5212 Hausen

Machine tools
056 42 24 54
5212 Hausen, 14.3.1986/G1/an

Brief—Operating Instructions MAZAK FLEX 1/3

***************************************

Sheet 1 Manual operation

Sheet 2 Parameters—Groups— “Species” (FLEX)

Sheet 3 Parameters—Operation "Change"

Sheet 4 Robot—Program “Writing”

Sheet 5 Starting position for "FLEX—Start"

Sheet 6 machine and FLEX start according to number of parts

(Sequence system)

Sheet 7 Machine and FLEX start with workpiece recognition

Sheet 8 sketch of distance parameters group 1

Sheet 9-14 Robot alarm list

Sheet 15 List of jaw dimensions

1
 Manual operation

1. Press CONTROL and CLEAR together

2. Press SET

Arm up A,UP in front of machine

Arm down A,DOWN in machine
Body high B,UP horizontal
Body down B,DOWN perpendicular
Blow air AB,SET
Open loading hand LH,OPEN
Close the loading hand LH,CLOS
Load hand selection LH,SET rotate
Open the unloading hand UH,OPEN
Close the unloading hand UH,CLOS
Unloading hand selection UH,SET rotate
Spindle orientation SO,SET
Pallet station in front CO,FOR
Pallet station back CO,BACK
Insert in front CP,FOR
Insert back CP,BACK
Centering before CE,FOR
Centering back CE,BACK
Lining up CH,OPEN
Feed too CH,CLOS

open the door DO,OPEN

close the door DO,CLOS
Quill in front TS, FOR
Quill back TS, BACK
Z-Achge in front Z,SET,+,CLR
Z-Achge back Z,SET,-,CLR
Zero the Z-axis Z,CONTROL+SET,START
Zero the Z display Z,CONTROL+SET,CLR

2
 P A R A M E T E R - groups

Group 0 = Operating parameters for robots

Group 1 = Distance parameters these parameters have the

the same function as the program data

D 1 to D10 and P 1 to P 2 in the
Program entry. The basic dates are always
same, but can be used for each program individually
be optimized. (All 50 programs)

Group 2 = Dimensions - parameters (data) manual - D:

Group 3 = Dimensions - parameters (data) hand - C:

Group 4 = Dimensions - parameters (data) manual - S:

Group 5 = Bit - (function) parameters with these

Parameters can be the corresponding
Functions made effective or ineffective
become. Only the values are allowed
Entered O (zero) or 1 (one)
become.

Group 6 = Dimensions - parameters (data) hand - O:

3
 PARAMETERS - Operation MAZAK Flex 1/3

Select parameter mode:

CONTROL + CLR or ROBOT=RESET (MANUAL Flashes)

CONTROL + SET
Select parameter group:
FOR BACK
With OPEN or CLOS PAM — — — O Flashes
UP DOWN

Enter parameter group:

SET

Select parameters within the group:

FOR BACK
With OPEN or CLOS
UP DOWN

Change parameters:

1. DATA Switch to ON
2. CLR (delete the old went)
3. Enter Newent
4. SET
5. DATA Switch to OFF

Back to parameter groups — list:

BACK
CONTROL + CLOS PAM — — — O Flashes
UP

Back from parameters - operating mode:

CONTROL + CLR MANUAL Flashes

Caution: No parameters are allowed during automatic operation

be changed.

The DATA switch must always be set to OFF

if no data has to be entered.

The standard parameters of groups O, 2, 3, 4 and 5

should be on a data sheet after commissioning
be held.

Richiger AG 25.08.85 GL.

4
 Write the Robot program

1, Starting point JOB MANUAL

2 Press CONTROL and CLEAR together
3. MANUAL flashes
4. Press CONTROL and FOR together
5. AUTO RDM flashes or AUTO SE
6. Press CONTROL and FOR together
7. TEACH flashes
8. Press SET
9. PRG .. appears
Program number
Bank number
10. Press SET
11. Answer all questions see form
12. DATA ON (memory protection)
13. Overwrite old value:
a) Press CLR
b) Enter new value
c) Press SET
d) Continue with FOR

When you have finished entering the program

that comes automatically
First parameter “d1” query from

Parameter group 1
When all the data has been entered
Press comtrol and CLR together
so the manual mode again is active.
Caution :
If no program changed
or must be re-entered
the data holder is always OFF

5
 Starting position for Flex

1. Z-axis zeroed (not necessary, just stand in Z-minus

2. BODY UP
3. No part excited Lining open
No part in the flex
4. Open both grippers
5. Door open
Direction of rotation of the conveyor
always automatic operation

Finished parts

This place must be at

Program always start
to be empty

Machine

Fex
6
 Robot FLEX 1/3 and machine start Number of Parts
============================
= (Sequence system)
1. Switch on the machine
2. Machine - approach zero points in X and Z.
3. In the Z axis, the revolver (s) as possible as possible In
plus — turn towards the tailstock. In the X axis to zero.
4. Select gear stage (1 or 2).
5. Provide machine for automatic operation and
set the NC to AUTO (automatic mode).

Provide Flex 1/3 without workpiece - recognition

6. CONTROL + CLR MANUAl Blinking

7. CONTROL + FOR AUTO SE Blinking

8. SET 0 PRG Blinking

9. Robot progr. Enter the number (1 to 50)

10. SET

11. FOR PC Blinking

** 12. Enter the number of parts to be machined

13. SET

14. FOR 1 PRG Blinking

15. START Z back

16. START S Call Blinking

17. CYCLE START on the machine

The plant begins to produce.

===============================================================

** In batch mode, one must always be straight at step 12.

Number of digits can be entered.
** In batch mode with two-sided processing must
Step 12. Same for both programs (even)
Number of digits to be entered.

Important: The Z axis of the Flex must not be on the Z + and

do not stand at the Z end if the automatic
is started.

7
 Machine tools
056 42 24 54
5212 Hausen, 14.3.1986/G1/an
MAZAK Robot FLEX 1/3

Program start with workpiece recognition

========================================

1. Mainswitch on

2. Control On

3. Approach zero

4. Turret in Z + max. put

Get ready for Progre Start

5. Select gear stage (must be)

Start the program at the FLEX (with workpiece recognition)

6. Press CONTROL + CLR together

7. Press CONTROL + FOR together

8. AUTO ROM flashes, press SET

9. DISP appears, enter machine program number

10. Press SET

11. PRG appears, Robot program number enter

12. Press SET

13. Press FOR

14. Press START

15. S CALL appears, cycle start on the machine

16. ROM END appears

17. Insert marker pen for last tell

8
Distance change parameter (group 1) for program

41

42

Position for
Arm for when he
that part of the
feed spawned
(A) wet and out of
43 machine goes
(-) (+)

Position for
Back
When he goes
(Á) to the unloader
44 inside the machine
(-) (+)

a b

45

9
 APPENDIX 7 ALARM LIST

10
The display shows the following alarm information for early detection of a fault and for prevention
from operator errors.

When an alarm is triggered, the alarm NC flashes on the display. followed by the indication "Err".
If the [CLR] button is pressed after the malfunction has been rectified, the alarm is cleared.

Alarm-
Alarm label Possible Cause Alarm reset
No.

00 Major servo error Defective servo motor or servo— Switch off the power supply and
amplifier (fuse or turn back on. Should the
Thermal relay has been triggered) If the fault persists, turn
Please contact our company immediately.

02 Robot — new hiring ROBOT RESET button • has been Pull out the ROBOT RESET button.
loaded active.

App 7.1
03 Safety mat Operator is on the safe— Do not step on the security guard.
kick mat.

04 Voltage drop The +24 volt power supply Check the +24 volt voltage supply.
is among the required
Value dropped.

05 + Overflow Z axis overflow into positive Press the [-] key. (Manual
Direction. Business)

06 - Overflow Z axis overflow in negative Press the [+] key. (Manual

Direction. Business)
11
Alarm- Alarm label Possible Cause Alarm — reset
No.

07 Servo amplifier Fuse of the servo amplifier Replace fuse and heat relay
is blown or its readjust. Should the disturbance
Thermal relay has tripped. continue to occur, see operating
manual.

09 Stop of danger by the By triggering the heat relay See circuit diagram of the NC rotation—
NC Lathe or some other cause machine.
Stop of danger triggered.

10 Low oil pressure. Defective pressure switch or Replace pressure switch or oil gate
oil— hydraulic motor works start.
Not.

11 Low air pressure Defective pressure switch or the The pressure source must be higher
Air source pressure source than 4 kg/cm² his.
has fallen off.
 

App 7.2
22 Load hand — closure end Operating errors Press the [OPEN] key.
The loading hand has the closing (manual mode)
end without gripping a workpiece  
reached.

23 Unloading hand—closing— Operating errors Press the [OPEN] key.

The End The unloading hand has the closing (manual mode)
end without gripping a workpiece
reached.

24 Measuring claws—closing— Operating errors Press the [OPEN] key.

The End Measuring claw has end of closure (manual mode)
without gripping a workpiece
aroused.

25 Putter closing end Operating errors Press the [OPEN] key.

Lining has no closing end (manual mode)
Gripping a workpiece
reached.
12
Alarm- Alarm label Possible Cause Alarm — reset
No.

27 Machine ready for operation NC — lathe is not The READY signal from the NC rotary—
ready for use. check machine.

29 Robot lock Roboeer — Locking Lift Was The robot—locking lever back—
becäcige. push.

30 Load hand — end with open Operating errors Press the [CLOSE] button.
position Loading hand does not close. (manual mode)

31 Unload hand—end at Operating errors Press the [CLOSE] key.

open position Unloading hand does not close. (manual mode)

41 Classification errors Parameter data for F0, F1 and Set more than "2".
Feed parameters FL are too low.

42 Defective interpolator No adjustment between The power supply off and on

rubbed and read data. turn back on. If the disturbance

App 7.3
Still there, contact
Contact us immediately.

51 Hull — upward end position Operating errors
Fuselage is not on the
Upward end position.
52 Hull—downward end position Service operator
Hull is not at dec
Downward end position.
Manually move the hull to the upward end
position bring.
Bring the fuselage manually to the removal
position.

53 Arm—upward end position Operating errors Manually arm to the upward end position
Arm is not on the arm bring.
Upward end position.

54 Arm—downward end position Operating errors Manually arm to the upward end position
Arm is not on the arm bring.
Downward end position.
13
Alarm- Alarm label Possible Cause Alarm — reset
No.

55 Arm & tailstock on Operating errors Both manually in the correct position
correct position Arm and tailstock are located bring.
not in the correct position.

56 LS hand ON Operating errors Switch on the LS.

LS of the hand S is not a—
switched.

57 LS of the hand S OFF Operating errors Switch off the LS.

The LS of the hand S is niche
switched off.

58 Hand not set Operating errors Hand in hand.

Neither the drawer nor the
drawer load hand is set.

61 Pallet — stop position Operating errors The pallet at the stop position
Pallet is not on bring.

App 7.4
the stop position.

62 Removable disk—leading Operating errors The removable plate at the leading end
end Removable disk is located bring.
not at the end.

63 Wechselptatte— Operating errors Removable plate gum return end

Rewind Removable disk is located bring.
niche at the return end.

64 Zentripetai unit Centripetal unit is located Centripetal — return end unit

returning not at the return end. bring.

65 Workpiece-inspection Measured workpiece diameter Use the correct workpiece.

deviate from the given
knife. (SE)
14
Alarm- Alarm label Possible Cause Alarm — reset
No.

Workpiece—through eyes— The set workpiece— Enter data correctly.

knife data diameters have an over
lapping area.

Program No. search The number for the program number Program number enter correctly.
Search was not entered.

Measurement error at six on— Measurement error with six successive Rearrange the workpieces.
successive work— following workpieces.
pieces

Not an empty station No hand became empty for hand C. Rearrange the workpieces.
Station prepared.

Lining — end with open Lining is on the Open the lining.

position open end position.

App 7.5
Door — end when open Door is not on the Open door.
position open position

Tailstock — retracts Tailstock is not Bring tailstock to the return end.

at the return end.

Tool offset limit— Tool offset limit is found The tool offset limit to return—
Rewind not at the return end. bring current.

Spindle stop No spindle stop signal.

Hand not open Loading and unloading are not Open manually.
open.

parameter Insufficient parameter data. Enter all parameter data.

Instruction data Inadequate instruction data Enter all instruction data.

15
Alarm- Alarm label Possible Cause Alarm — reset
No.

Same program number Setting error with automatic Set correctly.

operation.

Too many programs More than 10 programs have been Set programs correctly.
created adjusted.

No program definition Setting error in automatic Set programs correctly.

operation.

Hand setting Predetermined hand corresponds Enter data correctly.

not the instruction data.

2. Processing No adjustment for M-Code the Set correctly.

No M code adjustment 2. Processing.

Setting error at 2. Processing for hand S can Enter data correctly.

Hand S cannot be determined.

App 7.6
Number of workpieces For double stacking, one Enter data correctly.
with double stacking unequal number used.
 Alarms

311 Wrong contour

a - not enough material for roughing
b - max Ø outside dimensions
c - Intersection X
d - No finishing effect

305 X Cutting direction not defined

a - z value in the program
annoyed,sizes as
become long AL 309

309 Contour outside raw material

a - z sizes as length
b - x " " Ø max

495 Cutting conditions coefficient absence

e.g. cutting data for others -

(HSS or similar) not set.

355 Cutting direction not deff.

e.g. Question mark at cone could not
be calculated.

118 Tailstock yourself. Zone command,

murrying delete, reset

16
17
HAND D1
FLO D2
PRG2 D3
1L1 D4
1L2 D5
1D1 D6
1D2 D7
2L1 D8
2L2 D9
2D2 D10
CH P1
CH1 P1
P2

ä
Ø
ü
 Service Renishaw MMS MAZAK QT-10N

1. Screw the probe into the turret holder

and fix it with the sole nut

Attention tighten
at the back

2. Cut measuring probe to length.

    A. Set Z correction as known
    B. Scrub the Z-correctent
    D. Activate the part to be processed
so that the program number appears
on the TNR on command.
E. Turn on the workpiece and face up to
the position indicator. "Zero" is
displayed. Measure the turned Ø.
F. Select the Measure menu and use the
touch probe on the turned Ø toucher to
display the measurement menu tool at
SENS ( ) [ON].
G. Select tool setup with the cursor on
"Tool setup X" at station M Driving.
H. Press the ENTER menu, enter the measured
Ø and press input.
I. Use the touch probe in the Z axis to touch
with (safe bank F) Select tool set, with the
cursor on tool set Z At station M drive.

18