Alarm List for the INTEGREX 300/400-II II
6. Alarm 297 CHUCK PRESSURE DOWN or 296 TAIL SLEEVE PRESSURE
3. A milling spindle rotation command was given even though the milling head (B-axis) was not clamped.
3. After clamping the milling head (B-axis), designate the milling spindle rotation command and check the milling head clamp sensor.
X460
4. The M203, M204 or M219 command was given in the turning mode.
4. 1) Program error → Correct the program.
2) Switch to the milling mode and then designate the command.
―
5. A milling spindle rotation command was given with the door not closed when the door interlock switch was set to AUTO.
[When the door interlock option is provided.]
5. Close the door and start the milling spindle rotation.
X15 XA
6. Alarm 297 CHUCK PRESSURE DOWN or 296 TAIL SLEEVE PRESSURE DOWN is displayed.
6. Clear the alarm 297 or 296. X442 X443 X480 7. The touch sensor for workpiece
measurement is mounted on the milling head.
7. Change the touch sensor for a rotating tool in the MDI or automatic mode. ―
8. The milling tool rotation command is given though the TOOL EYE is not placed at the backward end.
8. Retract the TOOL EYE. Also check the
backward end sensor. X445
252: AXIS MOVE
MISOPERATION An attempt was made to execute an axis movement under the axis movement interdiction.
1. An attempt was made to execute an axis movement with the magazine cover opened.
1. First close the magazine cover and
then execute the axis movement. XD
2. An attempt was made to execute a movement along the axis with the X-axis interlock activated.
2. X-axis interlock is activated in the following states:
1) When the milling head is not clamped.
2) When the tool is not clamped.
3) When the milling head is not positioned at the indexing position.
4) When the arm is positioned somewhere between the stand-by position and the swinging-in position.
5) When the magazine cover is opened.
Note:
When states 1) to 5) occur, an axis movement can be executed by the manual pulse handle and the [ATC MENU] → [INTERLOCK NEG.] menu key operation. (Refer to PART 2.) 6) When the steady rest is connected.
7) When the tailstock body is connected.
X460
XD
Alarm No. and message Description Check and remedy Address 252: AXIS MOVE
MISOPERATION 3. An attempt was made to execute a movement along the axis with the Z-axis interlock activated.
3. Z-axis interlock is activated in the following states:
1) Same as states 1) to 7) for the X-axis interlock.
Note: An axis movement can be executed by the manual pulse handle and the [ATC MENU] → [INTERLOCK NEG.] menu key operation. (Refer to PART 2.)
―
4. An attempt was made to execute a C-axis movement with the C-C-axis interlock activated.
4. C-axis interlock is activated in the following states: When the C-axis is clamped.
―
Check the overload detection level.
253: OVERLOAD DETECTION
An overload has been detected in a machine having an overload detection
option. Reduce the cutting load. ―
This alarm display lights when an attempt has been made to turn the milling head or when the conditions were unstable.
― ―
1. When the arm is at the milling head side or at a swinging-in position between stand-by and the milling head side.
1. Set the arm to the stand-by position by using the ATC menu. (Refer to PART 2.)
― 256: TURRET ROTATION
PROHIBITED
In the automatic/manual mode:
2. The turning tool or milling tool has been unclamped.
2. Clamp the tool using the clamp switch. ―
257: ILLEGAL M-CODE An illegal M code has been specified. Correct the program. ― 258: TNo. MISMATCH Since ATC has been aborted by pressing
the emergency stop button in the middle of the ATC process, the number of the tool mounted on the milling head is different from that displayed on the NC display.
Change the “TURRET TOOL” number displayed in the DIAGNOSIS display to the number of the current tool (that is, the parenthesized numerals in alarm messages).
―
259: MODE CHANGE
IMPOSSIBLE The rapid feed mode or zero point return mode switch on the operating panel has been pressed during tool nose measurement with the TOOL EYE.
The rapid feed or zero point return mode cannot be selected during tool nose
measurement. ―
260: SLIDEWAY LUBRICATION ALARM
The pressure switch for slideway lubrication (SP67) does not turn on within a fixed time.
Check the lubricating grease amount, and replenish grease if required.
X465
261: HEAD LUBRICATION ALARM
The pressure switch (SP25, SP26, SP27) in the spindle cooling unit has worked.
Check the coolant level. X485
Thermal relay F13 for the coolant motor has tripped.
X5 264: THERMAL TRIP
(SINGLE BLOCK)
Thermal relay F14 for the chip conveyor has tripped.
Check the regarding unit (e.g. chip conveyor for clogging with chips) and then
reset the thermal relay. X6
The pressure switch (SP7) for ball screw and C-axis gear lubrication does not turn on or off within a fixed time.
X44C 267: BALL SCREW
LUBRICATION ALARM
The float switch (SL1) has turned off.
Check the lubrication oil level, and replenish lubricating oil if required.
X44D 270: SPINDLE ORIENT
EXCEED TIME Although a spindle orientation command is given, the orientation confirmation signal does not turn on within a predetermined time.
The spindle motor detector/controller is
abnormal. ―
272: TURRET INDEX EXCEED TIME
Although a milling head indexing command is given, the index confirmation signal does not turn on within a predetermined time.
The milling head index motor
detector/controller is abnormal. ―
Alarm No. and message Description Check and remedy Address 275: ROBOT SERVICE
EXCEED TIME For machines with an optional robot, although a robot service command is given, the confirmation signal does not turn on within a predetermined time.
The robot is malfunctioning (check the
robot controller to examine the cause). ―
276: ATC CYCLE EXCEED TIME
Although 120 seconds have passed since the issuance of the ATC command, the operation complete signal does not turn on.
Reset the ATC unit using either of the following methods:
(1) Cancel the ATC command by pressing the emergency stop button.
(2) Release the emergency stop status by pressing the RESET key.
(3) Execute the ATC reset function of the machine menu.
If the ATC unit cannot be reset, please contact your MAZAK service
representative.
―
279: PARTS CATCHER CYCLE EXCEED TIME
For the machine with an optional automatic parts catcher, although a parts catcher advance/retract command is given, the advance end confirmation sensor or retract end confirmation sensor does not turn on within a predetermined time.
The parts catcher advance/retract end confirmation sensor are faulty or
malfunctioning. ―
Adjust the chuck open/close end sensor.
Or the sensor is in trouble. X440/
X441 282: CHUCK CLAMP
EXCEED TIME Although a chuck open/close command is given, the confirmation signal does not turn on within a predetermined time.
The hydraulic system is abnormal. ― Adjust the front door open/close end
sensor.
Or the sensor is in trouble.
― 286: FRONT DOOR
EXCEED TIME For machines with an optional automatic door, although a door open/close command is given, the confirmation signal does not
turn on within a predetermined time. The pneumatic system is abnormal. ― 292: SENSOR
MALFUNCTION No. 3 The correction value has exceeded the limit set in the thermal displacement
compensation.
Check that the thermal sensor is correctly
wiring. R1, R2,
R3
293: SENSOR
MALFUNCTION No. 4 The correction value has changed largely than the previous one in the thermal displacement compensation.
Check that the thermal sensor is correctly
wiring. R1, R2,
R3
297: CHUCK PRESSURE
DOWN The spindle chuck pressure remains reduced in a machine having a spindle chuck pressure guarantee option.
Check the spindle chuck pressure. X442/
X443
300: START COND. ERR.
(DOOR OPEN) The cycle start button was pressed while
the front cover (front door) was opened. Close the front cover. XA 301: START COND. ERR.
(TUR UNCLAMP) The cycle start button was pressed while
the milling head was unclamped. Clamp the milling head. X460 302: START COND. ERR.
(EXT RESET) The cycle start button was pressed while
the external reset signal was ON. Check the controller of the external unit. ― 303: START COND. ERR.
(EXT FEED HOLD) The start button was pressed while the
external feed hold signal was ON. Check the controller of the external unit. ― 308: C/S ERROR (TOOL
EYE EXTEND) The cycle start button has been pressed with the TOOL EYE arm placed in a measurement position.
Retract (restore) the TOOL EYE arm into
position. X445
310: C/S ERROR
(TNo.MISMATCH) During the restart of operation after manual interruption, a tool number different from that which was valid before interruption has been specified.
Specify the same tool number as that which was valid before interruption. ―
311: C/S ERROR (TAIL
STOCK QUILL) The cycle start button has been pressed with the tail spindle not placed at its zero point or advance end.
Place the tail spindle at its zero point or
advance end. ―
Alarm No. and message Description Check and remedy Address 312: C/S ERROR
(PT-CATCHER EXTEND) The cycle start button has been pressed with the parts catcher (workpiece unloader) extended.
Retract (restore) the parts catcher into the
position. ―
313: C/S ERROR (C/S QUILL COMMAND)
A tailstock advance/retract command was given with the tail spindle advance/retract switch (SA2) not placed at the neutral position.
Place the tail spindle advance/retract
switch at the neutral position. ―
320: TOOL UNCLAMP
IMP. (M-SP ROT.) A milling head unclamping command has been given during rotation of the milling spindle motor.
After the milling spindle motor has stopped, perform the operations described at left. ―
321: MODE CHANGE IMPOSSIBLE (DURING ATC CYCLE)
Mode changing has been attempted during the ATC cycle.
The operation mode cannot be changed during ATC. To change the mode, wait until
ATC has been completed. ―
322: RAPID MODE IMP.
(ORIGIN RET UNF) The rapid feed mode was selected without carrying out the zero point return operation after the power supply had been turned on.
Carry out the zero-point return operation.
―
324: DIFF. MODE (ORIGIN RET UNFIN.)
The automatic operation mode was selected without carrying out the zero-point return operation after the power supply had been turned on.
Carry out the zero-point return operation.
―
325: TL. EYE EXT. IMP. A TOOL EYE extend/retract command has been given with the SET UP switch remaining set to “O” and the front door remaining open.
Change the setting of the SET UP switch to
“I”. Or close the front door. X11C/
XA
The tail spindle has advanced with the TOOL EYE arm extended.
Retract the TOOL EYE arm. X444
The tail spindle has advanced/retracted during the spindle rotation.
Stop the spindle.
326: T/S QUILL EXT. IMP.
The tail spindle has advanced/retracted
during the milling spindle rotation. Stop the milling spindle.
The condition to perform ATC is not appropriate. The details are described at the left. See D200/D201.
90 (D201)
The machine is under locking state. After releasing the machine lock, press the cycle start button. The ATC will be executed.
91
(D201) The tailstock is in the connection state. After releasing the connection of the tailstock, perform the ATC.
97 (D201)
When the loading tool is specified in the ATC, the shifter is not placed at the ATC side.
Move the shifter manually on the ATC side.
327: NOT IN ATC START POSITION
98 (D201)
The magazine cannot be rotated because the specified tool is different from the loading tool and the shifter is not placed on the ATC side. Move the shifter to the ATC side manually.
―
Alarm No. and message Description Check and remedy Address The condition to perform ATC is not
appropriate. The details are described at the left. See D200/D201.
99
(D201) The shifter is not placed in the magazine side without the loading tool when commanding the ATC.
Move the shifter to the magazine side/retract position manually.
9800
(D200) The tool command is given incorrectly. Perform again.
327: NOT IN ATC START POSITION
9900
(D200) The ATC arm is not at the reference point position. Move the ATC arm to the reference point position manually. Then perform again the ATC.
―
The inside/outside chucking selection is
performed with the chuck not opened. Open the chuck (and remove the workpiece.)
329: CHUCKING SELECTION
PROHIBITED The inside/outside chucking selection is performed when the spindle or milling spindle is not stopped.
Stop the spindle or milling spindle. ―
In a machine having a warming-up option 340: CONDITION No.1
MISSING - the warming-up program number is not
registered. Register the warming-up program number
(1 – 9999) in the MACHINE PARAMETER display.
R18
- the front cover (front door) is open. Close the front cover (front door). XA - The axis had not yet been initialized
when the NC unit was turned off. To warm up the machine, return all axes to their zero points before turning off the NC unit.
―
341: CONDITION No.2
MISSING The M-code command for milling spindle through air blowout has been issued during coolant injection.
Correct the program.
―
The tailstock amplifier has detected an overload or too great an error.
361: TAIL ALARM
The tailstock has moved during spindle rotation.
If the alarm is not cleared, please contact your MAZAK service representative.
―
365 CARRIER CONTROLER MALFUNCTION
An alarm signal has been sent from the
carrier-use amplifier to the NC unit. After turning NC power off, turn the main circuit breaker off and then turn it back on.
If the alarm is not cleared, please contact your MAZAK service representative.
―
366: SHIFTER CONTROLER MALFUNCTION
An alarm signal has been sent from the
shifter-use amplifier to the NC unit. After turning NC power off, turn the main circuit breaker off and then turn it back on.
If the alarm is not cleared, please contact your MAZAK service representative.
―
374: OPERATING
SWITCH FAULT A control (switch) on the operation panel
was ON upon turning-on. The control is faulty unless it has been
inadvertently turned on. ―
375: MOTOR & SERVO TURNING OFF ERR.
Since the electromagnetic switch OFF command for the motor and servo system has been issued by activation of the emergency stop or door interlock function under CE machine specifications, the electromagnetic switches did not turn off within the required time.
After turning NC power off, turn the main circuit breaker off and then turn it back on.
If the alarm is not cleared, please contact your MAZAK service representative.
X10
376: MAIN POWER TURNING OFF MALFUNCTION
When the front door of a CE specifications machine was opened with the setup key switch set to “O”, the electromagnetic switch for spindle power did not turn off within the required time.
After turning NC power off, turn the main circuit breaker off and then turn it back on.
If the alarm is not cleared, please contact your MAZAK service representative.
X11
377: COOLANT LEVEL The coolant level in the coolant unit of a Check the coolant level in the coolant unit X492
Alarm No. and message Description Check and remedy Address 378: HIGH PRESSURE
PUMP THERMAL TRIP
The thermal relays in the coolant unit of a machine of the high-pressure coolant specifications have become tripped.
Check the thermal relays of the coolant
unit. X490
379: TANK PRESSURE
LOW The pressure in the coolant unit tank of a machine of the high-pressure coolant specifications has decreased.
Check and adjust the coolant unit tank
pressure. X491
The cycle start button has been pressed in automatic operation mode with the front door open and the setup key switch set to
“O”.
Change the setting of the setup key switch to “I” and then press the cycle start button.
Single-block automatic operation will be activated.
381: CONDITION MISSING (SET UP SWITCH)
For a machine of the front door lock pin specifications, a manual-starting button has been pressed with the front door open and the setup key switch set to “O”.
Change the setting of the setup key switch to “I” and then press the desired manual-starting button. The override rate will be reduced to 25%.
―
382: COOLANT SYSTEM
MALF. An error signal has been sent from the coolant unit of a machine of the high-pressure coolant specifications.
Check the coolant unit for alarms. X493
383: ATC ALM:
CARRIER&SHIFT.
POS. MALF.
In a machine of the 80/120-tool magazine specifications, the cycle start command or the tool change command was issued when the carrier and the shifter were not present at their stand-by positions.
Before issuing the cycle start command or the tool change command, move the carrier and the shifter to their stand-by positions using the required switch of the magazine manual operations box.
―
385: START COND. ERR.
(Z-AXIS POS.) Under 20- or 40-tool magazine
specifications, executing the machine menu function for opening the ATC cover has been attempted with the Z-axis existing in the minus direction relative to its zero point.
Move the Z-axis in the plus direction relative to its zero point before opening the
ATC cover. ―
386: ATC STOP When the [ATC STOP] menu key in the machine menu was pressed (that is, when the menu was displayed in reverse mode), the axis was moved to the ATC position by the ATC command.
Cancel the ATC stop mode by pressing the [ATC STOP] menu key in the machine
menu. ―
390: TOOL ON INTERFER
ALARM An attempt has been made to return the tool to a magazine pocket containing another tool.
Check the tool number of the tool to be returned and that of the tool stored within the magazine pocket.
―
391: LD/ULD/ACHG CONDITION ALARM
During ATC, although returning the tool was attempted, the magazine pocket tool confirmation sensor did not detect that tool probably because of dropping.
Valid when bit 6 in parameter R59 is set to
“1”. (Standard setting: 1)
Confirm whether the tool is mounted in the ATC arm.
Check the magazine pocket tool confirmation sensor for normal operation.
X475
392: MAGAZINE MANUAL
INTERR. Under 20- or 40-tool magazine
specifications, the tool change command has been entered or the cycle start button pressed with the magazine manual interruption switch set to ON.
Change the setting of the magazine manual interruption switch to OFF. X1C
394: ATC CONTROLLER
MALF. An alarm signal has been received from the
ATC amplifier. After turning NC power off, turn off the main circuit breaker and then turn if back on.
If the alarm is not cleared, please contact your MAZAK service representative.
―
Alarm No. and message Description Check and remedy Address The positions of the operational check
sensors or watchdogs are not correct or the sensors themselves are malfunctioning.
Confirm the value of D199 on the DIAGNOSIS display and examine the sensor causing the alarm.
―
D199 Corresponding sensor ―
0 Normal ―
1 The X470 limit switch at the ATC side of the shifter has not turned on 20 seconds after the Y4F0 command for moving the shifter to the ATC side has been issued.
The X471 limit switch at the magazine side of the shifter has not turned on 20 seconds after the Y4F1 command for moving the shifter to the magazine side has been issued.
X470 X471
2 The X472 limit switch at the extending side of the shifter has not turned on 20 seconds after the Y4F2 command for extending the shifter has been issued.
The X473 limit switch at the retracting side of the shifter has not turned on 20 seconds after the Y4F3 command for retracting the shifter has been issued.
X472 X473
8 The chuck-clamping pressure switch (X442) and the chuck-unclamping pressure switch (X443) are both on.
X442 X443 395: CHECK SENSOR
MALF. (SEE D199) The operational check sensors at both ends of the stroke have turned on.
After the command has been issued, no sensors did not turn on within the required time.
12 The top door open end sensor switch (X14) and closed end sensor switch (X15) of the machine of the GL specifications
12 The top door open end sensor switch (X14) and closed end sensor switch (X15) of the machine of the GL specifications