Mazak VTC-200B User manual

Operating Manual
for
VTC-200B, VTC-200C & VTC-300C
(Mazatrol Fusion 640M)
Publication # C557SG0012E
7/99
CAUTION
This Manual is published to assist experienced personnel on the operation, maintenance
and/or programming of Mazak machine tools.
All Mazak machine tools are engineered with a number of safety devices to protect
personnel and equipment from injury or damage. Operators should not, however, rely
solely upon these safety devices, but should operate the machine only after fully
understanding what special precautions to take by reading the following documentation
thoroughly.
Do not attempt to operate or perform maintenance / repair on the machine without a
thorough understanding of the actions about to be taken. If any question exists, contact
the nearest Mazak service center for assistance.
Certain covers, doors or safety guards may be open or removed to more clearly show
machine components. These items must be in place before operating the machine.
Failure to comply with this instruction may result in serious personal injury or damage to
the machine tool.
This manual was considered complete and accurate at the time of publication, however,
due to our desire to constantly improve the quality and specification of all Mazak
products, it is subject to change or modification.
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Notes:
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VTC-200B,200C & 300C Operation....................................................
SAFETY PRECAUTIONS S-1....................................................................
LOCKOUT PROCEDURE S-4.................................................................................
INSTALLATION PRECAUTIONS S-5......................................................................
WARNINGS S-8.......................................................................................................
Sec. 1: Introduction...........................................................................
1 INTRODUCTION 1-1............................................................................................
1-1 List of Related Manuals and Documents 1-1.......................................................................
1-2 Pagination 1-1.....................................................................................................................
1-3 Numbering of Figures and Tables 1-2.................................................................................
2 SAFETY PRECAUTIONS 2-1..............................................................................
2-1 Rule 2-1...............................................................................................................................
2-2 Basic Safety Items 2-1.........................................................................................................
2-3 Clothing and Personal Safety 2-3........................................................................................
2-4 Operational Safety 2-3.........................................................................................................
2-5 Safety Considerations Relating to Holding Workpieces and Tooling 2-4............................
2-6 Maintenance Safety 2-5.......................................................................................................
2-7 Workplace Safety 2-6..........................................................................................................
2-8 Safety Considerations Relating to Chip Conveyor 2-6........................................................
2-9 Safety Equipment 2-7..........................................................................................................
2-10 Remarks on the Cutting Conditions Recommended by the NC 2-8..................................
2-11 Safety Nameplates 2-8......................................................................................................
Sec. 2: Machine Operation...............................................................
1 OUTLINE OF THE MACHINE 1-1........................................................................
1-1 Axis Definitions 1-1..............................................................................................................
1-2 Names and Locations of Machine Units 1-2........................................................................
2 OPERATION PANELS 2-1...................................................................................
2-1 Locations of Operation Panels 2-1......................................................................................
2-2 NC Operation Panel 2-2......................................................................................................
2-2-1 Arrangement of Switches on the NC Operation Panel 2-3........................................
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2-2-2 Names and Functions of Switches and Other Controls on the NC Operation 2-4.....
2-3 Auxiliary Operation Panel 2-9..............................................................................................
2-4 Data Input/Output Panel 2-10................................................................................................
2-5 Magazine Operation Panel 2-11............................................................................................
2-6 Main Power Disconnect Switch 2-12.....................................................................................
2-7 Operators Door Interlock 2-13..............................................................................................
2-7-1 MACHINE SET UP Switch (Key-lock Type Switch) 2-13.............................................
3 MANUAL OPERATION 3-1..................................................................................
3-1 Inspection before Starting Operation 3-1.............................................................................
3-2 Switching the Power ON 3-3...............................................................................................
3-3 Inspection after Switching the Power ON 3-5......................................................................
3-4 Switching the Power OFF 3-6..............................................................................................
3-5 Zero-Point Return 3-7..........................................................................................................
3-6 Warmup Operation 3-9........................................................................................................
3-7 Spindle Operation 3-10..........................................................................................................
3-7-1 Starting the Spindle 3-10.............................................................................................
3-7-2 Stopping the Spindle 3-10...........................................................................................
3-7-3 Jogging the Spindle 3-10.............................................................................................
3-7-4 Changing the Direction of Spindle Rotation 3-11.........................................................
3-8 Feed Operation 3-11.............................................................................................................
3-8-1 Rapid Traverse Operation 3-11...................................................................................
3-8-2 Cutting Feed Operation 3-11.......................................................................................
3-8-3 Pulse Handle Feed Operation 3-12.............................................................................
3-8-4 Clearing the Soft-Limit Alarm 3-13...............................................................................
3-9 Coolant System Operation 3-15............................................................................................
3-10 ATC Operation 3-16............................................................................................................
3-10-1 Manual ATC Operation 3-16......................................................................................
3-10-2 Recovering ATC Operation after Interruption 3-20....................................................
3-11 Chip Conveyor Operation (Optional Specifications) 3-22....................................................
4 PREPARING FOR MACHINING 4-1....................................................................
4-1 Procedure for Mounting or Removing a Tool in the Tool Magazine 4-1..............................
4-1-1 Procedure for Mounting Tools to the Magazine 4-1...................................................
4-1-2 Procedure for Removing Tools from the Magazine 4-4.............................................
4-1-3 Restrictions on Tools 4-5...........................................................................................
4-2 Mounting and Removing Workpieces 4-6............................................................................
4-2-1 Dimensional Restrictions on Workpieces 4-6............................................................
4-2-2 Procedure for Mounting and Removing Workpieces 4-7...........................................
4-2-3 Measuring Coordinate Values 4-7.............................................................................
4-3 Preparing Coolant 4-8.........................................................................................................
4-3-1 Selection of Coolant 4-8............................................................................................
4-3-2 Replenishing Coolant 4-8..........................................................................................
4-4 Adjustment of Coolant Nozzle Direction 4-9........................................................................
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Sec. 3: Operating NC Unit & Preparation for Auto Operation........
CONTENTS 4-2.......................................................................................................
1 PREPARATION FOR AUTOMATIC OPERATION 1-1.........................................
1-1 Preparation Steps for Automatic Operation 1-1...................................................................
2 DISPLAY OVERVIEW 2-1....................................................................................
2-1 Name of the Components of Each Display 2-1...................................................................
2-2 Types of Displays 2-3..........................................................................................................
2-3 Configuration of Displays 2-4..............................................................................................
2-3-1 DISPLAY MAP display 2-6........................................................................................
2-4 Windows 2-7........................................................................................................................
3 DATA SETTING METHODS 3-1..........................................................................
3-1 Setting Data and Address 3-2.............................................................................................
3-2 Selecting Menu Data 3-3.....................................................................................................
3-3 Erasing Data 3-3..................................................................................................................
3-4 Modifying Data 3-4..............................................................................................................
3-5 Incremental Input 3-4...........................................................................................................
3-6 Saving Data onto the Hard Disk 3-4....................................................................................
4 DISPLAYS RELATED TO THE MACHINE OPERATIONAL STATUS 4-1...........
4-1 POSITION Display 4-1........................................................................................................
4-1-1 Data display 4-1.........................................................................................................
4-1-2 Data registration 4-5..................................................................................................
4-1-3 Display operations 4-6...............................................................................................
4-2 TRACE Display 4-6.............................................................................................................
4-2-1 Data display 4-7.........................................................................................................
4-1-2 Displaying machining shape and tool tip 4-8.............................................................
4-1-3 Plane select 4-9.........................................................................................................
4-1-4 Change of scale values 4-9.......................................................................................
4-3 EIA MONITOR Display 4-11..................................................................................................
4-1-1 Data display 4-11.........................................................................................................
4-1-2 EIA/ISO monitor function 4-12.....................................................................................
4-1-3 Editing functions 4-12..................................................................................................
4-1-4 Restart 2 unmodal function 4-13..................................................................................
4-4 MACHINING - MONITORING Display 4-14..........................................................................
4-4-1 Data display 4-14.........................................................................................................
4-1-2 Display modes of the MACHINING - MONITORING display 4-17...............................
4-1-3 Selecting graphs to be displayed in the machining-monitoring mode 4-18.................
4-1-4 Setting the threshold in the drill-monitoring mode 4-19...............................................
4-1-5 Scale change in the drill-monitoring mode 4-20..........................................................
4-1-6 Setting the display time scale 4-20..............................................................................
5 DISPLAYS RELATED TO MACHINING SET UP 5-1...........................................
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5-1 TOOL LAYOUT Display 5-1................................................................................................
5-1-1 Data display 5-1.........................................................................................................
5-1-2 Tool layout procedure 5-2..........................................................................................
5-1-3 Clearing pocket numbers 5-7.....................................................................................
5-1-4 Specifying a spare tool 5-8........................................................................................
5-1-5 Erasing spare tool data 5-9........................................................................................
5-1-6 Erasing procedures for registered tool data 5-9........................................................
5-1-7 Other functions 5-10....................................................................................................
5-2 WORK OFFSET Display 5-11...............................................................................................
5-2-1 Data display 5-11.........................................................................................................
5-1-2 Data registration 5-12..................................................................................................
5-3 MACRO VARIABLE Display 5-15..........................................................................................
5-3-1 Data display 5-16.........................................................................................................
5-1-2 Data registration 5-17..................................................................................................
5-1-3 Display operations 5-18...............................................................................................
5-4 ADDITIONAL WPC Display 5-19...........................................................................................
5-1-1 Data display 5-19.........................................................................................................
5-1-2 Data registration 5-20..................................................................................................
5-1-3 Address setting 5-20....................................................................................................
5-1-4 Considerations to measurement 5-21..........................................................................
5-5 Manual Measurement 5-22....................................................................................................
5-5-1 Function overview 5-22................................................................................................
5-5-2 Use of manual measurement 5-22..............................................................................
5-1-3 Measurement pattern 5-23..........................................................................................
5-1-4 MEASURE display 5-27...............................................................................................
5-1-5 Mode changeover 5-29................................................................................................
5-1-6 Measuring procedure 5-30...........................................................................................
5-1-7 Other functions 5-33....................................................................................................
5-1-8 Graph of straightness data (option) 5-36.....................................................................
5-6 SPINDLE LOAD GRAPHIC DISPLAY Display 5-38..............................................................
5-6-1 Data display 5-38.........................................................................................................
5-1-2 Displaying spindle load data 5-39................................................................................
5-1-3 Display mode selection 5-39........................................................................................
5-1-4 Displaying additional data related to spindle load 5-40...............................................
5-7 MACHINING NAVIGATION - RESULT Display 5-41............................................................
5-7-1 Data display 5-41.........................................................................................................
5-1-2 Displaying data 5-43....................................................................................................
5-1-3 Display modes 5-43.....................................................................................................
6 DISPLAYS RELATED TO PROGRAM CREATION 6-1.......................................
6-1 PROGRAM Display 6-1.......................................................................................................
6-2 TOOL PATH CHECK Display 6-1........................................................................................
6-2-1 Data display 6-2.........................................................................................................
6-1-2 Displaying machining shape 6-3................................................................................
6-1-3 Displaying tool-tip path 6-3........................................................................................
6-1-4 Restarting tool path check 6-4...................................................................................
6-1-5 Block skip 6-4............................................................................................................
6-1-6 Other menu functions 6-4..........................................................................................
6-1-7 Solid Mode 6-5...........................................................................................................
6-3 SHAPE CHECK Display 6-19................................................................................................
6-3-1 Data display 6-19.........................................................................................................
6-1-2 Displaying machining shape 6-20................................................................................
6-1-3 Other menu functions 6-21..........................................................................................
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6-4 PLANE CHECK Window 6-22...............................................................................................
6-4-1 Data display 6-22.........................................................................................................
6-1-2 Displaying machining shape 6-23................................................................................
6-1-3 Others 6-23..................................................................................................................
6-5 SECTION CHECK Window 6-23...........................................................................................
6-5-1 Data display 6-24.........................................................................................................
6-1-2 Displaying sectional shapes 6-25................................................................................
6-1-3 Others 6-25..................................................................................................................
6-6 PROGRAM FILE Display 6-26..............................................................................................
6-6-1 Data display 6-26.........................................................................................................
6-1-2 Program name setting 6-27.........................................................................................
6-1-3 Work number change 6-28..........................................................................................
6-1-4 Program erasure 6-28..................................................................................................
6-1-5 Program copy 6-29......................................................................................................
6-1-6 All program erasure 6-29.............................................................................................
6-1-7 Converting MAZATROL program to EIA/ISO program 6-29........................................
6-1-8 Opening the shape drawing window 6-29....................................................................
6-1-9 Directory change 6-30.................................................................................................
6-1-10 Program transfer 6-31................................................................................................
6-1-11 Program management functions 6-31.......................................................................
6-7 PROCESS CONTROL Display 6-33.....................................................................................
6-7-1 Data display 6-33.........................................................................................................
6-1-2 Process-number search 6-34......................................................................................
6-1-3 Other functions 6-34....................................................................................................
6-8 PROGRAM LAYOUT Display 6-35........................................................................................
6-8-1 Data display 6-35.........................................................................................................
6-1-2 Priority number setting 6-36.........................................................................................
6-1-3 Delay priority designation 6-36....................................................................................
6-1-4 Priority number assignment 6-36.................................................................................
6-1-5 Priority number movement 6-37..................................................................................
6-1-6 Priority number all erase 6-38......................................................................................
6-1-7 Store 6-38....................................................................................................................
6-1-8 Program write 6-38......................................................................................................
6-1-9 Simultaneous use of functions 6-39.............................................................................
6-1-10 Program reference window 6-39................................................................................
6-9 MACHINING NAVIGATION - PREDICT Display 6-40...........................................................
6-9-1 Data display 6-40.........................................................................................................
6-1-2 Displaying data 6-43....................................................................................................
6-1-3 Display modes 6-44.....................................................................................................
6-1-4 Modifying the cutting conditions 6-46..........................................................................
7 DISPLAYS RELATED TO TOOLS 7-1.................................................................
7-1 TOOL DATA Display 7-1.....................................................................................................
7-1-1 Data display 7-1.........................................................................................................
7-1-2 Tool-data input procedures (for MAZATROL programs) 7-3.....................................
7-1-3 Interchanging pocket numbers (for MAZATROL programs) 7-7................................
7-1-4 Registering the tools to be used 7-8..........................................................................
7-1-5 Manual measurement of the tool lengths 7-9............................................................
7-1-6 Other functions (for MAZATROL programs) 7-10........................................................
7-1-7 Setting tool data (for EIA/ISO programs) 7-13.............................................................
7-1-8 Setting tool group numbers 7-16.................................................................................
7-1-9 Manual measurement of tool lengths (Setting tool length offset data 7-17..................
7-1-10 Other functions (for EIA/ISO programs) 7-17............................................................
7-1-11 MAZATROL tool data INVALIDATION (Option) 7-17..............................................
7-1-12 Tool length listing window 7-21..................................................................................
7-2 TOOL FILE Display 7-22.......................................................................................................
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7-1-1 Data display 7-23.........................................................................................................
7-1-2 Registering milling tool data 7-25................................................................................
7-1-3 Erasing a part of the registered data 7-29...................................................................
7-3 TOOL OFFSET Display 7-30.................................................................................................
7-3-1 Data display 7-30.........................................................................................................
7-1-2 Tool-compensation data setting procedures 7-31.......................................................
7-1-3 Setting the current position 7-33..................................................................................
7-1-4 EIA/ISO tool length measurement 7-33.......................................................................
8 DISPLAYS RELATED TO PARAMETERS 8-1....................................................
8-1 CUTTING CONDITION (W.-MAT./T.-MAT.) Display 8-1.....................................................
8-1-1 Data display 8-1.........................................................................................................
8-1-2 Registering data 8-2..................................................................................................
8-1-3 Read and Write of text file 8-3...................................................................................
8-2 CUTTING CONDITION Display 8-5....................................................................................
8-2-1 Data display 8-5.........................................................................................................
8-2-2 Data registration 8-7..................................................................................................
8-3 USER PARAMETER Display 8-8........................................................................................
8-3-1 Data display 8-8.........................................................................................................
8-4 MACHINE PARAMETER Display 8-10..................................................................................
8-4-1 Data display 8-10.........................................................................................................
9 DISPLAY RELATED TO DATA STORAGE 9-1...................................................
9-1 DATA I/O Display 9-1..........................................................................................................
9-1-1 Data display 9-1.........................................................................................................
9-1-2 DATA I/O operations (CARD) 9-2..............................................................................
9-1-3 DATA I/O operations (CMT) 9-6................................................................................
9-1-4 DATA I/O operations (TAPE) 9-10...............................................................................
9-1-5 DATA I/O operations (FLOPPY) 9-14..........................................................................
9-1-6 DATA I/O operations (DNC) 9-16................................................................................
9-1-7 DATA I/O operations (HARD DISK) 9-20....................................................................
9-2 Program Transfer from the Host PC to the Memory Card 9-23.............................................
9-2-1 Outline 9-23.................................................................................................................
9-2-2 Detailed description 9-23.............................................................................................
10 DISPLAYS RELATED TO DIAGNOSIS 10-1.......................................................
10-1 DIAGNOSIS (USER)  ALARM Display 10-1.......................................................................
10-1-1 Data display 10-2.......................................................................................................
10-2 DIAGNOSIS (USER)  ALARM HISTORY Display 10-5......................................................
10-2-1 Data display 10-5.......................................................................................................
10-3 DIAGNOSIS (USER)  PLC SIGNAL Display 10-6..............................................................
10-1-1 Data display 10-6.......................................................................................................
10-4 MAINTENANCE CHECK Display 10-7................................................................................
10-1-1 Data display 10-7.......................................................................................................
10-1-2 Data display for long-term check items (1500 and 3000 hours check items) 10-8....
10-1-3 Display operations 10-8.............................................................................................
10-1-4 Entry of the check items to be displayed 10-9...........................................................
10-5 PLC Display 10-11.................................................................................................................
10-5-1 Data display 10-11.......................................................................................................
10-6 RUNNING CONTROL Display 10-12....................................................................................
10-6-1 Data display 10-12.......................................................................................................
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10-1-2 Display modes 10-15...................................................................................................
10-7 DIAGNOSIS (MAKER)  VERSION Display 10-18................................................................
10-1-1 Data display 10-18.......................................................................................................
10-8 DIAGNOSIS (MAKER)  DIAGNOSIS MONITOR Display 10-19..........................................
10-1-1 Data display 10-19.......................................................................................................
10-1-2 Display operations 10-20.............................................................................................
10-9 DIAGNOSIS (MAKER)  OPTION Display 10-23...................................................................
10-9-1 Data display 10-23.......................................................................................................
11 OPTION 11-1........................................................................................................
11-1 Machining Management Functions 11-1.............................................................................
11-1-1 General 11-1..............................................................................................................
11-1-2 PALLET MANAGEMENT display 11-2......................................................................
11-1-3 Scheduled-operation function 11-3............................................................................
11-1-4 External unit skipping function 11-9...........................................................................
11-1-5 External multi-piece machining function 11-11............................................................
11-1-6 Jig offsetting function 11-13.........................................................................................
11-1-7 Parameters 11-16........................................................................................................
11-1-8 Machining management data writing macro-program 11-16.......................................
11-2 Function Relating EIA/ISO Program (Option) 11-21..............................................................
11-2-1 Configuration of displays 11-21...................................................................................
11-2-2 POSITION display 11-24.............................................................................................
11-3 Workpiece Measurement Printout System 11-26..................................................................
11-3-1 Function overview 11-26..............................................................................................
11-1-2 System configurations 11-32.......................................................................................
11-1-3 Parameter registration 11-34.......................................................................................
11-1-4 Program configuration 11-37.......................................................................................
11-1-5 Explanations of macro programs 11-42.......................................................................
11-1-6 Program and measurement pattern chart 11-64..........................................................
11-1-7 Output of measurement results 11-65.........................................................................
11-1-8 Alarm displays 11-68...................................................................................................
11-1-9 Program and printout example 11-69..........................................................................
11-4 Geometry Compensation Function 11-74..............................................................................
11-4-1 Function general 11-74................................................................................................
11-4-2 Detailed description 11-76...........................................................................................
11-1-3 Hold Status 11-81........................................................................................................
11-1-4 Notes 11-82.................................................................................................................
11-1-5 Parameters 11-82........................................................................................................
11-1-6 Appendix 11-83............................................................................................................
11-5 Hard Disk Operating Function 11-86.....................................................................................
11-5-1 Outline 11-86...............................................................................................................
11-5-2 Preparation for HD operation 11-86.............................................................................
11-5-3 Selection of operation mode 11-86..............................................................................
11-1-4 Program selection for HD operation 11-88..................................................................
11-1-5 Restart in the HD operation mode 11-89.....................................................................
11-1-6 Format for HD operation programs 11-89....................................................................
11-1-7 Alarms concerned 11-91..............................................................................................
11-6 IC Memory Card Operating Function 11-92..........................................................................
11-6-1 Outline 11-92...............................................................................................................
11-6-2 Preparation for CARD operation 11-92........................................................................
11-6-3 Selection of operation mode 11-92..............................................................................
11-1-4 Program selection for CARD operation 11-94.............................................................
11-1-5 Restart in the CARD operation mode 11-95................................................................
11-1-6 Format for CARD operation programs 11-95...............................................................
11-1-7 Alarms concerned 11-97..............................................................................................
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11-7 EIA/ISO Conversion 11-98....................................................................................................
11-7-1 Outline 11-98...............................................................................................................
11-7-2 EIA conversion program format 11-99.........................................................................
11-7-3 Output data unit11-99.................................................................................................
11-1-4 Operating procedure 11-100..........................................................................................
11-1-5 Supplementary description and precautions for conversion of 11-100..........................
11-1-6 Parameter and alarm lists 11-105..................................................................................
Sec. 4: Automatic Operation.............................................................
CONTENTS 2-7.......................................................................................................
1 AUTOMATIC OPERATION EXECUTION 1-1......................................................
1-1 Automatic Operation Execution Procedure 1-1...................................................................
1-2 Types of Automatic Operation Mode 1-3.............................................................................
1-2-1 Automatic operation 1-4.............................................................................................
1-2-2 Restart operation 1-8.................................................................................................
1-1-3 MDI operation 1-16......................................................................................................
2 SELECTING EXECUTION CONDITIONS 2-1.....................................................
2-1 Optional Stop 2-1.................................................................................................................
2-1-1 Procedure 2-1............................................................................................................
2-1-2 Description 2-2...........................................................................................................
2-2 Dry Run 2-2.........................................................................................................................
2-2-1 Procedure 2-2............................................................................................................
2-2-2 Description 2-3...........................................................................................................
2-3 Machine Lock 2-3................................................................................................................
2-3-1 Procedure 2-3............................................................................................................
2-3-2 Description 2-3...........................................................................................................
2-4 Work Light 2-3.....................................................................................................................
2-4-1 Procedure 2-3............................................................................................................
2-5 Block Skip 2-4......................................................................................................................
2-5-1 Procedure 2-4............................................................................................................
2-5-2 Description 2-4...........................................................................................................
2-6 Single Block 2-4...................................................................................................................
2-6-1 Procedure 2-4............................................................................................................
2-6-2 Description 2-4...........................................................................................................
2-7 Comparison Stop 2-5...........................................................................................................
2-7-1 Setting procedure 2-5................................................................................................
2-7-2 Description 2-5...........................................................................................................
2-8 Z-axis Cancel 2-7................................................................................................................
2-8-1 Procedure 2-7............................................................................................................
2-8-2 Description 2-7...........................................................................................................
2-9 MST Lock 2-7......................................................................................................................
2-9-1 Procedure 2-8............................................................................................................
2-9-2 Description 2-8...........................................................................................................
2-10 ATC Stop 2-8.....................................................................................................................
2-11 TUNING SV PARAM 2-8...................................................................................................
2-11-1 Operation procedure 2-9..........................................................................................
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2-11-2 Function description 2-10..........................................................................................
3 CHANGING THE CUTTING CONDITIONS 3-1...................................................
3-1 Rapid Feed Override 3-1.....................................................................................................
3-1-1 Procedure 3-1............................................................................................................
3-2 Cutting Feed Override 3-2...................................................................................................
3-2-1 Procedure 3-2............................................................................................................
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 (Option) 3-6..................................................................................................
3-5-1 Setting the desired current load value 3-7.................................................................
3-5-2 Tools available with AFC and AFC supervisory modes 3-8.......................................
3-5-3 Functional operation 3-8............................................................................................
4 STOPPING AUTOMATIC OPERATION 4-1........................................................
4-1 Emergency Stop 4-1............................................................................................................
4-1-1 Emergency Stop 4-1..................................................................................................
4-1-2 Releasing the emergency stop status 4-1.................................................................
4-2 Reset 4-2.............................................................................................................................
4-3 Feed Hold 4-2......................................................................................................................
4-4 Stopping by Changeover to a Manual Operation Mode 4-3................................................
4-5 Single-block Stop 4-3..........................................................................................................
4-5-1 Single-block stop by changing within automatic operation modes 4-3......................
4-5-2 Single-block stop using the SINGLE BLOCK key 4-4................................................
4-6 Program Stop 4-4................................................................................................................
4-7 Stopping by Turning the Power Off 4-4...............................................................................
5 MANUAL INTERRUPTION 5-1............................................................................
5-1 Handle Interruption (Option) 5-1..........................................................................................
5-1-1 Handle interruption 5-1..............................................................................................
5-1-2 Clearing the manual handle interruption 5-1..............................................................
5-2 TPS Function 5-2.................................................................................................................
5-2-1 Storing the data of only the stop point of automatic operation 5-2............................
5-2-2 Storing the data of both the stop point of automatic operation and the 5-3...............
5-2-3 Storing the data of only the passage point(s) existing during manual 5-4.................
5-2-4 General remarks on TPS function 5-4.......................................................................
6 OPERATIONS POSSIBLE DURING AUTOMATIC OPERATION 6-1.................
6-1 Data Rewriting 6-1...............................................................................................................
6-1-1 Data writing conditions 6-1........................................................................................
Sec. 5: Appendix ...............................................................................
1 STANDARD MACHINE SPECIFICATIONS 1-1...................................................
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1-1 Major Machine Specifications - VTC-200B 1-1....................................................................
1-2 Stroke Diagram and Spindle Interference Diagrams - VTC-200B 1-3.................................
1-3 Spindle Speed-Power-Torque Diagrams 1-4.......................................................................
1-4 Table Dimensions 1-5..........................................................................................................
1-5 Sub table Dimensions 1-5...................................................................................................
1-6 Workpiece Interference Diagram 1-6...................................................................................
2 ALARM LIST - VTC-200/300 (MAZATROL FUSION 640M) 2-1..........................
3 M CODE LIST - VTC-200/300 (MAZATROL FUSION 640M) 3-1........................
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SAFETY PRECAUTIONS
The machine is provided with a number of safety
devices to protect personnel and equipment from
injury and damage. Operators should not,
however, rely solely upon these safety devices,
but should operate the machine only after fully
understanding what special precautions to take by
reading the following documentation thoroughly.
• BASIC OPERATING PRACTICES
DANGER:
1) Some control panels, transformers, motors,
junction boxes and other parts have high
voltage terminals. These should not be touched
or a severe electric shock may be sustained.
2) Do not touch any switches with wet hands.
This too, can produce an electric shock.
WARNING:
1) The emergency stop pushbutton switch
location should be well known, so that it can be
operated at any time without having to look for
it.
2) Before replacing a fuse, turn off the main
incoming power switch to the machine.
3) Provide sufficient working space to avoid
hazardous falls.
4) Water or oil can make floors slippery and
hazardous. All floors should be clean and dry
to prevent accidents
5) Do not operated any switch without a thorough
understanding of the actions about to be taken.
6) Avoid accidental operation of switches.
7) Work benches near the machine must be
strong enough to hold materials placed on
them to prevent accidents. Articles should be
prevented from slipping off the bench surface.
8) If a job is to be done by two or more persons,
coordinating signals should be given at each
step of the operation. The next step should not
be taken unless a signal is given and
acknowledged.
CAUTION:
1) In the event of power failure, turn off the main
circuit breaker immediately.
2) Use the recommended hydraulic oils, lubricants
and grease or acceptable equivalents.
3) Replacement fuses should have the proper
current ratings.
4) Protect the NC unit, operating panel, electric
control panel, etc. from shocks, since this
could cause a failure or malfunction.
5) Do not change parameters or electrical
settings. If changes are unavoidable, record
the values prior to the change so that they can
be returned to their original settings, if
necessary.
6) Do not deface, scratch or remove any caution
plate. Should it become illegible or missing,
order another caution plate from the supplier,
specifying the part number shown at the lower
right corner of the plate.
• BEFORE POWERING UP
DANGER:
Cables, cords or electric wires whose insulation
is damaged can produce current leaks and
electric shocks. Before using, check their
condition.
WARNING:
1) Be sure the instruction manual and the
programming manual are fully understood
before operating the machine. Every function
and operating procedure should be completely
clear.
2) Use approved oil resistant safety shoes, safety
goggles with side covers, safe clothes, and
other safety protection required.
3) Close all NC unit, operating panel, electric
control panel doors and covers.
CAUTION:
1) The power cable from the factory feeder switch
to the machine main circuit breaker should
have a sufficient sectional area to handle the
electric power used.
2) Cables which must be laid on the floor must be
protected from hot chips, by using rigid or
other approved conduit, so that short-circuits
will not occur.
3) Before first time operation of the machine after
unpacking it or from being idle for a long period
of time (several days or more), each sliding
part must be sufficiently lubricated. To do so,
push and release the pump button several
times until the oil seeps out on the sliding
parts. The pump button has a return spring, so
do not force it to return.
4) Oil reservoirs should be filled to indicated
levels. Check and add oil, if needed.
5) For lubrication points, oil specification and
appropriate levels, see the various instruction
plates.
6) Switches and levers should operate smoothly.
Check that they do.
7) When powering the machine on, turn on the
switches in the following order: first the factory
feeder switch, then the machine main circuit
breaker, and then the control power on switch
located on the operating panel.
8) Check the coolant level, and add coolant, if
needed.
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• AFTER CONTROL POWER IS TURNED ON
CAUTION:
When the control power “ON” switch on the
operating panel is on, the "READY" lamp on
the operating panel should also be on (check to
see that it is).
• ROUTINE INSPECTIONS
WARNING:
When checking belt tensions, do not get your
fingers caught between the belt and pulley.
CAUTION:
1) Check pressure gages for proper readings.
2) Check motors, gear boxes and other parts for
abnormal noises.
3) Check the motor lubrication, and sliding parts
for evidence of proper lubrication.
4) Check safety covers and safety devices for
proper operation.
5) Check belt tensions. Replace any set of belts
that have become stretched with a fresh
matching set.
• WARM UP
CAUTION:
1) Warm up the machine, especially the spindle
and feed shaft, by running the machine for 10
to 20 minutes at about one-half or one-third the
maximum speed in the automatic operation
mode.
2) The automatic operation program should cause
each machine component to operate. At the
same time, check their operations.
3) Be particularly careful to warm up the spindle
which can turn above 4000 rpm.
If the machine is used for actual machining
immediately after being started up following a
long idle period, the sliding parts may be worn
due to the lack of oil. Also, thermal expansion
of the machine components can jeopardize
machining accuracy. To prevent this condition,
always make sure that the machine is warmed
up.
• PREPARATIONS
WARNING:
1) Tooling should conform to the machine
specifications, dimensions and types.
2) Replace all seriously worn tools with new ones
to prevent injuries.
3) The work area should be adequately lighted to
facilitate safety checks.
4) Tools and other items around the machine or
equipment should be stored to ensure good
footing and clear aisles.
5) Do not place tools or any other items on the
headstock, turret, covers and similar places
(For T/M).
CAUTION:
1) Tool lengths should be within specified
tolerances to prevent interference.
2) After installing a tool, make a trial run.
• OPERATION
WARNING:
1) Do not work with long hair that can be caught
by the machine. Tie it back, out of the way.
2) Do not operate switches with gloves on. This
could cause mis-operation.
3) Whenever a heavy workpiece must be moved,
if there is any risk involved, two or more people
should work together.
4) Only trained, qualified workers should operate
forklift trucks, cranes or similar equipment and
apply slings.
5) Whenever operating a forklift truck, crane or
similar equipment, special care should be taken
to prevent collisions and damage to the
surroundings.
6) Wire ropes or slings should be strong enough
to handle the loads to be lifted and should
conform to the mandatory provisions.
7) Grip workpieces securely.
8) Stop the machine before adjusting the coolant
nozzle at the tip.
9) Never touch a turning workpiece in the spindle
with bare hands, or in any other way.
10) To remove a workpiece from the machine other
than by a pallet changer, stop the tool and
provide plenty of distance between the
workpiece and the tool (for M/C).
11) While a workpiece or tool is turning, do not
wipe it off or remove chips with a cloth or by
hand. Always stop the machine first and then
use a brush and a sweeper.
12) Do not operate the machine with the chuck and
front safety covers removed (For T/M).
13) Use a brush to remove chips from the tool tip,
do not use bare hands .
14) Stop the machine whenever installing or
removing a tool.
15) Whenever machining magnesium alloy parts,
wear a protective mask.
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CAUTION:
1)During automatic operation, never open the
machine door. Machines equipped with the
door interlock will set the program to single
step.
2)When performing heavy-duty machining,
carefully prevent chips from being accumulated
since hot chips from certain materials can
cause a fire.
• TO INTERRUPT MACHINING
WARNING:
When leaving the machine temporarily after
completing a job, turn off the power switch on
the operation panel, and also the main circuit
breaker.
• COMPLETING A JOB
CAUTION:
1)Always clean the machine or equipment.
Remove and dispose of chips and clean cover
windows, etc.
2)Make sure the machine has stopped running,
before cleaning.
3)Return each machine component to its initial
condition.
4)Check the wipers for breakage. Replace
broken wipers.
5)Check the coolant, hydraulic oils and lubricants
for contamination. Change them if they are
seriously contaminated.
6)Check the coolant, hydraulic oil and lubricant
levels. Add if necessary.
7)Clean the oil pan filter.
8)Before leaving the machine at the end of the
shift, turn off the power switch on the operating
panel, machine main circuit breaker and factory
feeder switch in that order.
• SAFETY DEVICES
1)Front cover, rear cover and coolant cover.
2)Chuck barrier, tail barrier and tool barrier (NC
software).
3)Stored stroke limit (NC software).
4)Emergency stop pushbutton switch.
• MAINTENANCE OPERATION PREPARATIONS
1)Do not proceed to do any maintenance
operation unless instructed to do so by the
foreman.
2)Replacement parts, consumables (packing, oil
seals, O rings, bearing, oil and grease, etc.)
Should be arranged in advance.
3)Prepare preventive maintenance and record
maintenance programs.
CAUTION:
1)Thoroughly read and understand the safety
precautions in the instruction manual.
2)Thoroughly read the whole maintenance
manual and fully understand the principles,
construction and precautions involved.
• MAINTENANCE OPERATION
DANGER:
1)Those not engaged in the maintenance work
should not operate the main circuit breaker or
the control power "ON" switch on the
operating panel. For this purpose, "Do not
Touch the Switch, Maintenance Operation in
Progress!" or similar warning should be
indicated on such switches and at any other
appropriate locations. Such indication should
be secured by a semi-permanent means in the
reading direction.
2)With the machine turned on, any maintenance
operation can be dangerous. In principle, the
main circuit breaker should be turned off
throughout the maintenance operation.
WARNING:
1)The electrical maintenance should be done by
a qualified person or by others competent to do
the job. Keep close contact with the
responsible person. Do not proceed alone.
2)Overtravel limit and proximity switches and
interlock mechanisms including functional parts
should not be removed or modified.
3)When working at a height, use steps or ladders
which are maintained and controlled daily for
safety.
4)Fuses, cables, etc. made by qualified
manufacturers should be employed.
• BEFORE OPERATION & MAINTENANCE BEGINS
WARNING:
1)Arrange things in order around the section to
receive the maintenance, including working
environments. Wipe water and oil off parts and
provide safe working environments.
2)All parts and waste oils should be removed by
the operator and placed far enough away from
the machine to be safe.
CAUTION:
1)The maintenance person should check that the
machine operates safely.
2)Maintenance and inspection data should be
recorded and kept for reference.
000X717-KY 11/98
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ALWAYS TURN THE MAIN CIRCUIT BREAKER TO THE “OFF” POSITION & USE AN APPROVED
LOCKOUT DEVICE WHEN COMPLETING MAINTENANCE OR REPAIRS.
THE LOCKOUT PROCEDURE THAT FOLLOWS IS INTENDED TO SAFEGUARD PERSONNEL &
EQUIPMENT DURING MAINTENANCE OPERATIONS, AND, REPRESENTS THE MINIMUM
REQUIREMENTS. ANY ACTION SHOULD BE PRECEDED BY A “HAZARD ANALYSIS” TO DETERMINE
ANY ADDITIONAL SAFETY PRECAUTIONS THAT MAY BE NECESSARY TO ENSURE THE SAFETY OF
PERSONNEL AND EQUIPMENT.
NOTE : USE OF THE FOLLOWING LOCKOUT PROCEDURE IS MANDATORY WHEN COMPLETING
MAINTENANCE OR REPAIRS.
LOCKOUT PROCEDURE
1) THE LOCKOUT PROCESS MUST BE PERFORMED BY AUTHORIZED PERSONNEL ONLY.
2) INFORM ALL EFFECTED PERSONNEL OF YOUR INTENT TO LOCKOUT AND SERVICE THE
SPECIFIED MACHINE.
3) SHUT OFF MACHINE POWER USING NORMAL SHUT DOWN PROCEDURES.
4) TURN OFF THE MACHINE AND INDIVIDUAL BUILDING CIRCUIT BREAKERS. MAKE SURE ALL
STORED ELECTRICAL ENERGY IS RELIEVED. (EG: SPINDLE & AXIS SERVO CONTROLLERS)
5) CONNECT THE LOCKOUT DEVICE AS SHOWN IN FIGURE 1, AND ATTACH THE APPROPRIATE
TAG AT THE MACHINE CIRCUIT BREAKER. THE TAG MUST IDENTIFY THE PERSON
RESPONSIBLE FOR THE LOCKOUT. THIS WILL ENSURE THAT POWER CANNOT BE
RESTORED BY ANYONE ELSE.
6) TEST THE MACHINE TO VERIFY THAT MACHINE SYSTEMS DO NOT OPERATE IN ANY WAY.
ONCE TESTING IS COMPLETE, MAKE SURE ALL SWITCHES ARE IN THE “OFF” POSITION.
CONFIRM THAT THE LOCKOUT DEVICES REMAIN PROPERLY INSTALLED.
7) COMPLETE THE REQUIRED MAINTENANCE OPERATIONS.
8) MAKE SURE ALL PERSONNEL ARE CLEAR OF THE MACHINE.
9) REMOVE THE LOCKOUT DEVICE. MAKE SURE ALL PERSONNEL ARE AT A SAFE LOCATION
BEFORE RESTORING MACHINE POWER.
FIGURE
WARNING
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PADLOCK
S-4
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INSTALLATION PRECAUTIONS
The following subjects outline the items that
directly affect the machine installation and start-
up. To ensure an efficient and timely installation,
please follow these recommendations before
calling to schedule a service engineer.
• ENVIRONMENTAL REQUIREMENTS
Avoid the following places for installing the
machine:
1) Avoid exposure to direct sunlight and/or near a
heat source, etc. Ambient temperature during
operation: 0° thru 45°C (32°F to 113°F).
2) Avoid areas where the humidity fluctuates
greatly and/or if high humidity is present;
normally 75% and below in relative humidity. A
higher humidity deteriorates insulation and
might accelerate the deterioration of parts.
3) Avoid areas that are especially dusty and/or
where acid fumes, corrosive gases and salt are
present.
4) Avoid areas of high vibration.
5) Avoid soft or weak ground (minimum load
bearing capacity of 1025 lbs./ft2)
• FOUNDATION REQUIREMENTS
For high machining accuracy, the foundation
must be firm and rigid. This is typically
accomplished by securely fastening the
machine to the foundation with anchor bolts. In
addition, the depth of concrete should be as
deep as possible (minimum 6 - 8 inches). Note
the following:
1) There can be no cracks in the foundation
concrete or surrounding area.
2) Vibration proofing material (such as asphalt)
should be put all around the concrete pad.
3) Form a “cone” in the foundation for J-bolt
anchors, or use expansion anchors.
4) With the foundation anchor bolt holes open
pour the primary concrete at a minimum
thickness of 6 - 8 inches. Typically, the
concrete must have a minimum compression
rating of 2500 lbs. @ 250 lbs. compression
and strengthened with reinforcing rods. When
the concrete has cured, rough level the
machine, and install the J-bolts, leveling blocks,
etc., and pour grout into foundation bolt holes.
5) Mix an anti-shrinkage agent such as Denka
CSA with concrete, or use Embeco grout to fill
the foundation bolt holes.
6) In pouring grout, fasten the leveling block
base plates with the collar retaining screws
to prevent the base plates from dropping.
When the grout has completely hardened,
level the machine properly, and tighten M24
nuts to secure the machine to the
foundation.
Note:The machine must be anchored to the
foundation with J-bolts, expansion bolts or
other suitable method.
The machine accuracy and alignment
specifications quoted by Mazak can usually
be obtained when the minimum foundation
requirements are met. However, production
of close tolerance parts requires the use of an
appropriate certified foundation. Foundations
that do not meet certified specifications may
require more frequent machine re-leveling and
re-alignment, which can not be provided
under terms of warranty.
If any of these conditions cannot be met,
contact the nearest Mazak service office
immediately.
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• WIRING
1)Use only electrical conductors with
performance ratings equivalent or superior.
2)Do not connect any power cables for devices
which can cause line noise to the power
distribution panel, such as arc welders and high
frequency machinery.
3)Arrange for a qualified electrician to connect
the power lines.
4)Incoming supply voltage should not deviate
more than ±10% of specified supply voltage.
5)Source frequency should be±2 Hz of nominal
frequency.
[ CAUTION ]
VERIFY THE ACTUAL MACHINE ELECTRICAL
POWER REQUIREMENT AND THE MAIN
TRANSFORMER RATING (IF APPLICABLE), AS
WELL AS THE LOCAL ELECTRICAL CODE
BEFORE SIZING AND INSTALLING THE
INCOMING POWER WIRING.
PLEASE SEE THE ADDITIONAL CAUTIONS ON
THE FOLLOWING PAGE.
• GROUNDING
1)An isolated earth ground with a resistance to
ground of less than 100 ohms is required.
Typically, a 5/8” copper rod, 8 feet long, and
no more than 5 feet from the machine, is
sufficient. Building grounds or multiple
machines grounded to the same ground rod,
are not acceptable.
2)The wire size should be greater than AWG
(American Wire Gauge) No. 5 and SWG
(British Legal Standard Wire Gauge) No. 6.
Desirable Independent Grounding:
N C Earth resistance:
Machine Less than 100 ohms
Common Grounds:
Resistance to ground
= 100 ÷ the number of
devices connected to
the grounding (ohms)
Note: Never ground equipment as shown below:
000X713-KY 11/98
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A step-down transformer is optional on some machine models. Be certain to
verify the transformer Kva rating (where applicable), as well as local electrical
code requirements
before sizing and installing the incoming power wiring.
Machines not equipped with a main transformer are wired for 230 VAC, 3 phase.
The end user must supply a step-down transformer where factory electrical
power varies more than ± 10% of the 230 VAC rating.
NOTE:
Step-down or voltage regulating transformers are external (peripheral) to the
machine tool and are considered the primary input line (source) for the machine.
Local electrical code or practice may require a circuit breaker or other switching
device for the isolation of electrical power when this type of transformer is used.
In such cases, the machine tool end user is required to supply the necessary
circuit breaker or switching device.
FAILURE TO COMPLY CAN RESULT IN PERSONAL INJURY AND DAMAGE TO THE
MACHINE. IF ANY QUESTION EXISTS, CONTACT THE NEAREST MAZAK SERVICE
CENTER FOR ASSISTANCE.
CAUTION
!
S-7
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MAZATROLCNCCONTROLLERSPROVIDEPARAMETERSETTINGSTOLIMITSPINDLE
RPM. THESE SETTINGS ARE BASED ON THE MAXIMUM SPEED SPECIFIED BY THE
CHUCK/ACTUATORMANUFACTURER.
MAKE SURE TO SET THESE PARAMETERS ACCORDING TO CHUCK SPECIFICATION
WHEN INSTALLING A CHUCKING PACKAGE. ALSO, STAMP THE MAXIMUM SPINDLE
RPM ON THE CHUCK IDENTIFICATION PLATE LOCATED ON THE MACHINE TOOL
COVERS.
REFERENCETHECNCPARAMETERMANUALSUPPLIEDWITHTHE SPECIFICMACHINE
TOOL TO IDENTIFY THE REQUIRED PARAMETERS TO CHANGE.
FAILURE TO COMPLYWITH THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO
THE MACHINE, SERIOUS INJURYOR DEATH.
IF ANY QUESTIONS EXIST, CONTACT THE NEAREST MAZAK SERVICE CENTER FOR
ASSISTANCE.
S-8
MAZAK MACHINES ARE ENGINEERED WITH A NUMBER OF SAFETY DEVICES TO
PROTECT PERSONNELAND EQUIPMENTFROM INJURYAND DAMAGE.
DO NOT REMOVE, DISCONNECT, BYPASS OR MODIFYANYLIMIT SWITCH, INTERLOCK,
COVER, OR OTHER SAFETY FEATURE IN ANY WAY, EITHER MECHANICALLY OR
ELECTRICALLY.
FAILURE TO COMPLYWITH THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO
THE MACHINE, SERIOUS INJURYOR DEATH.
IF ANY QUESTIONS EXIST, CONTACT THE NEAREST MAZAK SERVICE CENTER FOR
ASSISTANCE.
WARNING
!
WARNING
!
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