VMC Series Vertical Machining Centers: Operator'S Manual

OPERATOR’S MANUAL
VMC Series II
Vertical Machining Centers
Equipped with the
Fanuc 0i-M or 18-MC Control
Revised: June 5, 2003
Manual No. M-400A Litho in U.S.A.

Part No. M A-0009500-0400 October, 2002
- NOTICE -
Damage resulting from misuse, negligence, or accident is not covered by the
Hardinge Machine Warranty.
Information in this manual is subject to change without notice.
This manual covers the operation of Hardinge VMC Series II Vertical

Machining Centers equipped with a Fanuc 0i-M or 18-MC Control.
In no event will Hardinge Inc. be responsible for indirect or consequential

damage resulting from the use or application of the information in this manual.
Reproduction of this manual in whole or in part, without written permission of

Hardinge Inc., is prohibited.
CONVENTIONS USED IN THIS MANUAL
- WARNINGS -
Warnings must be followed carefully to avoid the possibility of personal in-
jury or damage to the machine, tooling, or workpiece.
- CAUTIONS -
Cautions must be followed carefully to avoid the possibility of damage to the
machine, tooling, or workpiece.
- NOTES -
Notes contain supplemental information.
Hardinge Inc.
One Hardinge Drive
P.O. Box 1507
Elmira, New York 14902-1507 USA
www.hardinge.com
© 2002, Hardinge Inc. M-400A

READ COMPLETE INSTRUCTIONS CAREFULLY BEFORE OPERATING OR
PROGRAMMING HARDINGE VMC600II, VMC800II, OR VMC1000II
HIGH PERFORMANCE VERTICAL MACHINING CENTERS.
- WARNING -
Occupational Safety and Health Administration (OSHA) Hazard Communica-
tion Standard 1910.1200, effective September 23, 1987, and various state
“employee right-to-know laws” require that information regarding chemicals
used with this machine be supplied to you. The list of chemicals appears in
manual SP-134, the Material Safety Data Sheets (MSDS). Refer to the applica-
ble section of the MSDS supplied with your machine when handling, storing,
or disposing of chemicals. Store MSDS of other chemicals used with this ma-
chine in the same packet with manual SP-134.
HARDINGE SAFETY RECOMMENDATIONS

Your Hardinge machine is designed and built for maximum ease and safety of operation. Since
some previously accepted shop practices may not reflect current safety regulations and procedures,
they should be re-examined to insure compliance with the current safety and health standards.
Hardinge Inc. recommends that all shop supervisors, maintenance personnel, and machine tool
operators be advised of the importance of safe maintenance, setup, and operation of all equipment.
Our recommendations are described below. READ THESE SAFETY RECOMMENDATIONS
BEFORE PROCEEDING ANY FURTHER.
READ THE APPROPRIATE MANUAL OR INSTRUCTIONS before attempting operation,

programming, or maintenance of the machine. Make certain that you understand all in-
structions.
DON’T ALLOW the operation or repair of equipment by untrained personnel.
CONSULT YOUR SUPERVISOR when in doubt as to the correct way to do a job.
WEAR SAFETY GLASSES AND PROPER FOOT PROTECTION at all times. Wear a res-
pirator, helmet, gloves, and ear muffs or plugs when necessary.
DON’T OPERATE EQUIPMENT unless proper maintenance has been regularly per-
formed and the equipment is known to be in good working order.
WARNING and INSTRUCTION TAGS are mounted on the machine for your safety and
information. Do not remove them.
DON’T ALTER THE MACHINE to bypass any interlock, overload, disconnect switch, or
other safety devices.
DON’T OPERATE ANY MACHINE while wearing rings, watches, jewelry, loose clothing,
or neckties. Long hair must be contained by a net or shop cap for safety.
MAKE CERTAIN that the equipment is properly grounded. Consult and comply with the
National Electric Code and all local codes.
M-400A i
DISCONNECT MAIN ELECTRICAL POWER before attempting repair or maintenance.
DON’T OPERATE EQUIPMENT if unusual or excessive heat, noise, smoke, or vibration

occurs. Report any excessive or unusual conditions as well as any damaged parts to your
supervisor.
ALLOW ONLY AUTHORIZED PERSONNEL to have access to enclosures containing

electrical equipment.
DON’T REACH into any control or power case area unless electrical power is OFF.
DON’T TOUCH ELECTRICAL EQUIPMENT when hands are wet or when standing on a
wet surface.
REPLACE BLOWN FUSES with fuses of the same size and type as originally furnished.
ASCERTAIN AND CORRECT the cause of any shutdown before restarting the machine.
KEEP THE AREA AROUND THE MACHINE well lighted and dry.
KEEP CHEMICALS AND FLAMMABLE MATERIAL away from operating equipment.
HAVE THE CORRECT TYPE OF FIRE EXTINGUISHER handy when machining combus-
tible material and keep the chips clear of the work area.
DON’T USE a toxic or flammable substance as a solvent cleaner or coolant.
INSPECT ALL SAFETY DEVICES AND GUARDS to make certain that they are in good
condition and are functioning properly.
MAKE CERTAIN THAT PROPER GUARDS are in place and that all doors and covers
are in place and secured before starting a machining cycle.
DON’T OPEN GUARDS while any machine component is in motion. Make certain that all
people in the area are clear of the machine when opening the guard door.
MAKE SURE that all spindle tools and any tool-holding devices are properly mounted.
MAKE SURE that fixture plates and all other table-mounted work-holding devices are
properly mounted.
MAKE CERTAIN that all tooling is secured either in the tool magazine or spindle before
starting the machine.
DON’T USE worn or defective hand tools. Use the proper size and type tool for the job
being performed.
ii M-400A
USE CAUTION around exposed mechanisms and tooling especially when setting up. Be
careful of sharp edges on tools.
USE ONLY a soft-faced hammer on table work-holding devices and fixtures.
MAKE CERTAIN that all tool mounting surfaces are clean before mounting tools.
DON’T USE worn or broken tooling on the machine.
INSPECT ALL WORK-HOLDING DEVICES daily to make certain that they are in good
operating condition. Replace any defective devices before operating the machine.
ANY ATTACHMENT, TOOL, OR MACHINE MODIFICATION obtained from any source

other than Hardinge Inc., must be reviewed by a qualified safety engineer before installa-
tion.
USE MAXIMUM ALLOWABLE gripping pressure on work-holding devices. Consider the

weight, shape, and balance of the tooling.
DON’T EXCEED the rated capacity of the machine.
DON’T LEAVE tools, workpieces, or other loose items where they can come in contact
with a moving component of the machine.
REMOVE ANY LOOSE PARTS OR TOOLS from the work area before operating the ma-
chine. Always clear the machine and work area of tools and parts, especially after work
has been completed by maintenance personnel.
REMOVE SPINDLE WRENCHES before starting the machine.
CHECK THE SETUP, TOOLING, AND SECURE THE WORKPIECE if the machine has
been turned OFF for any length of time.
CHECK THE LUBRICATION AND COOLANT LEVELS and the status of control indicator
lights before operating the machine.
KNOW where all EMERGENCY STOP push buttons are located.
MAKE CERTAIN THAT PROPER FUNCTIONS are programmed and that all controls are
set in the desired modes before pressing the Cycle Start push button.
DRY CYCLE a new setup to check for programming errors.
DON’T ADJUST tooling, workpiece, or coolant hoses while the machine is running.
KEEP CLEAR of any “pinch point” and any potentially hazardous situation.
DON’T LEAVE the machine unattended while it is operating.
M-400A iii
DON’T REMOVE OR LOAD workpieces while any part of the machine is in motion.
BE CAREFUL of sharp edges when handling newly machined workpieces.
DON’T CHECK the finish or dimension of a workpiece near a running spindle or moving
slide.
DON’T ATTEMPT to brake or slow the machine with hands or any makeshift device.
DON’T REMOVE CHIPS with hands. Make certain that all machine movement has
stopped and then use a hook or similar device to remove chips and shavings.
DON’T CLEAN the machine with an air hose.
KEEP TOTE PANS a safe distance from machine. Don’t overfill the tote pans.
Unless otherwise noted, all operating and maintenance procedures are to be performed
by one person. To avoid injury to yourself and others, be sure that all personnel are clear
of the machine when opening or closing the coolant guard door and any access covers.
FOR YOUR PROTECTION - WORK SAFELY
iv M-400A
Table of Contents
CHAPTER 1 - MACHINE CONTROL FUNCTIONS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Control Display Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Control Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Manual Data Input Keyboard. . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Operator Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Selector Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Program Cycle Push Buttons . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Axis Direction Push Buttons and Indicator Lights . . . . . . . . . . . . . . . . 1-9
Miscellaneous Push Button Functions . . . . . . . . . . . . . . . . . . . . . 1-11
Spindle Jog Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Display Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Alarm Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Main Power ON Indicator Light. . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Tool Control Push Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Spindle Speed Range Indicator Lights . . . . . . . . . . . . . . . . . . . . . 1-17
Control Power Push Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Control Power ON Push Button . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Control Power OFF Push Button . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Manual Tool Magazine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Drum Tool Magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Swing Arm Tool Magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Emergency Stop Push Button . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Tool Release Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Manual Pulse Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Axis Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Increment Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Manual Pulse Generator Dial . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Axis and Spindle Monitor Display . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Accessing the Monitor Display . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
On-Line Help System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
P/S Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Methods of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Parameter Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Accessing the On-Line Help System . . . . . . . . . . . . . . . . . . . . . . 1-24
Alarm Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Operation Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Parameter Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Exiting the On-Line Help System . . . . . . . . . . . . . . . . . . . . . . . . 1-25
M-400A v
CHAPTER 2 - POWER-UP AND CONTROL STATUS
Machine Power-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Zero Return (Reference Home) Procedure . . . . . . . . . . . . . . . . . . . . . 2-2
Spindle Warm-Up Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Short Term Spindle Warm-Up . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Long Term Spindle Warm-Up . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Machine with Oil-Air Spindle Lubrication . . . . . . . . . . . . . . . . . . . 2-4
Machine with Grease Spindle Lubrication . . . . . . . . . . . . . . . . . . 2-4
Power-Down Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Reviewing Control Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
CHAPTER 3 - OPERATIONAL MODES AND EDITING

Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Single Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Edit Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Word Scan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Word Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Editing a Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Setting Program Protection . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
General Edit Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Altering a Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Inserting a Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Deleting a Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Deleting Up to an End of Block . . . . . . . . . . . . . . . . . . . . . . . 3-4
Deleting Data Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Deleting a Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Deleting a Range of Programs . . . . . . . . . . . . . . . . . . . . . . . 3-5
Deleting All Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Jog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
X, Y, and Z Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Spindle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Manual Data Input Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Using Manual Data Input . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Handwheel Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Moving the Axes in Handwheel Mode . . . . . . . . . . . . . . . . . . . . . 3-8
Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Entering a Program from the Keyboard . . . . . . . . . . . . . . . . . . . . . 3-10
Activating a Stored Program . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Running a Part Program for the First Time . . . . . . . . . . . . . . . . . . . 3-11
Stopping a Program Running in Automatic Mode . . . . . . . . . . . . . . . . 3-12
Restarting a Stopped Program . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Zero Return Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Dry Run and Machine Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Activating Dry Run and Machine Lock . . . . . . . . . . . . . . . . . . . . . 3-13
Exiting Dry Run and Machine Lock Mode . . . . . . . . . . . . . . . . . . . . 3-13
Z Axis Machine Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
vi M-400A
Background Editing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Entering Background Editing Mode . . . . . . . . . . . . . . . . . . . . . . . 3-15
Editing an Existing Program . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Creating a New Program from the Keyboard . . . . . . . . . . . . . . . . . . 3-15
Ending Background Editing . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Extended Part Program Editing . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Copying an Entire Program . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Copying Part of a Program . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Moving Part of a Program . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Merging a Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Search and Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Reorganizing Part Program Memory . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Displaying the Program Directory . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Editing Machine Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
CHAPTER 4 - WORK COORDINATE SYSTEMS

Zero Return (Reference Home) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
X, Y, and Z Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Coordinate System Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Programmable Work Coordinate Systems . . . . . . . . . . . . . . . . . . . . . 4-3
Establishing a Work Coordinate Offset. . . . . . . . . . . . . . . . . . . . . . . 4-6
Determining the Z Axis Work Coordinate Offset . . . . . . . . . . . . . . . . . 4-6
Determining the X and Y Axis Work Coordinate Offsets . . . . . . . . . . . . . 4-8
Referencing to External Surfaces . . . . . . . . . . . . . . . . . . . . . . 4-8
Referencing to an Internal Diameter. . . . . . . . . . . . . . . . . . . . . 4-11
Storing Coordinate System Data from the Manual Data Input Keyboard . . . . . . . 4-12
CHAPTER 5 - TOOLING AND TOOL OFFSETS

Automatic Tool Changer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Tool Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Tooling Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Manually Indexing the Drum Tool Magazine . . . . . . . . . . . . . . . . . . 5-4
Manually Controlling the Swing Arm Tool Magazine . . . . . . . . . . . . . . . 5-5
Tool Location Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Tool Change Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Diagnostic Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Sample Tool Data for Drum Magazine 1 (Standard) . . . . . . . . . . . . . 5-7
Sample Tool Data for Drum Magazine 2 [Option]. . . . . . . . . . . . . . . 5-8
Sample Tool Data for Swing Arm Magazine [Option] . . . . . . . . . . . . . 5-9
Tool Installation and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Non-Preset Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Preset Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Tool Wear Offsets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Accessing the Tool Wear Offsets . . . . . . . . . . . . . . . . . . . . . . 5-16
M-400A vii
Tool Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Tool Length Offsets (H Word) . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Tool Diameter Offsets (D Word) . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Storing Tool Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
CHAPTER 6 - OPERATOR MAINTENANCE

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Machine Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Air Line Filter/Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Adjusting the Machine Air Pressure . . . . . . . . . . . . . . . . . . . . . 6-1
Air/Oil Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Filling the Air/Oil Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Coolant Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Chip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
CHAPTER 7 - INPUT/OUTPUT DEVICES

Data Communications Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Baud Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Parity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Stop Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Checking and Modifying Communications Parameters . . . . . . . . . . . . . . . 7-2
I/O Port Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
I/O Port Parameter Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Baud Rate Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Stop Bit Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Data Transfer to the Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Uploading Control Parameters into Memory. . . . . . . . . . . . . . . . . . . 7-5
Uploading Part Programs into Memory . . . . . . . . . . . . . . . . . . . . . 7-6
Uploading Tool Offsets into Memory . . . . . . . . . . . . . . . . . . . . . . 7-7
Data Transfer from the Control . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Downloading Control Parameters from Memory . . . . . . . . . . . . . . . . . 7-8
Downloading Part Programs from Memory . . . . . . . . . . . . . . . . . . . 7-9
Downloading Tool Offsets from Memory . . . . . . . . . . . . . . . . . . . . 7-10
CHAPTER 8 - TOOL LIFE MANAGEMENT [Option]

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Tool Life Measurement Units . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Number of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Amount of Machining Time . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
General Program Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Determining Maximum Groups and Group Sizes . . . . . . . . . . . . . . . . 8-2
Verifying Maximum Groups and Group Sizes . . . . . . . . . . . . . . . . 8-3
Setting Maximum Groups and Group Sizes . . . . . . . . . . . . . . . . . 8-3
Determining the Default Measurement Unit . . . . . . . . . . . . . . . . . . . 8-4
Verifying the Measurement Unit Parameter Setting . . . . . . . . . . . . . . 8-4
Switching the Measurement Unit Parameter Setting . . . . . . . . . . . . . 8-4
Resetting a Tool Group Counter . . . . . . . . . . . . . . . . . . . . . . . . 8-5
viii M-400A
Tool Life Data Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Accessing the Data Screens . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
CHAPTER 9 - OPTIONS AND MISCELLANEOUS FEATURES

Graphic Display Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Accessing the Graphic Display Function . . . . . . . . . . . . . . . . . . . . 9-1
Soft Key Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Tool Path Display Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Setting the Tool Path Display Parameters . . . . . . . . . . . . . . . . . . . 9-4
Activating The Tool Path Display . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Machine Run Time Counter [Option]. . . . . . . . . . . . . . . . . . . . . . . . 9-5
Accessing the Limited Run Time Display . . . . . . . . . . . . . . . . . . . . 9-5
Accessing the Complete Run Time Display . . . . . . . . . . . . . . . . . . . 9-5
Resetting a Counter to Zero . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Parts Counter [Option] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Accessing the Parts Counter Display . . . . . . . . . . . . . . . . . . . . . . 9-7
Accessing the Parts Counter Registers . . . . . . . . . . . . . . . . . . . . . 9-7
Setting Parts Counter Values . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Parts Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Parts Required and Parts Count . . . . . . . . . . . . . . . . . . . . . . 9-8
Tool Changer Fault Recovery Procedures . . . . . . . . . . . . . . . . . . . . . 9-9
Drum Tool Changer 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Drum Tool Changer 2 [Option] . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Swing-Arm Tool Changer [Option] . . . . . . . . . . . . . . . . . . . . . . . 9-13
APPENDIX
Travel Specifications
X and Y Axis
VMC600II Machining Center . . . . . . . . . . . . . . . . . . . . . . . . A-1
VMC800II Machining Center . . . . . . . . . . . . . . . . . . . . . . . . A-2
VMC1000II Machining Center . . . . . . . . . . . . . . . . . . . . . . . A-3
Z Axis
VMC 600II, 800II, and 1000II Machining Centers . . . . . . . . . . . . . . A-6
VMC1250II and 1500II Machining Centers . . . . . . . . . . . . . . . . . A-7
Tool Slot Locations and Configuration
VMC600II Machining Center . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
VMC800II Machining Center . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
VMC1000II Machining Center . . . . . . . . . . . . . . . . . . . . . . . . . A-10
G Code List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13
M Code List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-16
Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-19
M-400A ix
- NOTES -
x M-400A
CHAPTER 1 - MACHINE CONTROL FUNCTIONS
INTRODUCTION
Most machine control functions are located on the front of the machine. The exceptions are:
• The Tool Release push button, located on the headstock cover inside the work
envelope.
• The index push buttons for the standard tool magazine, located on the left side of the
machine.
• The index push buttons for the optional tool magazine, located on the right side of the
machine.
Refer to the appropriate section in this chapter for specific information on the control functions.
CONTROL DISPLAY PANEL

- NOTE -
Figure 1.1 shows functions not present on all models of VMC Series II Vertical Ma-
chining Centers.
The control display panel, shown in Figure 1.1, consists of a display screen with associated soft
keys and a manual data input keyboard.
Control
Display Panel
Manual Data
Input Panel
Control ON/OFF
Push Buttons
Soft Keys
Machine
Control Panel
TP5007
Figure 1.1 - Main Control Panel

(High Torque Machine with Swing Arm Tool Changer)
M-400A 1-1
CONTROL DISPLAY SCREEN
SOFT KEYS
The soft keys have various functions, depending on the application. The soft key functions
are displayed at the bottom of the control display screen.
LEFT-HAND SOFT KEY

This key is used to return to the initial state after a function has been accessed by pressing
one of the soft keys.
RIGHT-HAND SOFT KEY

This key is used to display further soft key functions which are not currently displayed. This
key is also called the soft key expansion key.
MANUAL DATA INPUT KEYBOARD
ALTER
This key permits changes to an existing entry in an active program while in Edit mode.
Refer to Edit mode in Chapter 3.
CAN (Cancel)
This key is used to cancel or delete the last character or symbol which has been entered
into the input buffer. It is also used, together with the appropriate function key, to clear the
data displayed on the screen.
CURSOR CONTROL KEYS

These keys will shift the cursor forward or backward through the program or parameters,
depending on which mode is active.
CUSTOM
No function.
DATA INPUT KEYS

These keys are used to manually enter data into the control. These keys input alphabetic,
numeric, and other characters. In addition to these keys, the Alter, Insert, Delete, EOB, and
Cancel keys are active. Data entered with the data input keys is indicated at the bottom of the
display screen.
Each alphabetic data input key is capable of inputting two distinct characters. The input is
switched by pressing the Shift key.
The Rapid Traverse symbol on the 5 key has no function.
1-2 M-400A
DELETE
This key causes the data word directly above the cursor to be deleted. Refer to Edit mode
in Chapter 3.
EOB
This key is used to input an End of Block (;) character.
GRAPH (Graphics)
Pressing this key allows the operator to set graphic display parameters and display the tool
path or a solid model of the workpiece.
HELP
The Help key allows the operator to gain access to an on-line help system. For additional
information, refer to “On-Line Help System”, page 1-24.
INPUT
This key is used to set data, which has been entered into the input buffer area, into the ap-
propriate area in the control memory. Refer to Manual Data Input mode in Chapter 3.
INSERT
This key allows additional commands to be inserted in a program line while in Edit mode.
Refer to Edit mode in Chapter 3.
MESSAGE
This key allows the operator to display either alarm messages, operator messages, or the
alarm message history.
OFFSET / SETTING
This key allows the setting and display of the following values:
• Control System Variables (Refer to Chapter 2 for additional information)
• Work Coordinate (Refer to Chapter 4 for additional information)
• Tool Diameter and Length Offsets (Refer to Chapter 5 for additional information)
M-400A 1-3
PAGE UP
PAGE DOWN
The Page keys are used to display information which requires more than one display page.
Pressing Page é or Page ê causes the control the display the previous or next page, re-
spectively.
POS (Position)
Pressing the Position key will display the position data in one of three ways:
1. In the absolute mode of the work coordinate system by pressing the Absolute soft key.
2. In the relative coordinate system by pressing the Relative soft key.
3. In the overall mode, indicating relative, absolute, machine coordinate, and distance to go,
by pressing the ALL soft key.
Use the Page keys to switch between the various position display screens. Refer to Chap-
ter 2 for more information on the position display screens.
PROG (Program)
This key allows the operator to perform the following:

In Edit mode - edit and display program memory.
In Manual Data Input mode - Input and display Manual Data Input data.
In Automatic mode - display the active part program.
RESET
This key can be activated any time while a part program is being executed. When the Re-
set key is pressed, axis and spindle motion are stopped. The M and G codes are reset to the
power-up default status. The Reset key is also used to clear an alarm state after a fault has
been corrected.
- NOTE -
To return to the start of a main part program, select Edit mode and press Reset.
SHIFT
Each of the data input keys has one large and one small character. By pressing the shift
key, the user can switch between the two characters on the data input key. Pressing the Shift
key will alternate the screen cursor between “_” and “^”. The “_” cursor indicates that the
large character in the center of the data input key will be input. The “^” cursor indicates that
the small character in the lower right corner of the data input key will be input.
1-4 M-400A
SYSTEM
- WARNING -
Exercise caution when accessing control functions that allow parameter edit-
ing. Making incorrect changes in the parameter tables may disable the ma-
chine or cause undesirable machine behavior.
The System key allows access to the machine parameter and diagnostic information. This
key also toggles the display between the Parameter and Diagnostic screens.
The Parameter soft key allows display and setting of machine parameters.
The Diagnostic soft key allows display of machine diagnostic information.
The PMC soft key allows display of the following PMC information:
Ladder
Diagnostics
Parameters
The System soft key allows display of the control hardware and software configuration.
The Operator soft key provides the capability of searching, editing, uploading, or down-
loading machine parameters.
M-400A 1-5
OPERATOR CONTROL PANEL
Refer to Figure 1.2 for the location of the switches, push buttons, and indicator lights described in
this section.
- NOTE -
This section describes functions not present on all models of VMC Series II Verti-
cal Machining Centers.
SELECTOR SWITCHES
Emergency Stop
The Emergency Stop push button is located in the upper left corner of the operator control
panel. When pressed, all machine and chip conveyor motion is stopped. Pull the Emergency
Stop push button UP to release. Refer to Manual Tool Magazine Controls, page 1-19, for the
location of an additional Emergency Stop push button.
Rapid Override Switch
This switch can modify the machine rapid traverse rate on the X, Y, and Z axes in steps
from 0% ~ 100%. It is active in Positioning Mode (G00). It is also active during return passes
for machining cycles.
Feedrate / Jog Override Switch
In Automatic or Manual Data Input mode, this switch allows the operator to modify pro-
grammed feedrates from 0% ~ 150%. A setting of “0" will stop G01, G02, & G03 motion.
In Jog mode, this switch establishes the rate of motion when manually jogging the machine
axes. A setting of “0" will inhibit axis motion. When the Override switch is set to 100%, the
rate of motion is:
Inch mode: 0 ~ 787 inches/minute
Metric mode: 0 ~ 2000 millimeters/minute
Spindle Override Switch
This switch allows the operator to modify programmed spindle speeds from 50% ~ 120%.
1-6 M-400A
TI4693A
Figure 1.2 - Operator Control Panel

(High Torque Machine with Swing Arm Tool Changer)
Mode Select Switch
Edit Mode
This switch setting activates Edit mode. Edit mode allows the operator or programmer to
enter a new program or edit a stored program. To deactivate Edit mode, select another oper-
ating mode. Refer to Chapter 3 for more information on Edit mode.
Automatic Mode
This switch setting activates Automatic mode. Automatic mode allows execution of a part
program stored in control memory and modification of part programs using the Back Edit func-
tion. Refer to Chapter 3 for more information on Automatic mode.
Manual Data Input Mode
This switch setting activates Manual Data Input mode. Manual Data Input mode allows
manual input of a temporary program block. Refer to Chapter 3 for more information on Man-
ual Data Input mode.
M-400A 1-7
Direct Numerical Control (DNC) Mode
This switch setting activates Direct Numerical Control mode. Direct Numerical Control
mode allows execution of a part program read directly from an input device connected to the
machine control.
Jog Mode
This switch setting activates Jog mode. Jog mode allows non-programmed movement of
the axes through the use of the axis direction push buttons. Refer to Chapter 3 for more infor-
mation on Jog mode.
Handwheel (Manual Pulse Generator) Mode
This switch setting activates Handwheel mode. Refer to Manual Pulse Generator, page
1-21, for information on incrementally jogging the machine axes.
Zero Return Mode
This switch setting activates Zero Return mode. Zero Return mode allows the selected axis
to be moved to the “Home” position. This mode is activated automatically at Power-Up. Refer
to Chapter 2 for more information on the Zero Return procedure.
PROGRAM CYCLE PUSH BUTTONS
Cycle Start
This push button is a latching type switch that initiates program execution when the control
is in Automatic mode or Single mode. An additional function of this switch is to execute Man-
ual Data Input commands. This push button is illuminated when Cycle Start is active.
Feed Hold
The Feed Hold push button allows the operator to stop all programmed slide motion. How-
ever, the active spindle speed is not affected. Feed Hold can be activated while in Automatic,
Single Block, Dry Run, or Machine Lock modes. Cycle Start turns OFF when Feed Hold is ac-
tivated. Press Cycle Start to resume normal operation after a feed hold. This push button is il-
luminated when Feed Hold is active.
1-8 M-400A
AXIS DIRECTION PUSH BUTTONS AND INDICATOR LIGHTS
The X, Y, Z, and 4th axis push buttons are used to allow manual axis movement in Jog mode. The
X, Y, and Z axis push buttons are also used in conjunction with the Jog Feedrate switch.
X Axis
Table motion to the left or right, as viewed from the front of the machine. Pressing
one of the X directional push buttons causes the table to move in the corresponding di-
rection. Refer to Figure 1.3 for direction of table motion.
Y Axis
Table motion toward or away from the operator, as viewed from the front of the ma-
chine. Pressing one of the Y directional push buttons causes the table to move in the
corresponding direction. Refer to Figure 1.3 for direction of table motion.
Z Axis
Refers to the head, which contains the machine spindle. The head moves toward or
away from the machine table on the vertical axis. Pressing one of the Z directional push
buttons causes the head to move in the corresponding direction. Refer to Figure 1.4 for
direction of head motion.
4th Axis [Option]

Refers to the optional rotary table.
Indicator Lights
An indicator light will turn ON when the associated axis is at the Home position.
M-400A 1-9
-Y Motion
+X Motion -X Motion
Front of Machine
+Y Motion TI4061
Figure 1.3 - X and Y Axis Table Motion
+Z Motion
-Z Motion
Machine Table
TI4062
Figure 1.4 - Z Axis (Head) Movement
1-10 M-400A
MISCELLANEOUS PUSH BUTTON FUNCTIONS
Rapid
- CAUTION -
When jogging the machine axes, be sure no interference exists between fix-
tures, spindle, tooling, or workpiece.
This push button allows the machine operator to activate manual rapid traverse mode.
Activating this push button with Jog mode active and pressing one of the axis directional
push buttons causes the selected axis to move at the rapid jog rate. The Rapid Override
switch can be used to adjust the rapid traverse rate. Refer to Jog Mode, in Chapter 3.
M01 (Option Stop)
- CAUTION -
It is the responsibility of the part programmer to program M03, M04, M13, or
M14 to restart the spindle and coolant when program execution is resumed
after an Option Stop.
This push button allows the machine operator to alternately activate and deactivate
Option Stop. This function causes the control to stop execution of the part program
AFTER executing an active block that contains an M01 code. The M01 code is ignored
when Option Stop is not active.
This function may be activated before or during execution of the block containing the
M01 code. The indicator light is illuminated when Option Stop is active. When a block
containing an M01 code is encountered and this function is active, the following occurs:
The block is executed.
All slide motion and spindle motion stops.
The coolant pump turns OFF and Feed Hold turns ON.
To resume program execution, press the Cycle Start push button. The Feed Hold
push button light will turn OFF.
BDT (Block Skip)
Block Skip. When Block Skip is active, the control will ignore any program data block
preceded by a slash (/) code. The indicator light is illuminated when Block Skip is active.
M-400A 1-11
SBK (Single Block)
This push button allows the machine operator to activate Single Block. The indicator
light is illuminated when Single Block is active. Single Block provides the operator with
the ability to execute one block of data each time the Cycle Start push button is
pressed.
MLK (Machine Lock)
- NOTE -
This mode must be OFF for normal machine operation.
Machine Lock mode. When this mode is active, all axis and spindle motion is inhibited.
M, S, and T functions are also inhibited. The indicator light is illuminated when Machine
Lock is active. Refer to Chapter 3 for information on using Machine Lock.
ZMLK (Z Axis Machine Lock)
This push button allows the machine operator to disable all Z axis motion. When Z
Axis Machine Lock is OFF, Z axis motion will occur as programmed. When Z Axis Ma-
chine Lock is active, all Z axis motion is inhibited. When a part program is executed, all
other machine activity will occur as programmed. This push button is illuminated when Z
Axis Machine Lock is active. Refer to Chapter 3 for information on using Z Axis Machine
Lock.
DRN (Dry Run)
- NOTE -
This mode must be OFF for normal machine operation.
Dry Run mode. When this mode is active, programmed feedrates are ignored and cut-
ting moves are performed at a Jog feedrate of 50 inches [1260 millimeters] per minute.
The indicator light is illuminated when Dry Run is active. Refer to Chapter 3 for informa-
tion on using Dry Run.
1-12 M-400A
Coolant ON
This push button turns the coolant pump ON, regardless of the programmed M codes
for coolant control. Coolant ON deactivates Coolant Automatic and Coolant OFF.
Coolant OFF
This push button turns the coolant pump OFF, regardless of the programmed M
codes for coolant control. Coolant OFF deactivates Coolant Automatic and Coolant ON.
Coolant Automatic
This push button enables automatic coolant control from the part program. Coolant is
turned ON when an M08, M13, or M14 is read from the part program by the control.
Coolant is turned OFF when an M00, M01, M02, M05, M09, or M30 is read from the
part program. Coolant Automatic deactivates Coolant OFF and Coolant ON.
Chip Conveyor ON/OFF
This push button allows the machine operator to turn the chip conveyor ON or OFF.
This push button is illuminated when the chip conveyor is turned ON.
Chip Conveyor Direction
This push button allows the machine operator to reverse the direction of the chip con-
veyor motion. This push button is illuminated when the chip conveyor is running in the
reverse direction.
Chip Flush
This push button alternately activates and deactivates the optional coolant chip flush,
which is used to flush chips from the machine table into the chip pans or chip conveyor.
Chip flush is an optional feature on standard machining centers.
Chip flush is a standard feature on high performance machining centers.
Refer to Chapter 6 for information on removing chips from the chip pans.
M-400A 1-13
SPINDLE JOG FUNCTION
Spindle Jog Speed Control
This variable switch allows the machine operator to adjust the spindle speed while
jogging the machine spindle.
Clockwise Rotation
This push button allows the machine operator to jog the machine spindle in the clock-
wise direction (as viewed from the top of the machine) when Jog mode is active and the
guard doors are closed.
Spindle Stop
This push button allows the machine operator to cancel the spindle jog.
Counterclockwise Rotation
This push button allows the machine operator to jog the machine spindle in the coun-
terclockwise direction (as viewed from the top of the machine) when Jog mode is active
and the guard doors are closed.
Work Light
Turns the work light ON or OFF.
1-14 M-400A
Alarm Cancel
- NOTE -
Deactivating the audible alarm does not correct the condition that caused the
alarm.
This push button allows the machine operator to cancel the audible alarm, which is
activated when an alarm is issued by the machine control.
Emergency Stop Reset
- NOTE -
The condition that caused the machine to go into emergency stop MUST be cor-
rected before Emergency Stop can be cleared.
The Emergency Stop Reset push button, when pressed and held, also allows the
machine operator to jog the axes out of an overtravel condition.
The Emergency Stop Reset push button is used to reset the control once the Emer-
gency Stop push button has been released or the problem that caused the Emergency
Stop condition has been corrected.
To return the control to normal operation:
1. Correct the problem that caused the Emergency Stop condition.
2. If necessary, release the Emergency Stop push button by pulling it OUT.
3. Press the Emergency Stop Reset push button.
4. Move all axes to a safe program restart position.
M-400A 1-15
DISPLAY INDICATOR LIGHTS
- NOTE -
The Display indicator lights are the upper row of indicator lights.
COL. (Coolant)
Indicates that the coolant pump is ON.
M19
Indicates that the spindle is oriented to the tool change position.
ATC (Automatic Tool Changer)

Indicates that Tool Change mode is active.
TCL (Tool Clamp)

Indicates that a tool is clamped in the spindle.
ALARM INDICATOR LIGHTS

- NOTE -
The Alarm indicator lights are the lower row of indicator lights.
EM (Emergency Stop)
Indicates that an Emergency stop condition exists.
ATC (Automatic Tool Changer)

Indicates that an alarm associated with the tool magazine has occurred.
OL (Overload)
Indicates that a servo drive or electrical overload has occurred.
AL (Alarm)
Indicates that a general machine alarm has occurred. Refer to the control display
screen for the specific alarm message.
1-16 M-400A
MAIN POWER ON INDICATOR LIGHT
This indicator light turns ON when the main disconnect switch is turned ON.
TOOL CONTROL PUSH BUTTONS
Tool Change
This push button will exchange the tools in the spindle and the active station of the
tool magazine when Jog mode is active. This function is only on machining centers
equipped with the optional swing arm tool changer.
Tool List
Press the Tool List push button to access the tool location table
Index Tool Magazine
This push button will index the tool magazine in the clockwise direction when Jog
mode is active.
SPINDLE SPEED RANGE INDICATOR LIGHTS

- NOTE -
The spindle speed range indicator lights are only present on High Torque machin-
ing centers.
The spindle speed range is selected by the programmer through the use of M
codes.
H-GEAR (High Gear)
Indicates that the spindle drive is in high gear, which provides more speed and less
torque to the spindle.
L-GEAR (Low Gear)

Indicates that the spindle drive is in low gear, which provides less speed and more
torque to the spindle.
M-400A 1-17
CONTROL POWER PUSH BUTTONS
CONTROL POWER ON PUSH BUTTON
Press Control ON push button “A”, Figure 1.5, to apply power to the machine control. Refer
to Chapter 2 for the power-up procedure.
CONTROL POWER OFF PUSH BUTTON

Press Control OFF push button “B”, Figure 1.5, to remove power from the machine control.
Refer to Chapter 2 for the power-down procedure.
TI5007
Figure 1.5 - Control Power Panel
1-18 M-400A
MANUAL TOOL MAGAZINE CONTROLS
- WARNING -
Read and understand the Fault Recovery section in Chapter 9 before using
these controls.
- NOTE -
Refer to Chapter 5 for information on using the manual tool magazine controls.
DRUM TOOL MAGAZINE

Push buttons “C” and “D”, Figure 1.6, allow the machine operator to manually cycle the
drum tool magazine when Jog mode is active.
SWING ARM TOOL MAGAZINE

Switch “E” and push button “F”, Figure 1.7, allow the machine operator to manually control the
swing arm tool magazine and swap spindle tooling when Jog mode is active.
EMERGENCY STOP PUSH BUTTON

When the Emergency Stop push button is pressed, all machine and chip conveyor motion
is stopped. Pull the Emergency Stop push button UP to release. The operator control panel is
also equipped with an Emergency Stop push button.
Emergency
Stop
D
C
Emergency
Stop
E F
TI3651 TI5002
Figure 1.6 - Tool Magazine Push Figure 1.7 - Tool Magazine Controls
Buttons for Drum Tool Magazine for Swing Arm Tool Magazine
M-400A 1-19
TOOL RELEASE PUSH BUTTON
- WARNING -
this push button.
Be sure the spindle is stationary before attempting to remove or install a tool
in the spindle.
Exercise caution when releasing a tool holder held in the machine spindle.
DO NOT attempt to grip the cutting tool, personal injury may result.
Be prepared to accept the weight of the tool and tool holder. Do not drop the
tool and tool holder. Personal injury or damage to the tool, tool holder, or
workpiece may result.
Push button “G”, Figure 1.8, activates Tool Release, which will remain active as long as
this push button is held IN. The spindle clamps the tool when this push button is released.
TI3654
Figure 1.8 - Tool Release Push Button
1-20 M-400A
MANUAL PULSE GENERATOR
- CAUTION -
tures, tooling, or workpiece.
INTRODUCTION
The portable manual pulse generator, shown in Figure 1.9, allows the operator to jog the selected
axis by specific increments. The axis to be jogged is selected with axis select switch “I” and the
increment is selected with increment select switch “J”. The Mode Select switch must be set to
Handwheel mode for the manual pulse generator to function.
Refer to: Page 1-7 for information on the Mode Select switch.
Chapter 3 for information on Handwheel mode.
Figures 1.3 and 1.4 for axis definitions.
- NOTE -
The axis velocity (rate of travel) is determined by the rate at which the manual
pulse generator dial “H” is rotated. Be aware that the axis velocity will not be al-
lowed to exceed the maximum velocity of 1181 in/min [30 m/min]. Any pulses pro-
duced by the manual pulse generator that would cause the velocity to exceed this
maximum value will be ignored by the machine control. Accurate position data will
be maintained by the machine control.
TI3650A
Figure 1.9 - Manual Pulse Generator
M-400A 1-21
AXIS SELECT SWITCH
Axis select switch “H” determines which machine axis will move when the manual pulse generator
dial is turned while the control is in Handwheel mode.
INCREMENT SELECT SWITCH

X1 Selects the increment jog rate when Handwheel mode is active. The incremental jog
rate per division on the dial is .0001 inches in English mode or .001 mm in Metric
mode.
rate per division on the dial is .001 inches in English mode or .01 mm in Metric
mode.
rate per division on the dial is .01 inches in English mode or .1 mm in Metric mode.
MANUAL PULSE GENERATOR DIAL

After Handwheel mode has been activated and the desired axis and increment have been
selected, rotate dial “H” as follows:
Clockwise: Positive Axis Motion
Counterclockwise: Negative Axis Motion
1-22 M-400A
AXIS AND SPINDLE MONITOR DISPLAY
INTRODUCTION
The monitor display provides access to the following data:
X, Y, & Z axis load meters
Display the percentage of recommended maximum full load current being drawn by
the specified axis drive. Each asterisk displayed to the right of the axis designation rep-
resents 10% of the recommended maximum full load current.
Spindle load meter (S1)
Displays the percentage of recommended maximum full load current being drawn by
the spindle drive. Each asterisk displayed to the right of the “S1" designation represents
20% of the recommended maximum full load current.
Speed Meter (Spindle rpm)
Displays the speed of the spindle in rpm. Each asterisk displayed to the right of the
axis designation represents 10% of the maximum spindle speed.
ACCESSING THE MONITOR DISPLAY

1. Press the Position key.
2. Press the right-hand soft key.
3. Press the Monitor soft key.
M-400A 1-23
ON-LINE HELP SYSTEM
INTRODUCTION
The on-line help system provides information and instructions relating to P/S alarms, methods of
operation, and parameter tables.
P/S Alarms
- NOTE -
Only the more difficult to understand P/S alarms are supported by the on-line help
system.
Information and remedies concerning specific P/S alarms are supplied.
Methods of Operation
Information concerning CNC machining operations.
Parameter Table
Displays ranges of parameter numbers based on parameter functions.
ACCESSING THE ON-LINE HELP SYSTEM

Press the Help key to access the on-line help system. The following menu will be displayed:
1. Alarm Detail
2. Operation Method
3. Parameter Table
- NOTE -
When viewing “Operation Method” or “Parameter Screens”, the help system will
display two numbers in the upper right-hand corner of the screen; for example 1/4.
The upper number indicates the current page number and the lower number indi-
cates the total number of pages for that particular topic.
Alarm Detail
1. Press the 1 ALAM soft key.
2. Key in the alarm number and press the Select soft key. The alarm number and a detailed
explanation will be displayed.
3. Exit the on-line help system. Refer to “Exiting the On-Line Help system”, on the next page.
1-24 M-400A
Operation Method
1. Press the 2 OPR soft key.
2. Key in the topic number and press the Select soft key. The selected topic and a detailed
explanation will be displayed.
Parameter Table
1. Press the 3 PARA soft key. Page 1 of 4 will be displayed.
2. Use the Page keys to view the various pages, as needed.
EXITING THE ON-LINE HELP SYSTEM

Press the Help key again or press one of the following function keys to exit the on-line help system:
- GRAPH
- MESSAGE
- OFFSET/SETTING
- POS
- PROG
- SYSTEM
M-400A 1-25
- NOTES -
1-26 M-400A
CHAPTER 2 - POWER-UP AND CONTROL STATUS
- CAUTION -
The recommended operating temperature range is 50° to 114° F [7° to 46° C].
MACHINE POWER-UP PROCEDURE

- NOTE -
It is important that the power-up procedure is followed as described to ensure safe,
accurate, and repeatable machine operation.
1. Turn main disconnect switch “A”, Figure 2.1,
ON.
2. Push main air valve “B”, Figure 2.2, IN to
turn the machine air ON.
- NOTE -
Refer to Chapter 6 for information on A
refilling the coolant tank.
3. Check the coolant level. Add coolant, if
necessary.
- CAUTION -
When pressing the Control ON push
button, DO NOT press any other push
buttons or keys until the position or
alarm screen is displayed. Some TP3653
push buttons and keys are used for
control maintenance or special Figure 2.1 - Power Case Door
operation commands.
4. Press the Control ON push button and wait
until the control display screen is ON.
5. Pull the Emergency Stop push button OUT to
release.
6. If necessary, release the Emergency Stop
push button(s) located next to the manual in-
dex push buttons for the tool magazine(s).
7. Be sure the coolant guard door is closed.
8. The machine is now ready for the Zero Re-
B
turn (Reference Home) procedure, as out-
lined on page 2-2.
TP3664
Figure 2.2 - Main Air Valve
M-400A 2-1
ZERO RETURN (REFERENCE HOME) PROCEDURE
- CAUTION -
When homing the axes with the Zero Return (Reference Home) procedure, be
sure that no interference exists between the fixtures, tooling, or workpiece.
DO NOT attempt to home the machine axes if the tool change magazine(s) is
(are) not at the Home position.
1. Verify that the tool magazine is at the Home (retracted) position.
2. Select Jog mode
3. Set the Feedrate/Jog Override switch to the desired feedrate.
4. If necessary, move the machine axes to a safe location for axis motion.
5. Use the -Z push button to jog the head approximately 1 inch [25 mm] in the minus (down-
ward) direction.
6. Use the +X push button to jog the table approximately 1 inch [25 mm] in the plus direction.
7. Use the -Y push button to jog the table approximately 1 inch [25 mm] in the minus direc-
tion.
8. Select Zero Return mode.
9. Press the +Z push button. The Z axis will move to the Home position.
10. Press the -X push button. The X axis will move to the Home position.
11. Press the +Y push button. The Y axis will move to the Home position.
12. If the machine is equipped with an optional rotary table, press the +B push button to index
the rotary table to the Home position.
13. If powering up a High Torque machining center, the machine is ready for operation.
If powering up a High Speed machining center, proceed to the spindle warm-up proce-
dures.
2-2 M-400A
SPINDLE WARM-UP PROCEDURES
- CAUTION -
Failure to properly warm up the spindle can result in spindle failure.
Never run the spindle over 50 percent of the maximum rated speed without a
tool holder installed in the spindle.
- NOTE -
Spindle warm-up is only required on High Speed machining centers.
High Speed machining centers are equipped with an automatic timer that will inhibit
spindle operation for 5 minutes after the machining center has been powered up.
The purpose is to ensure proper lubrication of the spindle bearings. Perform the
appropriate spindle warm-up after the 5 minute period has expired.
High Speed machining centers equipped with a 12,000 RPM spindle are available
with either grease lubrication or oil-air lubricator “C”, Figure 2.3 .
High Speed machining centers equipped with a 15,000 RPM spindle are equipped
with oil-air lubricator “C”, Figure 2.3 .
1. On machining centers equipped with oil/air
spindle lubrication, make certain that oil-air
lubricator “C”, Figure 2.3, is ON. Allow 5 min-
utes BEFORE proceeding to step 2.
2. On machining centers equipped with oil/air C
spindle lubrication, turn spindle labyrinth air
seal pressure valve “D” ON. The recom-
mended pressure setting is 7.4 psi [0.5 bar].
3. Perform the appropriate spindle warm-up,
depending on how long the machining center
has been idle.
SHORT TERM SPINDLE WARM-UP

- CAUTION - D
Short term spindle warm-up should
only be used if the machining center
has been idle LESS than 2 weeks.
Refer to Long Term Spindle
Warm-Up if the machine has been
idle 2 weeks or more.
Use Manual Data Input mode to run the spindle at
25 percent of the maximum spindle speed for 15 TP4187
minutes.
Figure 2.3 - Oil-Air Lubricator and
Once the spindle warm-up is completed, the Labyrinth Air Seal Pressure Valve
machine is ready for operation.
M-400A 2-3
LONG TERM SPINDLE WARM-UP
- NOTE -
Use the appropriate procedure in this section if the machine has been idle 2 weeks
or more.
Machine with Oil-Air Spindle Lubrication
Use Manual Data Input mode to run the spindle at 25 percent of the maximum spindle speed for 30
minutes; then, 50 percent of the maximum spindle speed for 60 minutes.
Once the spindle warm-up is completed, the machine is ready for operation.
Machine with Grease Spindle Lubrication
Use Manual Data Input mode to run the spindle at 25 percent of the maximum spindle speed for 20
minutes; then, 50 percent of the maximum spindle speed for 30 minutes.
Once the spindle warm-up is completed, the machine is ready for operation.
POWER-DOWN PROCEDURE
1. Be sure “Cycle Start” is not active. The Cycle Start push button light will be OFF.
2. Be sure the program has been completed and that the spindle and slides are stationary.
3. Press the Emergency Stop push button.
4. Press the Control OFF push button.
- CAUTION -
If the machining center is a High Speed machining center, be sure the laby-
rinth air seal air pressure is left ON for a minimum of 15 minutes after the
spindle has stopped. This will allow the spindle to cool properly without
drawing contaminants into the spindle.
Failure to properly cool the spindle on a High Speed machining center can
result in spindle failure.
5. Turn main air valve “B”, Figure 2.2, OFF
6. Turn main disconnect switch “A”, Figure 2.1, OFF.
2-4 M-400A
REVIEWING CONTROL STATUS
The following descriptions refer to the control status displays. The keys discussed in this section
are located on the Manual Data Input keyboard.
POS (Position) Key

There are three (3) pages of position display data. After the POS key is pressed, the posi-
tion display page that was last active will appear on the control display screen. To access the
other position display pages, press the appropriate soft key. The three position display pages
are as follows:
1. ALL (Overall Position Display): This page shows the active program number and block
number are displayed in the upper right-hand corner of the control display screen if the
control is in AUTO.
a) Relative: The axis position on the Relative Coordinate System. Position is displayed as
X, Y, and Z coordinates.
b) Absolute: Axis position on the Work Coordinate System. After power-up, the origin of the
Work Coordinate System is the intersection of the spindle face and the spindle center-
line. Position is displayed as X, Y, and Z coordinates. This origin can be relocated by
any one of the following:
Active set of tool offsets
Position Reset operation
Work coordinate offset
c) Machine: Displays the axis position in relation to the Reference Zero position.
Refer to the Appendix for information on axis home positions.
d) Distance to Go: This is the distance remaining between the current axis position and the
programmed axis position. This register is displayed only while the control is in
Automatic or Manual Data Input mode.
2. ABS (Absolute Position Display). Refer to part “b” under “ALL (Overall Position Display)”.
3. REL (Relative Position Display). Refer to part “a” under “ALL (Overall Position Display)”.
M-400A 2-5
PROG (Program) Key
Press the Program soft key to display the active program number, and active block se-
quence number and eleven blocks of the active program on the control display screen. To
display other pages of the program, select Edit mode and use the Page é or Page ê keys to
read through the program.
During execution of the active part program, the cursor will be positioned under the se-
quence number of the active block. To return to the start of the program, press the following
keys in the sequence shown:
1. Reset key
2. Operator soft key
3. Rewind soft key
OFFSET SETTING key

When the Offset Setting key is pressed, the Offset and Setting soft keys are displayed.
From the first Offset Setting screen, press the soft key expansion key once to display
the Macro soft key.
From the first Offset Setting screen, press the soft key expansion key twice to display
the Work coordinate soft key.
OFFSET Soft Key
Press the Offset soft key to access the length and diameter offsets. The displayed page
will be the page which was active when the Offset display was last deactivated. To view other
pages, press the Page é or Page ê push button.
2-6 M-400A
SETTING Soft Key
Press the Setting soft key to access the system variables page, which allows the operator
or programmer to assign the system variables listed below. To modify these variables, move
the cursor to the variable which is to be modified, enter the desired value, and press the Input
key.
PARAMETER WRITE = _ (0:DISABLE 1: ENABLE)
TV CHECK = _ (0:OFF 1:ON)
PUNCH CODE = _ (0:EIA 1:ISO)
INPUT UNIT = _ (0:MM 1:INCH)
I/O CHANNEL = _ (0-3:CHANNEL NO.)
SEQUENCE NO. = _ (0:OFF 1:ON)
TAPE FORMAT = _ (0:NO CNV 1:ON)
SEQUENCE STOP = _ (PROGRAM NO.)
SEQUENCE STOP = _ (SEQUENCE NO.)
PARAMETER WRITE
This parameter allows the control parameters to be edited. When set to “0", param-
eter editing is disabled. When set to ”1", parameter editing is enabled. Refer to Chap-
ter 3 for information on editing machine parameters.
TV CHECK
This parameter allows the activation or deactivation of parity checking. When set to
“1", parity is checked from the beginning of each block to the beginning of the next
block. When set to ”0", vertical parity checking is disabled.
PUNCH CODE
This parameter allows the selection of EIA or ISO data input format through the
RS-232 serial port. When set to “0", the data input format is set to EIA. When set to
”1", the data input format is set to ISO.
INPUT UNIT
This parameter allows the selection of metric or inch operating mode. When set to
“0", the operating mode is Metric. When set to ”1", the operating mode is set to Inch.
I/O CHANNEL
This parameter allows the selection of the logical I/O to be used by the control.
The valid selections for the I/O port assignments are 0, 1, or 2. Refer to Chapter 7 for
a complete explanation of the I/O ports.
SEQUENCE NO.
This parameter allows the selection of “automatic sequence number insertion”.
When active, sequence numbers will be automatically inserted into a program which
is entered into memory from the Manual Data Input keyboard. When set to “0", auto-
matic sequence number insertion is inactive. When set to ”1", automatic sequence
number insertion is active.
M-400A 2-7
TAPE FORMAT
Not Active
SEQUENCE STOP (2 entries)
These two entries are used together to provide the machine operator with the ca-
pability of stopping automatic part program execution after the program block speci-
fied has been completed.
The first entry (Program No.) identifies the program to be monitored.
The second entry (Sequence No.) identifies the sequence number (N word) of the
last block to be executed by the CNC control during normal automatic operation.
Once this block is executed, the CNC control will stop program execution.
Press the Cycle Start push button to resume program execution.
MACROS Soft Key
Press the Macros soft key to display the macro variable registers.
WORK Soft Key
Press the Work soft key to display the work coordinate offset registers.
2-8 M-400A
SYSTEM Key
Press the System key to access the following information:
- Machine parameters and diagnostics
- PMC parameters, ladder, and diagnostics
- Control system configuration
One of four chapters will be displayed on the control display screen. The displayed page
will be the page which was active when the key was last deactivated. If necessary, press the
soft key to display the desired chapter. To view other pages within a chapter, press the Page
é or Page ê key.
Parameter Soft Key
Press the Parameter soft key to display machine parameters. These parameters establish
many of the characteristics, specifications, and functions of the machine tool. The page that
was active when the parameter chapter was last exited will be displayed. To view other pages
within the chapter, press the Page é or Page ê key to move to the desired page. Refer to
Chapter 3 for information on editing machine parameters.
Diagnostics Soft Key
Press the Diagnostics soft key to display the machine diagnostics chapter. The page that
was active when the diagnostics chapter was last exited will be displayed. To view other
pages within the chapter, press the Page é or Page ê key.
PMC Soft Key
Press the PMC soft key to display the PMC information screen. The purpose of this screen
is to view the PMC ladder, parameters, and diagnostics.
System Soft Key
Press the System soft key to display the control system information screen.
M-400A 2-9
MESSAGE key
If “ALM” is displayed at the bottom right-hand corner of the control display screen during
machine operation, press the Message key. After the Message key is pressed, one of the
three chapters will be displayed. To display one of the other chapters, press the appropriate
soft key.
Alarm Soft Key
Alarm Message chapter. This chapter displays alarms that create a feed hold condition.
One alarm will be displayed on the control display screen at a time. The display is formatted
to indicate which tool station has generated the alarm. Descriptions of each alarm are given in
the alarm list in the Appendix.
Message Soft Key
Operator Message chapter. Operator messages do not initiate a feed hold condition. They
call the operator’s attention to a particular condition that exists.
History Soft Key
The control is capable of storing the last 25 alarms generated by the machine control.
There are a maximum of five pages, with up to five alarms per page. Press the Page é or
Page ê key to display next or previous page.
- NOTE -
Alarm and Operator messages caused by an error generated in Background Edit
will have no affect on a part program which is executing in foreground.
2-10 M-400A
- NOTES -
M-400A 2-11
- NOTES -
2-12 M-400A
CHAPTER 3 - OPERATIONAL MODES AND EDITING
AUTOMATIC MODE
- CAUTION -
Before executing any part program in Automatic mode, it is recommended
that the program be cycled through one time in Single mode. Refer to the in-
structions for “Running a Part Program for the First Time”, page 3-11.
Automatic mode allows selection and execution of the active part program. The guard doors must
be closed to enable Automatic mode. When Automatic mode is active, the following soft keys are
displayed on the control display screen:
Program
Current
Next
Check
Press the right hand soft key to display the Background Edit and Extended Part Program Edit soft
keys. Refer to page 3-15 for an explanation of Background Edit. Refer to page 3-16 for an
explanation of Extended Part Program Edit.
SINGLE MODE
Single mode allows the operator to execute one block of data each time the Cycle Start push
button is pressed. Canned cycles are executed one pass at a time. Single mode is activated by
pressing Single push button. The Single push button indicator light is ON when Single mode is active.
The guard doors must be closed to enable Single mode.
Refer to the programmer’s manual (M-399) for descriptions of the machining cycles.
M-400A 3-1
EDIT MODE
Edit mode allows creation of new part programs or modification of existing part programs held in
memory. There are two ways to search through the program: Word Scan and Word Search.
WORD SCAN
The Word Scan function permits the operator to search through the program one word at a time.
- NOTE -
The cursor is displayed below the address character of the selected word.
Press the cursor è key to move the cursor forward word by word.
Press the cursor ç key to move the cursor backward word by word.
Press the cursor ê key to move the cursor forward block by block.
Press the cursor é key to move the cursor backward block by block.
Press the Page é or Page ê key to display the preceding or following pages and search
for the first word of that page.
WORD SEARCH
Word Search a specified word to be searched for from the current cursor position using the
following procedure:
1. Select Edit mode.
1. Key in the data word to be searched for.
2. Press the SRH ê soft key to search forward or SRH é soft key to search backward. If the
data word entered in step 1 is located, the cursor will be displayed below the first character
in the data word.
3-2 M-400A
EDITING A PROGRAM
Setting Program Protection
- NOTE -
KeySet must be set to ON to enable program and parameter editing. KeySet
should be set to OFF whenever program editing is not required.
1. Press the Offset Setting key.
2. Press the right-hand soft key to display additional soft key functions.
3. Press the Operator soft key.
4. If necessary, use the Page é or Page ê key to display the software operator’s panel that
has the KeySet field.
5. Use the cursor keys to move the cursor to the KeySet field on the control display screen.
6. Press the cursor keys to set KeySet as needed.
General Edit Procedure

- NOTE -
KeySet MUST be set to ON to allow creating, editing, or deleting of part programs.
Refer to “Setting Program Protection”, above.
2. Set KeySet to ON.
3. Press the Reset key.
4. Activate the program as follows:
a) Press the Program key.
b) Key in the letter O followed by the number for the desired program.
Example: O1111
c) Press the cursor ê key.
5. Search for the word to be modified using the Word Scan or Word Search function.
6. Alter, insert, or delete the word/block/program as described in the sections that follow.
- CAUTION -
If the Reset key is not pressed before selecting Automatic mode and the part
program is executed, the program will begin executing at the point in the
program where the cursor was located when Edit mode was exited.
7. Press the Reset key to “rewind” the part program back to the beginning.
8. Set KeySet to OFF.
M-400A 3-3
Altering a Word
- NOTE -
The cursor MUST be positioned under the word to be altered.
1. Use the Word Scan or Word Search function to locate the data word to be changed.
2. Key in the letter address and the new value.
3. Press the Alter key.
Inserting a Word
- NOTE -
The cursor MUST be positioned under the word immediately preceding the location
of the new data word.
1. Use the Word Scan or Word Search function to find the data word or EOB (;) immediately
preceding the point in the program where the new data word will be inserted.
2. Key in the data word to be inserted.
3. Press the Insert key.
Deleting a Word
- CAUTION -
The cursor MUST be positioned under the word which is to be deleted.
1. Use the Word Scan or Word Search function to find the data word which is to be deleted.
2. Press the Delete key.
Deleting Up to an End of Block

1. Position the cursor at the point where the deletion is to begin.
2. Press the EOB key.
- NOTE -
The data between the cursor and the next End of Block character will be deleted.
The cursor will move to the address character of the next data word in the pro-
gram.
3-4 M-400A
Deleting Data Blocks
- NOTE -
In the procedure which follows, all data from the cursor to, and including, the block
specified by the sequence number will be deleted. The cursor will move to the next
sequence number in the program.
1. Position the cursor at the point where the deletion is to begin.
2. Key in the sequence number where the deletion is to end.
Deleting a Program
1. Press the Program key.
2. Key in the name of the program to be deleted.
Example: O1111
3. Press the Delete key. The selected program will be deleted.
Deleting a Range of Programs

2. Key in:
a) The name of the first program in the range to be deleted.
b) Comma.
c) The name of the last program in the range to be deleted.
Example: O1111,O2222
3. Press the Delete key. All programs within the selected range will be deleted.
Deleting all Programs

2. Key in O-9999.
3. Press the Delete key. All program wills be deleted.
M-400A 3-5
JOG MODE
- NOTE -
The coolant guard doors must be closed to enable Jog mode.
Refer to Handwheel Mode, page 3-8, for information on incrementally jogging the
machine axes.
X, Y, AND Z AXIS
Jog mode permits continuous non-programmed movement of the axes. Jog mode is activated by
setting the mode select switch to Jog mode. While in Jog mode, press the axis direction push buttons
to obtain the desired X, Y, or Z axis movement.
The Jog Feedrate switch has a direct affect on the X, Y, and Z axis jog speeds. The Rapid push
button will increase normal jog speeds on the X, Y, and Z axes.
SPINDLE CONTROL
Pressing the Spindle Clockwise push button while Jog mode is active will allow the spindle to be
jogged in the forward (M03) direction. Pressing the Spindle Counterclockwise push button while Jog
mode is active will allow the spindle to be jogged in the reverse (M04) direction.
Spindle jog speed can be controlled with the spindle jog speed control switch.
Press the Spindle Stop push button or the control Reset key to cancel spindle motion.
3-6 M-400A
MANUAL DATA INPUT MODE
- NOTE -
The coolant guard doors must be closed to enable execution of data in Manual
Data Input mode.
Manual Data Input mode allows the operator to input a single block of non-stored data into Manual
Data Input memory. The data can then be executed by pressing the Cycle Start push button. Once
the data in Manual Data Input memory has been executed, it is automatically erased from memory.
USING MANUAL DATA INPUT

- NOTE -
Pressing the Reset key clears the Manual Data Input buffer.
1. Select Manual Data Input mode.
4. Enter the data into the Manual Data Input buffer using the data input keys.
- NOTE -
If an error is made while keying in the data and the Insert key has not been
pressed, press the Cancel key and key in the correct data.
To alter data after it has been entered into the Manual Data Input memory, key in
the correct data and press the Insert key. If it is necessary to delete a word, press
the Reset key and re-enter the data.
5. Close the coolant guard door and press the Cycle Start push button to execute the data.
M-400A 3-7
HANDWHEEL MODE
- NOTE -
Refer to Jog Mode, page 3-6, for information on continuously jogging the machine
axes.
Handwheel mode permits the head or table to be moved incrementally through the use of a
manual pulse generator. The axis to be moved is selected with axis select switch “B”, Figure 3.1 . The
movement increment is selected with increment switch “C”. The selected axis will move
incrementally when handwheel “A” is rotated. The direction and distance is determined by the
direction and amount of rotation of the handwheel.
MOVING THE AXES IN HANDWHEEL MODE

- CAUTION -
tures, tooling, or workpiece.
1. Select Handwheel mode.
2. Set switch “B”, Figure 3.1, to the desired axis.
TP3650A
Figure 3.1 - Manual Pulse Generator
3-8 M-400A
3. Set switch “C” to the desired increment (X1, X10, or X100). Refer to the following table.
Switch Incremental Jog Rate per Division

Setting Inch Mode Metric Mode
X1 .0001 .001
X10 .001 .01
X100 .01 .1
4. To view axis position on the control display screen:

a) Press the Position key.
b) Press the Page key until the desired position display appears on the control display
screen.
5. Turn handwheel “A” in the appropriate direction to obtain the desired movement. Observe
the axis position registers to determine when the axis has been moved the required dis-
tance.
• If the X axis was selected in step 2, turn the handwheel in the plus direction to move the
table to the left and turn the handwheel in the minus direction to move the table to the right.
• If the Y axis was selected in step 2, turn the handwheel in the plus direction to move the
table toward the front of the machine and turn the handwheel in the minus direction to move
the table toward the back of the machine.
• If the Z axis was selected in step 2, turn the handwheel in the plus direction to move the
head away from the table and turn the handwheel in the minus direction to move the head
toward the table.
M-400A 3-9
PROGRAMS
ENTERING A PROGRAM FROM THE KEYBOARD
2. Set KeySet to ON. Refer to “Setting Program Protection”, page 3-3.
4. Key in the letter O and the program number at the Manual Data Input panel.
Example: O1111
6. Press the EOB key.
8. Key in the letter address and value.
10. Press the EOB key and the Insert key at the end of each data block.
11. Repeat steps 8 through 10 until all data has been entered.
Refer to the Programmer’s Manual (M-399) for descriptions of the data words used with
this machine.
Refer to Chapter 7 of this manual for information on loading part programs through the
RS-232 serial port.
3-10 M-400A
ACTIVATING A STORED PROGRAM
3. Key in the letter O followed by the number for the desired program.
Example: O100
4. Press the cursor ê key.
5. Select Automatic mode.
RUNNING A PART PROGRAM FOR THE FIRST TIME

- CAUTION -
Before executing any part program, be sure that all offsets are correct and
that no interference exists in the working area of the machine tool.
4. Key in the letter O followed by the number for the desired program.
Example: O100
- NOTE -
Single mode is used for first part set up (Block-by-Block execution).
7. Press the Single Block push button.
8. Close the guard door.
- NOTE -
Program Check displays the Absolute Position and Distance to Go to complete the
move.
9. Press the Check soft key.
10. Press the Option Stop push button.
11. Turn the Rapid Override switch to 25%.
- NOTE -
Turning the Feedrate Override switch to zero percent stops axis motion. Axis mo-
tion will resume when the switch is turned to another setting.
12. Turn the Feedrate Override switch to 10%.
13. Press the Cycle Start push button to execute each block of data.
M-400A 3-11
STOPPING A PROGRAM RUNNING IN AUTOMATIC MODE
- CAUTION -
Pressing either the Reset key or Emergency Stop push button while a pro-
gram is running in Automatic mode will leave the tool against the workpiece
if performed at the wrong time. DO NOT stop the program with a tool against
the workpiece unless absolutely necessary. Damage to the workpiece and/or
tooling may result.
There are several ways to stop a program running in Automatic mode:
1. Program a stop command in the part program where it is to be stopped.
2. Press the Feed Hold push button.
- NOTE -
Automatic operation can be restarted by pressing the Cycle Start push button when
the Feed Hold push button has been used.
4. Press the Emergency Stop push button.
RESTARTING A STOPPED PROGRAM

If the program was stopped by pressing the Emergency Stop push button, perform steps 1 through
6.
If the program was stopped by pressing the Reset key, perform steps 3 through 6.
1. Release the Emergency Stop push button.
3. Key in the letter O; then, press cursor é. The control will go to the beginning of the pro-
gram.
4. Key in the letter N and the block number. For example, “N5".
5. Press cursor ê. The control will search the program for the block specified in step 5.
6. Press the Cycle Start push button. Program execution will resume at the block specified in
step 5.
ZERO RETURN MODE

- NOTE -
The coolant guard doors must be closed to enable axis motion in Zero Return
mode.
Zero Return mode is used to synchronize the control to the machine absolute coordinate system.
This mode is used:
• at power-up
• after machine lock is used
Refer to Zero Return Procedure, in Chapter 2.
3-12 M-400A
DRY RUN AND MACHINE LOCK
- CAUTION -
If Machine Lock is not activated with Dry Run, slide motion will occur at a
feedrate that is set using the Feedrate Override switch. The operator must
make certain that no interference exists between the tooling, workpiece, or
spindle before running the machine in Dry Run.
Cycle Start must be inactivate before Dry Run and Machine Lock modes can be activated. By
activating Dry Run and Machine Lock modes together, the operator can execute part programs
without axis or spindle motion.
ACTIVATING DRY RUN AND MACHINE LOCK

a) Select Automatic mode.
b) Press the Program key.
c) Press the Reset key.
d) Key in the letter O followed by the program number.
e) Press the cursor ê key.
2. Activate the Dry Run and Machine Lock functions.
3. Close the coolant guard door.
4. Press the Single push button if it is desired to run the program block-by-block.
- NOTE -
If Single mode is active, the Cycle Start push button must be pressed for each pro-
gram block.
5. Press the Cycle Start push button.
EXITING DRY RUN AND MACHINE LOCK MODE

1. Deactivate the Dry Run and Machine Lock functions. The indicator lights will turn OFF.
2. Zero Return (Reference Home) the axes as outlined in Chapter 2.
M-400A 3-13
Z AXIS MACHINE LOCK
Z Axis Machine Lock can be activated when Single Block mode is active to inhibit Z axis motion.
• When Z Axis Machine Lock is OFF all Z axis motion occurs as programmed.
• When Z Axis Machine Lock is ON, all Z axis motion is inhibited. When a part program is
executed, all other machine activity occurs as programmed.
Deactivating Z Axis Machine Lock
If the Z axis position register displays the same Z axis position as when Z Axis Machine
Lock was activated, it is not necessary to home the Z axis.
If the Z axis position register does not display the same Z axis position as when Z Axis
Machine Lock was activated, the machine axes must be homed. Refer to Chapter 2 for infor-
mation on homing the machine axes (Zero Return).
3-14 M-400A
BACKGROUND EDITING
The Background Edit function enables the operator or programmer to edit or create a part program
while a second program is being executed by the machine tool. Background Edit takes place while
the control is in Automatic mode. An alarm or warning in Background Edit mode does not affect the
program being executed in the foreground or vice-versa.
ENTERING BACKGROUND EDITING MODE

1. Set KeySet to ON. Refer to page 3-3 for information on setting Program Protection.
3. Press the far right soft key to display additional functions of the soft keys.
4. Press the Background Edit soft key.
- NOTE -
The editing functions which may be performed in Background Edit mode are the
same as the foreground editing functions. Descriptions of the foreground editing
functions begin on page 3-2.
EDITING AN EXISTING PROGRAM

1. Key in the letter O and the desired program number.
CREATING A NEW PROGRAM FROM THE KEYBOARD

1. Key in the letter O and the desired program number.
2. Press the EOB (;) key.
3. Refer to Entering a Part Program from the Keyboard, page 3-10.
ENDING BACKGROUND EDITING

- CAUTION -
If the Reset key is pressed while background edit is active, the part program
that is being executed will stop and the offset will be canceled. The operator
must escape Background edit (Press the Background End soft key) to return
to the main program. With the main program displayed, the operator must
jog the head to a safe area and restart the program at the beginning of the
tool operation.
1. Press the Background End soft key.
M-400A 3-15
EXTENDED PART PROGRAM EDITING
INTRODUCTION
Extended Part Program Editing provides the following capabilities:
• Copy or move all or part of a program to another program.
• Merge a program at any location within another program.
• Search for or replace one or all occurrences of a data word in a program.
COPYING AN ENTIRE PROGRAM

This procedure creates a new program by duplicating an existing program.
- NOTE -
KeySet MUST be set to ON to allow program editing. Refer to “Setting Program
Protection”, page 3-3.
Example: O1111
6. Press the Extended Edit soft key.
7. Press the Copy soft key.
8. Press the All soft key.
9. Key in only the number for the new program. DO NOT key in the letter “O”.
10. Press the Input key.
11. Press the Execute soft key.
3-16 M-400A
COPYING PART OF A PROGRAM
This procedure creates a new program by duplicating part of an existing program.
- NOTE -
Example: O1111
7. Press the Copy soft key.
8. Select the beginning of the range to be copied by moving the cursor to the beginning of the
range and pressing the Cursor~ soft key.
9. Select the end of the range to be copied by:
Moving the cursor to the end of the range and pressing the ~Cursor soft key.
- or -
Pressing the ~Bottom soft key to indicate the end of the program as the end of the range
to be copied.
M-400A 3-17
MOVING PART OF A PROGRAM
This procedure creates a new program by extracting part of an existing program.
- NOTE -
Example: O1111
7. Press the Move soft key.
8. Select the beginning of the range to be copied by moving the cursor to the beginning of the
range and pressing the Cursor~ soft key.
9. Select the end of the range to be copied by:
Moving the cursor to the end of the range and pressing the ~Cursor soft key.
- or -
Pressing the ~Bottom soft key to indicate the end of the program as the end of the range
to be copied.
3-18 M-400A
MERGING A PROGRAM
This procedure inserts a specified existing program within the currently active program.
- NOTE -
Example: O1111
7. Press the Merge soft key.
8. Select the location where the specified program will be inserted by:
Moving the cursor to the position where the program is to be inserted and pressing the
~Cursor soft key.
- or -
Pressing the ~Bottom soft key to indicate the end of the program as the position where the
program is to be inserted.
9. Key in only the number for the program to be inserted. DO NOT key in the letter “O”.
M-400A 3-19
SEARCH AND REPLACE
This procedure locates or replaces the specified data.
- NOTE -
Example: O1111
- NOTE -
Be sure the cursor is located at the appropriate position in the program. The
search or replace function will begin at the cursor position.
7. Move the cursor to the desired position in the program.
8. Press the Change soft key.
- NOTE -
A maximum of 15 characters can be input when specifying the Before or After
data.
Data words specified as Before or After data must be valid data words.
9. Key in the data word to be replaced.
10. Press the Before soft key.
11. Key in the new data word.
12. Press the After soft key.
13. Press the Execute soft key to replace all occurrences of the specified data word.
- or -
Press the 1-Execute soft key to replace only the first occurrence of the specified data word.
- or -
Press the Skip soft key to search for the first occurrence of the specified data word.
3-20 M-400A
REORGANIZING PART PROGRAM MEMORY
When Background Editing is used to edit an existing program, the program being edited will be
copied from memory and stored in a new location in the control memory after editing is completed.
The memory location of the old version of the program is unusable until the control memory is
reorganized to eliminate all unusable data stored in control memory.
- NOTE -
Reorganizing of program memory can only be done while the control is in Edit
mode. It is usually not necessary to reorganize program memory immediately. Re-
organize program memory at some convenient point in time.
Use the following procedure to reorganize the program memory:
3. Press the Library soft key.
4. Press the Reorganize soft key.
5. Press the far left soft key to exit.
DISPLAYING THE PROGRAM DIRECTORY

Use the following procedure to display program memory:
3. Press the Library soft key. The program library (directory) will be displayed.
M-400A 3-21
EDITING MACHINE PARAMETERS
- CAUTION -
Use extreme caution when editing machine parameters. Making incorrect
changes in the parameter table may disable the machine or cause undesir-
able machine behavior.
2. Set KeySet to ON. Refer to “Setting Program Protection”, page 3-3.
3. Access the Setting page with the Parameter Write Enable parameter as follows:
a) Press the Offset Setting key.
b) Press the Setting soft key.
4. Key in the number 1 to enable parameter editing.
5. Press the Input key. The control is placed in alarm No. 100.
6. Press the System key.
7. Press the Parameter soft key.
8. Use one of the following methods to position the cursor at the parameter to be modified:
• Key in the parameter number, press the Search soft key.
• Use the Page and/or cursor keys.
9. Key in the new parameter value.
11. Repeat steps 8 through 10. as needed.
13. Press the Setting soft key.
14. Use the Page keys to display the Setting page with the Parameter Write Enable parameter.
15. Key in the number 0 (zero) to disable parameter editing.
3-22 M-400A
18. Press the Reset key to cancel alarm No. 100.
- NOTE -
Depending on which parameters have been modified, the control may output alarm
No. 000. If this alarm message is displayed, it will be necessary to re-initialize the
control.
19. If necessary, re-initialize the control:
a) Press the Emergency Stop push button.
b) Press the Control OFF push button.
c) Wait approximately ten seconds.
d) Press the Control ON push button.
e) Release the Emergency Stop push button.
f) Perform a Zero Return (Reference Home) operation as outlined under “Zero Return Pro-
cedure”, in Chapter 2.
M-400A 3-23
- NOTES -
3-24 M-400A
CHAPTER 4 - WORK COORDINATE SYSTEMS
ZERO RETURN (REFERENCE HOME)
When the Control ON push button is pressed to start up the machine, the control does not know
the position of the slides. To synchronize the control/machine tool system, each slide must be moved
to its Zero Return (Reference Home) position. This position is also referred to as Reference Zero.
- NOTE -
The coordinate position values shown in this section assume that the Work
Coordinate is set to X0. Y0. Z0. and that no tool offset is active.
After the slides have been moved to the zero return position, the Absolute position registers are
automatically set at X0. Y0. Z0.
X, Y, AND Z AXES
The three standard machine axes are labeled as follows:
X Axis: Horizontal motion of the table parallel to the spindle face and parallel with the front of
the machine.
Y Axis: Horizontal motion of the table parallel to the spindle face and perpendicular with the
front of the machine.
Z Axis: Vertical motion of the head, which houses the machine spindle.
Throughout this manual the table will be referred to as the X and Y axes and the head, which
houses the machine spindle, as the Z axis. These letter designations for the three axes are
recommended by the Electronic Industries Association (EIA) and the International Standards
Organization (ISO). In an effort to promote interchangeability and prevent misunderstandings
between NC manufacturers and purchasers, EIA has set forth recommended standards for such
things as axis and motion nomenclature, character codes for perforated tape, operational command
and data format, and electrical interface between numerical controls and machine tools.
M-400A 4-1
COORDINATE SYSTEM DISPLAYS
The power-up procedure calls for a Zero Return operation to synchronize the control/machine tool
system. This operation sets the registers at their initial values. After performing the Zero Return
procedure, press the Position key; then, press the All soft key to display the following position
registers on the control display screen:
- ABSOLUTE
- DISTANCE TO GO
- MACHINE
- RELATIVE
- NOTE -
The “Distance To Go” registers are only displayed in Automatic or Manual Data In-
put mode.
For this discussion, we are concerned with the Machine and Absolute position registers. The
Machine registers display the position of axis reference points relative to the machine Zero Return
(Reference Zero) position.
The Zero Return coordinates are X0. Y0. Z0. The Machine registers display the position of axis
reference points relative to this position. These registers cannot be modified. They always display
the “true” axis position relative to the Reference Home position.
Of greater interest to the programmer are the Absolute position registers, which can be modified.
The Absolute position registers display the position of the tool reference point as a coordinate on the
work coordinate system. The work coordinate system is a rectangular coordinate system with it’s
origin (origin = X0 Y0 Z0) equal to the origin of the Absolute registers.
Unless a Work Coordinate offset is used after a Zero Return operation, the Z axis origin of
the work coordinate system is the face of the spindle.
Unless a tool offset is used, the tool reference point is the intersection of the spindle face
and the spindle centerline.
To simplify programming, the programmer can modify the coordinate system to relate the location
of the tool to coordinates on the workpiece.
4-2 M-400A
PROGRAMMABLE WORK COORDINATE SYSTEMS
The control is equipped with 6 programmable work coordinate systems. These work coordinate
systems are selected through the use of the G54 through G59 commands. G54 is the power-up
default and is active after a control reset.
The work Coordinate offset moves the origin of the work coordinate system according to the X, Y,
and Z values stored in the active work coordinate file. Immediately after a work coordinate is
commanded, the control adds it to the Absolute position registers. The values stored in a
commanded G54 coordinate system are active until canceled by another coordinate system
command. The values stored in a commanded G55, G56, G57, G58, or G59 coordinate system are
active until canceled by another coordinate system command, a control reset, or an “end of program”
command.
Multiple work coordinate systems allows the programmer to use the same part program to
machine several workpieces mounted on the machine table. Instead of programming each
workpiece, the program shifts the coordinate system to the next workpiece to be machined. Refer to
the illustration in Figure 4.1 .
- CAUTION -
Any non-zero value entered into the Z axis field of the active work coordinate
file must be a negative number.
The values stored in the work coordinate file are subtracted from the Absolute position registers,
thus shifting the origin of the work coordinate system by the amount stored in the work coordinate file.
For example, if the X axis is at 8 inches and the operator stores X2.5 in the active work coordinate file,
the Absolute position registers would then display X5.5 [8 - 2.5].
It may be desirable to store the location of a reference surface on the workpiece as the Z axis work
coordinate offset. When this value is stored and activated, the reference surface of the workpiece
becomes “Z0". The Z axis work coordinate is stored as a NEGATIVE value.
The X and Y work coordinate offsets are used to shift the X and Y zero coordinates as specified by
the values in the active work coordinate. The X axis work coordinate is stored as a POSITIVE value.
The Y axis work coordinate is stored as a NEGATIVE value.
SAMPLE WORK COORDINATE SYSTEM SHIFT
Figures 4.2 and 4.3 illustrate the work coordinate system shift when the registers for the active
programmable work coordinate system contain the following values: X8. Y-6. Z-15.75 .
M-400A 4-3
Machine X0. Y0. Z0.
Shifted Shifted Shifted

X0. Y0. Z0. X0. Y0. Z0. X0. Y0. Z0.
G54 G55 G56

Coordinate Coordinate Coordinate
System System System
Shift Shift Shift
Shifted Shifted Shifted

X0. Y0. Z0. X0. Y0. Z0. X0. Y0. Z0.
G57 G58 G59

Coordinate Coordinate Coordinate
System System System
Shift Shift Shift
TI4094
Figure 4.1 - Sample Coordinate System Shifts
4-4 M-400A
8.000
Machine X0. Y0.
6.000
Shifted X0. Y0.
TI4073
Figure 4.2 - X and Y Axis Work Coordinate System Shift
Spindle Home Position

Machine Z0.
15.75
Shifted Z0.
Table Surface
TI4074
Figure 4.3 - Z Axis Work Coordinate System Shift
M-400A 4-5
ESTABLISHING A WORK COORDINATE OFFSET
The machine has an established X, Y, and Z axis reference position. Unless modified by a work
coordinate offset, the machine X, Y, and Z axis reference position will be the program reference
position.
The program reference position is the location from which all programmed absolute movements
will be referenced. Typically a location on the workpiece will be established as the program reference
position, through the use of a work coordinate offset.
- CAUTION –
It is recommended that the Z axis work coordinate be established before the
X and Y axis work coordinates are established.
DETERMINING THE Z AXIS WORK COORDINATE OFFSET

1. Power up the machine and zero return the machine axes, as outlined in Chapter 2.
2. If a tool is in the spindle:
a) Obtain a firm grip on the tool holder body.
b) Press and hold the Tool Release push button long enough to release the tool holder.
c) Release the Tool Release push button.
3. Mount the fixture and workpiece at the desired location on the machine table.
5. Press the Work soft key.
6. Move the cursor to the correct Z work coordinate (G54 through G59).
7. Select a gauge block that is at least 1 inch [25 mm] in thickness.
- CAUTION -
The machine operator must be sure that no interference occurs between the
spindle, fixture, and workpiece.
8. Select Jog mode.
9. Jog the table to position the reference surface of the workpiece under the spindle.
10. Jog the spindle face down (-Z) to within 2 inches [50 mm] of the reference surface of the
workpiece.
11. Place the gauge block on the reference surface of the workpiece.
12. Select Handwheel (Manual Pulse Generator) mode.
13. Set the handwheel Axis Select switch to Z axis.
14. Set the handwheel Increment Select switch to “X10”.
15. CAREFULLY turn the handwheel in the minus direction to move the spindle face down
near the gauge block on the workpiece.
16. Constantly check the clearance between the spindle and the gauge block while gradually
moving the spindle in the -Z direction (downward).
4-6 M-400A
Machine
Spindle
Gauge Block
Workpiece
Machine Table
TI4088
Figure 4.4 - Z Axis Work Shift Calculation
17. Stop moving the spindle when the gauge block has a slip fit between the spindle and the
workpiece. The spindle is positioned correctly when a slight drag is felt when moving the
gauge block between the spindle and workpiece. Refer to Figure 4.4 .
18. Press address key “Z”.
19. Key in the thickness of the gauge block as a POSITIVE value.
20. Press the Measure soft key.
21. Turn the handwheel in the PLUS direction to move the spindle face a safe distance away
from the gauge block and workpiece.
M-400A 4-7
DETERMINING THE X AND Y AXIS WORK COORDINATE OFFSETS
Referencing to External Surfaces
- NOTE -
This procedure establishes the X and Y axis reference position at a corner of the
workpiece.
1. If not already performed, establish the Z axis work coordinate offset according to the proce-
dure beginning on page 4-6.
3. Mount the edge finder in the machine spindle.
6. Move the cursor to the correct Z work coordinate (G54 through G59).
8. Select Jog mode.
9. Jog the table to position the spindle clear of the workpiece on the X reference side.
10. Jog the spindle face down (-Z) to approximately 1 inch above the workpiece.
14. Turn the handwheel in the minus direction to move the edge finder approximately .200
inches [5 millimeters] below the work surface.
15. Press the Spindle Clockwise push button.
16. Set the Spindle Jog Speed control to obtain 1000 rpm.
17. Set the handwheel Axis Select switch to X axis.
18. Set the handwheel Increment Select switch to “X10” or “X1”.
19. CAREFULLY turn the handwheel in the appropriate direction to move the edge finder
against the side of the workpiece.
20. Stop turning the handwheel when the edge finder trips.
21. Press the Spindle Stop push button.
18. Press address key “X”.
19. Key in half the diameter of the edge finder. Refer to Figure 4.5 to determine if this value is
input as a positive or negative value.
4-8 M-400A
+Y Compensation Value
-X +X
Compensation Compensation
Value Value
-Y Compensation Value
Front of Machine
TI4947
Figure 4.5 - Signs for Edge Finder Compensation Value
22. Turn the handwheel in the plus direction to move the edge finder up a safe distance away
from the workpiece.
23. Select Jog mode.
24. Jog the table to position the spindle clear of the workpiece on the Y reference side.
25. Jog the spindle face down (-Z) to approximately 1 inch above the workpiece.
29. Turn the handwheel in the minus direction to move the edge finder approximately .200
inches [5 millimeters] below the work surface.
30. Press the Spindle Clockwise push button.
31. Set the Spindle Jog Speed control to obtain 1000 rpm.
32. Set the handwheel Axis Select switch to Y axis.
33. Set the handwheel Increment Select switch to “X10” or “X1”.
34. CAREFULLY turn the handwheel in the appropriate direction to move the edge finder
against the side of the workpiece.
M-400A 4-9
35. Stop turning the handwheel when the edge finder trips.
36. Press the Spindle Stop push button.
37. Press address key “Y”.
38. Key in half the diameter of the edge finder. Refer to Figure 4.5 to determine if this value is
input as a positive or negative value.
41. Turn the handwheel in the plus direction to move the edge finder up a safe distance away
from the workpiece.
4-10 M-400A
Referencing to an Internal Diameter
- NOTE -
This procedure establishes the X and Y axis reference position at the center of a bore in the
workpiece. Refer to Figure 4.6 .
1. If not already performed, establish the Z axis work coordinate according to the procedure
beginning on page 4-6.
3. Mount a dial indicator in the machine spindle.
4. Jog the indicator into position OVER the bore to be used as the program reference posi-
tion.
5. Visually position the indicator as close to the centerline of the bore as possible.
6. If necessary, adjust the position of the indicator such that no contact with the workpiece will
occur when the indicator is moved into the bore.
7. Use the handwheel to CAREFULLY move the indicator needle into the bore, as shown in
Figure 4.6 .
8. Position the indicator needle against the bore.
9. Sweep the bore and adjust the X and Y axis position until runout shown on the indicator is
within an acceptable range.
11. Use the handwheel to CAREFULLY move the indicator out of the bore at least 1 inch
[25 mm].
Workpiece
TI4031
Figure 4.6 - Reference to an Internal Diameter
M-400A 4-11
12. Press the Menu Offset key to display the offset pages.
13. If necessary, press the Work soft key to display the Work Shift registers.
14. Move the cursor to the correct X work coordinate (G54 through G59).
15. Key in “X0”.
16. Press the Measure soft key. The X axis work coordinate will be displayed in the X axis
work coordinate register.
17. Move the cursor to the correct Y work coordinate (G54 through G59).
18. Key in “Y0”.
19. Press the Measure soft key. The Y axis work coordinate will be displayed in the Y axis
work coordinate register.
20. Remove the indicator from the spindle.
STORING COORDINATE SYSTEM DATA FROM

THE MANUAL DATA INPUT KEYBOARD
Coordinate system data can be input directly from the Manual Data Input keyboard.
3. Use the page and cursor keys to position the cursor at the data field to be modified.
4. Enter the new value and press the Input key to enter the value in the data register.
5. Repeat steps 3 and 4 as needed to enter the required coordinate system data.
4-12 M-400A
- NOTES -
M-400A 4-13
- NOTES -
4-14 M-400A
CHAPTER 5 - TOOLING AND TOOL OFFSETS
AUTOMATIC TOOL CHANGER
DESCRIPTION
Three tool magazine configurations are available:
• The machining center is equipped with a single 20 station drum tool magazine (Magazine
1), located to the left of the machine spindle, as shown in Figure 5.1 . This is the standard
configuration.
• The machining center is equipped with two 20 station drum tool magazines; Magazine 1 is
located to the left of the machine spindle and Magazine 2 is located to the right of the
machine spindle. This is an optional configuration.
• The machining center is equipped with a single 24 station swing arm tool magazine
(Magazine 1), located to the left of the machine spindle, as shown in Figure 5.2 . This is an
optional configuration.
During a programmed tool change, the tool magazine automatically takes the shortest path to
move the selected tool to the tool change position.
TP5005 TP5004
Figure 5.1 - Drum Tool Changer Figure 5.2 - Swing Arm Tool Changer
M-400A 5-1
TOOL HOLDERS
- WARNING -
Be sure to use the correct type of tool holder, based on the configuration of
the machine.
- CAUTION -
All tool holders must conform to the appropriate specification, based on the
spindle configuration of the machine tool. Consult a Hardinge Applications
Engineer concerning ALL special tooling applications that require deviation
from the specification.
Apply Loctite® 242 threadlocker to the threads on each retention knob before
installing on the tool holder body. Refer to Figure 5.3 .
- NOTE -
A spindle configuration tag is located on the spindle enclosure, to the left of the
Tool Release push button.
The machine spindle is configured to use 40 taper V-Flange tool holders that conform to one of the
following specifications:
V40 CT [Standard]
BT-40 JIS [Optional]
Retention
Knob
Tool
Holder
TI4083
Figure 5.3 - Tool Holder Retention Knob
5-2 M-400A
TOOLING GEOMETRY
The tool magazine is designed to handle tooling that does not exceed the specifications shown in
the table below. Refer to Figure 5.4 .
- NOTE -
The maximum diameter is measured in relation to the centerline of the tool holder.
MAXIMUM VALUE
SPECIFICATION
English Metric
Tool Length 9.84 in. 250 mm
Tool Diameter 3.5 in. 88.9 mm
Tool Weight 13.2 lb 6.0 Kg
Gauge Line
Maximum
Length
Tool
Holder TI3026
Figure 5.4 - Tooling Geometry
M-400A 5-3
MANUALLY INDEXING THE DRUM TOOL MAGAZINE
- NOTE -
The tool pockets in the drum tool magazine are labeled “1" through ”20" for identifi-
cation.
Machining centers equipped with one 20 station drum tool magazine have tool
magazine push buttons and an Emergency Stop push button at the left end of the
machine.
Machining centers equipped with two 20 station drum tool magazines have tool
magazine push buttons and an Emergency Stop push button at each end of the
machine.
The tool magazine can be manually indexed when Jog mode is active.
The tool magazine push buttons, shown in Figure 5.5, are used to manually index the tool
magazine in the clockwise or counterclockwise direction, as viewed from the top of the machine.
- WARNING -
these push buttons.
Indexing the Tool Magazine:
1. Activate Jog mode.
2. Press the appropriate tool magazine push button (“A” or “B”) to rotate the tool magazine in
the desired direction.
3. Release the push button when the required tool pocket is positioned at the desired posi-
tion.
A B
Emergency
Stop
TP3651
Figure 5.5 - Push Buttons for

Drum Tool Magazine
5-4 M-400A
MANUALLY CONTROLLING THE SWING ARM TOOL MAGAZINE
- NOTE -
The tool pockets in the swing arm tool magazine are labeled “1" through ”24" for
identification.
Machining centers equipped with the 24 station swing arm tool magazine have tool
magazine controls and an Emergency Stop push button at the left end of the ma-
chine.
The tool magazine can be manually controlled when Jog mode is active.
Selector switch “C”, Figure 5.6, determines the active function for tool magazine push button “D”:
Manually index the tool magazine in the clockwise or counterclockwise direc-

tion, as viewed from the location of the operator’s panel.
Lower or raise the tool pocket
Exchange the tools in the spindle and the active station of the tool magazine
OFF Disables the tool magazine push button
- WARNING -
Read and understand the Fault Re-
covery section in Chapter 9 before
using these controls. Emergency
Stop
Manually Controlling the Tool Magazine:
2. Set selector switch “C” to the desired setting. C
3. Press tool magazine push button “D” to initi-
ate the action selected in step 2.
4. Set selector switch “C” to OFF when finished
with manual control.
D
TP5002
Figure 5.6 - Controls for

Swing Arm Tool Magazine
M-400A 5-5
TOOL LOCATION TABLE
DESCRIPTION
The tool location table monitors the position of the tool magazine and the location of the tools
installed on the machine. Diagnostic registers are used to store the tool number data.
The tools are loaded into the tool magazine such that the tool number matches the socket number
of the tool magazine. The valid ranges of programmable tool numbers are:
Drum Magazine 1 [Standard]: 1 through 20
Drum Magazine 2 [Option]: 21 through 40
Swing Arm Magazine [Option]: 1 through 24
The tool numbers commanded from the part program through the use of the T data word match
the tool numbers in the tool location table.
Accessing the Tool Location Table:
1. Press the Tool List push button to access the tool location table.
2. Use the page and cursor keys to access the screen containing the diagnostic register to be
viewed.
TOOL CHANGE POSITION

The tool change position for drum tool magazines is the position aligned with the machine spindle,
as illustrated in Figure 5.7 .
The tool change position for the swing arm tool magazine is the lowest tool position in the
magazine, as illustrated in Figure 5.8
TI4084 TI4946
Tool
Tool Magazine
Spindle
Magazine
Spindle
Tool Change Position
Tool Change Position
Front of Machine
Figure 5.7 - Top View of Drum Tool Figure 5.8 - Left End View of Swing
Magazine and Spindle Arm Tool Magazine and Spindle
(Tool Magazine 1)
5-6 M-400A
DIAGNOSTIC ADDRESSES
Sample Tool Data for Drum Magazine 1 (Standard)
Address D0000 contains the number of the tool currently in the spindle.
Address D0001 contains the number of the tool located at the tool change position.
Address D0002 contains the number of the tool pocket located at the tool change position.
Addresses D0010 through D0029 contain the tool numbers and do not change.
Location Diagnostic Address Number Tool Number

Tool in Spindle D0000 14
Tool Number in Change Position D0001 3
Tool Pocket in Change Position D0002 3
Position 01 D0010 1
Position 02 D0011 2
Position 03 D0012 3
Position 04 D0013 4
Position 05 D0014 5
Position 06 D0015 6
Position 07 D0016 7
Position 08 D0017 8
Position 09 D0018 9
Position 10 D0019 10
M-400A 5-7
Sample Tool Data for Drum Magazine 2 [Option]

Tool Number in Active Position D0001 23
Tool Pocket in Active Position D0002 23
5-8 M-400A
Sample Tool Data for Swing Arm Magazine [Option]

Tool Number in Change Position D0001 3
Tool Pocket in Change Position D0002 3
Position 01 D0010 1
Position 02 D0011 2
Position 03 D0012 3
Position 04 D0013 4
Position 05 D0014 5
Position 06 D0015 6
Position 07 D0016 7
Position 08 D0017 8
Position 09 D0018 9
M-400A 5-9
TOOL INSTALLATION AND REMOVAL
- WARNING -
DO NOT attempt to hold the tool and tool holder by gripping the cutting tool.
Personal injury could result. Be sure to have a firm grip on the tool holder
body.
When removing tooling from the machine spindle, be prepared to accept the
weight of the tool and tool holder.
- CAUTION -
When using non-preset tooling, the currently active work coordinate MUST
be set before the tool offsets are determined. Refer to Chapter 4 for informa-
tion on setting work coordinates.
NON-PRESET TOOLING
- NOTE -
The tool pockets are labeled numerically for identification.
1. Verify that the work coordinate is set. If necessary, refer to Chapter 4 for information on
setting work coordinates.
2. Refer to the tooling sheet supplied by the part programmer to determine the required tool-
ing, assigned tool numbers, and assigned offset numbers.
3. Place a shim on the reference surface of the workpiece for tool touch-off.
4. Close the main guard doors.
5. Activate Manual Data Input mode.
- NOTE -
Tool stations are identified by the T word, with a valid range of:
One Drum Tool Magazine [Standard]: T01 through T20
Two Drum Tool Magazines [Option]: T01 through T40
Swing Arm Tool Magazine [Option}: T01 through T24
6. At the manual data input keyboard, key in the tool change command and the desired tool
station:
a) Key in: M06
b) Press the Insert key.
c) Key in T and the desired tool number.
d) Press the EOB (End of Block) key.
5-10 M-400A
7. Press the Cycle Start push button. The tool magazine will execute a tool change:
If a tool is currently in the spindle, it will be removed from the spindle and loaded back
into the tool magazine.
If a tool is currently in the tool magazine specified in step 5, it will be loaded into the
spindle. The tool magazine will be positioned with the specified tool pocket at the tool
change position.
9. Open the main guard doors.
10. If the spindle is empty, proceed to step 11.
If a tool needs to be removed from the spindle, proceed as follows:
b) Press and hold Tool Release push button “E”, Figure 5.9, long enough to release the
tool holder.
c) Release Tool Release push button “E”.
11. Press and hold Tool Release push button “E”.
TP3654
Figure 5.9 - Tool Release Push Button
M-400A 5-11
- WARNING -
The tool holder will not be secured in the spindle until Tool Release push
button “E” is released. Maintain a grip on the tool holder until step 13 is
completed.
- NOTE -
On machines configured for V40 CT tooling, insert the tool holder into the spindle
with the short key slot facing toward the right side of the machine. Refer to Figure
5.10 to identify the short key slot in the tool holder.
On machines configured for BT-40 tooling, the tool holder can be oriented in either
direction.
12. Insert the tool holder into the spindle.
13. Release Tool Release push button “E”, Figure 5.9, to clamp the tool.
14. Verify the tool holder is clamped properly in the spindle.
15. Jog the tip of the tool to within 1 inch [25 mm] of the reference surface of the workpiece.
16. Carefully turn the handwheel counterclockwise until the tip of the cutting tool in the spindle
gently touches the shim on the workpiece.
17. Press the Menu Offset key.
18. If necessary, press the Geometry soft key.
Short
Key
Slot
TI4095
Figure 5.10 - Key Slot Identification

(End View of a V40 CT Tool Holder)
5-12 M-400A
- NOTE -
Refer to page 5-17 for additional information on tool offsets.
19. Set the tool length offset:
a) Move the cursor to the required offset number for the tool length offset.
b) Observe Z axis position displayed at the bottom of the screen. This will be a positive
value.
c) Subtract the thickness of the shim from the Z axis position observed in step 19b.
d) Key in the value calculated in step 19c and press the Input key.
20. If required, set the tool diameter offset:
a) Move the cursor to the required offset number for the tool diameter offset.
b) Key in the radius value of the tool and press the Input key.
21. Repeat steps 4 through 20 until all required tooling has been loaded.
22. If necessary, reset the tool wear offsets to “0". Refer to Tool Wear Offsets, on page 5-16.
M-400A 5-13
PRESET TOOLING
1. Verify that the work coordinate is set. If necessary, refer to Chapter 4 for information on
setting work coordinates.
2. Refer to the tooling sheet supplied by the part programmer to determine the required tool-
ing, assigned tool numbers, and assigned offset numbers.
3. Close the main guard doors.
4. Activate Manual Data Input mode.
- NOTE -
Tool stations are identified by the T word, with a valid range of:
One Drum Tool Magazine [Standard]: T01 through T20
Two Drum Tool Magazines [Option]: T01 through T40
Swing Arm Tool Magazine [Option}: T01 through T24
5. At the manual data input keyboard, key in the tool change command and the desired tool
station:
a) Key in: M06
b) Press the Insert key.
c) Key in T and the desired tool number.
d) Press the EOB (End of Block) key.
6. Press the Cycle Start push button. The tool magazine will execute a tool change:
If a tool is currently in the spindle, it will be removed from the spindle and loaded back
into the tool magazine.
If a tool is currently in the tool magazine specified in step 5, it will be loaded into the
spindle. The tool magazine will be positioned with the specified tool pocket at the tool
change position.
8. Open the main guard doors.
9. If the spindle is empty, proceed to step 11.
If a tool needs to be removed from the spindle, proceed as follows:
b) Press and hold Tool Release push button “E”, Figure 5.9, long enough to release the
tool holder.
c) Release Tool Release push button “E”.
5-14 M-400A
10. Press and hold Tool Release push button “E”.
- WARNING -
The tool holder will not be secured in the spindle until Tool Release push
button “E” is released. Maintain a grip on the tool holder until step 12 is
completed.
- NOTE -
On machines configured for V40 CT tooling, insert the tool holder into the spindle
with the short key slot facing toward the right side of the machine. Refer to Figure
5.10 to identify the short key slot in the tool holder.
On machines configured for BT-40 tooling, the tool holder can be oriented in either
direction.
11. Insert the tool holder into the spindle.
12. Release Tool Release push button “E”, Figure 5.9, to clamp the tool.
13. Verify the tool holder is clamped properly in the spindle.

15. If necessary, press the Geometry soft key.
- NOTE -
16. Set the tool length offset:
a) Move the cursor to the required offset number for the tool length offset.
b) Key in the preset tool length offset value and press the Input key.
17. If required, set the tool diameter offset:
a) Move the cursor to the required offset number for the tool diameter offset.
b) Key in the radius value of the tool and press the Input key.
18. Repeat steps 3 and 17 until all offset values have been entered.
19. If necessary, reset the tool wear offsets to “0". Refer to ”Tool Wear Offsets", on the next
page.
M-400A 5-15
TOOL WEAR OFFSETS
- NOTE -
Accessing the Tool Wear Offsets
2. If necessary, press the Wear soft key.
3. Adjust the Tool Wear Offset as needed.
Setting a Tool Wear Offset:
1. Move the cursor to the offset number to be adjusted.
2. Key in the new wear offset and press the Input key.
Clearing a Tool Wear Offset:
1. Move the cursor to the offset number to be adjusted.
2. Key in “0" (zero) and press the Input key.
5-16 M-400A
TOOL OFFSETS
INTRODUCTION
- NOTE -
The tool offset file consists of 200 offset registers (Offsets 01 through 200).
The tool offset file allows the operator to easily make adjustments that may result from tool
changes, thus large-scale modifications to the part programs are eliminated. These offset registers
are used for tool length and tool diameter offsets. The type of offset (length or diameter) is
determined by which data word is used to call the offset.
Examples:
If offset 01 is called as a tool length offset: H01 (or H1)
If offset 01 is called as a tool diameter offset: D01 (or D1)
If offset 02 is called as a tool length offset: H02 (or H2)
If offset 02 is called as a tool diameter offset: D02 (or D2)
- CAUTION -
Information stored in the tool offset files is NOT automatically converted into
the correct units when a programmed G20 or G21 command switches the
programming units from inch to metric or vice versa. Offsets in the desired
unit of measure should be entered after the control has been set to the
proper mode, inch (G20) vs metric (G21). If a G20 or G21 is programmed after
the tool offsets are entered, the decimal point will be shifted one place to the
left or right. If start-up mode is G20 (inch) and the program switches to G21
(metric), the offset decimal point will shift one place to the right. If start-up
mode is G21 (metric) and the program switches to G20 (inch), the offset deci-
mal point will shift one place to the left.
TOOL LENGTH OFFSETS (H WORD)

Tool length offsets shift the spindle reference point from the spindle face to the tip of the tool. This
value is entered into the tool offset register as a positive value. Refer to Figure 5.11 . Tool length
offsets are activated by commanding G43 with a valid H word from the part program. The machine
control uses the value in the specified tool offset register to properly position the tool on the Z axis.
The H word has the data word format H3, with a valid range of H00 to H200
When the control reads an H word from the part program, the specified offset is activated for tool
length compensation. Decimal point programming is not allowed with the H word.
When the control reads an “H00" or a G49 command (Tool Length Compensation Cancel), the
currently active tool length offset is canceled.
The machine operator can make adjustments to the tool offset register to compensate for tool
wear or variation. All adjustments for tool wear are negative values that are added to the value in the
offset register.
M-400A 5-17
TOOL DIAMETER OFFSETS (D WORD)
The distance from the cutting edge to the center of the tool. Tool length geometry offsets shift the
spindle reference point from the spindle centerline to the cutting edge to the center of the tool. This
value is entered into the tool diameter geometry offset register as a positive value. Refer to Figure
5.11 .
Tool diameter offsets are activated by programming a tool compensation command (G41 or G42)
with a valid D word from the part program. When a tool compensation command is active, the
machine control uses the value in the specified tool offset to properly position the tool on the X and Y
axes.
The D word has the data word format D3, with a valid range of D00 to D200
When the control reads a D word from the part program, the specified tool offset is activated for
tool diameter compensation. Decimal point programming is not allowed with the D word.
When the control reads a “D00” or a G40 command (Tool Compensation Cancel) from the part
program, the currently active tool diameter offset is canceled.
The machine operator can make adjustments to the tool offset register to compensate for tool
wear or variation. All adjustments for tool wear are negative values that are added to the value in the
offset register.
Refer to Chapter 2 in the programmer’s manual (M-377) for information on the tool compensation
commands.
STORING TOOL OFFSETS

Tool offsets can be input from either the part
program or the Manual Data Input keyboard. Refer
to the programmer’s manual (M-399) for information
on inputting tool offsets from the part program.
Refer to Non-Preset Tooling, page 5-10, or Preset Gauge Line
Tooling, page 5-14, for information on setting tool
offsets from the Manual Data Input keyboard.
H Word
H Word TI2986
Figure 5.11 - H and D Word Definitions
5-18 M-400A
- NOTES -
M-400A 5-19
- NOTES -
5-20 M-400A
CHAPTER 6 - OPERATOR MAINTENANCE
INTRODUCTION
Operator maintenance is normally confined to cleaning the machine, maintaining the lubrication
oil and coolant levels, and chip removal. It is a good practice to check all fluid levels at the beginning
of each shift. The operator should also check the cooling fans periodically to see that they are free of
obstructions and functioning properly.
For more extensive maintenance procedures, refer to the maintenance manual (M-401).
MACHINE AIR SYSTEM

A
The machine is equipped with a heavy duty air
filter/regulator and air/oil lubricator assembly, shown
in Figures 6.1 and 6.2 . B
AIR LINE FILTER/REGULATOR

C
- NOTE -
Main air valve “D”, Figure 6.1, should
be turned OFF when the machine is
not in use.
Adjusting the Machine Air Pressure D
The recommended range for machine air

pressure is 70 psig [4.8 bars] to 90 psig [6.2 bars]. E
The machine is equipped with an air pressure sensor
that will force the machine into Emergency Stop if TP3664
the air pressure is outside of this range. Machine air

Figure 6.1 - Air Control System
pressure is displayed on gauge “C”, Figure 6.1 .
If necessary, adjust the air filter/regulator to set
the machine air pressure to within the recommended
range.
1. Push main air valve “D”, Figure 6.1, IN to
F
turn the machine air ON.
2. Loosen lock nut “B”.
3. Turn handle “A” clockwise or counterclock-
wise to increase or decrease machine air
pressure.
4. Tighten lock nut “B”.
TP3668
Figure 6.2 - Air/Oil Lubricator Filler Cap
M-400A 6-1
AIR/OIL LUBRICATOR
- NOTE -
The air/oil lubricator DOES NOT mix oil with the air supplied to the operator air
nozzle located at the front of the machine.
Air/oil lubricator “E”, Figure 6.1, mixes oil with the air supplied to the machine.
FILLING THE AIR/OIL LUBRICATOR

- WARNING -
Failure to properly relieve the machine air pressure can result in personal in-
jury.
- NOTE -
Refer to the tag mounted near the air/oil lubricator to identify the lubrication oil to
be used.
1. Pull main air valve “D”, Figure 6.1, OUT to turn the machine air OFF.
2. Relieve the air system pressure:
a) Disconnect the air line from the main air valve.
b) Push the main air valve IN to open the valve and relieve the air pressure.
c) Pull the main air valve OUT to close the main air valve when system pressure is re-
lieved.
3. Unthread filler cap “F”, Figure 6.2 .
4. Fill the lubricator bowl to the top of the sight window with the specified oil.
5. Replace filler cap “F”.
6. Connect the air line to the main air valve.
7. Push the main air valve IN to turn the machine air ON.
8. Press the control Reset key to clear the alarm message.
6-2 M-400A
COOLANT SYSTEM
Hardinge machine tools are designed using the latest technology and highest quality materials
available. However, due to the ever-increasing number of coolant selections available, it is
impossible to test material compatibility with each and every coolant. For additional information
regarding the coolant facilities on this machine, refer to the maintenance manual (M-401).
- CAUTION -
Whenever water-soluble coolants are used it is important to use the manu-
facturer’s recommended mix ratio (concentration). It is also important to
maintain the coolant by keeping the proper concentration level when coolant
solution is added to compensate for evaporation. Another important factor is
coolant pH (acidity). Typically, the coolant pH should be in the range of 8.5 to
9. Below 8.5 the rust inhibitors in the coolant start depleting, which can re-
sult in corrosion of machine components. In addition, the quality of the water
should be tested by the coolant manufacturer so that the proper coolant ad-
ditives can be administered. Failure to follow these recommendations could
result in damage to the machine, seals, and paint.
If the coolant you have selected starts to react (cause material to rust, pit,
swell, soften, crack, blister etc.) with any portion of the machine tool,
Hardinge suggests that you discontinue use and contact your coolant repre-
sentative for alternative coolants.
It should also be noted that certain chemicals react with different metals.
Hardinge recommends that you consult with your coolant representative to
assure that the material you are cutting does not react with the coolant you
have selected.
The coolant level should not be allowed to fall below sight gauge “I”, Figure 6.4 . To fill the coolant
tank, open the front coolant guard doors and pour the required amount of coolant directly into the chip
pan. Fill the coolant tank to the “FULL” line on the sight gauge tag. Either water-based or oil-based
coolant can be used.
The coolant tank should be drained and cleaned at least every six months or whenever the type or
brand of coolant is changed. More frequent cleaning may be required if the material being machined
contaminates the coolant. Refer to the maintenance manual (M-401) for instructions on draining and
cleaning the coolant system.
COOLANT TANK CAPACITY

The coolant tank has a capacity of approximately 40 gallons [150 liters].
M-400A 6-3
CHIP REMOVAL
(Machines Without an Optional Chip Conveyor)
The machine is equipped with two chip pans. The chip pans are accessed from each side of the
machine. The chip pans are indicated by “G”, Figure 6.3, and “H”, Figure 6.4 .
1. Power down the machine as outlined in Chapter 2.
2. Wait a few minutes to allow the coolant to drain into the coolant tank.
3. Position the chip receptacle near the chip pan to be emptied.
4. Remove the chip pan from the machine.
- WARNING -
DO NOT remove chips with your hands.
5. Pour, rake, or shovel the chips into the chip receptacle.
6. Replace the chip pan.
7. Repeat steps 4 through 6 for the other chip pan.
TP3656 TP3657
Figure 6.3 - Left Side Chip Pan Figure 6.4 - Right Side Chip Pan
6-4 M-400A
- NOTES -
M-400A 6-5
- NOTES -
6-6 M-400A
CHAPTER 7 - INPUT/OUTPUT DEVICES
DATA COMMUNICATIONS SETTINGS
BAUD RATE
Baud rate is the speed at which data is transmitted from one device to another. To successfully
transmit data between two devices, it is necessary to have both devices set to the same baud rate.
The baud rate is set by two different parameters, depending on which I/O port is active. Refer to
the I/O setting on Setting Page #1 to determine which I/O port is active. Refer to “I/O Port
Assignment”, page 7-3.
Refer to the appropriate manual to set the tape punch, tape reader, or computer to the required
baud rate.
PARITY
Tapes punched in EIA format (EIA Standard RS-244-B) contain an odd number of holes in each
character and tapes punched in ASCII (ISO), (EIA Standard RS-358-B) contain an even number of
holes in each character. This characteristic of having an odd or even number of holes punched in
every character is called parity.
The control accepts tape punched in either code, but each tape must be programmed in only one
of the accepted codes. The control automatically determines the particular type of coding by
decoding the first End of Block (;) character on the tape. Each character is checked for parity as it is
read by the tape reader or computer.
parity.
STOP BITS
The control is capable of operating with 1 or 2 stop bits, depending on the requirement. The
number of stop bits active in the machine control is controlled by three different parameters,
depending on which I/O port is active. These parameters can be modified as required. Refer to “I/O
Port Assignment”, page 7-3.
number of stop bits.
M-400A 7-1
CHECKING AND MODIFYING COMMUNICATIONS PARAMETERS
Use the following procedure to check communications protocol parameters:
3. Use the Page keys to display the parameter page to be viewed.
Use the following procedure to check and modify communications protocol parameters as
needed:
2. Set KeySet to ON. Refer to Chapter 3 for information on Program Protection.
5. If necessary, use the Page/Cursor keys to position the cursor at the Parameter Write En-
able field on Setting Page #2.
6. Press the 1 key.
7. Press the Input key. Parameter editing will be enabled.
10. Key in the number of the parameter to be changed.
11. Press the Search soft key.
14. Repeat steps 10 through 13, as needed.
16. If necessary, use the Page/Cursor keys to position the cursor at the Parameter Write field.
17. Press the 0 (zero) key.
18. Press the Input key. Parameter editing will be disabled.
7-2 M-400A
I/O PORT ASSIGNMENT
The standard configuration for Hardinge VMC Series II Machining Centers is to be equipped with
one physical RS-232 port. When the machine tool is configured in this manner, two independent port
assignments are available to allow the operator or programmer to establish two different I/O port
configurations for the same physical I/O port. These two configurations are designated as channels
“0" and ”1".
Instead of changing the associated parameters to reassign the baud rate and stop bits, it is
possible to select a different I/O port assignment and have the changes implemented by the control
automatically. Refer to the description for Setting Page #1, in Chapter 2, for information on setting the
desired I/O port assignment.
Refer to “I/O Port Parameter Settings”, on the next page, for a listing of the parameter settings for
the I/O port assignments.
M-400A 7-3
I/O PORT PARAMETER SETTINGS
Refer to “Checking and Modifying Communications Parameters”, on page 7-2, for information on
modifying the parameter settings for the three I/O ports. These parameters can be modified as
required.
BAUD RATE PARAMETER SETTINGS
I/O Port Parameter Number

0 103
1 113
The valid parameter settings are as follows:
Setting Value Baud Rate

1 50
2 100
3 110
4 150
5 200
6 300
7 600
8 1200
9 2400
10 4800
11 9600
12 19200
STOP BIT PARAMETER SETTINGS
I/O Port Parameter Number Bit Number

0 101 0
1 111 0
The valid parameter settings are “0" for 1 Stop Bit and ”1" for 2 Stop Bits.
- NOTE -
The Stop Bit parameter settings are displayed as one bit in an 8 bit binary number
(0 or 1). The bits are read “0" to ”7", from right to left.
7-4 M-400A
DATA TRANSFER TO THE CONTROL
UPLOADING CONTROL PARAMETERS INTO MEMORY
- CAUTION -
Always connect the RS-232 cable before applying power to the external de-
vice and always remove power from the external device before disconnecting
the RS-232 cable.
1. Refer to the appropriate manual to set the tape reader or computer to the required commu-
nications settings.
2. Remove cover “A”, Figure 7.1, to gain access to the control serial port.
3. Connect the interface cable from the tape reader or computer to the control serial port.
6. Use the Page/Cursor keys to position the cursor at the Parameter Write field.
8. Press the 1 key.
9. Press the Input key to enable parameter editing.
14. Press the right-hand soft key until the Read soft key is displayed.
15. Press the Read soft key.
17. Set the tape reader or computer to transmit
data to the machine control.
18. After the control parameters have been up-
loaded, select Manual Data Input mode.
20. If necessary, use the Page/Cursor keys to A
position the cursor at the Parameter Write
field.
21. Press the 0 (zero) key to disable parameter
editing.
TP3913

Figure 7.1 - Control Serial Port
M-400A 7-5
23. Remove power from the external device; then, disconnect the interface cable from the con-
trol serial port.
24. Replace cover “A”.
25. Turn the control OFF and wait approximately 10 seconds.
26. Turn the control ON.
UPLOADING PART PROGRAMS INTO MEMORY

- CAUTION -
the RS-232 cable.
nications settings.
8. Key in the letter “O” and the program number. Example: O1111
- NOTE -
If the program has no program number or if the program number is to be altered,
key in the letter “O” and the desired program number.
12. Set the tape reader or computer to transmit data to the machine control.
- NOTE -
When the program has been completely loaded into the control, it will appear as
the active program on the control display screen.
13. After the part programs have been uploaded, set KeySet to OFF.
trol serial port.
7-6 M-400A
UPLOADING TOOL OFFSETS INTO MEMORY
- CAUTION -
the RS-232 cable.
nications settings.
8. Key in the letter “O” and the program number. Example: O1111
- NOTE -
If the program has no program number or if the program number is to be altered,
key in the letter “O” and the desired program number.
12. Set the tape reader or computer to transmit data to the machine control.
- NOTE -
When the program has been completely loaded into the control, it will appear as
the active program on the control display screen.
13. After the part programs have been uploaded, set KeySet to OFF.
trol serial port.
17. Press the Cycle Start push button. The tool offsets will be loaded.
M-400A 7-7
DATA TRANSFER FROM THE CONTROL
DOWNLOADING CONTROL PARAMETERS FROM MEMORY
- CAUTION -
the RS-232 cable.
1. Refer to the appropriate manual to set the tape punch or computer to the required commu-
nications settings.
4. Set the tape punch or computer to receive data.
9. Press the right-hand soft key until the Punch soft key is displayed.
10. Press the Punch soft key.
11. Select the parameters to be downloaded, as follows:
• Press the All soft key to download all parameters.
• Press the Non-0 soft key to download all parameters not set to zero.
- NOTE -
To stop the parameters from downloading, press the Reset key. Once the Reset
key has been pressed, it is not possible to download the rest of the parameters
without starting this procedure from the beginning.
13. After the control parameters have been downloaded, remove power from the external de-
vice and disconnect the interface cable from the control serial port.
7-8 M-400A
DOWNLOADING PART PROGRAMS FROM MEMORY
- CAUTION -
the RS-232 cable.
nications settings.
8. Specify the program(s) to be downloaded:
• To download one program, key in the letter “O” and the program number.
Example: O1111
• To download a range of programs, key in the first program number in the range, a comma,
and the last program number in the range.
Format: O____,O____
• To download all programs, key in the letter “O” and -9999.
- NOTE -
When outputting to a tape punch, the control will automatically output 3 feet of
leader and trailer tape. To shorten the leader or trailer length, press the Cancel key
while the leader or trailer is being punched, respectively.
To stop the part program from downloading, press the Reset key. Once the Reset
key has been pressed, it is not possible to download the rest of the part program
12. After the part programs have been downloaded, remove power from the external device
and disconnect the interface cable from the control serial port.
M-400A 7-9
DOWNLOADING TOOL OFFSETS FROM MEMORY
- CAUTION -
the RS-232 cable.
nications settings.
7. If necessary, press the Offset soft key to display an offset page.
- NOTE -
To stop the tool offsets from downloading, press the Reset key. Once the Reset
key has been pressed, it is not possible to download the rest of the tool offsets
12. After the tool offsets have been downloaded, remove power from the external device and
disconnect the interface cable from the control serial port.
7-10 M-400A
- NOTES -
M-400A 7-11
- NOTES -
7-12 M-400A
CHAPTER 8 - TOOL LIFE MANAGEMENT [Option]
GENERAL INFORMATION
INTRODUCTION
The basic concept of Tool Life Management is that after a specific number of parts or a specific
amount of machining time, the control will automatically begin using another tool in place of the
current tool being used for a particular operation.
Tools are assigned to specific groups, as designated by the programmer. The control will monitor
the measurement value assigned to each tool group and automatically switch to the next tool in the
group when the counter for that tool group reaches the measurement value specified by the
programmer.
TOOL LIFE MEASUREMENT UNITS

Tool life can be measured using one of the two following methods:
1. Number of parts (machined by the tool)
2. Amount of machining time (on the tool)
The tool life measurement unit for each tool group can be selected through the Tool Life
Management program or through parameter 6800, bit 2.
Parameter 6800, bit 2, selects the default measurement unit. “Number of parts” will be the
parameter setting when the machine is shipped from the factory. Refer to “Determining the Default
Measurement Unit”, page 8-4, for information on verifying or switching parameter 6800, bit 2.
An alarm message will be displayed when any tool group has reached its programmed tool life and
an “M30" (End of Program) is read by the control. At that point, the machine operator will replace the
tooling and reset the counter relating to the affected tool group. Refer to ”Resetting a Tool Group
Counter", page 8-5.
Number of Parts
When this type of measurement is used, the control will increment the tool group counter for the
active tool each time the tool group is called by the part program.
Amount of Machining Time
When this type of measurement is used, the control will run the tool group counter for the current
tool whenever G01, G02, or G03 is active.
M-400A 8-1
GENERAL PROGRAM DESCRIPTION
When using Tool Life Management, tools and offsets are assigned to specific groups. These
groups are established by the programmer through the use of a Tool Life Management program,
which is independent of the part program. The Tool Life Management program will define the
parameters required for Tool Life Management.
The Tool Life Management program defines the following parameters:
1. Group numbers.
2. Tool life value for each group.
3. Tool numbers and offsets for each group.
- CAUTION -
When the Tool Life Management program is executed, all Tool Life Manage-
ment counters will be reset to 0 (zero).
When using Tool Life Management, the machine operator MUST load and execute the Tool Life
Management program BEFORE executing the part program for the first time.
Refer to the programmer’s manual (M-399) for information on the Tool Life Management program
or how to incorporate Tool Life Management information in the part program.
DETERMINING MAXIMUM GROUPS AND GROUP SIZES

The maximum number of tool groups and maximum number of tools per group are established by
parameter 6800, bits 0 and 1. Be sure that bits 0 and 1 are set to appropriate values to allow for the
necessary number of tool groups and tools per group to be programmed in the Tool Life
Management Program.
The bits in parameter 6800 are numbered as follows:
7 6 5 4 3 2 1 0
Set bits 0 and 1 according to the following chart:
Maximum Number Maximum Tools

Bit 1 Bit 0
of Groups per Group
0 0 16 16
0 1 32 8
1 0 64 4
When the machine is shipped from the factory, the maximum number of groups and maximum
tools per group will be set to 16.
8-2 M-400A
Verifying Maximum Groups and Group Sizes
3. Use the Page keys to display the page that contains parameter 6800.
4. Compare bits 0 and 1 to the chart on page 8-2 to determine the maximum groups and
group sizes.
Setting Maximum Groups and Group Sizes
3. If necessary, use the Page keys to display the Setting page with the Parameter Write field.
4. If necessary, use the cursor keys to position the cursor at the Parameter Write field.
6. Key in the number 1 (one).
8. Press the System function key.
10. Use the Page and Cursor keys to position the cursor at parameter 6800.
11. Record the current number in parameter 6800.
12. Key in the entire parameter value with bits 0 and 1 set to the appropriate values.
17. Key in the number 0 (zero).
20. Select and execute the Tool Life Management program to make the new settings effective.
M-400A 8-3
DETERMINING THE DEFAULT MEASUREMENT UNIT
The two types of measurement units available are “Number of Parts” and “Amount of Machining
Time”. The active measurement unit is determined by a parameter setting. To verify the parameter
setting, it is necessary to view parameter 6800, bit 2. The bits in parameter 6800 are numbered as
follows:
7 6 5 4 3 2 1 0
Verifying the Measurement Unit Parameter Setting

3. Use the Page keys to display the page that contains parameter 6800.
If parameter 6800, bit 2 is set to 0, “Number of Parts” is active.
If parameter 6800, bit 2 is set to 1, “Amount of Machining Time” is active.
Switching the Measurement Unit Parameter Setting
3. If necessary, use the Page keys to display the Setting page with the Parameter Write field.
5. Select Manual Data Input mode .
6. Key in the number 1 (one).
8. Press the System function key.
10. Use the Page and Cursor keys to position the cursor at parameter 6800.
11. Record the current number in parameter 6800.
12. Key in the entire parameter value with bit 2 set to the appropriate value.
17. Key in the number 0 (zero).
8-4 M-400A
RESETTING A TOOL GROUP COUNTER
Resetting the control or turning the control OFF will have NO EFFECT on the tool group counters.
When all of the tools in a tool group have reached the tool life specified in the Tool Life Management
program and an M30 “End of Program” is read, an alarm message will be displayed.
The expired tool groups will be listed near the bottom of the Tool Life Management screen on the
control display screen. The control can display more than one tool group number at a time, when
applicable. Resetting the counter for the expired tool group(s) will clear the alarm and allow machine
operation.
- NOTE -
It is not necessary to change machine modes to reset tool group counters.
Use the following procedure to reset the tool group counter(s):
3. Press the Tool Life soft key.
- NOTE -
Each time a cursor control key is pressed, the cursor will move to the next tool
group in the corresponding direction.
4. Use the cursor control keys to move the cursor to the desired tool group.
5. Using the data input keys, enter -9999 and press the INPUT key. The tool group counter at
the cursor position will be reset to 0 (zero).
6. Repeat steps 4 and 5 to reset additional tool group counters, as needed.
TOOL LIFE DATA SCREENS

The tool life data screens are used to display tool life. It is not possible to edit tool life data through
the data display screen.
ACCESSING THE DATA SCREENS

3. Press the Tool Life soft key to display the tool life data screen.
M-400A 8-5
- NOTES -
8-6 M-400A
CHAPTER 9 - OPTIONS AND
MISCELLANEOUS FEATURES
GRAPHIC DISPLAY FUNCTION
INTRODUCTION
The graphic display function can be used to display the programmed tool path of the workpiece on
the control display while the part program is being executed.
The tool path is displayed as solid lines for feedrate moves (G01, G02, G03) and dashed lines for
rapid traverse moves (G00).
Six different viewing planes are available. Refer to Tool Path Display Parameters, page 9-2, for
information on selecting the viewing plane.
- NOTE -
When Dry Run and Machine Lock are active, the operator can view the graphic
display without machine movement.
ACCESSING THE GRAPHIC DISPLAY FUNCTION

1. Press the Graph key to access the Graphic Display function.
2. If necessary, press the Parameter soft key to access the Graphic Display parameter screen
shown in Figure 9.1 .
GRAPHIC PARAMETER O____ N____
AXES P= __
(XY=0, YZ=1, ZY=2, XZ=3, XYZ=4, ZXY=5)
RANGE (MAX.)
X= __ Y= __ Z= __
RANGE (MIN.)
X= __ Y= __ Z= __
SCALE K= __
GRAPHIC CENTER
X= __ Y= __ Z= __
PROGRAM STOP N= __
AUTO ERASE A= __
( PARAM ) ( GRAPH ) ( ) ( ) ( ) TI4694
Figure 9.1 - Tool Path Display Parameters
M-400A 9-1
SOFT KEY DESCRIPTIONS
- NOTE -
To obtain meaningful results, it is necessary to properly set the parameters before
activating the tool path display.
PARAM
This soft key provides access to the tool path display parameter page. Refer to “Setting
the Tool Path Display Parameters”, page 9-4.
GRAPH
This soft key initiates the tool path display. Refer to “Activating the Tool Path Display”,
page 9-4.
The machine must be in Automatic mode to activate the tool path display.
TOOL PATH DISPLAY PARAMETERS

AXES
The value entered into this register determines which viewing plane is used for the
graphic display. Enter the number corresponding to the desired viewing plane. Refer to Fig-
ure 9.2 .
RANGE (MAX.)
The values entered into the X, Y, and Z fields define the upper limits for the graphic dis-
play. The values entered should be based on the location of the graphic center point and
the size of the workpiece. If necessary, use the Scaling function, described below, to view
the entire tool path on the control display.
RANGE (MIN.)
The values entered into the X, Y, and Z fields define the lower limits for the graphic dis-
play. The values entered should be based on the location of the graphic center point and the
size of the workpiece. If necessary, use the Scaling function, described below, to view the
entire tool path on the control display.
SCALE
The value entered into this register determines the normal viewing scale of the graphic
display. Automatic scaling is enabled when this parameter is set to zero. When not set to
zero, the valid range of values is “0.01" to ”100.00".
9-2 M-400A
GRAPHIC CENTER
The values entered into the X, Y, and Z fields establish the center of the graphic display,
based on the active workpiece coordinate system.
PROGRAM STOP
This register allows the operator to specify a program block number at which the graphic
tool path display will stop. This register is automatically reset to “-1” after the graphic tool
path display has been completed.
AUTO ERASE
This register allows the operator to determine if the display screen is refreshed by auto-
matically clearing a previous graphic tool path from the display when a new tool path is to
be displayed.
Set this register to “0” to disable the automatic display refresh feature.
Set this register to “1” to enable the automatic display refresh feature.
+Y +Z
XY Plane YZ Plane
P=0 P=1
+X +Y
+Y +Z
ZY Plane XZ Plane
P=2 P=3
+Z +X
+Z +Y
+X +Z
ZXY Plane
XYZ Plane P=5
+X P=4 +Y
TI3117
Figure 9.2 - Graphic Viewing Planes
M-400A 9-3
SETTING THE TOOL PATH DISPLAY PARAMETERS
1. Press the Graph key.
2. Use the cursor keys to position the cursor on the parameter field to be changed.
5. Repeat steps 2 through 4, as needed.
ACTIVATING THE TOOL PATH DISPLAY

1. Check all tool path display parameters to be sure they are properly set.
3. Press the Graph soft key.
9-4 M-400A
MACHINE RUN TIME COUNTER [Option]
- NOTE -
The Run Time Counter function is displayed, but not active, unless this option is
active.
The machine Run Time counter function consists of the following active counters:
Power ON
Operating Time
Cutting Time
Cycle Time
ACCESSING THE LIMITED RUN TIME DISPLAY

The Operating Time and Cycle Time counters are displayed on the Position Display screens.
Press the Position key to access any Position Display screen.
ACCESSING THE COMPLETE RUN TIME DISPLAY

2. If the Setting (Timer) page is not displayed:
a) Press the Setting soft key.
b) Use the page keys to display the Setting (Timer) page.
RESETTING A COUNTER TO ZERO

The counters can only be reset by setting the associated machine parameter to zero. Refer to
page 3-22 for information on editing parameters.
Power ON Counter
Parameter Number: 6750
Data Type: 2 word
Unit of Measure: 1 Minute
Valid Range: 0 to 99999999
M-400A 9-5
Operating Time Counter
Data Type: 2 word
Unit of Measure: 1 Millisecond
- or -
Data Type: 2 word
Cutting Time Counter

Data Type: 2 word
- or -
Data Type: 2 word
Cycle Time Counter

Data Type: 2 word
- or -
Data Type: 2 word
9-6 M-400A
PARTS COUNTER [Option]
The Parts Counter shows the total number of times a program has been run during automatic
operation. The Parts Counter is increased by one (1) each time an End of Program (M02/M30) is
read by the control.
ACCESSING THE PARTS COUNTER DISPLAY

1. Press the Position key. The Parts Counter is displayed at the bottom of the page.
ACCESSING THE PARTS COUNTER REGISTERS

2. If the Setting (Timer) page is not displayed:
a) Press the Setting soft key.
b) Use the page keys to display the Setting (Timer) page.
Parts Total: represents the total number of parts that have been run.
Parts Required: represents the total number of parts that are to be run. Setting this value to
“0" effectively turns the parts counter OFF.
Parts Count: represents the number of parts that have been run since this register was last
set to “0". When this value equals the Part Required value, the following mes-
sage will be displayed:
“Count Equals Parts Required”
SETTING PARTS COUNTER VALUES

Parts Total
- NOTE -
The Parts Total register cannot be modified through the Parts Counter display
screen. Parameter 6712 must be modified to change the value displayed in the
Parts Total register. Refer to page 3-22 for information on editing parameters.
Data Type: 2 word
Unit of Measure: 1 Piece
M-400A 9-7
Parts Required and Parts Count
1. Access the parts counter registers, as described on page 9-7.
3. Set Program Protect to ON.
5. Move the cursor to the number to be modified.
6. Key in the desired value.
7. Repeat steps 5 and 6 as needed.
8. Set Program Protect to OFF.
9-8 M-400A
TOOL CHANGER FAULT RECOVERY PROCEDURES
DRUM TOOL CHANGER 1
4. Cancel tool change mode:
a) Key in M77.
b) Press the EOB key.
c) Press the Insert key.
d) Press the Cycle Start push button.
5. Activate tool change mode:
a) Key in M76.
6. Clamp the tool:
a) Key in M73.
7. Move the tool magazine to the home position:
a) Key in M71.
a) Key in M77.
M-400A 9-9
12. Change Parameter Write Enable to 1.
15. Press the PMC soft key.
16. Press the PMCPRM soft key.
17. Press the Data soft key.
18. Press the G.Data soft key.
19. Check the value of D00 and D01.
D00 is the number of the tool in the spindle.
D01 is the number of the pocket in the tool change position.
20. Verify that D00 and D01 are both equal to the number of the tool pocket at the tool change
position. Modify D00 and D01, if necessary.
21. Press the far left soft key.
22. Press the Counter soft key.
23. Check the values of C00 and C04 Preset and Current.
C00 and C04 Preset should be 20.
C00 Current and C04 Current should equal to the number of the tool pocket at the tool
change position.
Modify C00 Current and C04 Current if necessary.
9-10 M-400A
DRUM TOOL CHANGER 2 [Option]
a) Key in M77.
5. Activate tool change mode:
a) Key in M76.
6. Clamp the tool:
a) Key in M73.
7. Move the tool magazine to the home position:
a) Key in M81.
a) Key in M77.
M-400A 9-11
15. Press the PMC soft key.
16. Press the PMCPRM soft key.
17. Press the Data soft key.
18. Press the G.Data soft key.
19. Check the value of D00, D01, and D02.
D00 is the number of the tool in the spindle.
D01 is the number of the pocket in the tool change position for magazine 1.
D02 is the number of the pocket in the tool change position for magazine 2.
20. Verify that D01 matches the tool pocket at the tool change position for magazine 1.
Verify that D02 matches the tool pocket at the tool change position for magazine 2.
Modify D01 or D02, if necessary.
C00, C04, C08, and C12 Preset should be 20.
change position for magazine 1.
change position for magazine 2. (1 = T21, 2 = T22, ...)
Modify C00 Current, C04 Current, C08 Current, and C12 Current, if necessary.
9-12 M-400A
SWING-ARM TOOL CHANGER [Option]
1. Correct the condition that caused the fault.
2. Press the Reset key to clear condition alarms.
- NOTE -
After resetting the condition alarm, the “ATC Arm Not In Position” alarm will remain
active. The Cycle Start and Feed Hold lights will be flashing.
3. Select Jog mode.
4. Check the TCL indicator light, located on the operator control panel.
If the light is not ON, proceed to step 5a.
If the indicator light is ON, proceed to step 5b.
5a. Press and hold the Coolant OFF push button until the tool change sequence is completed
and the ATC arm and tool pocket return to their correct positions.
5b. Press and hold the +X jog key until the tool change sequence is completed and the ATC
arm and tool pocket return to their correct positions.
7. Press the tool data table button, located on the operator control panel.
8. Note the values of D0000, D0001 and D0002.
D0000 = Tool in spindle
D0001 = Tool number in change position
D0002 = Tool pocket in change position
C00 and C04 Preset should be 23 (VMC 600II, 800II, & 1000II Machining Centers)
C00 and C04 Preset should be 31 (VMC 1250II & 1500II Machining Centers)
C00 and C04 Current should be 1 less than the tool pocket in the tool change position.
Example: Tool pocket 11 is in tool change position.
Preset Current
C00 23 10
C04 23 10
M-400A 9-13
- NOTE -
If the values in the Current column needs to be altered, you must first turn on the
parameter write enable.
If changes are not required, the recovery procedure is finished. DO NOT proceed
to step 12.
12. If necessary, select Manual Data Input mode.
13. Press Offset Setting key.
14. Press Setting soft key.
15. Change the value of PWE to a 1.
16. Press the Input key. Alarm 100 will appear. Disregard this alarm.
17. Repeat steps 7 through 11 and make necessary corrections.
18. When finished, repeat steps 13 through 16 to change PWE back to 0.
9-14 M-400A
- NOTES -
M-400A 9-15
- NOTES -
9-16 M-400A
APPENDIX
29.53
[750]
2.85 23.62
[72.5] [600]
.08
[2]
.08
.98 X0. Y0.
[2]
[25] Home Position
Software Limits
20.08 20.16
[510.0] [512]
NOTE:
All dimensions shown in inches [millimeters]. TI4067
Software limits indicated by dashed line.
Figure A.1 - X and Y Axis Travel

Specifications with Work Envelope
(VMC600II Machining Center)
M-400A A-1
36.40
[925]
2.38 31.50
[60.5] [800]
.08
[2]
.08
.20 X0. Y0.
[2]
[5] Home Position
Software Limits
20.08 20.16
[510] [512]
NOTE:

A-2 M-400A
44.09
[1120]
1.89 40.16
[48.0] [1020]
.08
[2]
.08
.20 X0. Y0.
[2]
[5] Home Position
Software Limits
20.08 20.16
[510] [512]
NOTE:

M-400A A-3
53.94
[1370]
1.89 49.21
[48.0] [1250]
.08
[2]
.08
.20 X0. Y0.
[2]
[5] Home Position
Software Limits
25.98 26.06
[660] [662]
NOTE:

A-4 M-400A
63.94
[1624]
1.89 60.00
[48.0] [1524]
.08
[2]
.08
.20 X0. Y0.
[2]
[5] Home Position
Software Limits
25.98 26.06
[660] [662]
NOTE:

M-400A A-5
NOTE: All dimensions shown in inches [millimeters].
Machine
Spindle
.08 [2.0]
+Z Software Limit
Z Axis
Home Position
20.08 [510.0]
-Z Software Limit
6.10 [155.0]
Machine
Table
TI4069A
Figure A.6 - Z Axis Travel Specifications

(VMC600II, VMC800II, and VMC1000II Machining Centers)
A-6 M-400A
NOTE: All dimensions shown in inches [millimeters].
Machine
Spindle
.08 [2.0]
+Z Software Limit
Z Axis
Home Position
25.00 [635.0]
-Z Software Limit
6.10 [155.0]
Machine
Table
TI4069A
Figure A.7 - Z Axis Travel Specifications

(VMC1250II and VMC1500II Machining Centers)
M-400A A-7
20.08
[510]
10.04
[255]
6.30 6.30
[160] [160]
29.53
[750]
.71
.75 [18]
[19]
.47
[12]
1.18
[30]
TI4070
Figure A.8 - Tool Slot Locations and Configuration

A-8 M-400A
20.08
[510]
10.04
[255]
6.30 6.30
[160] [160]
36.42
[925]
.71
.75
[18]
[19]
.47
[12]
1.18
[30]
TI4071

M-400A A-9
20.08
[510]
10.04
[255]
6.30 6.30
[160] [160]
44.09
[1120]
.71
.75
[18]
[19]
.47
[12]
1.18
[30]
TI4071

A-10 M-400A
NOTE:
All dimensions shown in inches [millimeters].
25.98
[660]
3.15 4.92
[80] [125]
53.94
[1370]
.71
[18]
.75
[19]
.47
[12]
1.18
[30]
TI4923

M-400A A-11
NOTE:
All dimensions shown in inches [millimeters].
25.98
[660]
3.15 4.92
[80] [125]
63.94
[1624]
.71
[18]
.75
[19]
.47
[12]
1.18
[30]
TI4923

A-12 M-400A
G CODE LIST
(Preparatory Codes)
G Word Group Definition

G00 1 Rapid Traverse Positioning Mode
G01 1 Linear Interpolation
G02 1 Clockwise Circular / Helical Interpolation
G03 1 Counterclockwise Circular / Helical Interpolation
G04 0 Dwell
G09 0 Exact Stop, Non-Modal
G10 0 Data Setting Mode ON
G11 0 Data Setting Mode OFF
Circular Pocket Milling - Clockwise Motion
G12 -
(Machine without Tool Probe)
Circular Pocket Milling - Counterclockwise Motion
G13 -
G15 17 Polar Coordinates Command OFF
G16 17 Polar Coordinates Command ON
G17 2 XY Plane Selection
G18 2 XZ Plane Selection
G19 2 YZ Plane Selection
G20 6 Inch Data Input
G21 6 Metric Data Input
G22 4 Stored Stroke Check ON
G23 4 Stored Stroke Check OFF
G27 0 Reference Position Return Check
G28 0 Return to Reference Position
G29 0 Return from Reference Position
G30 0 Return to Tool Change Position
G31 0 Skip Function
G39 0 Corner Offset Circular Interpolation
M-400A A-13
G40 7 Tool Diameter Compensation Cancel
G41 7 Tool Diameter Compensation Active (Part Right)
G42 7 Tool Diameter Compensation Active (Part Left)
G43 8 Tool Length Compensation Active
G49 8 Tool Length Compensation Cancel
G50 11 Scaling OFF
G51 11 Scaling ON
G52 0 Set Local Coordinate System
G54 14 Work Coordinate System 1
G60 0 Single Direction Positioning
G61 15 Exact Stop Mode
G62 15 Automatic Corner Override
G63 15 Tapping Mode
G64 15 Cutting Mode
G65 0 Non-Modal Macro Call
G66 12 Modal Macro Call
G67 12 Modal Macro Call Cancel
G68 16 Coordinate Rotation ON
G69 16 Coordinate Rotation OFF
Rectangular Pocket Milling - Clockwise Motion
G71 -
Rectangular Pocket Milling - Counterclockwise Motion
G72 -
G73 9 Peck Drilling Cycle
G74 9 Tapping Cycle (Left-hand)
A-14 M-400A
G76 9 Fine Boring Cycle
G80 9 Cancel Cycle
G81 9 Drilling Cycle
G82 9 Drilling Cycle
G83 9 Peck Drilling Cycle
G84 9 Tapping Cycle (Right-hand)
G85 9 Boring Cycle
G86 9 Boring Cycle
G87 9 Back Boring Cycle
G88 9 Boring Cycle (Manual Retract)
G89 9 Boring Cycle
G90 3 Absolute Positioning Mode
G91 3 Incremental Positioning Mode
G92 0 Coordinate Shift / Constant Surface Speed RPM Limit
G94 5 Inches / Millimeter per Minute Feedrate
G95 5 Inches / Millimeter per Revolution Feedrate
G96 13 Constant Surface Speed
G97 13 Direct RPM Programming
G98 10 Tool to Start Point in Machining Cycles
G99 10 Tool to Return Point in Machining Cycles
M-400A A-15
M CODE LIST
(Miscellaneous Codes)
M Word Definition Standard/Option

M00 Program Stop S
M01 Optional Stop S
M02 End of Program S
M03 Spindle Forward S
M04 Spindle Reverse S
M05 Spindle Stop S
M06 Automatic Tool Change S
M08 Coolant Pump ON S
M09 Coolant Pump OFF S
M10 Rotary Table Brake ON O
M11 Rotary Table Brake OFF O
M13 Spindle Forward / Coolant Pump ON S
M14 Spindle Reverse / Coolant Pump ON S
M15 Spindle Stop / Coolant OFF S
M16 Spindle Air Blast OFF S
M17 Spindle Air Blast ON S
M19 Spindle Orient S
M20 Spindle Orient Cancel S
M21 X Axis Mirror Image ON S
M22 Y Axis Mirror Image ON S
M23 Mirror Image Cancel S
M24 Work Light ON S
M25 Work Light OFF S
M29 Rigid Tapping Mode ON S
M30 End of Program S
M41 Spindle Low Gear (High Torque Machine only) S
A-16 M-400A
M42 Spindle High Gear (High Torque Machine only) S
M48 Enable Feedrate and Spindle Override S
M49 Disable Feedrate and Spindle Override S
M51 Chip Coolant ON S
M52 Chip Coolant OFF S
M53 Thru-Spindle Coolant ON O
M54 Thru-Spindle Coolant OFF O
M68 Chip Conveyor ON O
M69 Chip Conveyor OFF O
M71 Tool Magazine 1 Arm IN (Home Position) S
M72 Tool Magazine 1 Arm OUT (Spindle) S
M73 Tool Magazine 1 Spindle Tool Clamp S
M74 Tool Magazine 1 Spindle Tool Unclamp S
M75 Search Spindle Tool Number (Magazine 1) S
M76 Activate Tool Change Mode (Magazine 1) S
M77 Cancel Tool Change Mode (Magazine 1) S
M80 Auto Power OFF S
M81 Tool Magazine 2 Arm IN (Home Position) O
M82 Tool Magazine 2 Arm OUT (Spindle) O
M83 Tool Magazine 2 Spindle Tool Clamp O
M84 Tool Magazine 2 Spindle Tool Unclamp O
M85 Search Spindle Tool Number (Magazine 2) O
M86 Activate Tool Change Mode (Magazine 2) O
M87 Cancel Tool Change Mode (Magazine 2) O
M98 Subprogram Call S
M99 Subprogram End S
Circular Pocket Milling - Clockwise Motion
M100 O
(Machine with Tool Probe)
Circular Pocket Milling - Counterclockwise Motion
M101 O
M-400A A-17
Rectangular Pocket Milling - Clockwise Motion
M102 O
Rectangular Pocket Milling - Counterclockwise Motion
M103 O
A-18 M-400A
ALARM MESSAGES
Alarm #: 1000 Alarm Message: MAG. POS. AL.

CAUSES: SOLUTIONS:
Tool magazine extended for a time greater Check the tool magazine OUT switch for
than the time limit set by diagnostic register proper adjustment.
305.
Check the tool magazine HOME switch for
Tool magazine was commanded to retract proper adjustment.
and it has not retracted within the time limit
set by diagnostic register 305. Check the value in diagnostic register 305.
Tool magazine “In Position” switch not Check the tool magazine OUT signal.
detected while the spindle is running. Check the tool magazine HOME signal.
Tool magazine “Home” switch not detected
during an X, Y, Z, or 4th axis move.
Alarm #: 1001 Alarm Message: PART REACH

CAUSE: SOLUTIONS:
The number in the Parts Count register is To run the machine with the parts counter
equal the number in the Parts Required active, set the Parts Count register to “0”
register. and restart the machine.
Deactivate the parts counter by setting the
Parts Required register to “0”.
Alarm #: 1002 Alarm Message: SPD.CLAMP AL.

CAUSE: SOLUTIONS:
The Spindle Clamp signal is not detected Check the Spindle Clamp signal.
while the spindle is running. Diagnostic 16, bit 2 should be “1”.
If diagnostic 16, bit 2 is “0”, check the
hardware.
Check the clamp detect switch for proper
adjustment.
M-400A A-19
Alarm #: 1003 Alarm Message: SPD.UNCLAMP AL.
CAUSE: SOLUTIONS:
The Spindle Unclamp signal is detected Check the Spindle Unclamp signal.
while the spindle is running. Diagnostic 16, bit 3 should be “0”.
If diagnostic 16, bit 3 is “1”, check the
hardware.
Check the unclamp detect switch for proper
adjustment.
Alarm #: 1004 Alarm Message: M06 TIME OVER

CAUSE: SOLUTION:
Tool change time is greater than the time Press the Reset key.
limit set by diagnostic register 355. Command the magazine to the Home
position.
Alarm #: 1005 Alarm Message: AIR PRESSURE LOW

CAUSE: SOLUTIONS:
Main air pressure has dropped below the Adjust the main air pressure setting.
minimum setting for a period exceeding the
time limit set by diagnostic register 375. Check the pressure sensor on the air
The minimum pressure setting is control assembly.
established by the pressure sensor on the Check the Air Pressure Detect signal,
air control assembly. Diagnostic 18, bit 3.
Alarm #: 1006 Alarm Message: D402 NE D407

CAUSE: SOLUTION:
Magazine #1: counter 1 and counter 2 are Refer to Chapter 9 for the fault recovery
not equal after magazine rotation has procedure.
stopped.
A-20 M-400A
Alarm #: 1007 Alarm Message: D400 SET ERR.
CAUSE: SOLUTION:
Diagnostic register 400 is set incorrectly. Set diagnostic register 400 to a value of
“20”.
Alarm #: 1008 Alarm Message: FUSE BLOW

CAUSE: SOLUTION:
A fuse failure has been detected. Remove all power from the machine and
replace the fuse.
Alarm #: 1009 Alarm Message: D412 NE D417

CAUSE: SOLUTION:
Magazine #2: counter 1 and counter 2 are Refer to Chapter 9 for the fault recovery
not equal after magazine rotation has procedure.
stopped.
Alarm #: 2000 Alarm Message: LUB. TIME OVER

CAUSE: SOLUTION:
Lubrication time has expired. Single Block Grease the machine as outlined in the
mode is forced. lubrication chapter in the maintenance
manual (M-401).
Alarm #: 2001 Alarm Message: DOOR OPEN

CAUSES: SOLUTIONS:
In Automatic mode, the main guard door or In Automatic mode, close the guard door
magazine side door was opened while axis and press the Cycle Start push button to
motion was occurring. resume program execution.
In Manual mode, the main guard door or Restart the required manual axis motion.
magazine side door was opened while axis
motion was occurring.
M-400A A-21
Alarm #: 2002 Alarm Message: MAG. INITIAL SET
CAUSE: SOLUTION:
Power was turned OFF or the Reset key Perform the following:
was pressed while the magazine was
moving IN or OUT. 1. Press Power ON, if necessary.
3. Set diagnostic register 520, bit 6 to “1”.
4. Input an M76 command and execute.
8. Zero return the machine axes.
was pressed while the spindle tool was
unclamped with the tool magazine in 1. Press Power ON, if necessary.
position, but before the Z axis began 2. Select Manual Data Input mode.
moving into position.
A-22 M-400A
CAUSE: SOLUTION:
was pressed while the Z axis was moving
into position for a tool change. 1. Press Power ON, if necessary.
6. Select the x1 or x10 increment.
7. Move the Z axis in the + direction until the
tool releases.
8. Manually remove the tool from the
magazine.
14. Install the tool in the spindle.
M-400A A-23
CAUSE: SOLUTION:
was pressed while the tool magazine was
rotating. 1. Press Power ON, if necessary.
4. Select Jog mode.
5. Rotate the tool magazine to the correct
position.
magazine.
9. Input an M76 command and execute
16. Verify the values in tool changer
diagnostic registers 402, 407, 450, &
451.
A-24 M-400A
CAUSE: SOLUTION:
was pressed while the Z axis was moving
into position after the tool magazine 1. Press Power ON, if necessary.
stopped rotating. 2. Select Manual Data Input mode.
6. Select the x1 or x10 increment.
7. Move the Z axis in the + direction until the
tool releases.
magazine.
14. Verify the values in tool changer
diagnostic registers 450 & 451.
M-400A A-25
Alarm #: 2003 Alarm Message: COL. LOW PRESSURE
CAUSE: SOLUTIONS:
Thru-spindle coolant pressure has dropped Check the coolant flow. If insufficient
below the minimum setting for a period coolant is flowing, check the coolant filter.
exceeding the time limit set by diagnostic
register 390. Single Block mode is forced. Check the coolant solenoid. Refer to the
electrical diagram.
Check the setting of the coolant pressure
switch. The switch should be set to
1Kg/cm3.
Check the pressure switch operation.
Alarm #: 2004 Alarm Message: SCALE AIR LOW P

CAUSE: SOLUTIONS:
Linear scale air pressure has dropped below the minimum Adjust the air pressure
setting of 1Kg/cm3. setting for the optional
The minimum pressure setting is established by the linear scales.
pressure sensor on the air control assembly.
Check the pressure sensor
on the linear scale air
control assembly.
Check the air filter for the
linear scale air supply.
A-26 M-400A
- NOTES -
“Performance Has Established Leadership for Hardinge”®
Hardinge Inc.
Elmira, New York 14902-1507 USA
Phone: 607-734-2281 Fax: 607-734-8819
www.hardinge.com

VMC Series Vertical Machining Centers: Operator'S Manual

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VMC Series Vertical Machining Centers: Operator'S Manual

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OPERATOR’S MANUAL

Revised: June 5, 2003

Manual No. M-400A Litho in U.S.A.

Information in this manual is subject to change without notice.

This manual covers the operation of Hardinge VMC Series II Vertical

In no event will Hardinge Inc. be responsible for indirect or consequential

Reproduction of this manual in whole or in part, without written permission of

CONVENTIONS USED IN THIS MANUAL

© 2002, Hardinge Inc. M-400A

HARDINGE SAFETY RECOMMENDATIONS

READ THE APPROPRIATE MANUAL OR INSTRUCTIONS before attempting operation,

DON’T ALLOW the operation or repair of equipment by untrained personnel.

CONSULT YOUR SUPERVISOR when in doubt as to the correct way to do a job.

DON’T OPERATE EQUIPMENT if unusual or excessive heat, noise, smoke, or vibration

ALLOW ONLY AUTHORIZED PERSONNEL to have access to enclosures containing

KEEP CHEMICALS AND FLAMMABLE MATERIAL away from operating equipment.

DON’T USE a toxic or flammable substance as a solvent cleaner or coolant.

USE ONLY a soft-faced hammer on table work-holding devices and fixtures.

DON’T USE worn or broken tooling on the machine.

ANY ATTACHMENT, TOOL, OR MACHINE MODIFICATION obtained from any source

USE MAXIMUM ALLOWABLE gripping pressure on work-holding devices. Consider the

DON’T EXCEED the rated capacity of the machine.

REMOVE SPINDLE WRENCHES before starting the machine.

KNOW where all EMERGENCY STOP push buttons are located.

DRY CYCLE a new setup to check for programming errors.

DON’T LEAVE the machine unattended while it is operating.

BE CAREFUL of sharp edges when handling newly machined workpieces.

DON’T CLEAN the machine with an air hose.

FOR YOUR PROTECTION - WORK SAFELY

CHAPTER 1 - MACHINE CONTROL FUNCTIONS

CHAPTER 3 - OPERATIONAL MODES AND EDITING

CHAPTER 4 - WORK COORDINATE SYSTEMS

CHAPTER 5 - TOOLING AND TOOL OFFSETS

CHAPTER 6 - OPERATOR MAINTENANCE

CHAPTER 7 - INPUT/OUTPUT DEVICES

CHAPTER 8 - TOOL LIFE MANAGEMENT [Option]

CHAPTER 9 - OPTIONS AND MISCELLANEOUS FEATURES

CONTROL DISPLAY PANEL

Figure 1.1 - Main Control Panel

LEFT-HAND SOFT KEY

RIGHT-HAND SOFT KEY

MANUAL DATA INPUT KEYBOARD

CURSOR CONTROL KEYS

DATA INPUT KEYS

This key allows the operator to perform the following:

Rapid Override Switch

Feedrate / Jog Override Switch

Spindle Override Switch

Figure 1.2 - Operator Control Panel

Mode Select Switch

Manual Data Input Mode

Handwheel (Manual Pulse Generator) Mode

Zero Return Mode

PROGRAM CYCLE PUSH BUTTONS

4th Axis [Option]

Figure 1.3 - X and Y Axis Table Motion

Figure 1.4 - Z Axis (Head) Movement

M01 (Option Stop)

BDT (Block Skip)

MLK (Machine Lock)

ZMLK (Z Axis Machine Lock)

DRN (Dry Run)

Chip Conveyor ON/OFF