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INT100,200,300,400mk4

Installation procedure and acuracy sheet

This procedure for when you install INTmk4 machine. And after follow step
by step on this procedure, you will get all accuracy sheet and parameter
sheet in the last 2 pages. Print this sheet and keep it in the machine
cabinet and send another copy to office for record.

This procedure for both Metric and Inch system, However some of
point in this procedure require to use Metric only because of avoid
confusion.
Each sheet give you a
for input value and a
for output.
Please read carefully each caution.

Rough Level

Original Parameter
inch
Chuck Width(SP face to Chuck face)

BA2

TR1

Z-axis distance (work center to Home)

66535 0.00001inch

Correction of center rotation on B-axis (X-direction: from Home)

BA61

TR1

28 1.0um

X-coordinate of the sensors reference point

BA97
BA97

TR1
TR2

*Please input "inch" or "mm"

BA19

TR1

264961 0.00001inch

Correction of center rotation on B-axis (Z-direction: from Mill SP face)

BA62

TR1

586674 0.00001inch

Z-coordinate of the sensors reference point

-1314391 0.00001inch
0 0.00001inch

BA99
BA99

TR1
TR2

-1476157 0.00001inch
0 0.00001inch

Offset amount (X) during automatic tool setting value calculation

BA109

TR2

0 0.00001inch

Height axis rotational center offset of the first rotary axis(Tool tip point control)

K124

1490152 0.1um

Z-axis stroke for tip position memory(TEACH function)

L5

1704666 0.00001inch

Second zero-point coordinating value

M5

X1

4550 0.1um

M5

-803900 0.1um

90600 0.1um
28490 0.1um
39194 0.1um

M16
M16

Y
X2

14711 0.1um
0 0.1um

Zero-point shift amount

M16
M16
M16

X1
Z1
Z2

W-AXIS REVISION (X-AXIS REV.)

RS11

W-AXIS REVISION (Yt-AXIS REV.)

0 0.1um

W-AXIS REVISION (X2-AXIS REV.)

RS13

0 0.1um

Y-AXIS REVISION(B=180 )

RS16

RS12

0 0.1um

Y-AXIS REVISION(B=90)

0 0.1um

RS15

0 0.1um

Final Z-axis Level

Pitch:
Twist:

When bubble move to HD2 side "-", HD1 side "+".


When bubble move to Magazine side "-", Operater side "+".
Level
HD1
MID
HD2
Pitch
-0.005
0
0
Twist
-0.005
-0.005
0

mm/M
mm/M

Level
Pitch
Twist

mm/M
mm/M

Tolerance
HD1
+/- 0.02
+/- 0.01

MID
+/- 0.01
+/- 0.005

HD2
0
0

Final W-axis Level

Pitch:
Twist:

When bubble move to HD2 side "-", HD1 side "+".


When bubble move to Magazine side "-", Operater side "+".
Level
HD1
MID
HD2
Pitch
-0.01
-0.005
0
Twist
+0.005
0
0

mm/M
mm/M

Level
Pitch
Twist

mm/M
mm/M

Tolerance
HD1
+/- 0.02
+/- 0.01

MID
+/- 0.01
+/- 0.005

HD2
0
0

Spindle Taperness Check


This form useable both for inch and metric.
*If you got result with "-" which means B-side is smaller than A-side
Do not use harder material on this test, you will get different result. (aluminium or brass is OK.)
Also do not deep cut, it will get different result.
Headstock Check
inch *Please input "inch" or "mm"
A=
1.7826 inch
B=

1.7826 inch

C=

6.1 inch

0.0000 /

10

inch

0.0000 /

10

inch

0.0000 /

10

inch

Tailstock Check
A=

0 inch

B=

0 inch

C=

1 inch

C
B

Headstock #2 Check

A=

1.9665 inch

B=

1.9665 inch

C=

6 inch

Tolerance
B-side smaller than A-side
/
-0.0003
10
inch

Transfer Position Check


This form useable both for inch and metric.
After SP Taper check, leave cutting material in 2nd SP and grab indicater in 1st SP.
Indicator inch *Please input "inch" or "mm"
Reading Indicator
0.0001 inch
Tolerance
0.0004 inch
You have a procedure in Japanese website as you see in berrow, however useally when you
install new machine you do not need this process to make machine straight.

to make this condition with Level adjustment.

You need

Turret Straightness
This form useable both for inch and metric.
inch *Please input "inch" or "mm"
Test Bar Length:
7
inch
Specify to + and - direction.

1,Y

-0.0005 inch

2,X

-0.0003 inch

B=0

B=180

6,Y

0.0005 inch

5,X

0.0007 inch

B=90
0

-0.0007

1,Y
2,X
3,Z
4,Y
5,X
6,Y

-0.0003
-0.0002
-0.0004
-0.0001
0.0004
0.0003

inch/4inch
inch/4inch
inch/4inch
inch/4inch
inch/4inch
inch/4inch

-0.0001 inch

Indicate from HD1 for B=0 and 90.

Indicate from HD2 for B=180.

3,Z

4,Y

0.0004

Tolerance
+/-

inch

B-axis rotation center BA61,BA62,K124


This form useable both for inch and metric.
inch

T= Test bar Length


D/2= Test bar Diameter
X= Distance of X move
Z= Distance of X move
BA61=(Xx25.4)-(Zx254)/2x1000
BA62=(X+Z)/2x100000
BA62 Data before change
BA61 Data before change
K124 Data before change
BA61= Metric

Different between OLD and NEW

BA62=Inch or Metric

Different between OLD and NEW

New BA61= Metric


New BA62=Inch or Metric
New K124= Metric

*Ex: When you want to input "inch" value, please input "inch" if not "mm".

Data
7.874228
0.984426
9.548198
9.486078
788.924
951713.8
951766 0.00001inch
1000 1.0um
2417485 0.1um

D Test Bar

Mill SP

T
T= 7.874228 inch
D= 1.968852 inch

#1

#2

Machine pos.
Z=
-10.21627 inch
Distance move
Z=

Machine pos.
Z=
6.15961 inch
9.48608

#1

#2

Machine pos.
X(D)=
-37.9883 inch
X/2(r)= -18.99415
Distance move + L
X=

Machine pos.
X=
-5.1123 inch
X/2=
-2.55615
9.5482

789 1.0um
-52.2 0.00001inch
1789 1.0um
951714 0.00001inch
2417353 0.00001inch

* When you check this test, you need to find highest point
on the testbar by moving Y-axis. And after found the
position do not move Y-axis until check tip of testbar.

Tolerance
When finished this test, try this test again and if
you get a result with in 1~2um different(as much
smaller), it is OK, because there has no specified
tolerance.

These parameters offset the tip coordinates and the tool length on B-axis turn.
The settings differ between BA61 and BA62.
BA61The machine end is offset with actual axes travels according to B-axis turn angle.
BA62The value is automatically calculated on tool length measurement, but without machineend offset.

X1,Yt,Z1-axis Home Posion Adjustment


This form useable both for inch and metric.

Integrex

100
inch

Machine Position
X
-44.1003 inch
Y
-0.0003 inch
-44.09892
Tolerance

100mm = 4"

+/-

0.0008 inch

M16
M16

Current Parameter
X
50040 0.1um
Y
24410 0.1um

*Please input "100","200","300","400"


*Please input "inch" or "mm"
Target
-44.10000 inch
0.00000 inch

New Parameter
50002 0.1um
24334 0.1um

*Find Center of Test Bar by Rotation"

INTE
INTE
INTE
INTE

100
200
300
400

X-axis target
mm
Radias Diameter
-390
-780
-560
-1120
-610
-1220
-610
-1220

Gage Block
Length

Gage Block

Chuck Width(BA2)

inch
Radias Diameter
-15.35
-30.7
-22.05
-44.1
-24.02
-48.04
-24.02
-48.04

Machine Position
Target
Z
-11.06797 inch
-11.06556 inch
Gage Block Length
3 inch
Chuck Width
BA2
40551 0.0001inch
Z-axis distance
BA19
276378 0.0001inch
Different between Turret face to Home position
BA62
951714 0.00001inch

M16
L5

Current Parameter
Z1
22797 0.1um

New Parameter
22185 0.1um
1406556 0.00001inch

*If machine has not standered KITAGAWA Chuck, You can not use this form unless you find correct Chuck width(BA2).

Y-axis Compansation
This form useable both for inch and metric.
Indicator inch *Please input "inch" or "mm"
Find center and set indicater "0" from HD1.
(If it is not make indicator "0" with home position, please check home position adjustment one more time.)

100mm = 4"

Move B-axis 90 degree touch same point which you setted indicater on B-axis 0 degree. And find
highest point.

Indicate from front side and read "+/-" direction also.


Reading Indicater
0 inch
Current Parameter
New Parameter
RS15
225 -0.0006
225 0.1um
*Max input value on this parameter +/-500.

100mm = 4"

Select HD2 side on select switch.


Attach indicator on HD2 with no movement on Y,B-axis.
Indicate from front side and read "+/-" direction also.
Reading Indicater
Y
0.00005 inch
Current Parameter
New Parameter
RS12
-474 0.1um
-468 0.1um
*Max input value on this parameter +/-1000.
This parameter effecteve when you select HD2 side.

First set indicator "0" on


backside of test bar.

100mm

Read indicator at
front side.
100mm = 4"

Set again indicator setting "0" with both front and back side, Then move B=180 and check center with HD2. (ex:
X=1120mm(44.1") Y=0mm(0"))
Indicate from front side and read "+/-" direction also.
Reading Indicater
-0.008 inch
Current Parameter
New Parameter
RS16
0 0.1um
-2032 0.1um
*Max input value on this parameter +/-500.

X
100mm = 4"

Yt

Indicate from Top side and read "+/-" direction also.


Reading Indicater
X
0.008 inch

100mm = 4"

Yt

Current Parameter
New Parameter
RS11
0 0.1um
2032 0.1um
*Max input value on this parameter +/-1000.
This parameter effecteve when you select HD2 side.

*Note: After changing "X"(RS11), Please check "Yt"(RS16) again until X and Yt are "0".

X2-axis Home Position


This form useable both for inch and metric.

Integrex
Machine

200
inch

*Please input "100","200","300","400"


*Please input "inch" or "mm"

Call "T1" by MDI mode

M16

100
200
300
400

Machine Position
X2
-10.2397 inch

Target
-10.62000 inch

Current Parameter
X2
8046 0.1um

New Parameter
56344 0.1um

X2-axis target
mm
inch
Radias Diameter Radias Diameter
-205
-410
-8.07
-16.14
-135
-270
-5.31
-10.62
-215
-430
-8.46
-16.92
-215
-430
-8.46
-16.92

Select HD2 side on select switch.


Call "T101" by MDI mode
Machine Position
X2
-10.236 inch

Target
-10.62000 inch

Current Parameter
New Parameter
RS13
-100 0.1um
-48868 0.1um
*Max input value on this parameter +/-1000.
This parameter effecteve when you select HD2 side.
*Since Lower turret does not has Y-axis, If you see different on Y-direction, you can only adjust by shim.
However, usually new machine does not required to grind shim because already adjustd at Factory.
So if you need to adjust Y-direction on new machine, you need to adjust by Level.

ATC Adjustment
This form useable both for inch and metric.
Set ATC alignment tool

Magazine

Taper Shaft
(3piece alignment tool)

Machine

inch

*Please input "inch" or "mm"

Mill Spindle

t
ZDirectio

Machine Position
X1
-0.001177 inch
Yt
-3.65171 inch

Ring
(3piece alignment tool)

Up/Dow
n
Directio

M5
M5

ATC Arm

Shaft
(3piece alignment tool)

New Parameter
X1
-149 0.1um
Yt
-927534 0.1um

Tooleye Sensor Adjustment


This form useable both for inch and metric.

Machine

inch

*Please input "inch" or "mm"

All measuurment must be unclamp on Mill coupling

Set BA95,96,97,99 to all "0" before doing this test.


Orient 180
degree

#2

#1
Tool OD
Orient 0
degree

#4

#3

Orient 180
degree

Orient 0
degree

Tool OD

Upper Turret
BA95
34.96 inch

Original BA95

#1
#2

0.00001inchNew BA95

-479.7816 inch
-548.6806 inch
3393900 0.00001inch

BA96
#3
#4
Original BA96

0.00001inchNew BA96

378.5863 inch
447.4895 inch
3394320 0.00001inch

Please set BA95,96 with new number before goint to next test.
BA97
#1
#2
Original BA97 -1314391

NEW BA97

-479.9562 inch
-514.7079 inch
-49733205 0.00001inch

BA99
#3
#4
NEW BA99

378.6094 inch
413.5769 inch
-39609315 0.00001inch

Lower Turret
Gage block
#5

3 inch
-7.37902 inch

Target

13.38 inch

New BA97

-49 0.00001inch

Gage block
0.622 inch
#6
14.56057 inch
#7 -12.05669 inch
New BA99

Target

27.64 inch

0.00001inch
-19.647975
27.64 20.3597
15.58331
-1558331

Adjusted Parameter Sheet


Customer:
Inspected by (Customer):
Machine anchored:
Yes

Model:
No

Installer:

Factory Setting
BA2
BA19
BA61
BA62
BA97
BA99
BA97
BA99
BA109

TR1
TR1
TR2
TR2
TR2

Serial:
Title:
Date:

Current Setting
66535
264961
28
586674
-1314391
-1476157
0
0
0

0.00001inch
0.00001inch
1.0um
0.00001inch
0.00001inch
0.00001inch
0.00001inch
0.00001inch
0.00001inch

BA2
BA19
BA61
BA62
BA97
BA99
BA97
BA99
BA109

TR1
TR1
TR2
TR2
TR2

40551
276378
1789
951714
########
########
-49
0

0.00001inch
0.00001inch
1.0um
0.00001inch
0.00001inch
0.00001inch
0.00001inch
0.00001inch
0.00001inch

K124

1490152 0.00001inch

K124

2417353 0.00001inch

L5

1704666 0.00001inch

L5

1406556 0.00001inch

M5
M5
M16
M16
M16
M16
M16
RS11
RS12
RS13
RS15
RS16

X1
Y
X1
Y
Z1
X2
Z2

4550
-803900
90600
14711
28490
0
39194

0.1um
0.1um
0.1um
0.1um
0.1um
0.1um
0.1um

M5
M5
M16
M16
M16
M16
M16

0
0
0
0
0

0.1um
0.1um
0.1um
0.1um
0.1um

RS11
RS12
RS13
RS15
RS16

X1
Y
X1
Y
Z1
X2
Z2

If you have any other parameters were changed, Please write down.

-149
-927534
50002
24334
22185
56344

0.1um
0.1um
0.1um
0.1um
0.1um
0.1um
0.1um

2032
-468
-48868
225
-2032

0.1um
0.1um
0.1um
0.1um
0.1um

Integrex mk4 Accuracy Form


Customer:
Inspected by (Customer):
Machine anchored: Yes

Model:

Serial:
Title:

No

Installer:

Date:

Z1-axis Level

Check
Level
Pitch
Twist

HD1
-0.005
-0.005

MID
0
-0.005

HD2
0
0

mm/M
mm/M

PASS
PASS

Level
Pitch
Twist

HD1
-0.01
+0.005

MID
-0.005
0

HD2
0
0

mm/M
mm/M

PASS
PASS

Level
Pitch
Twist

HD1
+/- 0.02
+/- 0.01

MID
+/- 0.01
+/- 0.005

HD2
0
0

mm/M
mm/M

W-axis Level

Tolerance

Spindle straightness test


Check
Headstock Check

C
B

A=

inch
1.7826 inch

B=

1.7826 inch

C=

6.1 inch
0.0000 /

PASS

10

inch

10

inch

Tailstock Check

C
B

A
B

A=

0 inch

B=

0 inch

C=

1 inch
0.0000 /

A
C

Headstock #2 Check
A=

1.9665 inch

B=

1.9665 inch

C=

6 inch
0.0000 /

10

inch

-0.0003

10

inch

Tolerance
/

Transfer Position
inch
Reading Indicator
0.0001 inch

Check
PASS

Tolerance
0.0004

inch

Turret straightness test


Check
1,Y

6,Y

B=0

2,X

5,X

B=90
B=180

1,Y
2,X
3,Z
4,Y
5,X
6,Y

-0.0003
-0.0002
-0.0004
-0.0001
0.0004
0.0003

inch/4inch
inch/4inch
inch/4inch
inch/4inch
inch/4inch
inch/4inch

Tolerance
3,Z

4,Y

+/- 0.0004

inch

PASS

Data
Section
03/20/2007 release Ver1.0

Description

04/05/2007 Ver1.01

Tooleye Adjustment

1, Drawing of #1,#2(BA97) and #3,#4(BA99) was opposite. Darren Millson(National training)

Adjusted Parameter Sheet

1, correct link to other sheet

04/30/2007 Ver1.02

B-axis Rotation Center(BA61,62) 1, "mm" mode does not works correctly for BA61

Info from

Tac
Brandon Church(AT Service)

05/29/2007 release Ver1.1 X1,Yt,Z1-axis Home position


All sheet

1, Z1-axis Home position calculation was not correctly


Adjusted printable setting for all sheet

Pierre Gendron(Canada service)


Tac

07/13/2007 Ver1.11

X2,Z2-axis Home Position

INT400 X2 storke information(inch only) was wrong

Tac

09/11/2007 Ver.1.12

X2,Z2-axis Home Position

HD2 side Target number was not link correctlly

Tac

Y-axis compensation

On RS16 of indicator unit was always "mm", This should be Tac


a changeable when choose a "inch" unit.

Tooleye Adjustment

Upper Turret BA97,BA99 calculation was not correct.

Tac