. :
01
UNo. UNIT WNo. : Cannot be specified as a

)2
3 SUB PRO 101 G0X-10. restart position.

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UNo. UNIT DIA :

:
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4 DRILLING 20.
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:
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Note 2: The RESTART window will disappear when the button is pressed.
1-11
Serial No. 289476
B. Restarting a program with processes to be executed repeatedly

If a program has a multi-piece machining command specified in the common unit or a repetition
command specified in a subprogram unit, the program contains some processes to be executed
repeatedly in one cycle of operation. When such a process is specified in the SELECT PRO-
CESS window as a restart position, the RESTART (MAZATROL) window will be displayed as
follows:
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Use the NUMBER field to specify the desired process with a sequence number of the workpiece
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or repetition, with reference to the indication of the setting range in parentheses (from 0 to 2 in
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the above example).
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The following example is given for a program with a multi-piece machining command.
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Example : If program structure is as shown below:
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Main program (WNo. 10)
N
UNo. SNo.
O
0 Common unit
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OFS-1
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OFS-2 A
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1 WPC unit
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2
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3 DRILLING unit
N
1 CTR-DR
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2 DRILL
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FIG: PT
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Subprogram (WNo. 11)

A
4 SUB PRO unit

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(for WNo. 11) UNo. SNo.

5 DRILLING unit 0 Common unit
K
1 CTR-DR OFS-3
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2 DRILL OFS-4
A
FIG: PT 1 LINE CTR unit

M
6 SUB PRO unit 1 END MILL

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(WNo. 11) FIG: SQR

7 2 END unit
3
END unit
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1-12
Serial No. 289476

The machining order is as follows:
Work number and unit number

Order number Tool of the program to be executed
1) OFS-1 Spot drill
2) OFS-2 Spot drill
WNo. 10, UNo. 3
(1st time) 3) OFS-1 Drill
(A) ⇒ (2nd time) 4) OFS-2 Drill
[1st time] 5) (OFS-1)+(OFS-3) End-mill
[2nd time] 6) (OFS-1)+(OFS-4) End-mill WNo. 11, UNo. 1
[3rd time] 7) (OFS-2)+(OFS-3) End-mill (First call of the subprogram)
[4th time] 8) (OFS-2)+(OFS-4) End-mill
9) OFS-1
.
Spot drill
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10) OFS-2 Spot drill
WNo. 10, UNo. 5
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(3rd time) 11) OFS-1 Drill
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(4th time) 12) OFS-2 Drill
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(B) ⇒ [6th time] 14) (OFS-1)+(OFS-4) End-mill WNo. 11, UNo. 1
(Second call of the subprogram)
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N
The SELECT PROCESS window will be displayed for this program as follows:
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(A): To restart from machining order 4), perform settings as follows:

[1] Select the second line in the SELECT PROCESS window and tap the [OK] button.
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1-13
Serial No. 289476
[2] Set “2” in the NUMBER field of the RESTART (MAZATROL) window.
 Setting of “2” is required since machining order 4) refers to drilling process of the drilling
unit on the second workpiece as specified in the main program.
[3] If necessary, set the M-codes to be executed preparatory to the restart operation.
d.
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(B): To restart from machining order 14), perform settings as follows:
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[1] Select the sixth line in the SELECT PROCESS window and tap the [OK] button.
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O
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Set “2” in the NUMBER field of the RESTART (MAZATROL) window.

A
[2]
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3
01
 Setting of “2” is required since machining order 14) refers to end-milling process of the
)2
line-center unit on the second workpiece as specified in the subprogram.

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[3] If necessary, set the M-codes to be executed preparatory to the restart operation.
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1-14
Serial No. 289476

2. Smooth restart operation for a MAZATROL program
(1) Press the key.

 The SELECT PROCESS window will be displayed.
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(3) Tap the button.
.A
N
O
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N
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A
 A search will be performed for the process the execution of which has been interrupted.
M
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(4) Confirm the process that is selected as restart position in Step (3) by tapping the [OK]
button.
3
01
(5) Proceed with the same steps as for normal restart operation up to starting the machine.
)2
 See the description given above under 1 “Restart operation for a MAZATROL
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program” for more information.

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1-15
Serial No. 289476
3. Restart operation for an EIA/ISO program
(1) Press the key.

 The RESTART (EIA/ISO) window will be displayed.
(3) Perform settings as required to specify the restart position.
[1]
[2]
[3]
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[4]
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Remark : The following window will be displayed ｆor machines with lower turret.
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[1]
N
[2]
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[3]
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[4] A
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[1]
O
N
[2]
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[3]
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[4]
A
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K
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[1] Work No.

A
[2] Sequence No.

M
[3] Block No.

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[4] If the sequence specified in [2] is repeatedly used in the program, specify how many
3
times of use are required to reach the intended position for restart.
01
)2
Example : If the program is constructed as follows:

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Main program 2nd and 3rd Subprogram O9001

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(b, c)
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1st
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a N5 G01... N5 M...
M98 P9001
M98 P9001
1-16
Serial No. 289476

In this example, sequence number 5 is used in three different positions.
Therefore:
Input “1” to restart from position a.
Input “2” to restart from position b.
Input “3” to restart from position c.
Note : Tap [PROGRAM LIST] button to specify the work No., item [1], by selecting from
the WORK No. SELECT window opened.
d .
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.A
N
(4) Make sure that all the data fields [1] to [4] above have been filled in and tap the [RESTART
O
SEARCH] button.
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 A search will be made for the restart position.

A
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Note : The search can be started by tapping the key on the screen keyboard.
28
 After the search is completed, the current status of S-, F-, T- and M-codes resulting from
R
o.
O
N
the restart position search will be indicated in the EIA/ISO RESULT window.
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A
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3
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Remark : The following window will be displayed ｆor machines with lower turret.
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Note 1: If the restart position was not found, then an alarm message will be displayed. In
that case, the restart command data must be checked for errors.
1-17
Serial No. 289476
Note 2: Since the sequence numbers (preceded by N) used in a section of high-speed

machining mode (G05P2) are always skipped as meaningless codes, use of such
a sequence number for specifying the restart position will always cause the search
operation to fail.
 Set the M-codes to be executed preparatory to the restart operation.
Example : Setting M19 (Spindle orient)
Tap 1 , 9 and on the screen keyboard to enter “19” in the M CODE
field.
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.A
N
O
Note 1: Up to six M-codes can be set for each restart operation.
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Note 2: Use the A

key as required to delete the M-code last specified.
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28

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o.
N
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 The
ri
button will light up, the M-codes set in Step (5) will be executed in order, and
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Se

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K
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A
M
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3
01
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1-18
Serial No. 289476

4. Smooth restart operation for an EIA/ISO program
(1) Press the key.

(2) Call up the EIA MONITOR display by tapping on the POSITION display or in another
way.
(3) Tap on the EIA MONITOR display.
 A window with the setting items for smooth restart operation will be opened on the
screen.
[1]
.
[3]
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[2]
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[4]
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[5]
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A
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28
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[6]
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K
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No. Item Description

K
[1] WNo. Work number, or name, of the (main) program the execution of which has
ZA
been interrupted.
If the program concerned is a subprogram, the work number, or name, of the
A
subprogram is indicated additionally on the lower row in parentheses.

M
YA
[2] RESTART START Indication of the starting and ending point, in machine coordinates, of the
POSITION, block from which to restart the operation.
3
START/END
01
[3] Selection of the restart Select the position for smooth restart. (*1)
)2
position Selection is to be done from among the options not grayed out.
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HOLD Block that was being executed at the moment of reset-

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POSITION ting, occurrence of an alarm, or power failure.

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TOOL
CHANGE Blocks of the last tool change commands
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HOLD Block preceding an operation that cannot be stored as

POSITION an information item on the interruption. (*2, *3, *4)
[4] Modal S, F, M, B, G Modal conditions under which the block at the restart position is executed.
[5] M-codes executed List of the M-codes that have been executed up to the restart block.
[6] M CODE Up to six M-codes to be executed preparatory to the smooth restart operation.
1-19
Serial No. 289476
*1 As for smooth restart operation on machines equipped with a lower turret, do not fail to
specify a restart position for both the upper and the lower turret; otherwise an attempt
to start a restart operation can only cause an alarm (144 ILLEGAL CYCLE START) to
be raised.
*2 Interruption of the execution of the following functions causes the preceding block to be
stored in the memory as an information item on the interruption.
 Fixed cycle operation flow (except hole machining fixed cycles),
 Hob milling, Polygonal machining,
 Block in a section of polar coordinate interpolation,
 Orbit machining,
 NURBS interpolation,
 Cylindrical interpolation, or
d.
 WHILE loop
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*3 As for interruption of a cycle operation in the mode of hole machining fixed cycle, the
s
block which has brought about the cycle operation interrupted will be stored in the
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memory as an information item on the interruption.
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*4 Execution of the following functions causes, in the whole succeeding section and for
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any interruption, the preceding block to be stored in the memory as an information item
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on the interruption.
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As for smooth restart operation on machines equipped with a lower turret, the block
N
O
that is being executed on the other turret’s side in the moment where the execution of
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one of the following functions is started will be stored in the memory as an information
76
item on the interruption. A

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94
PO
If the block in question on the other turret’s side, moreover, is also of the same type,
28
then blocks of tool change command are only available as the position for smooth
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o.
restart.
N
 Maker macroprogram (prepared by Mazak for internal processing, including macro-

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K
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call G-codes and M-codes, as specified in J parameters, for moving the tailstock,
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mounting an attachment, etc.),

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 Call of a MAZATROL program as a subprogram,

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 Cross machining control,

K
 W-axis thrust control,

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 Parallel axes composition control,

A
 Measurement macro, Compensation macro,

M
 Ethernet operation,
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 Subprogram call from a program stored in the HDD OPERATION PROGRAM area,
3
or
01
 Selection of a tool for “pinch cut” (PINCHCUT) or “turning with Y-axis control”
)2
(Y TURNING).
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(4) Select the restart position from among the options provided in the column [3].
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(5) Set in the M CODE field [6] as required the M-codes to be executed preparatory to the
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restart operation.
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 The button will light up, the M-codes set in Step (5) will be executed in order, and
1-20
Serial No. 289476

5. Limitations and notes on restarting
1. Before restarting, data of the items listed below must be made to coincide with those which
are required for the restarting position.
1) For EIA/ISO programs
 Pallet number
 M-, S-, T-, and B-codes
2) For MAZATROL programs
 Pallet number
 Index angle
 Position of the 4th axis
Note : For programs using the M-code index table, it is possible to restart only from the
d .
machining program unit whose table angle is 0 degrees.
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2. All the data items must be filled in with data when setting restart data.
ser
3. In the case of EIA/ISO programs, the initial motion to the machining restart position occurs
re
using dry run when bit 7 of parameter K104 is set to 0. Therefore, the alarm 132 FEED-
ts
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RATE ZERO will be raised at the start of restart operation if the rate of feed for manual
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operation should be set to 0.
ll
When bit 7 of parameter K104 is set to 1, the initial motion occurs under the modal con-
.A
ditions (G00 or G01) resulting from the restart position search.
N
In the case of smooth restart for EIA/ISO programs, in particular, the initial motion occurs
O
with return to the machine zero point on the axes for which no movement commands are
TI
76
programmed when bit 4 of parameter F329 is set to 0. Change the parameter setting to 1,
A
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94
therefore, if the named return to the machine zero point is not desirable.
PO
28
4. Machining cannot be restarted from the middle of a MAZATROL subprogram.

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Example :
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G28U0W0
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… UNo. 1
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… UNo. 2
A
…
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M98 P100 Operation cannot be restarted from this

UNo. 5
… … section.
K
… UNo. 10
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M30
A
M
5. The restart search completion status is released only by pressing the key. Press the
YA
key and then the button to execute the program from the head.
3
01
6. The WNo. cannot be changed immediately after the restart search is finished. Before you
)2
change the WNo., press the reset key. Attempting to change the WNo. without pressing the
(c
key causes the 449 RESTART SEARCH FINISHED alarm.

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7. On machines equipped with a lower turret, operation should be restarted from a section
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where there is no risk of interference between the upper turret and the lower turret (for
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example, a section where their stand-by M-codes agree with each other) to avoid accidental
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mechanical interference.
As for smooth restart operation on machines equipped with a lower turret, do not fail to
specify a restart position for both the upper and the lower turret; otherwise an attempt to
start a restart operation can only cause an alarm (144 ILLEGAL CYCLE START) to be
raised.
8. Operation cannot be restarted from a section where cross machining is currently in
progress.
1-21
Serial No. 289476
9. If the upper turret and the lower turret (if provided) use the same spindle at the same time,
operation should be restarted from a section where both the upper and lower turrets are
placed in the milling or turning mode.
10. The position of restarting with an operation of the lower turret (if provided) must be in the
mode of G97 (cancellation of G96).
11. Current information on the interruption (for smooth restart operation) will be deleted by the
following operations.
 Pressing the button,

 Replacing the foreground program with another one on the POSITION display,
 Renumbering (Renaming) a program on the PROGRAM FILE display,
 Deleting a program on the PROGRAM FILE display,
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 Moving a program through the PROGRAM FILE display to another storage area,
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 Using the [PROGRAM COPY] menu function on the PROGRAM FILE display,
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 Converting a MAZATROL program into an EIA/ISO program on the PROGRAM FILE
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display, or
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 Loading a program on the DATA I/O display.
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Note : Current information on the interruption will be deleted by the above operations
.A
even if the program in question (i.e. foreground program) is not concerned.
N
12. As for smooth restart operation for a MAZATROL program, if the program layout has been
O
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changed in the meantime, then the SELECT PROCESS window can only be displayed by
76
tapping the A
button in its initial state (with the first process being marked with the
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94
PO
cursor). The operations that cause the program layout to change are as follows.
28
(a) Performing one of the following operations on the PROGRAM (MAZATROL) display
o.
 Changing the priority number setting

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 Enabling Control Out

K
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 Tapping the [PROGRAM COPY] menu item

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 Tapping the [UNIT COPY] menu item

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 Tapping the [MULTIPLE UNIT COPY] menu item

K
 Tapping the [ERASE] menu item

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 Tapping the [INSERT] menu item

A
M
 Tapping the [PRI. No. CHANGE] menu item

YA
 Tapping the [PRI. No. ASSIGN] menu item

3
 Tapping the [PRI. No. ALL ERAS] menu item

01
 Tapping the [DELAY PRIORITY] menu item

)2
 Tapping the [SUB PROG PROC END] menu item

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(b) Executing the [PROGRAM WRITE] menu function on the PROGRAM LAYOUT dis-
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play
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13. As for smooth restart operation for an EIA/ISO program, information on the interruption is
C
cleared from the memory if a program has been edited in the meantime.
Note : Current information on the interruption will be cleared by an editing operation even
if the program in question (i.e. foreground program) is not concerned.
14. As for smooth restart operation for an EIA/ISO program, the restart block’s starting and
ending point are in general indicated in the setting window in machine coordinates, but, in
particular, in workpiece coordinates if the block stands in the mode of five-axis machining or
inclined Y-axis control.
1-22
Serial No. 289476

15. As for smooth restart operation for an EIA/ISO program, operation is restarted without any
preparatory tool change operation if a HOLD POSITION is selected as restart position.
Make a preparation, therefore, for the tool to be used first if another tool has been made
ready for operation in the meantime.
16. As for smooth restart operation for an EIA/ISO program, only a modal M- and S-code con-
cerning the spindle rotation are automatically taken into account when bit 3 of parameter
F329 is set to 0. If it is set to 1, only an S-code concerned is automatically made valid. Use
the M CODE field in the setting window as required to set the M-codes to be executed
preparatory to the smooth restart operation.
On machines equipped with a lower turret, the last specified S-code is automatically output
for the selected turning spindle with reference only to that program section for a system
(upper or lower turret) in which an M-code for turning spindle selection is given later than in
.
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the other section. The spindle speed at the beginning of the restart operation may differ,
ve
therefore, from that of the stopped operation.
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–1
Example : If, after the cutting operation with the 2nd spindle being rotated at 1000 min
re
(according to S1000 in the program section for the lower turret) is interrupted for
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example by resetting, a restart operation is started with the blocks marked with an
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arrow as the restart positions (according to the proposal by the smooth restart
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function), the turning operation (by G1X_F_) will be executed with the 2nd spindle
.A
–1
being rotated at 500 min (since S500 is specified last in the program section for
N
the upper turret, in which an M-code for turning spindle selection [M902] is given
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later than in the other section).
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76
Program section for Upper turret A Program section for Lower turret
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94
G109L1 G109L2
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28
S500M3 M902 (2nd turning spindle selection)

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・・・ M302 (2nd spindle in turning mode)

o.
M950 (Waiting command) S1000M3

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M902 (2nd turning spindle selection) G1X_F_

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M302 (2nd spindle in turning mode) ・・・

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G1X_F_ M950 (Waiting command)

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・・・ M30
A
M30
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K
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17. As for smooth restart operation for an EIA/ISO program, the restart position automatically
A
determined may sometimes be a block in the preceeding section of the interrupted block if
M
the interruption has occured in the mode of high-speed machining (G5P2).

YA
18. As for smooth restart operation for an EIA/ISO program, Block Skip (menu) function cannot
3
be taken into account at all. The calculated position for restart operation may differ, there-
01
fore, from the real stop position if the interrupted operation was executed with the Block Skip
)2
function being activated.

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19. Smooth restart operation is always run under the current conditions (at the moment of
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pressing the start button ) concerning the parameters, system variables, macro-
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variables as well as the SMC data selection.

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20. Smooth restart operation cannot be run with manual interruption amount (for shifting the tool
path) being taken into consideration. The calculated position for restart operation may differ,
therefore, from the real stop position if manual interruption function was executed before the
interrupted operation.
21. Depending on the restart position and the machining contour, restart operation as well as
smooth restart operation may inappropriately be stopped due to an alarm raised by the
interference check function for automatic operation.
To avoid this problem, turn on the [STORE WORKPCE MATERIAL] menu function before-
hand, or rather turn off the [AUTO OP. SAFETY SHIELD] menu function.
1-23
Serial No. 289476
22. The function for smooth restart operation is not available on the TOOL PATH CHECK or
VIRTUAL MACHINING display.
23. No information on the interruption (caused by turning off) will be stored for a smooth restart
operation which is executed immediately after turning on.
24. As for an operation started using the normal [RESTART] or [RESTART2 NONMODAL]
menu function, the smooth restart function can or cannot be used after stopping the flow of
program execution as follows:
 [RESTART] ............................ Smooth restart function can be used,
 [RESTART2 NONMODAL] .... Smooth restart function cannot be used. (*)
* If the automatic operation has been stopped and then restarted by using the [RE-
START2 NONMODAL] menu function, then a smooth restart operation can be started
.
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from a block in the preceding section of that block the execution of which has been
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stopped before using the above-mentioned menu function unless the restarted operation
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should have been stopped by turning off.
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A
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K
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1-24
Serial No. 289476

1-2-3 Single-process mode operation
Select the single-process operation when a specific process within the program is to be
re-executed for an improved finish of workpieces.
This mode is also available for executing only the final machining phase (re-finishing) of a
threading unit.
The operating procedure for executing single-process mode operation is described below. This
description assumes that operations, such as work number search for the program to be used for
single-process mode operation, selection of execution conditions, etc. have already been
completed.
Note 1: Single-process mode operation can be executed only for machines with the turning
capability.
.
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Note 2: Single-process mode operation can be executed only for MAZATROL programs.
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 See Subsection 1-2-1, “Automatic operation” for more details of operations
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such as a search for the work number of the program you may wish to restart
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and selection of execution conditions.
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(1) Press the key.
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(2) Tap the [SINGLE PROCESS] menu item.
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 The SELECT PROCESS window will be displayed .
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A
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28
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K
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K
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A
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(3) Select the process to be executed.

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 Select the process using same procedure as for restart operation for MAZATROL
3
program.
01
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 See the step (3) of “To restart a MAZATROL program”.

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 After selecting the process, the SELECT PROCESS window will close and the SINGLE
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PROCESS window will open.

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1-25
Serial No. 289476

 Select the process using same procedure as for restart operation for MAZATROL
program.
 See the step (5) of “To restart a MAZATROL program”.
(5) For the THREAD unit, select whether the workpiece is to be refinished.
 When the process to be performed is THREAD (threading), select whether all threading
or only re-finishing (only the last cutting operation) is to be executed.
 To select only re-finishing, tap REFINISH OF THREAD. The check mark will be
d .
displayed at REFINISH OF THREAD in the window.
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 If re-finishing is to be canceled, tap REFINISH OF THREAD once again.
N
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The check mark will be cleared from REFINISH OF THREAD in the window.
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76

A
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28
 The
R
button will light up to indicate that the execution of the process you selected
o.
O
N
in procedural step (2) above has begun.

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 The
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button will go out when the execution of the selected process ends.
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Note 1: If remachining of workpieces is performed using the single-process mode, the

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cumulative tool operation time (CUT TIME of the TOOL DATA display) will be counted
K
but the cumulative number of machined workpieces (COUNTER of the POSITION

ZA
display) will not.

A
Note 2: Do not execute the single-process mode operation for synchronous or cross-
M
machining.
YA
Note 3: If F167 bit 3 = 0, when single-process machining is completed, the program header has
3
01
been called up automatically.

)2
If F167 bit 3 = 1, the [SINGLE PROCESS] menu function remains valid, even when
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single-process machining is completed. Pressing the button after completion of

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single-process mode operation causes the 763 START PROCESS ILLEGAL alarm.
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Cancel the [SINGLE PROCESS] menu function before restarting operation.

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Note 4: The machine status after single-process mode operation is as follows:

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TC144 bit 4 Machine status after single-process mode operation

0 Neither return operation nor tool change is executed.
1 Operation follows the settings of RETURN/ATC in the end unit (*) of the program.
Remark : The settings of TPC relay points, subprogram calls and barrier cancel teach are
displayed in the SELECT PROCESS window and the SINGLE PROCESS window.
1-26
Serial No. 289476

 For the settings in the end unit of the program, refer to the section of end unit
described in the PROGRAMMING MANUAL (MAZATROL Program).
 For the settings of TPC relay points, subprogram calls and barrier cancel
teach, see Subsection 1-2-2, “Restart operation/Smooth restart operation”.
1-2-4 MDI operation

MDI operation refers to the operation in which data that corresponds to an EIA/ISO program is
set by operator as required and executed. MDI operation is used to check particular machine
operation, to carry out operational setup, to execute simple EIA/ISO program, etc.
1. Basic operation
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(1) Press the key.
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 The MDI window will be displayed.
s
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ts
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MDI window
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.A
N
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TOOL TOOL M CODE T MSR T MSR MSR UNIT MSR UNIT
76
SELECT CHANGE
A AUTO SEMIAUTO IN OUT
R
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PO
28
Remark : Menu fonctions for MDI operation differ according to the particular machine
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o.
model.
O
N
(2) Input MDI data as required using the screen keyboard.

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K
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Note 1: Input data in the same format as an EIA/ISO program. Up to 247 characters can
Se
be set. (An EOB code (line feed code) requires two characters.)
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Note 2: To erase input data, following two methods are used:

K
 Using the
ZA
key causes the preceding character to be cleared.

A
 Use the key to cancel the entire data that has been set.
M
YA

3
01
 The button will light up and the data that was set in procedural step (2) will be
)2
executed.
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 After the entire data has been processed, the button will go out and the set data
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will be cleared.
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1-27
Serial No. 289476
2. Tool select
This operation should be carried out to move the tool accommodated in a magazine pocket to
the tool change position.
The operation procedure is described below.
(1) Press the key.
(2) Tap the [TOOL SELECT] menu item.
 This will cause the menu function to be enabled and a message box with TOOL
NUMBER? in it to be displayed.
(3) Specify the identification number of the pocket that accommodates the tool to be moved to
the tool change position.
d.
 “T M149” will then be displayed in the MDI window and the [TOOL SELECT] menu
ve
function will be disabled. ( above denotes the input pocket number.)
ers
(4) Select the conditions for executing the TOOL SELECT operation.
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 See the description of procedural step (3) of the item 1 in Subsection 1-2-1
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“Automatic operation”.
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N
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 This will cause the
76
button to light up and the tool that was specified in procedural

R
A
94
step (3) above to start moving to the tool change position.

PO
28
[When two or more tools are registered for the specified pocket]
R
o.
O
N
After entering the pocket number in step (3), the tool suffix.
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<Input format>
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“. ”
A
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: Number of the tool to be specified

: Suffix of the tool (see the table below.)
K
ZA
Normal tool
A
Suffix None A B C D E F G H J K L M
M
00 01 02 03 04 05 06 07 08 09 11 12 13
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Suffix N P Q R S T U V W X Y Z
3
01
14 15 16 17 18 19 21 22 23 24 25 26
)2
Heavy tool
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Suffix A B C D E F G H J K L M
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61 62 63 64 65 66 67 68 69 71 72 73
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Suffix N P Q R S T U V W X Y Z
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74 75 76 77 78 79 81 82 83 84 85 86
1-28
Serial No. 289476

3. Tool change
This operation should be carried out to mount a tool from the magazine onto the spindle.
If this operation is carried out with another tool being mounted on the spindle, then this tool will
be automatically returned to the required pocket and then the specified tool will be mounted on
the spindle.
The procedure for tool change operation is described below.
(1) Press the key.
(2) Tap the [TOOL CHANGE] menu item.
d .
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(3) Specify the identification number of the pocket that accommodates the tool to be mounted
er
on the spindle.
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 “Txxx T0 M6” will then be displayed in the MDI window and the [TOOL CHANGE] menu
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function will be disabled. (xxx denotes the specified pocket number, and “T0” denotes
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the identification number of the next tool specified. In the MDI operation mode, the next
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tool command is generally displayed as “T0”.)
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Example : To mount on the spindle the tool accommodated in pocket number 12:
.A
Tap 1 , 2 and in that order.
N
O
 This will cause “T012 T0 M6” to be displayed in the MDI window.
TI
76
A
(4) Select the conditions for executing the TOOL CHANGE operation.
R
94
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 See the description of procedural step (3) of the item 1 in Subsection 1-2-1
28
“Automatic operation”.
o.
O
N
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K
ri
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A
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 This will cause the button to light up and the tool that was specified in procedural
K
step (3) above to be mounted on the spindle.

ZA
 When the tool has been mounted on the spindle, the

A
button will go out.

M
[When two or more tools are registered for the specified pocket]
YA
After entering the pocket number in step (3), enter the tool suffix.
3
01
 See suffix tables in the item 2 “Tool select” for the tool suffix.
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<Input format>
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“XXX.”
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XXX: Number of the tool to be specified

: Suffix of the tool
1-29
Serial No. 289476
4. Setting the M-code

Two methods are available for setting the M-code in the MDI window. One is by using the menu
items, and the other by specifying the M-code using the screen keyboard. The procedure for
setting the M-code is described below.
(1) Press the key.
(2) Tap the [M CODE] menu item.
 This will cause a message box with M CODE (MDI)? in it to be displayed and the
following “M-code (auxiliary-function code) menus” to appear in the menu display area:
01 OPT 03 SPNDL 04 SPNDL 05 SPNDL 19 SPNDL 33 OUT 34 IN >>>
STOP. FWD REV STOP ORIENT MSR UNIT MSR UNIT
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 Each time the [>>>] menu item is selected, menu changeover occurs.
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Note : The items that will be displayed in the menu vary from model to model.
s
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(3) Set the M-codes as required.
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A. Setting the M-code by using the menu
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Select the function to be used, and tap the menu item appropriate to that function.
ll
.A
 “M” will then be displayed in the MDI window.
N
( denotes the identification number of the selected M-code.)
O
Example : If the [19 SPNDL ORIENT] menu item is selected, “M19” will be displayed in
TI
76
the MDI window. A

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94
B. Setting the M-code by using screen keybord

PO
28
Input the identification number of the desired M-code by using screen keybord.
R
o.
O
N
 “M” will then be displayed in the MDI window.

C
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( denotes the identification number of the selected M-code.)

ri
ZA
Se
Example : To set M71:

A
Tap 7 , 1 and in that order.

IM
 This will cause “M071” to be displayed in the MDI window.

K
ZA
 With this method, up to three digits are available for one M-code.
A
Remark : When executing the M-code which has been set as described above, first verify the
M
YA
execution conditions and then press the button.

3
01
 For details of the functions, see the Programming Manual (MAZATROL

)2
Programming) and the Operating manual of the machine.

(c
 For details of the execution conditions, see the description of procedural step
ht
(3) of the item 1. in Subsection 1-2-1 “Automatic operation”.

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1-30
Serial No. 289476

5. Measuring unit IN/OUT
This function is enabled only on machines equipped with the measuring unit for tool length
measurement. (It is disabled on machines with the laser measuring unit.)
Except some models, the measuring unit must be moved out of its storage position before the
tool length can be measured automatically or semi-automatically. In addition, after measurement
has been completed, the measuring unit must be replaced in its storage position.
 See the following Item 6, “Tool-length measurement”, for details of tool-length

measurement.
The operating procedures for moving the measuring unit in or out (MSR UNIT IN or OUT) are
d.
described below.
ve
er
A. Measuring unit OUT
s
re
(1) Press the key.
ts
gh
(2) Tap the [33 OUT MSR UNIT] menu item.
ri
 “M33” will be displayed in the MDI window.
ll
.A
N
O
TI
 This will cause the button to light up and move the measuring unit out of its
76
storage position. A
R
94
PO
28
When the measuring unit has reached the measurement position, the button will
R
o.
go out and menu function will be enabled.

O
N
C
al
B. Measuring unit IN
K
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Se
(1) Press the key.

A
IM
(2) Tap the [34 IN MSR UNIT] menu item.

 “M34” will be displayed in the MDI window.
K
ZA
A

M
YA
 This will cause the button to light up and move the measuring unit back to its
3
storage position.
01
)2
When the measuring unit has reached the storage position, the button will go out
(c
and the menu function will be disabled.

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6. Tool-length measurement
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This function is enabled only on machines equipped with the measuring unit for tool length
C
measurement. (It is disabled on machines with the laser measuring unit, and for the VORTEX i
series.)
Before starting a machining operation, it is necessary to measure the lengths of the tools that
have been mounted in the tool magazine and then to input the measured data to the LENGTH
item of the TOOL DATA display.
This operation is called “tool-length measurement”, for which are available the following three
methods:
1-31
Serial No. 289476
A. Full-automatic tool-length measurement

In the MDI operation mode, the length of a tool in the tool magazine can be measured
automatically. The measured data will be automatically set in the LENGTH item of the
TOOL DATA display. However, the tools whose lengths can be measured using this
method are limited to end-mills, chamfering cutters, and tools whose tips are on the
centerline of the spindle, that is, spot drills, drills, reamers, and taps.
Depending on the machine type, however, end-mill tools may not be measurable.
Also, chamfering tools can be measured only when the minimum tool diameter registered in
the TOOL FILE display is equal to or less than the value of the parameter L139.
B. Semi-automatic tool-length measurement
It is possible to semi-automatically measure the lengths of tools whose tips are not on the
centerline of the spindle, that is, end-mills, face-mills, chamfering cutters, boring bars, etc.
d .
ve
The measured data will be automatically set in the LENGTH item of the TOOL DATA
er
display.
s
re
C. Manual tool-length measurement
ts
It is possible with the TEACH function to manually measure the lengths of all types of tools.
gh
The measuring unit must be used for methods A and B, but not be used for method C. The
ri
operating procedures for full-automatic tool-length measurement and semi-automatic tool-length
ll
.A
measurement are described below.
N
 For details of the manual tool-length measurement procedure and measured-
O
TI
data setting procedure, refer to the section related to “TOOL DATA Display”
76
in PART 3. A
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94
PO
28
Note : Tool-length measurement for EIA/ISO program

R
On machines with the EIA/ISO option, the results of full- and semi-automatic
o.
O
N
tool-length measurement can directly be registered in data items on the TOOL

C
al
OFFSET display, under the following conditions:

ri
ZA
 Parameter F93 bit 3 = 0, and

Se
 Menu item of [EIA/ISO ONLY] is selected.

IM
K

ZA
data setting procedure for EIA/ISO programs, refer to the section related to
A
“TOOL OFFSET Display” in PART 3.

M
YA

3
01
(1) In the MDI operation mode, move the measuring unit out of its storage position.
)2
Remark : Depending on the model of machine being used, the measuring unit may have
(c
been locked in the measurement position. If this is the case, then it is not
ht
necessary to carry out the “measuring unit OUT” operation (nor “IN” operation).
ig
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(2) Call the TOOL DATA display on the screen.

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(3) Tap the [T MSR AUTO] menu item.

C
1-32
Serial No. 289476

(4) Specify the identification number (pocket number) of the tool whose length is to be
measured.
The number of tools that can be specified at one time is up to 39.
 When the tool number is input,
M196
T
T
:
M197
will be displayed in the MDI window. ( and  denote the tool numbers that
have been input.)
d.
Example : If the lengths of the tools with tool numbers 4, 5, and 6 (tools accommodated in
ve
pockets numbered 4, 5, and 6) are to be measured:
er
s
4 5 6
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Tap , , , , and in that order.
ts
gh
ri
This will cause
ll
M196
.A
T004
N
T005
O
T006
TI
M197
76
A
R
94
to be displayed in the MDI window.

PO
28
TOOL DATA display

R
o.
O
N
C
al
K
ri
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Se
A
IM
K
ZA
A
M
YA
Display becomes highlighted.

3
01
)2

(c
ht
 This button action causes the button to light up and the lengths of the tools which
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were specified in procedural step (4) above to be measured in sequence. (Tool change
yr
op
occurs automatically.)
C
Upon completion of measurement of each tool length, the measured values are auto-
matically indicated in the LENGTH item of the TOOL DATA display and the highlighted
state of the TNo. item is cleared.
After the lengths of all the specified tools have been measured, the button goes
out and the [T MSR AUTO] menu function will be disabled.
1-33
Serial No. 289476
Machine zero-point
Tool
length
Moving
distance
d.
ve
d b
er
s
c
re
Measurement sensor action point
(Skip signal turns on)
ts
Plunger
gh
Table Support
column
ri
ll
.A
Measuring unit
D735S0023
N
Fig. 1-1 Machine action in full-automatic tool length measurement
O
TI
Machine action in full-automatic measurement
76
A
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94
1. The specified tool is automatically mounted on the spindle.

PO
28
2. The tool moves downward along an extension of the centerline of the measuring unit.
R
o.
(See a.)
O
N
3. The tool tip touches the top face of the plunger, forcing it downward. (See b.)
al
K
ri
ZA
4. The downward moving speed of the tool decreases and the tool tip pushes the plunger
Se
down to the measurement sensor action point. (See c.)

A
IM
5. When the skip signal turns on, the tool starts moving upward and returns to the
K
machine zero-point. (See d.)

ZA
6. The NC equipment measures the distance the tool has moved, and calculates the
A
length of the specified tool.

M
YA
(6) Move the measuring unit back into its storage position.
3
Note : Do not touch the screen keybord while full-automatic tool-length measurement is in
01
progress. Otherwise, measured data may become invalid.

)2
(c

ht
(1) Mount on the spindle the tool whose length is to be measured.

ig
Use procedural steps (1) through (5) of Item 3, “Tool change”.

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(2) Move the measuring unit out of its storage position.

C
(3) Call the TOOL DATA display on the screen.

(4) Bring the tool tip close to the plunger of the measuring unit by manual operation. (Action a in
Fig. 1-2)
Note : Bring the tool tip close to the centerline of the plunger to increase the accuracy.
(5) Press the key to switch over from the manual mode to the MDI operation mode.
(6) Tap the [T MSR SEMIAUTO] menu item.
 This will cause the menu function to be enabled and a message box with MEAS. WITH
SPINDLE TOOL <INPUT>? in it to be displayed.
1-34
Serial No. 289476

(7) Tap the [OK] button in the message box.
 Subsequently, “M198” will be displayed in the MDI window.
Example : If the tool accommodated in pocket number 2 has been mounted on the spindle
in procedural step (1):
TOOL DATA display
.
d
Display becomes highlighted.
ve
er
s
re
 The machine acts in the same way as in full-automatic tool-length measurement, and the
ts
length of the tool which has been mounted on the spindle will be measured automatically.
gh
Upon completion of measurement of the tool length, the measured value will be auto-
ri
matically displayed in the LENGTH item of the TOOL DATA display and highlighted
ll
.A
N
O
At the same time, the button will go out and the [T MSR SEMIAUTO] menu
TI
function will be disabled.
76
A
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94
PO
Tool length
28
Machine zero-point
o.
O
N
C
al
K
ri
ZA
a
Se
A
IM
Moving
K
distance
ZA
A
M
YA
3
01
Plunger
)2
Measurement sensor action point

(Skip signal turns on)
(c
Measuring unit
ht
Support
ig
Table
column
yr
op
D735S0025
C
Fig. 1-2 Machine action in semi-automatic tool length measurement
(9) Move the measuring unit back into its storage position.
1-35
Serial No. 289476
7. Tool-length measurement (for VORTEX i series)
(1) Select the MDI operation mode by pressing the key.

SELECT CHANGE AUTO SEMIAUTO IN OUT

d .
ve
measured.
er
 The following is displayed in the MDI window.
s
re
G850Q0T##W1
ts
gh
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G850: G-code for calling the measuring macroprogram.
ll
.A
Argument Q: Measuring method. 0: Full- or 1: Semi-automatic.
Argument T: No. of the tool to be measured. (Only required for “Q0”)
N
Measurement continued? 0: Continued. 1: Terminated. (Only required for “Q0”)
O
Argument W:
TI
76
A
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94
pockets numbered 4, 5, and 6) are to be measured, tap 4 , , 5 , ,

PO
28
6 and in that order.

R
o.
 The following is displayed in the MDI window.

O
N
C
al
G850Q0T4W0
ri
ZA
G850Q0T5W0
Se
G850Q0T6W1
A
IM
K

ZA
A
M
YA
3
 Upon completion of measurement of each tool, the measured value is automatically dis-
01
)2
played in the LENGTH item of the TOOL DATA display and the highlighted state of the
(c
TNo. item is cleared. After measurement of all the specified tools the button goes
ht
out and the [T MSR AUTO] menu function will be disabled.

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 Finally the measuring unit is retracted (into the waiting position).

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C

(1) Mount the tool to be mesured onto the spindle (by tool change operation or manually).
(2) Press the key to display the following menu.

(3) Tap the [MSR UNIT OUT] menu item.

 “M33” is displayed in the MDI window.
1-36
Serial No. 289476

 The measuring unit is moved out of its waiting position.
(5) Perform a B-axis movement to the 90° position.
(6) Press one of the cutting feed/manual pulse feed keys ( , , or ).
(7) Bring the tool tip close to the plunger of the measuring unit by manual operation.
Remark : Bring the tool tip close to the centerline of the plunger to increase the accuracy.
Note, however, that the measurement cannot be started from an area where the
deceleration sensor is turned ON.
.
d
ve
s er
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(10) Tap the [OK] button in the message box. The following is displayed in the MDI window.
ts
gh
G850Q1
ri
ll
.A
N
O
TI
 The length of the tool mounted on the spindle is measured automatically.
76
A
 Upon completion of measurement of the tool, the measured value is automatically dis-
R
94
PO
played in the LENGTH item of the TOOL DATA display. Then the highlighted state of the
28
R
o.
TNo. item is cleared, the button goes out and the [T MSR SEMIAUTO] menu
O
N
function will be disabled.

al
 Return to the second zero point occurs on the X-axis upon completion of measurement.
ri
ZA
Se
(12) After measurement, tap the [MSR UNIT IN] menu item.
IM
 “M34” is displayed in the MDI window.

K
ZA

A
 The measuring unit is retracted (into the waiting position).

M
YA
C. Tool breakage detection

3
01
<MAZATROL program>
)2
Insert the following M-code into the machining program.

(c
M35
ht
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Sample program:
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op
UNo. UNIT DIA DEPTH CHAMF

C
3 DRILLING 8. 10. 0
SNo. TOOL NOM- No. HOLE- HOLE-DEP PRE-DIA PRE-DEP RGH DEPTH C-SP FR M M M
1 CTR-DR 20. 8.    90° CTR-D 35
2 DRILL 8. 8. 10. 0. 100 DRIL T 4.
Execution of the M35 command calls up M195 automatically before return of the tool concerned
for ATC. M195 calls up a macroprogram for checking the tool mounted on the spindle for
breakage.
1-37
Serial No. 289476
Remark : If a breakage amount exceeding the tool breakage margin (L6) is detected by the
measurement, processing will be executed in accordance with the particular setting of
parameter L7. Details of parameter L7 are shown below.
1: Single-block stop.
2: Machining is continued from the next process.
3: Single-block stop after preparation for continuing the operation from the next
process.
 For the definitions, description, and usage of processes, refer to the

description of the process end unit in the PROGRAMMING MANUAL
(MAZATROL Program).
<EIA/ISO program>
d .
ve
er
M195
s
re
ts
M195 calls up a macroprogram for checking the tool mounted on the spindle for breakage.
gh
If the tool is judged to be broken, 1 is written into common variable #532. Use #532 as required in
ri
an EIA macroprogram that includes breakage detection.
ll
.A
Sample program:
N
O
N001 
TI
T03M06
76
G90G54X100.Y-50. A
R
94
S1592M03
PO
28
G98G81R3.Z-5.F127M08
R
o.
G80G00Z50.M09
O
N
M195 ................................................ M-code for tool breakage detection

C
al
IF[#532 EQ 1] GOTO 003...... Stopping the program at alarm display

K
ri
ZA
G91G28Z0
Se

A
IM
N002 (DRL D13) .................................... Machining section of the next tool

G90G00G40G49G80
K
G91G30Y0Z0
ZA
T04T00M06
A
G90G54X100.Y-50.
M

YA
N003 M30................................................... Destination of jumping upon detection of tool breakage

3
01
Note 1: The result of breakage detection is stored in variable #532 when M195 is executed in
)2
the flow of an EIA program. Do not use common variable #532 for another purpose in
(c
an EIA program including M195 command.

ht
ig
Note 2: Breakage detection does not occur properly if tool offset data (stored on the TOOL
yr
OFFSET display) are used for tool length offset. Use MAZATROL tool data (stored on
op
the TOOL DATA display).

C
1-38
Serial No. 289476

8. Tool-length measurement (for VERSATECH)
A. Automatic tool-length measuring unit (Optional)

During measurement, the automatic tool-length measuring unit is positioned as in Fig. 1-3. This
unit conducts measurements by operating the Y-axis with the B-axis positioned at –90 deg and
the C-axis also at –90 deg. The automatic tool-length measuring unit is mounted on the cross rail,
and measurements can be conducted at any positions of the X-axis and the W-axis. The Z-axis
needs to be moved to the position of the third zero point (Z = –23) to measure the tool length.
The third zero point is the machine coordinate position used for full-automatic tool length
measurement and tool breakage detection. See Table 1-2 for further details.
.
d
ve
ser
re
ts
gh
ri
ll
.A
N
O
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76
A
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94
PO
28
R
o.
O
N
Z=0
C
(Upward stroke limit)

al
K
ri
ZA
Se
Z = –23
IM
(Tool length measuring position) D740S40001

K
Fig. 1-3 Tool length measuring position

ZA
Note 1: During measurement, tools exceeding 170 mm interfere with the open/close cover of
A
the automatic tool-length measuring unit.

M
YA
Note 2: The lengths of large-size tools exceeding 170 mm cannot be measured with the tool
center as its reference position.
3
01
Note 3: The minimum measurable tool length is limited to 110 mm by the maximum permissible
)2
stroke length of the Y-axis.

(c
ht
ig
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C
Tools exceeding 170 mm interfere

with the open/close cover. D740S40002
Fig. 1-4 Interference diagram of automatic tool-length measuring unit
1-39
Serial No. 289476
 During tool length measurement, pay extra careful attention to interference between the
spindle and the workpiece or other sections.
CAUTION
B. Full-automatic tool-length measurement

In the MDI operation mode, the length of a tool in the tool magazine can be measured
automatically. The measured data will be automatically set in the LENGTH item of the TOOL
DATA display. However, the tools whose lengths can be measured using this method are limited
to tools whose tips are on the centerline of the spindle.
(1) Tap the [TOOL DATA] menu item to display the following menu.
d .
ve
EDIT LENGTH LENG-OFS TOOL LIFE TOL LIST TOOL TOOL
TEACH TEACH SEARCH SEARCH INPUT OFFSET FILE
er
s
re
(2) Press the key to select MDI operation mode.
ts
gh
ri
ll
.A
N
 This will cause a menu changeover and a message box with MEASUREMENT
O
TI
POSITION? in it to be displayed.
76
X,W
A
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94
W ZERO X ZERO X,W ZERO

CURRENT
PO
POSITION POSITION POSITION

28
POSITON
R
o.
(4) Select the appropriate menu item according to the route along which the spindle is to be
N
moved.
al
K
ri
 To move the X- or W-axis to a position to reliably avoid tool-workpiece interference, it is

ZA
Se
suggested that the [X, W ZERO POSITION] menu item be selected.

A
IM
K
ZA
A
measured.
M
YA
 The number of tools that can be specified at one time is up to 31.

 When the tool number is input,
3
01
)2
G65P205420001Q
(c
M6TT0
G65P205420001Q2
ht
M6TT0
ig
yr
G65P205420001Q2
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M6TT0
C
G65P205420001Q2
M34
will be displayed in the MDI window.

Selection of [X, W CURRENT POSITON], [W ZERO POSITION], [X ZERO POSITION] , or
[X, W ZERO POSITION] displays the numeral 3, 4, 5, or 6, respectively, at the position of
“”.
1-40
Serial No. 289476

pockets numbered 4, 5, and 6) are to be measured:
Tap 4 , , 5 , , 6 and in that order.

This will cause
G65P205420001Q
M6T4T0
G65P205420001Q2
M6T5T0
G65P205420001Q2
M6T6T0
.
d
G65P205420001Q2
ve
M34
s er
re
to be displayed in the MDI window.
ts
gh
ri
ll
.A
N
O
TI
 Upon completion of measurement of each tool length, the measured values are auto-
76
A
matically indicated in the TOOL LENGTH item of the TOOL DATA display and the
R
94
PO
highlighted state of the TNo. item is cleared.

28
After the lengths of the specified tools have been measured, the button goes out
o.
O
N
and the the [T MSR AUTO] menu function will be disabled.

al
Machine action in full-automatic measurement

ri
ZA
Se
1) Extension of the tool length measuring table

A
IM
2) W-axis movement to the menu-selected position

K
3) Z-axis movement to the measurement position (the third zero point return)
ZA
4) X-axis movement to the menu-selected position

A
M
5) Tool change by ATC operation

YA
6) Repetition of above steps 2) - 4) after ATC operation in step 5)

3
7) Zero point return on the B-axis (If the C-axis positioned at –90 deg, the B-axis will not move
01
to its zero position.)

)2
(c
8) Y-axis movement to the measurement starting point (the third zero point return)
ht
9) C-axis movement to the measurement starting point (the third zero point return)
ig
yr
10) B-axis movement to the measurement starting point (the third zero point return)
op
11) Y-axis movement to the deceleration sensor position (feed rate = 2000 mm/min)
C
12) Y-axis movement to the skip sensor position (feed rate = 30 mm/min)
13) Tool length data writing into the MAZATROL tool data field
14) Y-axis movement to the measurement starting point
Above steps 5) - 14) will be repeated if multiple tools have been specified.
15) Retraction of the tool length measuring table
16) Completion
1-41
Serial No. 289476
Note 1: ATC operation will not be performed in step 5) if the tool to be measured is already
mounted in the spindle.
Note 2: The full-automatic tool-length measuring program is executed on the assumption that
the tool length to be measured is equal to or smaller than the maximum tool length of
the tools which can be accommodated in the magazine. If the tool length exceeds the
maximum tool length of the tools which can be accommodated, use semi-automatic
measurement, even when the tool tip is positioned on the centerline of the spindle.
Note 3: Do not touch the screen keybord while full-automatic tool-length measurement is in
C. Semi-automatic tool-length measurement
.
It is possible to semi-automatically measure the lengths of tools whose tips are not on the
d
ve
centerline of the spindle. Tool lengths exceeding the maximum tool length of the tools which can
er
be accommodated in the magazine can also be measured. The measured data will be
s
re
automatically set in the LENGTH item of the TOOL DATA display.
ts
(1) Mount a tool to be mesured onto the spindle (by tool change operation or manual
gh
operation).
ri
(2) Press the key to display the following menu.
ll
.A
N
O
TI
76
(3) Tap the [MSR UNIT OUT] menu item. A

R
94
 “M33” will then be displayed in the MDI window.

PO
28
R
o.

N
 The measuring unit is moved out of its storage position.

al
K
ri
ZA
(5) Move the B-axis/C-axis to the position of –90 deg (the third zero point) in manual operation
Se
mode or MDI mode.

IM
Example : MDI operation mode

K
ZA
G90G00B-90.0C-90.0
A
Note 1: Take great notice of head movement and rotation/swinging.

M
YA
Note 2: When the B-axis and the C-axis are positioned at 90 deg, although the direction of
the head is the same as –90 deg, an error will be displayed during measurement.
3
01
(6) Press one of the cutting feed/manual pulse feed keys ( , , or ).

)2
(c
(7) Bring the tool tip close to the plunger of the measuring unit by manual operation.
ht
Remark : Bring the tool tip close to the centerline of the plunger to increase the accuracy.
ig
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op

C
(10) Tap the [OK] button in the message box.
 Subsequently, “G65P205420001Q1” will be displayed in the MDI window.

 The length of the tool which has been mounted on the spindle will be measured
automatically.
1-42
Serial No. 289476

 Upon completion of measurement of the tool length, the measured value will be auto-
matically displayed in the LENGTH item of the TOOL DATA display and the highlighted
state of the TNo. item is cleared. The button goes out and the the [T MSR
SEMIAUTO] menu function will be disabled.
(12) After the tool-length measurement, tap the [MSR UNIT IN] menu item.
 “M34” will then be displayed in the MDI window.

 The measuring unit is moved back into its storage position.
Machine action in semi-automatic measurement
d.
1) Confirmation of the fact that the B-/C-axis is set to the correct measuring position (–90 deg)
ve
er
s
re
ts
4) Tool length data writing into the MAZATROL tool data field
gh
ri
ll
6) Completion
.A
Note 1: Pay careful attention to safety when aligning the tool tip with the center of the plunger
N
O
on the tool length measuring table.
TI
76
Note 2: Although tool lengths up to 1999.9999 mm (78.74 in) can be measured during semi-
A
R
94
automatic tool length measurement, the maximum tool length of the tools which can be
PO
28
accommodated in the magazine is predetermined by machine specifications. When

R
changing tools, confirm the tool length of the tool mounted in the spindle.
o.
O
N
D. Tool breakage detection

al
K
ri
ZA
<MAZATROL program>
Se

IM
M35
K
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Sample program：
A
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UNo. UNIT DIA DEPTH CHAMF

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3 DRILLING 8. 10. 0
SNo. TOOL NOM- No. HOLE- HOLE-DEP PRE-DIA PRE-DEP RGH DEPTH C-SP FR M M M
3
01
1 CTR-DR 20. 8.    90° CTR-D 35

2 DRILL 8. 8. 10. 0. 100 DRIL T 4.
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Execution of the M35 command calls up M195 automatically before ATC operation is performed
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prior to the return of the tool.

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Remark 1: This command calls up the macroprogram for checking the tool mounted on the
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spindle for breakage.

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Remark 2: After the measurement, if a breakage exceeding the tool breakage margin (L6) is
detected, processing will be executed in accordance with the particular setting of
parameter L7. Details of parameter L7 are shown below.
1: Single-block stop.
2: Machining is continued from the next process. Jumped to the execution of the END
unit if there are no more machining processes remaining in the program.
3: Single-block stop after preparation for continuing the operation from the next
process.
1-43
Serial No. 289476
 For the definitions, description, and usage of processes, refer to the

description of the process end unit in the PROGRAMMING MANUAL
(MAZATROL Program).
<EIA/ISO program>
M195
If the tool is a broken one, 1 is written into common variable #532. Use #532 to create an EIA
macroprogram that includes breakage detection.
Sample program:
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N001 :
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T03M06
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G90G54X100.Y-50.
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S1592M03
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G98G81R3.Z-5.F127M08
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G80G00Z50.M09
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M195 ................................................. M-code for tool breakage detection
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IF[#532 EQ 1] GOTO 003 ...... Stopping the program at alarm display
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G91G28Z0
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:
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N002 (DRL D13) ..................................... Machining section of the next tool
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G90G00G40G49G80
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G91G30Y0Z0 A
T04T00M06
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G90G54X100.Y-50.
28
:
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N003 M30 ................................................... Destination of jumping upon detection of tool breakage

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Note 1: The result of breakage detection is stored in variable #532 when M195 is executed in
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the flow of an EIA program. Do not use common variable #532 for another purpose in
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an EIA program including M195 command.

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Note 2: Breakage detection does not occur properly if tool offset data (stored on the TOOL
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OFFSET display) are used for tool length offset. Use MAZATROL tool data (stored on
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the TOOL DATA display).

A
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Series of tool breakage detection operations

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1) Extension of the tool length measuring table

3
2) Zero point return on the B-axis (except when the C-axis is positioned at –90 deg)
01
)2
3) Y-axis movement to the measurement starting point (rapid feed rate, the third zero point
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return)
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4) C-axis movement to the measurement position (the third zero point return)
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5) B-axis movement to the measurement position (the third zero point return)
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9) Retraction of the tool length measuring table
10) Judgement of measurement (setting of #532 to “1” for the detection of breakage in the EIA
program format)
11) Completion
1-44
Serial No. 289476

E. Parameter settings
Skip sensor position
Deceleration sensor position

Machine zero point Measuring table
Plunger
RL20
Deceleration sensor ON
.
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RL21
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Skip sensor ON
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A Tool length
D740S40003
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Fig. 1-5 Parameter settings

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Table 1-1 PLC parameter

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Address Description Setting unit

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RL20 Distance from machine zero point to skip sensor 1/10 m

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RL21 Distance from deceleration sensor to skip sensor 1/10 m

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RL22 Tool breakage margin (same value as L6) 1/10 m

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RL23 Maximum permissible tool length for ATC 1/10 m

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RL24 Minimum measurable tool length 1/10 m

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Table 1-2 Machine parameter

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Address Description Setting unit

3
Measurement starting point of Y-axis 1/10 m

01
M6 Y
(third zero point)
)2
Full-automatic measurement position of Z-axis 1/10 m

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M6 Z
(third zero point)
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M6 B Measurement position of B-axis (third zero point) 1/10 m

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Measurement position of C-axis (third zero point) 1/10 m

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M6 C
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1-45
Serial No. 289476
9. Laser measurement of tool length/diameter (for the INTEGREX e-Series)

This function is enabled only on machines equipped with a laser measuring unit.
Before starting a machining operation, it is necessary to measure the length/diameter of the tools
that have been mounted in the tool magazine and then to set the measured data on the TOOL
DATA display.
This operation is called “tool length/diameter measurement”, for which are available the following
two methods:
A. Automatic tool-length measurement
In the MDI operation mode, the length of a tool can be measured automatically. The mea-
sured data will be automatically set in the LENGTH item of the TOOL DATA display. How-
ever, the tools whose lengths can be measured using this method are limited to milling tools
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(end mill, reamer, tap, etc.).
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B. Automatic tool-diameter measurement
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It is possible to measure the diameters of tools at the same time when the tool-length mea-
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surement is executed. The measured data will be automatically set in the ACT- item of the
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TOOL DATA display. However, the tools whose diameters can be measured using this
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method are limited to end-mills, face-mills, special tools and ball end-mills.
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Turning tools cannot be measured automatically.
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Tool-length measurement for EIA/ISO program
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On machines with the EIA/ISO option, the results of automatic tool-length/diameter measure-
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ment can directly be registered in data items on the TOOL OFFSET display, under the following
76
conditions: A
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 Parameter F93 bit 3 = 0, and

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 Parameter F80 bit 0 = 1.

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N

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data setting procedure or EIA/ISO program, refer to the section related to

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“TOOL OFFSET Display” in PART 3 for further details.

A
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A. Automatic tool length/diameter measurement

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(1) After selecting the MDI mode, select the [LASER MEASURE] menu item.
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TOOL TOOL M CODE HEAD HEAD LASER DIAMETER

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SELECT CHANGE CHANGE INDEX MESURE MEASURE

3
(2) Using the screen keyboard, specify the TNo. and suffix of the tool in the following format.
01
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<Input format>
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“. ”
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: Number of the tool to be specified

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: Suffix of the tool

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 See suffix tables in the item 2 “Tool select” for the tool suffix.
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(3) Based on the tool that has been specified above, MDI command data is set in the MDI
window in the format that the measurement macro-instruction call block (G136) and the
correction macro-instruction call block (G137) are inserted between the measurement cover
opening M-code (M33), the laser measurement setup M-code (M187), and the measure-
ment cover closing M-code (M34).
1-46
Serial No. 289476

<Example of setting: “001.02”>
MDI
M33 Laser Measurement Cover Open
M187 Laser measurement setup (calibration of the laser measuring unit)
G136 T001.02 M1 Q51 Measurement of the TNo.1B tool length
G137 V001.02 Storage of the previous measuring results (tool length) into the TNo. 1B tool
data
M34 Laser Measurement Cover Close
Note 1: When another tool than milling tool is specified in step (2) above, the alarm 436
UNREGISTERED TNo. will occur and no data will be set in the MDI window.
Note 2: On the TOOL DATA display, TNo. of the tool specified for the measurement is
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highlighted in red.
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<Example of setting: “001.02” when [DIAMETER MEASURE] is enabled>
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MDI
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M187 Laser measurement setup (calibration of the laser measuring unit)
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G136 T001.02 M2 Q51
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Measurement of the TNo.1B tool diameter
G137 V001.02 Storage of the previous measuring results (tool length and diameter) into the
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TNo. 1B tool data
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A
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(4) Repeat the operation described in step (2) above for all the tools to be measured.
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Each time the operation described in step (2) above is performed, the measurement
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macro-instruction call block and the correction macro-instruction call block relating to the
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tool specified in this step will be inserted between the specified measurement macro-
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instruction call block and correction macro-instruction call block and measurement cover
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closing M-code (M34).

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<Example of setting: “002.3” in the example above>

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MDI
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M187
A
Laser measurement setup (calibration of the laser measuring unit)

M

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G137 V001.02 Storage of the previous measuring results (tool length) into the TNo. 1B tool
data
3
01
G136 T002.03 M1 Q51 Measurement of the TNo.2C tool length

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G137 V002.03 Storage of the previous measuring results (tool length) into the TNo. 2C tool
data
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 This button action causes the button to light up and the lengths of the tools (also
diameters of the tools if specified) which were specified in procedural step (4) above to
be measured in sequence. (Tool change occurs automatically.)
 Upon completion of measurement of each tool length, the measured values are auto-
matically indicated in the LENGTH item of the TOOL DATA display and the highlighted
 After the lengths of all the specified tools have been measured, the button goes
out and the [LASER MEASURE] menu function will be disabled.
1-47
Serial No. 289476
Note 1: Do not touch the screen keybord while full-automatic tool-length measurement is in
Note 2: If the first tool to be measured is currently mounted on the spindle, set the B-axis angle
at 0° before starting the measurement.
Note 3: The measurement should be conducted in conditions as clear of coolant as possible.
After a machining operation with coolant feed, therefore, insert a dwell command, if
required, to make a pause long enough to prevent the measuring accuracy from being
deteriorated by trickling drops of coolant.
10. Setting the pallet No.

This operation, which is required only when an automatic pallet change function is provided,
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should be carried out to register the identification number of the pallet provided in the machine.
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Since registered pallet number will still remain in memory of the NC equipment even after power
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has been turned off, usually, this operation should be carried out only when using pallets for the
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first time or when a manual pallet-changing operation has been carried out.
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(1) Press the key.
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(2) Tap the menu changeover button (located to the right of the menu) to call the following
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menu on the screen:
.A
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PALLET SP.TOOL NXT TOOL TOOL TO
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No.SET No.SET No.SET SELECT CHA
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(3) Tap the [PALLET No. SET] menu item.

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 This will cause the menu function to be enabled and a message box with PALLET No.?
28
in it to be displayed.
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(4) Specify the pallet number to be registered.

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 The input pallet number will be displayed in the PALLET No. item of the POSITION
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display.
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Example : If pallet No. 2 is to be registered:

Tap 2 and in that order.
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11. Setting the spindle-tool No.

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The identification number of the tool currently mounted on the spindle is to be registered by this
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operation. The identification number of the tool currently mounted on the spindle will still remain
3
stored within the memory of the NC equipment even after power has been turned off.
01
This operation should be carried out only when tools have been manually changed, when the
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tool has been manually dismounted from, or mounted onto the spindle.
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(1) Press the key.

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(2) Tap the menu changeover button (located to the right of the menu) to call the following
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menu on the screen:

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PALLET SP.TOOL NXT TOOL TOOL TO

No.SET No.SET No.SET SELECT CHA
(3) Tap the [SP. TOOL No. SET] menu item.

1-48
Serial No. 289476

(4) Specify the identification number of the tool currently mounted on the spindle.
 The input tool number and tool name will be displayed in the (left) TNo. item of the
POSITION display. Subsequently, the [SP. TOOL No. SET] menu function will be
disabled.
Example : If the tool with tool number 5 has been manually mounted on the spindle:
Tap 5 and in that order.
Remark : If the tool has been manually dismounted from the spindle and no tool is
currently mounted on it, the tool number 0 should be input.
Note 1: The magazine pocket corresponding to the tool number which was input in procedural
step (4) must be left empty.
.
Note 2: If an ATC operation was aborted by pressing the key or the emergency stop
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button, the tool number of the tool currently mounted on the spindle may have been
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erased from the memory. In such a case, therefore, check the tool number being
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displayed in the TNo. item of the POSITION display for actuality.
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12. Setting the next-tool No.
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The identification number of the tool currently in the standby state is to be registered by this
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operation.
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The identification number of the tool currently in the standby state will still remain stored within
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the memory of the NC equipment even after power has been turned off. This operation should be
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carried out in case such as those where tools have been manually changed.
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A
The operation procedure is basically the same as that for the item 11 “Setting the spindle-tool
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No.” For this operation, tap the [NXT TOOL No. SET] menu item instead of the [SP. TOOL No.
28
SET] menu item .

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13. Group-number specification for tool management

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A. Tool change with group-number specification

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In a tool-management system which applies group numbers for T-code specification in EIA/ISO
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programming, the MDI tool-change operation using the [TOOL CHANGE] menu function can
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also be managed by specifying 8-digit group numbers.

A
(1) Press the key.

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(2) Tap the [TOOL CHANGE] menu item.

 This will cause the menu function to be enabled and a message box with SAME TOOL
3
01
GROUP No.? in it to be displayed.

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(3) Specify the group number of the tool to be mounted on the spindle.
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 “Txxxxxxxx T0 T6” will then be displayed in the MDI window and the [TOOL CHANGE]
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menu function will be disabled. (xxxxxxxx denotes the input group number, and “T0”
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denotes the identification number of the next tool specified.)

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For the following operation steps, perform the same operation as described in the item 3 “Tool
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change”.
B. Next-tool command with group-number specification

The next-tool command can be executed by specifying a group number in the free-format for the
MDI operation mode.
Example : If a tool registered under group number 12 is to be mounted on the spindle and a
tool of group number 13 is to be indexed as the next tool:
Enter “T00000012 T00000013 M6” on the MDI window.
1-49
Serial No. 289476
C. Tool select with group-number specification

In a tool-management system which applies group numbers for T-code specification in EIA/ISO
programming, the MDI tool-select operation using the [TOOL SELECT] menu function can also
be managed by specifying 8-digit group numbers.
(1) Press the key.
(2) Tap the [TOOL SELECT] menu item.
 This will cause the menu function to be enabled and a message box with SAME TOOL
GROUP No.? in it to be displayed.
(3) Specify the group number of the tool to be moved to the tool change position. Then, press
the enter key.
d.
 “TM149” will then be displayed in the MDI window and the [TOOL
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SELECT] menu function will be disabled. ( above denotes the input
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group number.)
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For the following operation steps, perform the same operation as described in the item 2 “Tool
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select”.
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D. Parameters related to TOOL CHANGE and TOOL SELECT
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L51 0: Pocket-number specification
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1: Group-number specification
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F94 bit 4 0: Group number
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(Tool searching) 1: Tool (pocket) number A

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If the EIA/ISO option is not provided, only pocket-number specification is valid, irrespective of the
28
value of parameter L51.

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N
Note : If the value “0” (group number specification) is set in parameter F94 bit 4, group-
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number specification is valid even during automatic operation.

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Remark : Register group numbers by setting them in the data item GROUP No. of the TOOL
A
DATA display.
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01
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1-50 E
Serial No. 289476
SELECTING EXECUTION CONDITIONS 2

2 SELECTING EXECUTION CONDITIONS
The following functions are available with the execution conditions selection menu or key for
automatic operation:
1) Optional Stop
2) Dry Run
3) Machine Lock
4) Work Light
5) Barrier cancel function
6) Barrier cancel teach function
7) Block Skip (for EIA/ISO programs only)
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8) Single Block
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9) Comparison Stop (for EIA/ISO programs only)
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10) Z-axis Cancel
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11) MST Lock
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12) ATC Stop
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13) Threading position storage (optional)
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These functions excepting 13) can be selected for all automatic operation modes (memory
operation mode, tape operation mode, and MDI mode). During automatic operation, these
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functions can also be selected or canceled.
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Functions 3) and 4) listed above can also be selected during the manual operation mode.
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Function 13) listed above can only be selected during the manual operation mode.
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The execution conditions selection menu for automatic operation can be displayed while any one
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of the following displays stays on the screen:

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 POSITION display
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 TRACE display
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 EIA MONITOR display

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 PALLET MANAGEMENT display

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Note : If the execution conditions selection menu is not displayed when one of these displays
has been selected, then tap the menu selector button.
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A description of each function and its usage follows.

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2-1
Serial No. 289476
2-1 Optional Stop

Optional Stop refers to the function with which the automatic operation can be optionally stopped
at the end of a block containing M01 code.
Select this function when you want to decide step by step whether to continue or to discontinue
the automatic operation.
2-1-1 Procedure
Set M01 (optional stop) in the position where automatic operation is to be halted.
 For MAZATROL programs, the M-code can be set in the following positions:
M-code unit: Data item M1 through M12
.
Machining unit: Sequence data item M
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 For EIA/ISO programs, the M-code can be set in any block.
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(1) Tap the [OPTIONAL STOP] menu item.
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 The Optional Stop function will be active.
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Remark : Performing the operation step (1) again makes this function inactive.
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2-1-2 Description
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1. If the above procedure is followed by automatic operation, it will stop when the execution of
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the block containing M01 is completed.
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A
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2. Pressing the button causes automatic operation to be restarted from the next block.
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28
3. Procedural step (1) above can also be carried out during automatic operation.
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2-2
Serial No. 289476

2-2 Dry Run
Dry Run refers to the function that allows you to execute a program using user-adjusted rate of
feed, instead of using the rate of feed specified in the program.
Select this function when checking the machining status.
2-2-1 Selecting Dry Run function

(1) Tap the [DRYRUN] menu item while pressing the key on the operating panel.
 The Dry Run function will be active. At the same time, the machine opration will be
brought into Feed Hold stop and the cutting feed override display will change over to the
display for manual operation, with SAME TOOL GROUP No.? displayed in a message
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box.
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Remark : For the machine with the lower turret, this function works independently for the
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lower turret as well.
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<Dry run function invalid> <Dry run function valid>
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(displayed in orange) (displayed in green)
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DRYRUN DRYRUN
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Menu
.A
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Override
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display
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Cutting feed
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override switch
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A relative value with respect to Dieplay of the rate of feed for

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the programmed rate of feed is manual operation (See Section 3-2.)

displayed in percentage terms.
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D747S40004
A
Fig. 2-1 Menu and override display with the Dry Run function made valid/invalid
M
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(2) Adjust the rate of feed using the cutting feed override switch.
3
01

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 The above-mentioned message box (DRYRUN WORKS CHECK OVERRIDE) will dis-
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appear and the program will be executed using the adjusted rate of feed.
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2-3
Serial No. 289476
2-2-2 Cancelling Dry Run function

Follow the procedure below to cancel the Dry Run function.
(1) Tap the [DRYRUN] menu item while pressing the key on the operating panel.
 The Dry Run function will be cancelled. At the same time, the machine opration will be
brought into Feed Hold stop and the cutting feed override display will return to the
display for automatic operation, with DRYRUN CANCEL CHECK OVERRIDE displayed
in a message box.
<Dry run function valid> <Dry run function invalid>

(displayed in green) (displayed in orange)
DRYRUN DRYRUN
.
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Menu
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ers
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Override
display
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.A
Cutting feed
override switch
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Dieplay of the rate of feed for

A A relative value with respect to
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manual operation (See Section 3-2.) the programmed rate of feed is

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28
displayed in percentage terms.

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D747S40005
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Fig. 2-2 Menu and override display with the Dry Run function made valid/invalid
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(2) Adjust the rate of feed using the cutting feed override switch.
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(3) Press the button .

 The above-mentioned message box (DRYRUN CANCEL CHECK OVERRIDE) will dis-
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appear and the program will be executed using the adjusted rate of feed.
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2-4
Serial No. 289476

2-3 Machine Lock
Machine Lock refers to the function that runs the program with no axis movement.
Selecting this function makes the current-position counter indicate the programmed axis
movements, even though they do not actually take place.
Use this function when the program execution status is to be checked.
2-3-1 Procedure
(1) Tap the [MACHINE LOCK] menu item while pressing the key on the operating panel.
 The Machine Lock function will be active.
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2-3-2 Description
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1. When the above procedure is followed by automatic operation, the program will be executed
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without actual movements of all axes excepting the spindle.
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2. Selecting the Machine Lock function during automatic operation brings automatic operation
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to single-block stop at the end of the block being executed. If automatic operation is
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.A
subsequently restarted, then the succeeding portion of that program will be executed with
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the machine remaining locked.
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If the Machine Lock function is canceled during automatic operation with the machine
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remaining locked, actual movements of the axes will begin at the end of the block being
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executed.
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28
However, under a machine locked status, the machine position that the NC unit stores in its
R
memory will differ from the actual machine position. After the Machine Lock function has
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N
been canceled, therefore, a collision of the machine can arise since the axis movement will
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be carried out in such a disturbed coordinates system.

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Do not cancel the Machine Lock function while the machine is in automatic operation.
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Note : The current position on the display will not show the correct position until the key
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is pressed, if an axis movement is executed with the machine remaining locked. After
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disabling the Machine Lock function, be sure to press the key to restore the
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correct display of the current position.

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2-4 Work Light

3
Work Light refers to the function that turns on or off the illumination lamps mounted on the
01
machine.
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2-4-1 Procedure
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(1) Tap the [WORK LIGHT] menu item.

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 The lamps will turn on.

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2-5
Serial No. 289476
2-5 Barrier Cancel Function

“Barrier cancel” refers to the function of canceling barriers, such as tool barriers and chuck
barriers, set with parameters or in the TOOL DATA display.
2-5-1 Procedure
(1) Tap the [BARRIER CANCEL] menu item.
 All barriers will be cancelled.
Note : The barrier cancel function cannot be used for some models.
.
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2-6 Barrier Cancel Teach
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“Barrier cancel teach” refers to the function of storing barrier cancel teach in a program upon
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occurrence of alarms, allowing you to resume automatic operation after making sure by a visual
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check that everything is all right.
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The barrier function can be automatically disabled for the next automatic operation onward by
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storing barrier cancel teach in the program.
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2-6-1 Procedure
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(1) Check to see that automatic operation can be resumed in safety from the position where it
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was interrupted because of a barrier alarm.
76
A
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(2) After making sure that automatic operation can be resumed in safety, tap the [BARRIER
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28
CANCEL TEACH] menu item.

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 The [BARRIER CANCEL TEACH] and [BARRIER CANCEL] menus functions will be
O
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enabled, and the barrier cancel teach will be written in the program.
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Remark : Areas in which barrier cancel teach is set differ according to the types of program.
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MAZATROL: Barrier cancel teach can be specified on a tool sequence-by-tool

IM
sequence/unit-by-unit basis.
K
EIA/ISO: Barrier cancel teach can be specified on a program-by-program basis.

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Note: Barrier cancel teach can be written only in programs stored in the MEMORY operation
A
area, but not in programs stored in the external operation area, such as the hard disk
M
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operation area.
3
(3) Press the button to resume automatic operation.

01
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Remark : Programs in which barrier cancel teach is written are displayed, as shown in the
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figures below.
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1) PROGRAM (MAZATROL) display

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UNo. UNIT DIA DEPTH CHMF

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7 DRILLING 10. 20. 1.

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SNo. TOOL NOM- No. HOLE-

/ 1 CTR-DR 20. 12.
/ 2 DRILL 10. 10.
FIG PTN Z X Y
1 PT –100. 40. 0.
A highlighted slash (/) is displayed in front of each tool sequence/unit for which barrier
cancel teach function is set. If an R (rough) or F (finish) is displayed, for example, in the
case of turning units, the R or F will be highlighted.
2-6
Serial No. 289476

2) PROGRAM (EIA/ISO) display
The setting status of barrier cancel teach is displayed at the upper part of the
PROGRAM (EIA/ISO) display.
3) PROGRAM MONITOR window
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If barrier cancel teach is set for tool sequences/units in a MAZATROL program, the
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icon will be displayed in the PROGRAM MONITOR window.
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Note 1: If barrier cancel teach is set during high-speed smoothing control function, automatic
N
operation cannot be resumed. (Barrier cancel teach can be written in programs.)
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Note 2: Barrier cancel teach function cannot be used for any programs (programs stored in
76
A
MDI mode (including MDI interrupt) or on hard disk, Ethernet or tape operation area)
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other than those stored in the MEMORY area. If the [BARRIER CANCEL TEACH]
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28
menu item is selected, the alarm 192 EXECUTION IMPOSSIBLE will be displayed.
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o.
Note 3: The barrier alarm is turned off when operation is restarted after barrier cancel teach
N
has been stored in memory.

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Note 4: Barrier cancel teach can be deleted by editing the program.

Se
Note 5: If a measurement unit in a MAZATROL program of workpiece scheme is executed

IM
when bit 7 of the parameter K68 is 1, all barrier cancel teach in the program will
K
become invalid.
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K68 bit 7: All the barrier cancel teach in the program is cleared by executing the MES
A
unit in a MAZATROL program.

M
0: Invalid
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1: Valid
3
01
Note 6: The barrier cancel teach function cannot be used for some models.
)2
Note 7: If the machining end point is set in barrier area, the alarm will be displayed at the head
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of the next machining. In this case, a TPC escape point is to be input to move the tool
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outside of barrier.
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2-7
Serial No. 289476
2-7 Block Skip

Block Skip refers to the function with which the specific blocks can be optionally skipped during
program execution. This function is only valid for EIA/ISO programs.
2-7-1 Procedure
Include “/” (or one of “/1” to “/9”) in the starting part of the block(s) to be optionally skipped.
Example : /G ～
(1) Tap the [BLOCK SKIP] menu item.
 The following menu will be displayed.
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BLOCK BLOCK BLOCK BLOCK BLOCK BLOCK BLOCK BLOCK BLOCK
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SKIP 1 SKIP 2 SKIP 3 SKIP 4 SKIP 5 SKIP 6 SKIP 7 SKIP 8 SKIP 9
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(2) Tap the corresponding menu item. (Select [BLOCK SKIP 1] for “/” without suffix.)
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 The Block Skip function will be active.
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Remark : Tapping the menu item again makes this function inactive.
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2-7-2 Description
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When the above procedure is followed by automatic operation, the program will run skipping
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through the designated block(s).
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A
 Slash can be set only at the head of the block or after the sequence number.
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For further details see the Programming Manual (EIA/ISO Programming).

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2-8
Serial No. 289476

2-8 Single Block
Single Block refers to the function used to execute a program on a block-by-block basis.
Select this function to check the machine actions and the machining status.
2-8-1 Procedure
(1) Press the key.
 The Single Block function will be active.
2-8-2 Description
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1. When the above procedure is followed by automatic operation, the button will go out
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when the first block of the program is executed. At the same time, automatic operation will
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stop.
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When automatic operation is restarted by pressing the button once again, the next
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block will be executed and automatic operation will stop once again.
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In this manner, once Single Block has been selected, automatic operation restarts each
.A
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time the button is pressed, and stops each time one block is executed.
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2. When the above procedure is performed during automatic operation, it will stop at the end of
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the block being executed. The Single Block function will become active when automatic
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operation is restarted by pressing the button .

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The stop of automatic operation at the end of the block being executed is referred to as
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single-block stop.
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2-9
Serial No. 289476
2-9 Comparison Stop

Comparison Stop refers to the function with which the automatic operation can be placed into the
single-block stop in any position as occasionally specified with work No., sequence No. and
block No. in EIA/ISO programs.
2-9-1 Setting procedure

(1) Tap the [COMPARSN STOP] menu item.
 The COMPARISON STOP window will be displayed.
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(2) First, specify the stop position with the work No. of the program.
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(3) Then, specify the stop position with the sequence No.
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(4) Finally, specify the stop position with the block No.
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(5) Tap the [APPLY] button. A

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 CHECKING will be displayed at the left bottom of the COMPARISON STOP window.
28
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Remark 1: Tap the [PROGRAM LIST] button in Step (2) as required to specify the work No. by
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selecting from the WORK No. SELECT window opened.

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Remark 2: The comparison stop can also be applied by tapping the key on the screen
keyboard.
2-10
Serial No. 289476

2-9-2 Description
1. Comparison stop
On completion of the above procedure, start the automatic operation. The machine will come to a
single-block stop when execution of the specified block is completed.
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2. Setting conditions
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1. Comparison stop can be set or cancelled even during automatic operation.
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2. Setting of comparison stop will be automatically cancelled in the following cases:
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 The machine operation has come to the comparison stop correctly as specified.
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 The system has entered the reset status (at the end of a cycle or by pressing the
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key).
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3. Comparison stop is only available in MEMORY, HARD DISK or ETHERNET operation
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mode. A
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4. For the machine with the lower turret, this function works independently for the lower turret
28
as well.
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Use the turret select switch to select the turret for which the check is to be stopped, and
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then tap the [COMPARSN STOP] menu item to display the COMPARISON STOP window
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for the selected turret.

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3. Detailed description
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1. If the program has multiple blocks which correspond with the specified sequence No. and
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block No., comparison stop will occur at the first of such blocks.
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2. Comparison stop function does not include checking for the presence of the specified block
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in the respective program.

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3. The sequential operation of tapping cannot be brought half-way to a comparison stop.

3
01
4. The setting of comparison stop is not valid for a block which is currently executed.
)2
5. Only the setting of 0 for the block No. can be omitted.

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6. The head block containing a program No. cannot be effective for comparison stop. In other
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words, the setting of 0 for both sequence and block Nos. is ineffective.
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7. Setting the work No. of a MAZATROL program will cause an alarm (439 MAZATROL
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PROGRAM DESIGNATED).
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8. Comparison stop for a subprogram which is called multiple times will occur on the first call.
9. The sequential operation of high-speed machining cannot be brought half-way to a
comparison stop.
10. If a block for fixed-cycle call is specified, comparison stop will occur on completion of the
first block of fixed-cycle macroprogram.
2-11
Serial No. 289476
11. Whichever block in a series of macro statements is specified, comparison stop will always
occur at the first block.
Example : In case of NNo. = 1 and BNo. = 2:
G28 X0 Y0 Z0
G01 X50.
N01 #100 = 1. ......................... Actual stop position
#101 = 2.
#102 = 3. ......................... Specified position
N02 M02
The designation of any block of the above-mentioned type, however, can be validated for
comparison stop by setting parameter F93 bit 6 (User-macro-statement processing for
single-block operation) to “1”.
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12. When specifying the block number of the stop position, take into consideration that the
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internal counting of block numbers depends upon whether the block skip function is
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currently selected or not, as shown in the example below.
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Example : In case of NNo. = 1 and BNo. = 1
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[BLOCK SKIP 1] ON [BLOCK SKIP 1] OFF
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G28 X0 Y0 Z0 Block No. Block No.
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N01 G91 G01 X10. F1000 0 0
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/1 X10. 1 Stop position
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Y10. 1 Stop position 2
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Z10. 2 A 3
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N02 M02
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13. Even if the succeeding block of M98 in the calling program is specified during comparison
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stop after the M99 block of the called program, the restarted operation will not come to a
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comparison stop at the required position.

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Example :
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WNo. 100 (Main program) WNo. 200 (Subprogram)

G28 X0Y0Z0 X10.
K
G91 G01 X10. F1000 X10.

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M98 P200 X10.

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M98 P200.....Specified position X10.

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M02 M99 ............. Specification during

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comparison stop here

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2-12
Serial No. 289476

2-10 Z-axis Cancel
Z-axis Cancel is a function that allows automatic operation to be performed with the Z-axis
remaining locked in place. This function should be selected when checking the movements of
the X-axis and Y-axis. Even when this function is selected, all machine actions (including the
Z-axis movement) will also be displayed on the screen.
2-10-1 Procedure
(1) Tap the [Z AXIS CANCEL] menu item while pressing the key.
 The menu function will be enabled.
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2-10-2 Description
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1. When the automatic operation is started on completion of the above procedure, the
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specified program will be executed with the Z-axis remaining locked in place.
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2. If procedural step (1) is carried out during automatic operation, it will stop after completion of
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the block being executed (single-block stop), and then the button will go out. If the
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button is subsequently pressed again, automatic operation will restart, at which time
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the Z-axis Cancel function will be operative.
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Note : After the Z-AXIS CANCEL function has been cleared, the actual position of the Z-axis
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may differ from the programmed position of the Z-axis.

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2-13
Serial No. 289476
2-11 MST Lock

MST Lock is a function that allows the M-, S-, T- and B-codes to be disregarded during automatic
operation. When checking the contents of a program, this function should be selected.
The following codes, however, will be implemented even when this function is selected:
 M00 (Program stop)
 M01 (Optional stop)
 M02 (Program end)
 M30 (Reset and rewind)
 M98 (Subprogram call)
 M99 (Subprogram end)
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2-11-1 Procedure
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(1) Tap the [MST LOCK] menu item while pressing the key on the operating panel.
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 The menu function will be enabled.
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2-11-2 Description
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1. When the button is pressed on completion of the above procedure, the specified
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program will be executed with the axis movement and M-, S-, T- and B-code functions
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remaining locked.
28
2. All the programmed machine actions will be displayed on the screen.

o.
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3. If procedural steps (1) is carried out during automatic operation, it will stop after the end of
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the block being executed (single-block stop), and then the

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button will go out.

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If the button is subsequently pressed again, automatic operation will restart, at which
IM
time the MST LOCK function will be operative.

K
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Note : After the MST LOCK function has been cleared, the actual operational status of the
machine may differ from the corresponding contents of the program.
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M
Remark : If MST LOCK function is selected together with the MACHINE LOCK function, the
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program is run only inside the NC unit and no action of the machine will be carried out.
3
Use these functions together when the program is to be checked in the first stage.
01
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2-12 ATC Stop

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If the [ATC STOP] menu function is selected during automatic operation, the machine action will
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stop at the ATC position after the machining with the tool currently used has been completed.
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If the [ATC STOP] menu function is selected during ATC, then the ATC operation will be
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completed and the machine action will stop immediately before the next ATC operation.
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Automatic operation can be restarted by pressing the button after cancellation of the
[ATC STOP] menu function.
 Operating actions associated with ATC operation slightly differ according to

the machine models. For details, refer to the Operating Manual for your
machine.
2-14
Serial No. 289476

2-13 Threading Position Teach (Optional)
Threading Position Teach refers to the menu function of teaching a threading position on a
workpiece that was detached from and has been set again in the chuck for rethreading.
To teach a threading position to cut a thread that passes through the memorized position, select
the [THR. POS. TEACH] item from the menu and align the tip of the threading tool with a root
position of the thread.
Trial threading is conventionally required for rethreading a workpiece that was detached from
and has been set again in the chuck, because of a shift in the threading start position. The use of
this function, however, eliminates the need for trial threading and facilitates rethreading.
2-13-1 Procedure
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(1) Rotate the spindle used for rethreading at least one full turn.
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(2) Chuck the workpiece that is to be rethreaded.
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(3) Align the tip of the threading tool manually with the root of the thread to be cut again.
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 Match the positions of the tool tip and the root in the Z-axis direction. The X-axis
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components of the tool path for rethreading depend on the programmed data concerned.
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Tool
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Angular position of
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the turning spindle

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Z-axis machine
(SPINDLE)
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position
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(MACHINE Z)
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(4) Tap the [THR. POS. TEACH] menu item.

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 The menu function will be enabled and the THREAD POSITION TEACH window will be
K
displayed.
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The initial contents of the window opened refer to the previous operation, if performed,
A
for teaching the threading position.

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(5) Tap the [TEACH] button.

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 A message box will be displayed.

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(6) Tap the [OK] button.

 The MACHINE Z and SPINDLE positions on the selected spindle side will be displayed
in the window and stored into the memory.
2-15
Serial No. 289476
(7) Move the threading tool away from the workpiece.

(8) Initiate automatic operation.
 A thread that passes through the stored position will be cut automatically.
1. Correcting the stored threading position

The stored threading position can be corrected as follows:
(1) Tap the desired data item.
 Tap the [INCREMENT] button. The incremental input function will be active. To cancel
incremental input, tap once again the [INCREMENT] button.
(2) Enter a correction value using the screen keyboard.
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(3) Tap the key.
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 The position obtained by adding the correction value to the previously stored position is
N
O
stored into the memory.
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2. Erasing the stored threading position

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(1) Tap the [ERASE] button.

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 A message box will be displayed.

A

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 The stored position is erased.

3
3. Remarks
01
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 The rethreading function is optionally available.

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 The rethreading program can be of the MAZATROL as well as of the EIA format.
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 The threading position, once stored, will remain intact even when power is turned off and then
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back on. Do not forget to clear the stored threading position manually if the rethreading in
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question is not required any more; otherwise the threading start position will unnecessarily be
C
shifted with respect to the stored data.

 Be sure to rotate the spindle at least one full turn before storing the threading position;
otherwise the alarm 489 CANNOT SET THREAD POSITION will occur.
 For rethreading on the side of the second spindle, select the second spindle using the
corresponding selector switch beforehand to follow above teaching procedure. (Only for
machines with headstock 2).
 During automatic operation, the threading position cannot be stored, edited, or erased. The
alarm 428 MEMORY PROTECT (AUTO OPERATION) will occur if such an operation is
attempted during automatic operation.
2-16
Serial No. 289476

 The rethreading function can be used only for cutting threads with an even pitch.
 The rethreading function can be used only for threads to be cut by feeding the tool mainly in
the Z-axis direction (parallel threads or tapered pipe threads). It cannot be used for face
threading.
 The rethreading function cannot be used for simultaneous threading with both the upper and
lower turrets.
 The rethreading function is not valid for threading by synchronized rotation of both spindles.
(Only for machines with headstock 2).
 If address Q (shift angle) is specified in an EIA/ISO program for rethreading, the tool path will
shift through the specified angle with respect to the stored position of the thread.
 The rethreading function cannot be used at all for cutting left-handed threads or threading by
d.
reversed cutting feed (from the chuck to the face of the workpiece).
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2-17
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SELECTING EXECUTION CONDITIONS
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2-18 E
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Serial No. 289476
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Serial No. 289476
CHANGING THE CUTTING CONDITIONS 3

3 CHANGING THE CUTTING CONDITIONS
During automatic operation, especially during test cutting, the cutting parameters specified in the
program may require changing according to the shape of cutting chips, the status of its flyabout,
the load status display of the spindle and axis driving motors on the POSITION display, the
degree of as-finished surface roughness of the workpieces, and other factors.
This chapter describes how to modify cutting parameters using the override switches and keys
and how to update cutting parameters using the VFC function.
3-1 Rapid Traverse Override

Using the rapid traverse override switch, the rapid traverse speed during automatic operation
.
d
can be adjusted to within the range from 0 to 100 percent of the maximum rapid traverse speed
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specified by parameter M1. The values of R0, R1 and R2 are set in other parameters.
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3-1-1 Procedure
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(1) Turn the rapid traverse override switch to the position of the required speed.
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Rapid traverse
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override switch A
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D747S40006
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Example : If the maximum speed of rapid traverse for each axis is preset as follows:
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30000 mm/min for the X-axis

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30000 mm/min for the Y-axis

24000 mm/min for the Z-axis
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ZA
Setting the override switch to 50 (%) changes actual rapid traverse speed into:
X-axis: 30000 × 50/100 = 15000 mm/min,
A
M
Y-axis: 30000 × 50/100 = 15000 mm/min,

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Z-axis: 24000 × 50/100 = 12000 mm/min.

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3-1
Serial No. 289476
3-2 Cutting Feed Override

Using the cutting feed override switch, the rate of cutting feed specified in the program can be
changed within the range from 0 to 200 percent.
3-2-1 Procedure
(1) Turn the cutting feed override switch to the position of the required speed.
d.
switch
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D747S40007
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Example : If the programmed rate of feed is 1000 mm/min:
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Setting the override switch as shown in the figure below will change the rate of
N
feed into:
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1000 × 50/100 = 500 mm/min.
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switch
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D747S40008
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Note : The rate of cutting feed will not change even if the setting of the cutting feed override
A
switch is changed while a tapping cycle is in progress.

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Remark : Axis movement will not occur if 0 is displayed as the current overriding value.
3
01
3-2-2 Rate of feed during dry run

)2
With the dry run function selected, axis movement occurs at the last specified rate of feed for
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manual operation, not at the programmed or overridden rate.

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When the current rate of cutting feed for manual operation is 160 mm/min, for example, then the
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dry run operation will be executed at that rate of feed.

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3-2
Serial No. 289476

3-3 Spindle Speed Override
Using the spindle speed override keys, the programmed rpm (revolutions per minute) value of
the spindle can be changed within the range from 0 to 150 percent of the original value.
3-3-1 Procedure
(1) Press the spindle speed override key or .
 The spindle speed increases in 10% steps each time the key is pressed, and
continuously increases when this key is pressed and held down continuously decreses
when this key is pressed and held down.
 The spindle speed decreases in 10% steps each time the key is pressed, and
.
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held down.
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 The current spindle speed relative to the programmed value is displayed in percentage
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terms in the status display area of the screen.
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Spindle speed
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override keys
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D747S40003
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–1
Example : If the programmed spindle speed is 2000 min :
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Overriding by 150% as shown in the figure below will change the spindle speed into:
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–1
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2000 × 150/100 = 3000 min .

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150
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D747S40010
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Note 1: The spindle will not rotate if 0 is displayed as the current overriding value.
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When synchronous feeding, neither occurs axis movement.

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Note 2: The spindle speed will not change even if the spindle speed override keys are pressed
while a tapping cycle is in progress.
Note 3: Even if the spindle speed specified using the spindle speed override keys is in excess
of the maximum allowable value, the actual spindle speed will not become higher than
the maximum allowable value.
3-3
Serial No. 289476
3-4 VFC Function

VFC refers to the function that automatically overrides the cutting conditions in the actual
program, such as rate of feed, surface speed (or rotational speed) of the spindle, with the new
data that have been set using the override switches and keys.
The VFC function can be used only for MAZATROL programs.
The cutting conditions that can be overriden using the VFC function are limited to the rate of
cutting feed and the surface speed (or rotational speed) of the spindle.
3-4-1 Procedure
(1) Change the rate of cutting feed and the surface speed as required during automatic
.
operation.
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 See Section 3-2, “Cutting Feed Override” and 3-3, “Spindle Speed Override”.
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(2) Press the key.
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 The key will be effective.
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3-4-2 Description
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1. When machining in the tool sequence being executed is completed, the rate of cutting feed
76
A
and the surface speed that have been changed in procedural step (1) above will be auto-
R
94
PO
matically written into the program, the key will be ineffective, and the machine
28
operation will be brought into single-block stop.

o.
O
N
Example : When the rate of cutting feed and the surface speed have been specified in the
al
program as follows:
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ZA
Se
Rate of cutting feed: 20 mm/min

A
Surface speed: 2 m/min

IM
After changing these values as follows in procedural step (1),

K
ZA
Rate of cutting feed: 150% (i.e., 20 × 150/100 = 30 mm/min)

A
Surface speed: 120% (i.e., 2 × 120/100 = 2.4 m/min)

M
Press the key.

YA
3
01
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ht
Rate of feed 30 mm/min

Surface speed 2.4 m/min
ig
Lights up in green
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(effective)
Program
op
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Surface speed 2 m/min
D747S40011
Fig. 3-1 Reserved status of updating the cutting conditions data in the program  VFC
3-4
Serial No. 289476

By this time, the actual rate of cutting feed and surface speed will have already
been changed, but not yet the corresponding values in the program.
Displayed in orange
(ineffective)
Program
Surface speed 2.4 m/min
d .
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D740S0014
ts
Fig. 3-2 Updating the cutting conditions data in the program  VFC
gh
ri
Upon completion of machining in the tool sequence being executed when the key
ll
was pressed, the corresponding values in the program will be automatically overridden.
.A
N
2. The VFC function is invalid for EIA/ISO programs.
O
3. The VFC function becomes invalid if the cutting feed override switch is operated or a spindle
TI
76
speed override key ( or A

) is pressed while the key stays effective. That is,
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94
overriding of the values in the program does not occur.

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28
4. Upon completion of machining in the tool sequence being executed when the key
o.
O
N
was pressed, the corresponding values in the program are overridden with the new values
C
al
and the machine operation will be brought into single-block stop with VFC FINISH-CHECK
K
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OVERRIDE DIAL displayed in a message box. To continue the machining operation, return
Se
the override settings concerned to 100% and then press the button.
IM
5. Even if during automatic operation feed-hold stop is executed, the VFC function will remain
K
ZA
active.
A
6. The VFC function is inactive if the Dry Run function is active.

M
YA
7. When one unit is repeated to perform multiple-piece machining or because CONTI. item of
the end unit is set to “1”, data that has been updated using the VFC function becomes valid
3
for the third unit onward from that unit.

01
)2
8. When the parameter E29 (modification of the cutting conditions in the shape sequence
(c
during VFC mode) is set to “1”, the rate of cutting feed changed in step (1) will be
ht
incorporated into both the feed command in the tool sequence and the feed command in the
ig
shape sequence.
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3-5
Serial No. 289476
Example 1: In the case that a program that includes multiple-piece machining is executed
(Roughing)
During machining with the OFS-1 unit, when a feed override value of 200% is selected
and VFC is turned ON, the rate of feed in the program will be updated to 0.2 mm/rev on
completion of the OFS-1 unit. However, since the NC unit has already pre-read the
OFS-2 and OFS-3 units, VFC data will not be incorporated into the machining.
UNo. MAT INITIAL-Z ATC

0 CST-IRN 50.
OFS X Y
1 0 0
2 100 0
3 200 0
4 300 0
.
5 400 0
d
ve
UNo. UNIT DEPTH SRV-Z
1
er
POCKET 5 5
SNo. TOOL NOM- No. APRCH-X APRCH-Y TYPE ZFD DEP-Z WID-R C-SP FR M M
s
re
R1 END MILL 10.A ? ? CW G01 5. 5. 30. 0.1
FIG PTN P1X/CX P1Y/CY P3X/R P3Y CN1 CN2 CN3 CN4
ts
1 SQR 0 0 80 80
gh
UNo. UNIT
ri
2 END
ll
.A
N
Fig. 3-3 Program example 1
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A Data is already created since

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pre-reading has been completed

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28
during OFS-1 execution.

R
o.
O
N
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OFS-1 OFS-2 OFS-3 OFS-4 OFS-5

K
ri
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Se
A
IM
Feed override 200% 100% 100% 100% 100%

K
Programmed rate of feed 0.1 0.2 0.2 0.2 0.2

ZA
VFC ON OFF OFF OFF OFF

A
Actual rate of feed (mm/rev) 0.2 0.1 0.1 0.2 0.2

M
YA
Fig. 3-4 Operation and the feed during the use of VFC
3
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3-6
Serial No. 289476

Example 2: In the case that a program that includes multiple-piece machining is executed
(Roughing + finishing)
During machining with the OFS-1 unit, when a feed override value of 200% is selected
and VFC is turned ON, the rate of feed in the program will be updated to 0.2 mm/rev on
completion of the OFS-1 (R1) unit. However, since the NC unit has already pre-read
the OFS-1 (R1) and OFS-2 (F1) units, VFC data will not be incorporated into the
machining.
UNo. MAT INITIAL-Z ATC

0 CST-IRN 50.
OFS X Y
1 0 0
2 100 0
3 200 0
.
d
4 300 0
ve
5 400 0
er
UNo. UNIT DEPTH SRV-Z
s
1 POCKET 5 5
re
SNo. TOOL NOM- No. APRCH-X APRCH-Y TYPE ZFD DEP-Z WID-R C-SP FR M M
ts
R1 END MILL 10.A ? ? CW G01 5. 5. 30. 0.1
gh
F1 END MILL 10.A ? ? CW G01  5. 30. 0.05
FIG PTN P1X/CX P1Y/CY P3X/R P3Y CN1 CN2 CN3 CN4
ri
1 SQR 0 0 80 80
ll
UNo.
.A
UNIT
2 END
N
O
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Fig. 3-5 Program example 2 A

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28
Data is already created since

R
o.
pre-reading has been completed

O
N
during OFS-1 (R1) execution.

C
al
K
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R1 F1 R1 F1 R1
A
OFS-1 OFS-1 OFS-2 OFS-2 OFS-3

IM
K
ZA
Feed override 200% 100% 100% 100% 100%

Programmed rate of feed 0.1 0.05 0.2 0.05 0.2
A
M
VFC ON OFF OFF OFF OFF

YA
Actual rate of feed (mm/rev) 0.2 0.05 0.1 0.05 0.2

3
01
)2
Fig. 3-6 Operation and the feed during the use of VFC
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3-7
Serial No. 289476
3-5 AFC Function

The AFC (Adaptive Feedrate Control) is a function that provides automatic control of the rate of
feed to prevent overloading of the spindle motor and the servo motor of the feed axis (the most
loaded axis among the X-, Y- and Z-axes). After detecting the cutting current load on the spindle
motor or feed axis servo motor, this function compares the current load value with the
corresponding presetting (relative value in percentage terms with respect to the rated load) on
the TOOL DATA display and then automatically changes the rate of feed if any deviation from
the preset value is found.
The actual current load varies according to the loaded states of the motors and the state of the
cutting edge; however, in order not to allow the equipment to operate because of these variations
alone, the current load is continually supervised with a certain tolerance of the current load
. d
presetting. The rate of feed is changed if this tolerance is overstepped. If five seconds have
ve
elapsed since the rate of feed was reduced to 50% in order to maintain the current load
er
presetting, this condition is judged as an overloaded one and operation comes to a temporary
s
re
stop (feed-hold stop).
ts
gh
ri
ll
Load
AFC invalid
.A
Load tolerance
N
AFC valid
O
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Maximum load
10%
76
Preset value A
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94
10%
PO
Minimum load
28
R
o.
O
N
C
al
K
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ZA
Feed
Se
Time
A
override
IM
Override step AFC ON

K
100%
ZA
(Upper limit)
A
50%
M
(Lower limit)
YA
(A) (B) (C) (E)

3
01
(D) Time
)2
D735S0037
(c
Fig. 3-7 Load tolerance and rate of feed

ht
ig
Area Loaded state Feed override

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A Load  Maximum load The feed override value of 100% is maintained.

op
B Load  Maximum load The feed override value is stepped down depending on the
C
load (clamped at a minimum of 50%) so that

“load  maximum load”.
C Load  Maximum load The feed override value appropriate for the actual load is set
automatically. Feed-hold stop occurs if the feed override
value of 50% is forced for 5 seconds in succession.
D Load  Minimum load The feed override value is stepped up (clamped at a
maximum of 100%).
E Load  Minimum load The feed override value of 100% is maintained.
3-8
Serial No. 289476

3-5-1 Setting the desired current load value
Set the desired current load value in percentage terms on the TOOL DATA display.
If the current load on the spindle motor is to be supervised, set the desired horsepower value
(HORSE PW) (this renders the AFC function valid for the spindle).
If the current load on the feed axis motor is to be supervised, set the desired thrust force value
(THRUST F.) (this renders the AFC function valid for the feed axis).
AFC valid for spindle (for 60%)

AFC valid for feed axes (for 85%)
d .
ve
ser
re
ts
Remark : The AFC function is invalid if the horsepower or thrust force is set equal to zero.
gh
ri
1. Setting of the desired value through trial cutting
ll
.A
Carry out a trial cutting operation using the machining program for which the AFC function is to
N
be executed, and then read the load values displayed on the POSITION display and take the
O
displayed value (or a value close to it) as the load value to be set. Use of this calculation method
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76
allows highly accurate setting of the current load value.

A
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28
2. Setting of the desired value through auto-setting

R
o.
Selection of the [AUTO SET] menu item on the TOOL DATA display with the cursor set on the
O
N
item THRUST F. and HORSE PW allows automatic setting of the horsepower and thrust force
al
values. This auto-setting, however, is just a simplified one that is performed according to the
ri
ZA
Se
diameter of the tool used. Therefore, the auto-set values will usually be larger than the values set
A
through trial cutting.

IM
Note : The auto-setting is not available for tools of types BAL EMIL (ball end-mill) and OTHER
K
(special cutter).
ZA
A
M
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3-9
Serial No. 289476
3-5-2 Tools available with AFC and AFC supervisory modes

The tools for which AFC can be executed and the modes of AFC supervision are listed below.
Tool name AFC supervisory mode

DRILL (Drill)
END MILL (End-mill)
Spindle and feed axis AFC
OTHER (Special cutter)
(Simultaneous)
FCE MILL (Face-mill)
CHAMFER (Chamfering cutter)
BOR BAR (Boring bar)
BCK FACE (Back-spot facer) Spindle AFC only
.
B-B BAR (Back-boring bar)
d
ve
The following tools are not available with AFC and AFC supervisory modes.
ser
re
1. CTR-DR (Center drill)
2. REAMER (Reamer)
ts
gh
3. TAP (Tap)
ri
4. TOL SENS (Touch sensor)
ll
5. CHIP VAC (Chip vacuum)
.A
6. BAL EMIL (Ball end-mill)
N
7. Turning tool
O
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3-5-3 Functional operation A

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28
1. Spindle AFC function

R
o.
O
N
C
al
Start setting End of cutting

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ZA
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Idle cutting Cutting Idle cutting

A
IM
Feedrate 100% AFC valid 100%

K
ZA
A
Workpiece
M
YA
Cutting direction
3
D735S0040
01
)2
Fig. 3-8 Spindle AFC function

(c
When the spindle AFC function starts operating, the corresponding lamp in the machine status
ht
indicator window lights up.

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3-10
Serial No. 289476

2. Feed axis AFC function
Start of cutting End of cutting
Rapid traverse speed
Idle
Cutting
cutting
Rate of 100% AFC valid

feed
.
d
ve
Workpiece
er
s
re
D735S0040
ts
Fig. 3-9 Feed axis AFC function
gh
Note 1: When the feed axis AFC function starts operating, the status of AFC function can be
ri
ll
checked in the machine status indicator window.
.A
Note 2: During AFC operation, the rate of feed is automatically overridden, but the override
N
display on the screen does not change.
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A
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28
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N
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Se
A
IM
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A
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3-11
Serial No. 289476
3-6 Spindle Speed Waving Function (Optional)

The function is designed to suppress the chatter vibrations between cutting tool and workpiece
during light-duty machining [finishing among others] by waving (cyclically raising and lowering)
the spindle speed so as to describe triangular waveforms. Cycle and amplitude of the triangle
waves can be changed in the flow of (test) machining to find out the conditions for the least
chattering.
In the spindle speed waving mode the spindle speed is waved, with the command value as re-
ference, for commands of linear interpolation (G01) or circular interpolation (G02/G03).
The spindle speed waving function can only be used for EIA/ISO programs.
Spindle speed
[min–1]
.
d
ve
ser
Waved spindle speed
re
Waving amplitude
Command value of
ts
spindle speed
gh
ri
ll
.A
Waving cycle
N
O
Time
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76
D747S40016
A
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PO
Note 1: Chatter vibrations may not be suppressed completely.

28
R
o.
Note 2: The cyclic variation in cutting speed as a result of spindle speed waving may affect the
O
N
surface quality by leaving a striped pattern on the machined surface.

C
al
Note 3: A long waving cycle may cause corners to be rounded improperly. Use a command of
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ZA
Se
dwell (G04) or exact stop check (G09) as required to suppress the roundness.
A
IM
Note 4: If the feed hold or resetting function is executed during machining operation in the
spindle speed waving mode, the axis movement may not be stopped immediately, but
K
within quarter the waving cycle.

ZA
Note 5: If the overriding function (for spindle speed or axis feed) is applied in the spindle speed
A
M
waving mode, the acceleration or deceleration cannot occur linearly, but in waveforms;
YA
it takes, therefore, longer than usual to reach the required new reference value of
spindle speed.
3
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3-12
Serial No. 289476

3-6-1 Procedure
Add the following commands before and after the machining process to be executed using the
spindle speed waving function.
(1) Enable the spindle speed waving function with the command blocks described below before
the machining process.
Variable Contents Description Setting Setting

unit range
M-code to enable the syn- Used to synchronize the spindle rotation and axis feed.
M [SA231] chronization mode for Fetch the setting in parameter SA231 as the number of the M-code. — —
spindle speed waving (Note 1, Note 2)
#50800 Waving cycle Specify the desired waving cycle. (Note 3) 0.1 s 1 to 50
d .
Set the desired waving amplitude with respect to the command
#50801 Waving amplitude % 1 to 50
ve
value of spindle speed. (Note 4)
er
Select the desired type of waving the spindle speed. (Note 5)
s
re
0: MODE1 .... Waving (raising and lowering) the spindle speed with
the command value as the medium.
ts
gh
Spindle speed [min–1]
ri
ll
Waving Waved spindle speed
.A
amplitude
Command value of
spindle speed
N
O
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Waving cycle
A
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Time
Spindle speed waving type
PO
#50802 — 0 or 1
28
(MODE)
1: MODE2 .... Waving (raising and lowering) the spindle speed with
R
o.
the command value as the peak.

O
N
Spindle speed [min–1]

al
K
ri
ZA
Se
Waving amplitude Command value

IM
of spindle speed
Waved spindle speed
K
ZA
Waving cycle
A
Time
M
YA
Used to automatically change the spindle speed in the mode of

M-code to enable the linear interpolation (G01) or circular interpolation (G02/G03) so as
3
to describe triangular waveforms. — —

01
M [SA233] function for waving the

spindle speed Fetch the setting in parameter SA233 as the number of the M-code.
)2
(Note 1)
(c
ht
Remark : When the synchronization mode for spindle speed waving is enabled, REV. FLUCT.
ig
SYNC is displayed in the status display area.

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op
(2) Disable the spindle speed waving function with the command blocks described below after
C
the machining process.
Variable Contents Description

M-code to disable the function for waving
M [SA234] Used to cancel the spindle speed waving function. (Note 1, Note 2)
the spindle speed
M-code to disable the synchronization Used to cancel the synchronization mode for spindle speed waving.
M [SA232]
mode for spindle speed waving (Note 1)
Note 1: Enter the M-codes for enabling and disabling the synchronization mode as well as the
spindle speed waving function always in a single-command block.
3-13
Serial No. 289476
Note 2: Give a command of the M-codes to enable and disable the synchronization mode for
spindle speed waving always after the spindle rotation and axis feed are stopped
completely. If the enabling M-code should be executed with the spindle being rotated,
then the spindle is brought to a temporary stop, the spindle and the feed axes fall under
the synchronization control and the spindle is rotated anew up to the original speed.
Likewise if the disabling M-code should be executed with the spindle being rotated,
then the spindle is brought to a temporary stop, the spindle and the feed axes are
released from the synchronization control and the spindle is rotated anew up to the
original speed.
Note 3: If the waving cycle should be set to a value less than or equal to zero (0) and greater
than or equal to 51, respectively, “1” (0.1 s) and “50” (5.0 s) will be made valid as the
d.
setting. If a command of the M-code for enabling the spindle speed waving function
ve
should be given without preceding #50800 setting after turning on the NC, the function
er
will be executed according to the setting in parameter MS26.
s
re
Note 4: If the waving amplitude should be set to a value less than or equal to zero (0) and
ts
gh
greater than or equal to 51, respectively, “1” (1%) and “50” (50%) will be made valid as
ri
the setting. If a command of the M-code for enabling the spindle speed waving function
ll
should be given without preceding #50801 setting after turning on the NC, the function
.A
will be executed according to the setting in parameter MS27.
N
O
Note 5: If a command of the M-code for enabling the spindle speed waving function should be
TI
given without preceding #50802 setting after turning on the NC, the function will be
76
A
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94
executed according to the setting in bit 0 of parameter MS125.

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O
N
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A
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K
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A
M
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3-14
Serial No. 289476

Example : Programming for waving the spindle speed with 1.0 s as waving cycle, 10% as
waving amplitude and using the waving type 1 (MODE1; waving with the command
value as the medium).
G91G28X0Z0
G54
G18
M202
M[SA231] : M-code to enable the synchronization mode for spindle speed waving
#50800=10 : Setting the waving cycle to 1.0 [s]
#50801=10 : Setting the waving amplitude to 10 [%]
#50802=0 : Selection of spindle speed waving type 1 (MODE1)
M[SA233] : M-code to enable the function for waving the spindle speed
G96S100.P1R1
d .
ve
S100.M203
er
G95
s
G90
re
G00X35.Z0.
ts
N10 G01Z-50.F0.5  Cutting with the spindle speed being waved
gh
N20 G01X60.Z-70.  Cutting with the spindle speed being waved
ri
N30 G00X80.
ll
N40 G00Z10.
.A
M205
N
M[SA234] : M-code to disable the function for waving the spindle speed
O
M[SA232]
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: M-code to disable the synchronization mode for spindle speed waving
76
G97 A
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M30
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28
+X
o.
O
N
N40
C
al
N30
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N20
A
IM
N10
K
ZA
A
M
+Z
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D747S40017
3
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3-15
Serial No. 289476
3-6-2 Adjusting the spindle speed waving conditions

If chatter vibrations occur in the execution flow of a machining program, follow the procedure
below to use the REV FLUCTUATION SETTING window in order to find out the spindle speed
waving conditions for the least chattering and to insert in the program the relevant commands for
specifying the optimum waving cycle and waving amplitude.
<Procedure>
(1) Bring the automatic operation into feed hold stop or single-block stop immediately before
the machining process where chatter vibrations are likely to occur.
(2) Call up the POSITION display on the screen.
(3) Tap the [REV FLUCTUATION SETTING] menu item.
.
 The REV FLUCTUATION SETTING window appears on the screen.
d
ve
[9]
s er
[8]
re
ts
gh
[1] [4]
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ll
.A
[2]
N
[5]
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[3]
A [6]
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[7]
28
R
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No. Item Unit Description

al
K
ri
ZA
Select the desired type (MODE) of waving the spindle speed.

Se
MODE1...... Waving (raising and lowering) the spindle speed with the
A
command value as the medium.

IM
[1] MODE SELECT — MODE2...... Waving (raising and lowering) the spindle speed with the
K
command value as the peak.

ZA
Remark : Initial value (selection) in the window (displayed for the first
time after turning on) refers to the setting in bit 0 of parameter MS125.
A
M
FLUCTUATION Specify the desired waving cycle. (Setting range: 0.1 to 5.0 s)
YA
[2] CYCLE (under SET 0.1 s Remark : Initial value in the window (displayed for the first time after
VALUE) turning on) refers to the setting in parameter MS26.
3
01
FLUCTUATION Specify the desired waving amplitude. (Setting range: 1 to 50%)

)2
[3] RANGE (under SET % Remark : Initial value in the window (displayed for the first time after
VALUE) turning on) refers to the setting in parameter MS27.
(c
Mode (under
ht
[4] — Currently selected type (MODE) of waving the spindle speed

CURRENT VALUE)
ig
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FLUCTUATION
[5] CYCLE (under 0.1 s Currently active waving cycle
op
CURRENT VALUE)
C
FLUCTUATION
[6] RANGE (under % Currently active waving amplitude
CURRENT VALUE)
Used to reset the settings (Type, Cycle and Amplitude) to the default
state.
Tap the button and then tap the [OK] button in the resulting message
[INIT CONFIG]
[7] — box to restore the default state:
button
 Type (MODE) as set in bit 0 of parameter MS125
 Cycle as set in parameter MS26
 Amplitude as set in parameter MS27
3-16
Serial No. 289476

No. Item Unit Description
Used to display a graphical representation for the waving cycle and
waving amplitude to be specified.
Example :
1. For the selection of Type 1 (MODE1) for [1] MODE SELECT:
Waving the spindle speed with the command value as the
medium.
+[3]
–[3]
d .
[8] Help button —
ve
[2]
s er
2. For the selection of Type 2 (MODE2) for [1] MODE SELECT:
re
Waving the spindle speed with the command value as the peak.
ts
gh
+[3]
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.A
N
–[3]
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A [2]
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28
On machines equipped with a lower turret, an extension is added to the

[9] Window title — title to indicate the currently active turret: [TR1] and [TR2], respectively,
R
o.
for the selection of the upper and the lower turret.

N
C
al
(4) Select the desired type (MODE) of waving the spindle speed.
ri
ZA
Se
Tap the MODE1 or MODE2 button on the MODE SELECT bar.

A
(5) Specify the desired waving cycle.

IM
Use the screen keyboard or the arrow buttons at the right end of the FLUCTUATION
K
CYCLE bar.
ZA
A
(6) Specify the desired waving amplitude.

M
Use the screen keyboard or the arrow buttons at the right end of the FLUCTUATION
YA
RANGE bar.
3
01
(7) While holding down the key, tap the [REV FLUCTUATION ON] menu item.
)2
 REV. FLUCT. SYNC is displayed in the status display area.

(c
Note : If the spindle speed waving function should be enabled with the spindle being
ht
rotated, then the spindle is brought to a temporary stop, the spindle and the feed
ig
axes fall under the synchronization control and the spindle is rotated anew up to
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op
the original speed.

C

(9) Repeat Steps (4) to (6) in the flow of machining to find out the spindle speed waving con-
ditions for the least chattering.
(10) After the optimum conditions are determined, execute the current program to the end or
stop the operation by tapping the key.
(11) Call up the PROGRAM display and select the EIA/ISO program into which to insert the
relevant commands for specifying the optimum waving type, waving cycle and waving
amplitude.
3-17
Serial No. 289476
(12) Select the Edit mode (by tapping the [PROGRAM EDIT] menu item) and move the cursor to
the place at which to insert the commands.
G91G28X0Z0
G54
G18
M202
 G96S100.P1R1  Move the cursor to the place at which to insert the commands.
S100.M203
G95
G90
G00X35.Z0.
N10 G01Z-50.F0.5
N20 G01X60.Z-70.
.d
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N30 G00X80.
N40 G00Z10.
er
s
M205
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G97
ts
M30
gh
ri
(13) Tap the [REV FLUCTUATION INPUT] menu item.
ll
 The commands for specifying the optimum waving type, waving cycle and waving ampli-
.A
tude are inserted according to the current settings in the REV FLUCTUATION SETTING
N
window.
O
TI
76
G91G28X0Z0 A
G54
R
94
PO
G18
28
M202
R
o.

N

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G96S100.P1R1
Se
S100.M203
IM
G95
G90
K
ZA
G00X35.Z0.
N10 G01Z-50.F0.5
A
M
N20 G01X60.Z-70.
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N30 G00X80.
N40 G00Z10.
3
M205
01
G97
)2
M30
(c
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3-18
Serial No. 289476

(14) Finally insert command blocks of the M-codes for enabling and disabling the synchroni-
zation mode as well as the spindle speed waving function manually at the right places.
G91G28X0Z0
G54
G18
M202
M[SA231] : M-code to enable the synchronization mode for spindle speed waving
M[SA233] : M-code to enable the function for waving the spindle speed
G96S100.P1R1
S100.M203
d.
G95
ve
G90
ser
G00X35.Z0.
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N10 G01Z-50.F100.  Cutting with the spindle speed being waved
ts
N20 G01X60.Z-70.  Cutting with the spindle speed being waved
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N30 G00X80.
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N40 G00Z10.
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M205
.A
G97
N
M[SA234] : M-code to disable the function for waving the spindle speed
O
M[SA232]
TI
: M-code to disable the synchronization mode for spindle speed waving
76
M30 A
R
94
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28
R
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O
N
C
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A
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A
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3
01
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3-19
3
C
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01
3
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M
CHANGING THE CUTTING CONDITIONS
A Se
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N
A o.
ZA 28
K
3-20 E
94
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Serial No. 289476
R
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d.
Serial No. 289476
STOPPING AUTOMATIC OPERATION 4

4 STOPPING AUTOMATIC OPERATION
All machine actions must be emergently stopped if any abnormalities occur during automatic
operation, such as in the case where the tool is likely to contact the workpiece, the fixture, etc.
When machining has been executed to a certain extent, it may be also necessary to bring
automatic operation to a halt so that you can check the finished status of the workpieces.
This section describes several types of methods of stopping automatic operation.
Select the best-suited stop method according to the particular machine or machining status and
your requirements.
 Those indicated as Sections 4-1, 4-2 and 4-3 below, in particular, are most
important methods for safety purposes.
d.
ve
In emergencies, immediately carry out one of these methods.
ser
re
ts
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.A
N
O
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76
A
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28
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01
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4-1
Serial No. 289476
4-1 Emergency Stop
4-1-1 Emergency stop

(1) Press the emergency stop button.
 All machine actions will then stop immediately and an alarm message 3 EMERGENCY
STOP will be displayed.
d.
ve
er
s
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Emergency stop button
ts
D735S0043
gh
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4-1-2 Releasing the emergency stop status
ll
.A
If automatic operation has been brought to an emergency stop, it is possible to carry out manual
N
operations or restart automatic operation just by releasing the emergency stop status using the
O
TI
following procedure:
76
A
(1) Turn the emergency stop button clockwise (direction of the arrow).
R
94
PO
 Turning the emergency stop button clockwise and then releasing the switch will return it
28
to the original position from the depressed state.

o.
O
N
C
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A
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K
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A
Emergency stop button

M
D735S0043
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3
(2) Press the key.

01
 The alarm message 3 EMERGENCY STOP will disappear.

)2
(c
 The color of the key changes to orange to indicate that the emergency stop status
ht
has been released.

ig
Note : This procedure can be different according to the machine model.

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op
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4-2
Serial No. 289476
STOPPING AUTOMATIC OPERATION 4

4-2 Reset
(1) Press the key.
 The machine actions (such as the actions of the spindle, axes, etc.) will stop immedi-
ately.
Note : After a reset operation has been carried out, the program will restart from the beginning,
not from the stop position if automatic operation is restarted by pressing the
button.
Select the Restart mode if automatic operation is to be restarted from the aborted
portion of the program.
.
Remark : The system of coordinates as the initial state after resetting (using the key) is
d
ve
selected as follows according to the related parameter:
er
F95 bit 7 = 0: G54 system after resetting
s
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= 1: The same system after as before resetting
ts
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4-3 Feed Hold
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ll
.A
N
 The actions of the axes will stop immediately.
O
TI
 The action of the spindle will not stop even when this feed hold operation is carried out.
76
A
R
94
PO
Remark : When the button is pressed following the feed hold operation, axis feeding
28
will restart and the succeeding portion of the program will be executed through to
R
o.
completion.
N
C
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4-4 Stopping by Changeover to a Manual Operation Mode

ri
ZA
Se
(1) Press one of the manual operation mode selector keys.

IM
 The machine actions (movements of the spindle, axes, etc.) will stop immediately.
K
ZA
Remark : Changing back to the original automatic operation mode and then pressing the
A
button will let automatic operation restart.

M
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3
01
)2
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D740S40015
4-3
Serial No. 289476
4-5 Single-block Stop

Carrying out one of the two methods described below will stop all machine actions when the
block being executed terminates.
Such a stop is referred to as “single-block stop”.
4-5-1 Single-block stop by changing within automatic operation modes

(1) Change the existing automatic operation mode over to another automatic operation mode.
 Machine actions will stop at the end of the block being executed.
Note : Single-block stop does not occur if the tape operation key is pressed.
Remark : Changing back to the original automatic operation mode and then pressing the
.
d
ve
button will let automatic operation restart from the next block.
er
s
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4-5-2 Single-block stop using the single block key
ts
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(1) Press the key.
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 The color of the single block key changes to green to indicate that the Single Block
ll
.A
function has become active and the machine actions will stop at the end of the block
being executed.
N
O
TI
4-6 Program Stop
76
A
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(1) Set previously M00 (M-code for program stop) in the program to be executed.
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28
Automatic operation will always stop at the position of M00 in the flow of program execution.
R
o.
O
N
Remark : Automatic operation can be restarted by pressing the button.

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K
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ZA
Se
4-7 Stopping by Turning the Power Off

A
IM
(1) Tap the button in the upper left corner of the NC screen to call the Home screen.
K
ZA
(2) Tap the button in the lower left corner of the NC screen.
A
M
(3) Tap the button which will appear next.

YA
(4) Tap the [OK] button in the resulting confirmation dialog box.
3
01
 This will stop all machine actions and turn off the power to the NC unit.
)2
However, if the spindle is rotating it will take some time for the machine actions to stop,
(c
since the spindle will continue rotating due to its inertia.

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ig
 Using this method causes shocks to the NC unit and the machine, and trouble can result
yr
from repeated use.

op
Therefore, use this method as the last available means only.

C
CAUTION
Remark : When the power of the NC unit is turned off, the power of the machine will be turned
off automatically.
 See PART 3 “OPERATING NC UNIT AND PREPARATION FOR

AUTOMATIC OPERATION” of the Operating Manual for the details of the
home screen.
4-4 E
Serial No. 289476
MANUAL INTERRUPTION 5
5 MANUAL INTERRUPTION
Interrupting automatic operation for you to carry out manual operations is referred to as manual
interruption.
Carry out manual interruption in cases that the tool path specified in the programs is to be shifted,
that a damaged tool-tip is to be replaced, etc.
To carry out manual interruption, first interrupt automatic operation using one of the following
three methods:
 Feed hold
 Stopping by changeover to a manual operation mode
 Single-block stop
d .
If you do not wish to use these three methods, carry out manual interruption after automatic
ve
operation has been stopped by Program Stop or Optional Stop.
ser
re
5-1 TPS Function
ts
gh
TPS refers to the function that lets the NC unit store the tool-tip position during manual
ri
interruption into the memory of the unit. With this function, those positions of the tool-tip at up to
ll
five different points during manual- interruption axis movement can be stored into the memory of
.A
the NC unit. Therefore, even after axis movement during manual interruption, automatic
N
operation can be restarted without disturbing the tool path specified in the program.
O
TI
This function comes in handy during automatic operation if a tool is to be replaced because of
76
A
damage to the tool-tip or the presence of swarf entangling the workpiece.
R
94
PO
The following gives three examples of application of the TPS function and related machine
28
actions.
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O
N
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5-1
Serial No. 289476
5-1-1 Storing the data of only the stop point of automatic operation
(1) Abort automatic operation.
(2) Change the automatic-operation mode over to any manual mode.
 This can be accomplished simply by pressing one of the manual-mode selector keys
( , , , , or ).
 This changeover is not required if automatic operation has been aborted with a
manual-mode selector key in procedural step (1) above.
(3) Press the key.
 The key will be effective, the TPS data in the status display area of the screen will
.
become 1 and the tool-tip position will be stored into the memory of the NC unit.
d
ve
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TPS data
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.A
N
O
(4) Manually move the tool.
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76
 The A
key will be ineffective when tool movement is started.
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94
PO
(5) Change the operation mode back to the original one.

28
R
o.

N
C
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 This will cause the button to light up and the tool tip to return to the position
ri
ZA
Se
existing when the key was pressed and then, automatic operation will restart from
A
IM
that position.
Example : If, as shown below, the tool has been moved in order of a→b→c→N in
K
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procedural step (4):

A
M
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c
N
3
01
)2
(c
a
b
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Stop point of
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automatic operation
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D747S40013
Fig. 5-1 Tool path
When the button is pressed, the tool will linearly move from N to a at the feedrate
existing when automatic operation was stopped.
5-2
Serial No. 289476
MANUAL INTERRUPTION 5
5-1-2 Storing the data of both the stop point of automatic operation and the passage
point(s) existing during manual interruption
(1) Abort automatic operation.
(2) Change the automatic-operation mode over to any manual mode.
 See the description of procedural step (2) in Section 5-1-1 above.
(3) Press the key.
 See the description of procedural step (3) in Section 5-1-1 above.
(4) Manually move the tool, and press the key during tool movement.
 The TPS data in the status display area of the screen increases by 1, and the tool-tip
. d
position at that time will be stored into the memory of the NC equipment.
ve
 The key will be ineffective next time the tool is moved.
s er
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(5) Repeat step (4) above. (Up to five points can be stored.)
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(6) Change the operation mode back to the original one.
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ri
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 The button will then light up, and the tool tip will move through the position
N
O
existing when the key was pressed in step (4) and will finally return to the point at
TI
which the automatic operation was stopped and then, automatic operation will restart
76
from the position in which it was stopped.

A
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28
Example : If, as shown below, the tool has been moved in order of a→b→c→d→e→N in
R
o.
procedural step (4) and the key has been pressed at the points a, b, c and
O
N
d:
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K
ri
ZA
Se
e N
A
IM
K
(R)
ZA
c
d
A
M
(R)
(R)
YA
3
a b
01
)2
R: Rapid feed
F: Feedrate existing when automatic
(c
(F)
Stop point of operation was stopped.
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automatic operation
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D747S40014
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Fig. 5-2 When pressing the TPS key at stop point and passage points
C
When the button is pressed, the tool will move at the current rapid traverse speed
from point N to d directly, then from d through c to b. Then, the tool will move linearly from b
to a at the feedrate existing when automatic operation was stopped.
5-3
Serial No. 289476
5-1-3 Storing the data of only the passage point(s) existing during manual interruption
Carry out the same operation except the procedural step (3), as described in Section 5-1-2
above.
Example : If, as shown below, the tool has been moved in order of a→b→c→d→e→N and the
key has been pressed at the points c and d:
e N
(R)
c d
. d
ve
(F)
s er
a
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b
ts
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R: Rapid feed
F: Feedrate existing when automatic
ri
Stop point of operation was stopped.
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automatic operation
.A
D747S40015
N
Fig. 5-3 When pressing the TPS key only at the passage points during manual interruption
O
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76
When the button is pressed, the tool will move at the rapid traverse speed from point
A
R
94
N directly to d. Then, the tool tip will move linearly from d to c at the feedrate existing when
PO
28
automatic operation was stopped.

R
o.
Note : Automatic operation will restart from the position where the key was pressed for
N
the first time in the manual interruption (c in above example). That is, the restarted
al
K
ri
automatic operation will be performed on the basis of that workpiece coordinate system
ZA
Se
to which the programmed system is shifted in accordance with the distance from the
A
IM
abort position of automatic operation to the position of the first depression of the
key.
K
ZA
5-1-4 General remarks on TPS function

A
M
1. Operating procedure of Subsection 5-1-3 above must be carried out only when automatic
YA
operation is to be restarted on the basis of a shifted system of coordinates.

3
Operating procedure Subections 5-1-1 or 5-1-2 must be carried out when automatic
01
operation is to be restarted in such a manner that the tool tip follows the path specified in the
)2
program.
(c
2. Do not apply the 1. nor the 2. zero-point return mode to interrupt the automatic operation
ht
ig
under control of tool-length or -diameter offset.

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Otherwise, the tool offsetting may not correctly be performed any more in the restarted
op
automatic operation.
C
5-4 E
Serial No. 289476
OPERATIONS POSSIBLE DURING AUTOMATIC OPERATION 6

6 OPERATIONS POSSIBLE DURING AUTOMATIC OPERATION
6-1 Data Rewriting
6-1-1 Data writing conditions

Data setting and other operations on each display are restricted by the operational status of the
machine at a particular time. Also, while the reprogramming is disabled, writing or updating the
current program or several other types of data cannot be performed.
This section gives a listing as to what types of data can be set, and what types of display
operations can be carried out, according to the particular operational status (during execution of
d.
automatic operation, during automatic operation mode, or during manual operation mode) of the
ve
machine as well as according to the status (reprogramming is enabled or disabled).
ser
Follow the procedure below to make possible/impossible reprogramming.
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ts
1. To disable reprogramming
gh
ri
(1) Tap the protect button in the of status display area of the screen.
ll
.A
N
O
 A message box will appear.
TI
76
A
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94
PO
28
R
o.
O
N
C
al
K
ri
ZA
Se
A
IM
K

ZA
 The display of the protect button will be changed and the reprogramming will be
A
disabled.
M
YA
3
01
)2
2. To clear reprogramming disabled status

(c
(1) Touch the protect button in the status display area of the screen.
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ig
 PASSWARD SETTING window will appear.

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C
(2) Enter the passward and tap the [OK] button.
 See the section concerning to the data guard function in PART 3

“OPERATING NC UNIT AND PREPARATION FOR AUTOMATIC
OPERATION” of the Operating Manual for the details of the password setting.
6-1
Serial No. 289476
6 OPERATIONS POSSIBLE DURING AUTOMATIC OPERATION
○: Possible
×: Impossible
△: Impossible only for the program being executed.
▲: When parameter L57 is 0: Impossible 1: Possible
: When parameter F166 bit 0 is 0: Possible 1: Impossible
■: When parameter F166 bit 0 is 0 and L57 is 1: Possible
Reprogramming switch status

Reprogramming impossible Reprogramming possible
Display Data item Operation Autom. mode Autom. mode Remarks
Manu. Manu.
Machn. Machn. mode Machn. Machn. mode
running halted running halted
POSITION Workpc. qty      
.
Desired qty      
d
ve
Counter set      
er
Work No. search      
s
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TRACE Work No. search      
ts
Shape display      
gh
EIA MONITOR Program editing (*) Possible only
ri
    during single-
 
ll
(*) block or feed-
.A
hold stop
N
PROGRAM Display of program      
O
TI
Creation/edition of
     
76
program A
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94
PROGRAM Program name      

PO
FILE
28
Work No. change      

R
o.
Prg. deletion      
O
N
All prgs. deletion      

al
PROCESS Process No.

ri
ZA
     
Se
CONTROL search
A
PROGRAM Lay-out
IM
     
LAYOUT
K
TOOL PATH Display of shape/

     
ZA
CHECK path
A
TOOL LAYOUT Entire data      

M
TOOL DATA LENGTH/ACT-

YA
(Note 1) LENG.CO./ACT-CO.
     
OFFSET No.
(*) (*)
3
(length/dia.)
01
LENGTH A/B
)2
LENG COMP.
(c
EASY COMP
ht
CONS.COMP
ig
NOM-/NOM.
     
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THRUST F.
(*) (*)
HORSE PW
op
NOSE-R
C
OFS COMP Y
SPDL ROT.
MAX WEAR
LIFE TIME      
CUT TIME (*) (*)
LIFE NUM. (**) (**)
USED NUM.
WEAR COMP.      
(***) (***)
6-2
Serial No. 289476
OPERATIONS POSSIBLE DURING AUTOMATIC OPERATION 6

Reprogramming switch status
Reprogramming impossible Reprogramming possible
Display Data item Operation Autom. mode Autom. mode Remarks
Manu. Manu.
Machn. Machn. mode Machn. Machn. mode
running halted running halted
TOOL DATA Other data      
(Note 1) (*)
(*) Possible only for tools not in use during execution of an EIA/ISO program, and for tools that are not to be used
during execution of a MAZATROL program including its subprograms
(**) If bit 2 of parameter J144 is 0: Possible for tools not in use even during execution of a MAZATROL program.
(***) If bit 7 of parameter F82 is 1, even data on a tool in use can be rewritten during operation. If bit 7 is 0, data can be
rewritten in the same conditions as for ▲.
.
TOOL FILE Entire data      
d
ve
TOOL OFFSET Entire data      
er
PARAMETER Entire data      
s
re
WORK OFFSET Entire data      
ts
MACRO Common var.      
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VARIABLE
Common var. (Check)      
ri
ll
Local var.      
.A
Local var. (Check)      
N
DATA I/O LOAD (prg.)       CMT (Note 2)
O
HARD DISK
TI
LOAD (other)      
76
USB
SAVE,
A SD
R
94
     
CONTENTS
PO
28
LOAD, TAPE
     
R
o.
ALL LOAD
O
N
PUNCH,
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ALL PUNCH,
K
     
ri
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COMPARE,
Se
ALL COMP
A
LOAD (prg.)       DNC

IM
LOAD (other)      
K
ZA
SAVE      
A
M
Note 1: The available displays and data items depend on the specifications of the machine.
YA
Note 2: The SAVE function is not available in the CMT I/O mode.
3
01
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(c
ht
ig
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6-3
6
C
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ig
ht
(c
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01
3
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M
A Se
ZA
K ri
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N
A o.
OPERATIONS POSSIBLE DURING AUTOMATIC OPERATION
ZA 28
K
6-4 E
94
C
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Serial No. 289476
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d.
Serial No. 289476
COMPLETION OF OPERATION 7
7 COMPLETION OF OPERATION
7-1 Procedure for Switching the Power OFF
 Do not touch the switches with wet hands.
DANGER
 Do not turn power off during spindle rotation or axis movement. Failure to observe this
instruction may result in machine damage due to collision, or personal injury due to flyout
of the workpiece.
d.
CAUTION
ve
 If power is to be left turned off for three months or more in succession, copy the NC-stored
er
parameters and other data beforehand to provide against possible data loss.
s
re
(1) Make sure that neither spindle rotation nor axis movement is in progress (program operation,
ts
gh
input/output with external devices, etc.).
ri
(2) Select the manual operation mode and return the machine to its zero point or move the
ll
turret to a safe position.
.A
N
(3) Tap the button in the upper left corner of the NC screen to call the Home screen.
O
TI
76
(4) Tap the button in the lower left corner of the NC screen.
R
A
94
PO
(5) Tap the button which will appear next.

28
(6) Tap the [OK] button in the resulting confirmation dialog box.
o.
O
N
(7) Set the main power breaker to “OFF” position after the display on the screen and the logo
al
on the top of the operating panel have disappeared.

ri
ZA
Se
Note : If the main power breaker is turned off before the logo on the top of the operating
A
IM
panel disappears, normal NC function is not guaranteed. It takes maximum one

minute until the logo disappears.
K
ZA
(8) Switch off the factory power supply.

A
 See PART 3 “OPERATING NC UNIT AND PREPARATION FOR

M
YA
AUTOMATIC OPERATION” of the Operating Manual for the details of the

home screen.
3
01
 If the machine features the automatic power off function (option), refer to the
)2
separately provided specifications for options.

(c
ht
ig
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op
C
7-1
Serial No. 289476
7 COMPLETION OF OPERATION
7-2 Cleaning and Inspections on Completion of Operation

Carry out inspections and cleaning in the following order:
 To prevent accidents, wipe off all oil and water from the floor and dry the floor.
 The use of badly worn tools can result in injury. Replace worn tools with appropriate new
ones.
WARNING
 When all machine operations are complete, execute steps (1) to (7) in Section 7-1
“Procedure for Switching the Power OFF”, set the main power breaker on the electrical
control panel to OFF, then switch off the factory power supply.
CAUTION
 Check that all machine operations have stopped, and then clean the machine and
d.
peripheral units.
ve
 Do not use compressed air to clean the machine or remove chips.
ser
 Do not clear away chips with your bare hands.
re
ts
 Make sure that all parts of the machine are ready for use in the initial status.
gh
(1) Execute steps (1) to (7) in Section 7-1 “Procedure for Switching the Power OFF”.
ri
ll
(2) Remove chips from the machine and peripheral equipment.
.A
(3) Tidy the area around the machine and peripheral equipment.
N
O
(4) Inspect each unit and equipment for damage.
TI
76
(5) Inspect the tools for wear and damage. A

R
94
PO
(6) Check that the levels of the lubrication unit, the coolant unit, and the hydraulic unit are
28
correct.
R
o.
O
N
(7) Check that the filters in the lubrication unit, the coolant unit, and the hydraulic unit are not
C
al
clogged.
K
ri
ZA
Se
A
IM
K
ZA
A
M
YA
3
01
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(c
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7-2 E

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Serial No.

nearest Technical Center or Technology Center.

2. No modifications are to be performed that will affect operation safety.

such items are in place.

Center or Technology Center.

Copyright (C) 2017 YAMAZAKI MAZAK CORPORATION. All Rights Reserved.

It is to be understood, therefore, that functions not clearly written as “executable” are

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

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

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

function is executed without its thorough understanding.

understanding the functions of the corresponding parameters. Modifications usually affect

without a thorough understanding.

Remarks on the Cutting Conditions Recommended by the NC

 Before using the following cutting conditions:

• Cutting conditions suggested by the Machining Navigation Function

– especially for workpiece fixturing/clamping and tool setup.

be interchanged. (This precaution applies only to NC units provided with EIA/ISO

applies only to NC units provided with EIA/ISO functions.)

 If machine coordinate system commands or reference position returning commands are

units provided with EIA/ISO functions.)

function will not work correctly.

machines of INTEGREX i/e-Series and the other turning machines.

Issuance of the wrong G-code or M-code command results in totally non-intended

before using this system.

Sample program Machines of INTEGREX i/e-Series Turning machines

workpiece specified in the common unit of the MAZATROL program.

 If axis-by-axis independent positioning is selected and simultaneously rapid feed selected

As a result, serious machine damage will result.

axial movement will become faster than that expected.

REQUEST TO THE USER

REQUEST TO THE USER

Request for Saving Data of Machining Programs

BEFORE USING THE NC UNIT

BEFORE USING THE NC UNIT

Note : As humidity increases, insulation deteriorates causing electrical component parts to

The NC unit operates using dedicated network adapters.

prevent the NC unit from operating normally.

 Ethernet_NC (IP address:192.168.100.2)

 NC Trainer Virtual Network (IP address:192.168.202.10)

BEFORE USING THE NC UNIT

 If the setting of the network adapter “Ethernet_PC” is changed, other systems

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

1-1 Automatic Operation Execution Procedure......................................................... 1-2

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

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

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

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

2-2 Dry Run .............................................................................................................. 2-3

2-2-1 Selecting Dry Run function .................................................................................... 2-3

2-2-2 Cancelling Dry Run function .................................................................................. 2-4

2-3 Machine Lock ..................................................................................................... 2-5

2-3-1 Procedure ............................................................................................................. 2-5

2-3-2 Description ............................................................................................................ 2-5

2-4 Work Light .......................................................................................................... 2-5

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

2-5 Barrier Cancel Function ...................................................................................... 2-6

2-5-1 Procedure ............................................................................................................. 2-6

2-6 Barrier Cancel Teach.......................................................................................... 2-6

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