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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