Ashill Intergrex Probing Manual

Programming manual
H-2000-6443-0E-A
Inspection Plus software for Mazak

INTEGREX-IV series lathes
for Mazatrol Matrix ‘T’ controllers

© 2006 – 2011 Renishaw plc. All rights reserved.
This document may not be copied or reproduced in whole or in

part, or transferred to any other media or language, by any means,
without the prior written permission of Renishaw plc.
The publication of material within this document does not imply

freedom from the patent rights of Renishaw plc.
Disclaimer
RENISHAW HAS MADE CONSIDERABLE EFFORTS TO ENSURE

THE CONTENT OF THIS DOCUMENT IS CORRECT AT THE
DATE OF PUBLICATION BUT MAKES NO WARRANTIES OR
REPRESENTATIONS REGARDING THE CONTENT. RENISHAW
EXCLUDES LIABILITY, HOWSOEVER ARISING, FOR ANY
INACCURACIES IN THIS DOCUMENT.
Trademarks
RENISHAW® and the probe emblem used in the RENISHAW logo

are registered trademarks of Renishaw plc in the UK and other
countries.
apply innovation is a trademark of Renishaw plc.
All other brand names and product names used in this document
are trade names, service marks, trademarks, or registered
trademarks of their respective owners.
Renishaw part no: H-2000-6443-0E-A
Issued: 04.2011
IMPORTANT – PLEASE READ CAREFULLY
RENISHAW PRODUCT LICENCE

Licensee: you, the person, firm or company accepting the terms of this Licence
Renishaw: Renishaw plc, New Mills, Wotton-under-Edge, Gloucestershire, GL12 8JR, United Kingdom
Product: the software, which is designed to operate on machine tool numeric controllers, supplied by
Renishaw for use with Renishaw’s machine tool probing systems
Licence to use: a non-exclusive licence to use the Product on a single machine tool only
By installing and/or using the Product you indicate your acceptance of the terms of this Licence.
Renishaw grants the Licensee a Licence to use the Product on condition the Licensee accepts the following
terms and conditions:
1. All rights in and title to the Product are and shall remain vested in Renishaw and its licensors.
2. Renishaw shall replace or repair the Product if it does not materially perform to specification under proper use
within 90 days of delivery. This warranty does not apply where the Product has been modified in any manner
that is not specifically described in the Product or in the installation or programming manuals supplied with the
Product, or where the Product is used with probing systems that have not been produced by Renishaw.
Except as stated in this paragraph, all warranties, conditions and terms implied by law are excluded. In
particular, no warranty is given that the Product is bug or error-free.
3. NOTE - LIMITATION OF LIABILITY IN CONNECTION WITH USE OF THE PRODUCT

Renishaw does not exclude liability for personal injury or death caused by Renishaw’s negligence.
Renishaw’s liability is limited to (a) the warranty contained in paragraph 2 and (b) direct losses up to a
maximum of £50,000.
Renishaw has no liability to the Licensee for any indirect, consequential or economic loss (including,
without limitation, loss of data, profits or goodwill).
The Product has been designed for use with Renishaw’s machine tool probing systems. Renishaw has
no liability for the results of using the Product with another manufacturer’s machine tool probing systems.
By accepting the terms of this Licence the Licensee agrees that this limitation of liability is reasonable.
4. The Licensee may not make any copies of the Product except as provided in this Licence or as permitted by
applicable law. The Licensee is authorised to make a backup copy of the Product for security purposes. The
Licensee must not remove any licence and copyright notices, labels or marks contained in the original and shall
ensure all copies contain such notices without modification.
5. If the Product contains electronic manuals the Licensee may print out the manuals in part or in full, provided
that the print outs or copies are not supplied to any third party that is not an employee or contractor for the
Licensee without Renishaw’s written permission
6. The Licensee shall not reverse engineer, decompile, or modify the Product or re-use any components
separately from the Product unless permitted by a specific instruction contained in the Product or the
programming or installation manuals supplied with the Product or by applicable law provided that in the latter
case, Licensee has first contacted Renishaw to request any information required to interface with Licensee’s
other software.
7. The Licensee shall not make the Product available to any third party in any manner whatsoever nor may this
Licence and the Product be transferred to a third party without Renishaw’s prior written agreement. Any
agreement by Renishaw is conditional on the permitted transferee agreeing to all terms of this Licence and the
Licensee not retaining any copies of the Product. Where the Licensee is a reseller of Renishaw’s machine
tool probing systems, Licensee may transfer the Product for ultimate use by an end user with Renishaw’s
machine tool probing systems.
8. Renishaw shall have the right to terminate this Licence immediately if the Licensee fails to comply with any of
these terms and conditions. The Licensee agrees upon receipt of notice of termination from Renishaw to
immediately return or destroy all copies of the Product in its possession or control.
9. This Licence is governed by English law and the parties submit to the exclusive jurisdiction of the English
courts.
Renishaw Product Licence (EN) – Issue 1: February 2007

Form 1
EQUIPMENT REGISTRATION RECORD
Please complete this form (and Form 2 overleaf if applicable) after the Renishaw equipment has been installed on your
machine. Keep one copy yourself and return a copy to your local Renishaw office (for contact details, see our main web site on
www.renishaw.com/contact). The Renishaw installation engineer should normally complete these forms.
MACHINE DETAILS
Machine description..................................................................…………….........................................................
Machine type........................................................……………….........................................................................
Controller................................……………………….............................................................................................
Special control options.............................................................................….......................................….............
....................................................................................................................………………………………..............
....................................................................................................................………………………………..............
RENISHAW HARDWARE RENISHAW SOFTWARE
Inspection probe type ..................................……..... Inspection disk(s)......................................……...............
Interface type .................................................……. ..........................................................................…...........
.............................................................................…........
Tool setting probe type ................................…...…. Tool setting disk(s) ......................…......................…......
Interface type .................................................……. ..................................................................................…...
.........................................................................................
SPECIAL SWITCHING M CODES (OR OTHER) WHERE APPLICABLE
Dual systems only
Switch (Spin) probe on ............................……....... Switch on inspection probe ..................……...................
Switch (Spin) probe off ..........................……......... Switch on tool setting .............................…….................
Start/Error signal .........................................…….... Other .....................................................….....................
...........................................................................…...........
ADDITIONAL INFORMATION Tick box if Form 2 overleaf
has been filled in.
Customer's name……….................................................................. Date installed ..........…...........................

Customer's address..……................................................................
.....................................…................................................................. Installation engineer …............................
.........................................................................................................
…...................................................................................................... Date of training........................................
Customer's tel. no..........................……..........................................
Customer's contact name…………..................................................
Form 2
SOFTWARE DEVIATION RECORD
Standard Renishaw kit no. Software disk nos.
Reason for deviation
Software no. and Comments and corrections

macro no.
The software product for which these changes are authorised is subject to copyright.
A copy of this deviation sheet will be retained by Renishaw plc.
A copy of the software amendments must be retained by the customer – they cannot be retained by
Renishaw plc.
Cautions i
Caution – Software safety

!
The software you have purchased is used to control the movements of a machine tool. It
has been designed to cause the machine to operate in a specified manner under operator
control, and has been configured for a particular combination of machine tool hardware
and controller.
Renishaw has no control over the exact program configuration of the controller with which
the software is to be used, nor of the mechanical layout of the machine. Therefore, it is
the responsibility of the person putting the software into operation to:
z ensure that all machine safety guards are in position and are correctly working
before commencement of operation;
z ensure that any manual overrides are disabled before commencement of operation;
z verify that the program steps invoked by this software are compatible with the
controller for which they are intended;
z ensure that any moves which the machine will be instructed to make under program
control will not cause the machine to inflict damage upon itself or upon any person
in the vicinity;
z be thoroughly familiar with the machine tool and its controller, understand the
operation of work coordinate systems, tool offsets, program communication
(uploading and downloading) and the location of all emergency stop switches.
IMPORTANT – READ THIS

! Updating the SET UP INFO
The Mazak SET UP INFO can be updated only when the following conditions apply:
z The Mazak software version is B5A or higher.
z Option parameter O93.5 = 1 must be set.
If the option parameter is not set because you do not use SET UP INFO, then manual
edits to the software are required. These edits are described in the Readme.txt
document.
Publication No. H-2000-6443

ii
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Contents iii
Contents
Before you begin

Before you begin ................................................................................................................. 1
Measurement values used in this manual .......................................................................... 2
Vertical machines................................................................................................................ 2
List of associated publications ............................................................................................ 2
About the Inspection Plus software .................................................................................... 2
Software kit no. A-4013-0106 ............................................................................................. 2
File 1: Probe at B0 cycles ............................................................................................ 3
File 2: Probe at B90 cycles .......................................................................................... 3
File 3: C-axis cycles and datum sphere calibration macros ........................................ 3
Macro memory requirements .............................................................................................. 3
Macro numbers and functions ............................................................................................ 4
Calibrating a probe using a datum sphere .......................................................................... 5
Using probe cycles in a Mazatrol program and updating the SET UP INFO...................... 6
Mazatrol programming ................................................................................................. 6
ISO/EIA programming.................................................................................................. 6
Using the probe on S2 ................................................................................................. 6
Making a program RESTART ............................................................................................. 7
Updating the tool offset on the lower turret (O9832) .......................................................... 7
Using the virtual simulation mode with Renishaw probes .................................................. 9
Renishaw customer services .............................................................................................. 9
Calling Renishaw ......................................................................................................... 9
Chapter 1 Installing the software

Installing the software ...................................................................................................... 1-2
Setting and adjusting the software................................................................................... 1-2
Chapter 2 Optional inputs

Optional inputs ................................................................................................................. 2-2
Chapter 3 Variable outputs

Variable outputs (probe at B90) – table 1 ........................................................................ 3-2
Variable outputs (probe at B0) – table 3 .......................................................................... 3-4

iv Contents
Chapter 4 Protected positioning cycles

Probe protected positioning (probe at B90) – O9610 ...................................................... 4-2
Probe protected positioning (probe at B0) – O9810 ........................................................ 4-4
Chapter 5 Calibrating the probe

Why calibrate a probe? .................................................................................................... 5-3
Calibrating in a bored hole or on a turned diameter ........................................................ 5-3
Calibrating in a ring gauge or on a datum sphere ........................................................... 5-3
Calibrating the probe length ............................................................................................. 5-4
Calibration cycles – an overview ..................................................................................... 5-4
Before calibrating a probe using a datum sphere ............................................................ 5-5
Calibrating the probe length (probe at B90) – O9601...................................................... 5-6
Establishing the position of a bore/boss (probe at B90) – O9600 ................................... 5-8
Calibrating the stylus Z and Y offsets (probe at B90) – O9602 ..................................... 5-10
Calibrating the vector stylus ball radius (probe at B90) – O9604 .................................. 5-12
Example 1: Full calibration in an internal feature ........................................................... 5-15
Example 2: Full calibration on an external feature ........................................................ 5-17
Calibrating the probe length (probe at B0) – O9801...................................................... 5-19
Establishing the position of a bore/boss (probe at B0) – O9800 ................................... 5-21
Calibrating the stylus X and Y offsets (probe at B0) – O9802 ....................................... 5-23
Calibrating the vector stylus ball radius (probe at B0) – O9804 .................................... 5-25
Example 4: Full calibration on an external feature ........................................................ 5-30
Calibrating on a datum sphere (O8000) ........................................................................ 5-32
Editing macro O8000 .............................................................................................. 5-33
Calibrating on a datum sphere S2 (O8001) ................................................................... 5-35
Editing macro O8001 .............................................................................................. 5-35
Chapter 6 Standard measuring cycles

X Y Z single surface measurement (probe at B90) – O9611 .......................................... 6-2
Web/pocket measurement (probe at B90) – O9612 ........................................................ 6-5
Bore/boss measurement (probe at B90) – O9614........................................................... 6-9
X Y Z single surface measurement (probe at B0) – O9811 .......................................... 6-13
Bore/boss measurement (probe at B0) – O9814 ........................................................... 6-20

Contents v
Chapter 7 Vector measuring cycles

Angled single surface measurement (probe at B90) – O9621 ........................................ 7-2
Angled web or pocket measurement (probe at B90) – O9622 ........................................ 7-4
3-point bore or boss measurement (probe at B90) – O9623 ........................................... 7-7
Angled single surface measurement (probe at B0) – O9821 .......................................... 7-9
Angled web or pocket measurement (probe at B0) – O9822 ........................................ 7-11
Chapter 8 Additional cycles

Bore/boss on PCD measurement (probe at B90) – O9619 ............................................. 8-2
Storing multi-stylus data (probe at B90) – O9630 ........................................................... 8-5
Loading multi-stylus data (probe at B90) – O9631 .......................................................... 8-7
Determining feature-to-feature data in the ZY plane (probe at B90) – O9634 ................ 8-9
Determining feature-to-feature data in the X plane (probe at B90) – O9634 ................ 8-13
Storing multi-stylus data (probe at B0) – O9830 ........................................................... 8-20
Loading multi-stylus data (probe at B0) – O9831 .......................................................... 8-22
Determining feature-to-feature data in the XY plane (probe at B0) – O9834 ................ 8-24
Determining feature-to-feature data in the Z plane (probe at B0) – O9834................... 8-28
Chapter 9 C-axis cycles

C-axis measurement (probe at B90) – O9618 (S1) / O9840 (S2) ................................... 9-2
C-axis find (probe at B90) – O9650 (S1) / O9841 (S2) ................................................... 9-5
C-axis measurement (probe at B0) – O9818 (S1) / O9842 (S2) ..................................... 9-7
C-axis find (probe at B0) – O9850 (S1) / O9843 (S2) ................................................... 9-10
Chapter 10 Alarms and error messages

General alarms .............................................................................................................. 10-2
Chapter 11 Settings, macros and variables

Customising the software .............................................................................................. 11-2
Editing the settings macro (O9724) ........................................................................ 11-2
Setting the tool offset (#120) .................................................................................. 11-3
Variable base number setting (#111 and #112) ..................................................... 11-4
Selecting the call method from a Mazatrol program ............................................... 11-4
Alarm settings (#704).............................................................................................. 11-5
Process alarms ....................................................................................................... 11-5

vi Contents
Use of macro variables .................................................................................................. 11-6

Local variables ........................................................................................................ 11-6
Common variables .................................................................................................. 11-6
Common retained variables .................................................................................... 11-7
Chapter 12 General information

Tolerances ..................................................................................................................... 12-2
True position tolerances ................................................................................................ 12-3
Experience values Ee .................................................................................................... 12-3
Reason for using this option ................................................................................... 12-3
Additional spare tool offsets ................................................................................... 12-4
Printing ........................................................................................................................... 12-4
Setting the print parameter ..................................................................................... 12-4
Example of printing a macro output ........................................................................ 12-5
Considerations when using vector cycles O9621 (O9821), O9622 (O9822) and
O9623 (O9823) .......................................................................................................... 12-5
Use of 3-point bore/boss macros O9623 and O9823 ............................................. 12-5
Mathematical precision ........................................................................................... 12-6
Effect of vector calibration data on results.............................................................. 12-6
General probing applications ......................................................................................... 12-6
Example 1: Part identification ................................................................................. 12-6
Example 2: Probe measure every nth component ................................................. 12-7
Output flow (bore/boss and web/pocket cycles) ............................................................ 12-9
Appendix A Probing with G68.5 active

Introduction ...................................................................................................................... A-2
Program example............................................................................................................. A-2
Appendix B Features, cycles and limitations

Features of the Inspection Plus software ........................................................................ B-2
Cycles .............................................................................................................................. B-2
Limitations ........................................................................................................................ B-3

Before you begin 1
Before you begin

This programming manual contains detailed information on using the Inspection Plus
software for programming, operating and controlling Mazak INTEGREX-IV series machine
tools.
Comprising 12 self-contained chapters and two appendices, the manual is structured to

provide the information you require to use the Inspection Plus software effectively:
z Chapter 1, “Installing the software” describes how to install the Inspection Plus
software on your machine.
z Chapter 2, “Optional inputs” describes the optional inputs that are required by some
of the macro cycles.
z Chapter 3, “Variable outputs” provides a complete list of the optional outputs that are
produced by some of the macro cycles.
z Chapter 4, “Protected positioning cycles” describes how to use the protected

positioning macros (O9610 and O9810). When correctly used, these macros prevent
damage to the probe’s stylus in the event of the probe colliding with the workpiece.
z Chapter 5, “Calibrating the probe” why a probe’s stylus must be calibrated before
you start using it then describes how to use the macros that are provided for
calibrating a probe. Cycles are provided for calibrating an inspection probe when it is
vertically mounted and horizontally mounted.
z Chapter 6, “Standard measuring cycles” describes how to use the non-vector

measuring cycle macros.
z Chapter 7, “Vector measuring cycles” describes how to use the vector measuring
cycle macros.
z Chapter 8, “Additional cycles” describes how to use the macro cycles that are not
described in previous chapters.
z Chapter 9, “C-axis cycles” describes how to use C-axis measuring cycles.
z Chapter 10, “Alarms and error messages” describes the macro alarm numbers or
messages that are displayed on the screen of the Mazatrol Matrix control when an
error occurs. An explanation of the meaning and possible cause of each alarm
message is provided, together with typical actions you must take to correct the fault
causing the message.
z Chapter 11, “Settings, macros and variables” describes how to customise the
Inspection Plus software on your machine. It also covers setting information and
details about the macro variables used in the software.
z Chapter 12, “General information”, contains general information and reference

material that is relevant to the Inspection Plus software package.

2 Before you begin
Measurement values used in this manual

Throughout this manual metric units of measurement (for example, millimetres) are used
in the examples. Where appropriate, the equivalent imperial values (for example, inches)
are shown in brackets.
Vertical machines
This programming manual and the software it supports have been designed for use with
Mazak INTEGREX-IV series machines. As a result, whilst this publication may be used
when working with vertical machines, it is important to note that the figures used
throughout the manual may not reflect this.
List of associated publications

When you are using the Inspection Plus software, you may find it useful to refer to the
following Renishaw publications:
z Installation manual Probe systems for machine tools (Renishaw part no.
H-2000-6040).
z Data sheet Probe software for machine tools (Renishaw part nos. H-2000-2289 and
H-2000-2298).
About the Inspection Plus software

For a comprehensive description of the facilities provided by the software and also the
limitations of the software, refer to Appendix B, “Features, cycles and limitations”.
Software kit no. A-4013-0106

This kit comprises the following item:
z CD assembly (one CD) – part no. A-4013-0107
The CD contains the following data:
Probe at B0 cycles File1 (40130108)
Probe at B90 cycles File2 (40130109)
C-axis cycles and datum File3 (40130110)

sphere calibration macros

Before you begin 3
File1: Probe at B0 cycles

O9721 O9722 O9723 O9724 O9726 O9727
O9730 O9731 O9732 O9733 O9800 O9801
O9802 O9804 O9810 O9811 O9812 O9814
O9819 O9821 O9822 O9823 O9830 O9831
O9834
File2: Probe at B90 cycles

O9521 O9522 O9526 O9527 O9530 O9531
O9532 O9600 O9601 O9602 O9604 O9610
O9611 O9612 O9614 O9619 O9621 O9622
O9623 O9630 O9631 O9634
File3: C-axis cycles and datum sphere calibration macros

O8000 O8001 O9550 O9551 O9618 O9650
O9818 O9832 O9840 O9841 O9842 O9843
O9845 O9846 O9850
Macro memory requirements

This section lists the amount of memory (in kilobytes) that is required by all macros
contained on the software CD. Before you load macros, first calculate the total amount of
memory required by the macros you wish to load. Next, check that the machine controller
has sufficient memory capacity for these macros.
If memory capacity of the controller is stated in “metres of tape”, use the following data to
convert from kilobytes to length or vice-versa:
Conversion: 1 KB = 2.5 m (8.2 ft) of software tape.

8 KB = 20 m (65.6 ft) of software tape.
File1: total amount of memory = 40.0 KB.

4 Before you begin
Macro numbers and functions

Macro No. Function
File1
O9721 X diameter move

O9722 Y diameter move
O9723 Active tool offset macro
O9724 Setting macro
O9726 X,Y,Z, basic move
O9727 Vector diameter move
O9730 Print macro
O9731 Vector calibration data find (also used for ATAN calculation)
O9732 Offset update macro
O9733 WPC update
O9800 Bore or boss centre line find
O9801 Probe length calibration
O9802 Stylus X,Y offset calibration
O9804 Vector stylus ball radius calibration
O9810 Protected positioning
O9811 XYZ single surface measure
O9812 Web / pocket measure
O9814 Bore / boss measure
O9819 Bore / boss on PCD
O9821 Angle single surface measure
O9822 Angle web / pocket measure
O9823 3-point bore / boss measure
O9830 Multi-stylus store
O9831 Multi-stylus load
O9834 Feature-to-feature measure
File2
O9521 Z diameter move

O9522 Y diameter move
O9526 X, Y, Z basic move
O9527 Vector diameter move
O9530 Print macro
O9531 Vector calibration data find (also used for ATAN calculation)
O9532 Offset update macro
O9600 Bore or boss centre line find
O9601 Probe length calibration

Before you begin 5
O9602 Stylus Z,Y offset calibration

O9604 Vector stylus ball radius calibration
O9610 Protected positioning
O9611 XYZ single surface measure
O9612 Web / pocket measure
O9614 Bore / boss measure
O9619 Bore / boss on PCD
O9621 Angle single surface measure
O9622 Angle web / pocket measure
O9623 3-point bore / boss measure
O9630 Multi-stylus store
O9631 Multi-stylus load
O9634 Feature-to-feature measure
File3
O8000 Sphere calibration macro (S1)

O8001 Sphere calibration macro (S2)
O9550 C-axis basic move (S1)
O9551 C-axis offset update (S1)
O9618 C-axis measure – B90 (S1)
O9650 C-axis find – B90 (S1)
O9832 Offset update lower turret
O9845 C-axis basic move (S2)
O9846 C-axis offset update (S2)
Calibrating a probe using a datum sphere

Pages 5-32 and 5-35 of Chapter 5, “Calibrating the probe” describe how to fully calibrate a
probe and stylus using a datum sphere. This is the method recommended by Renishaw. If
you choose to use this method to calibrate your probe and stylus, you will need a datum
sphere. A suitable datum sphere calibration kit can be purchased from Renishaw –
contact your nearest Renishaw sales office and quote part number A-1034-0519.

6 Before you begin
Using probe cycles in a Mazatrol program and updating the

SET UP INFO
Mazatrol programming
On the Mazatrol Matrix control, 'SUB PROGRAM UNIT' is used to call a probe cycle.
NOTE: The 'MEASURE MACRO' method must be selected when calling a Renishaw
probing cycle.
To ensure that the Mazatrol SET UP INFO is updated at the correct point in a program,
use only 'SUB PROGRAM UNIT' in ‘MEASURE MACRO’ mode when calling an individual
Renishaw cycle from a Mazatrol main program.
To ensure that the Mazatrol SET UP INFO is updated from an ISO/EIA program, set
parameter F161.7 = 1.
An option parameter must also be set. Contact either Renishaw or Mazak for details.
ISO/EIA programming
If the probe cycle is used to update SET UP INFO, G52.5 G53.5 must then be
programmed after the probing cycle has finished to activate the new offset.
Using the probe on S2

The probe can be used on S2 with the same level of functionality as on S1.
Renishaw recommends that the multi-stylus option is used to store a different set of
calibration data for B0 and B180 orientations. The B90 orientation uses the same
calibration data for both spindles.
Program O8001 calibrates the probe using the sphere calibration cycle on S2.
It is recommended that calibration on S2 takes place in a bored hole of known diameter.

There is no requirement to recalibrate the length of the probe.
Note that Renishaw’s macros will not function if the “Mirror image” function is active.

Before you begin 7
Making a program RESTART

It is possible to make a program RESTART even if a probe cycle is used prior to the
program search position. Normally a probe alarm would be generated when reading the
program in the probe cycles because there is no probe triggering feedback, but the
macros now contain jump commands to skip through the macro without reading the code.
This feature can be used, provided the probe is NOT the active tool in the spindle when
searching for the unit number.
Updating the tool offset on the lower turret (O9832)

The Inspection Plus software can update a tool offset on the lower turret when the
machine’s software is version B6 or higher.
Macro O9832 must be manually loaded into the controller. This macro is situated in
macros\file3.
F109 = 2 must be set to make #100 / #101 common between the upper and lower turret.
To enable this feature, remove the brackets from the following lines of macros:
O9811 O9812 O9814 O9821 O9822 O9823 O9834

O9611 O9612 O9614 O9621 O9622 O9623 O9634.
()
(#100=[#143*#9]/2(LOWER T TL)
(#101=[#146*#9](LOWER M TL)
()
NOTE: Some programs contain only: (#101=[#146*#9](LOWER M TL)
When the measuring cycle has finished, the feature error is stored in #100 – #101.
Macro O9832 is used to update the tool offset on the lower turret. Wait commands must
be used to ensure that the correct update takes place.

8 Before you begin
T<1000 - Milling tool update
T>1000 - X wear update
T>2000 - Z wear update
O102(UPDATE EXAMPLE)
G90G21G80G17
G69.5
G109L1 Upper turret
G28U0
G28W0
M901
T40T0M6 Probe
M200
G52.5
G53.5
M81 Probe On
G65P9810Z10.Y0.F2000.
G65P9810X0
G65P9812Y16.Z-6. Web measure Y axis
G28U0
G28W0
P10 Wait command
P20 Wait command
M30
G109L2 Lower turret
M901
P10 Wait command
G65P9832T9.01 Update milling tool 9A
P20 Wait command
M30

Before you begin 9
Using the virtual simulation mode with Renishaw probes

Mazak Matrix has an additional simulation mode that is called virtual machining. If a
customer’s program contains a tool call for the probe or Renishaw probing cycles,
simulation mode will stop with no alarm.
Mazak has supplied a new variable:
#50601 = 1 Machine in simulation mode.
#50601 = 0 Machine in normal mode.
This variable is included in the Renishaw macros. However, the tool call that contains the
probe will also have to be jumped. For Mazatrol programmers, the tool call must be
moved into an ISO program and jumped using the above variable.
Renishaw customer services

Calling Renishaw
If you have a question about the software, first consult the documentation and other
information included with your product. If you cannot find a solution, you can receive
information on how to obtain customer support by contacting the Renishaw company that
serves your country (for worldwide contact details, see our main web site at
www.renishaw.com/contact).
When you call, it will help the Renishaw support staff if you have the appropriate product
documentation at hand. Please be prepared to provide the following information (as
applicable):
z The version of the product you are using (see the Equipment registration record
form).
z The type of hardware that you are using (see the Equipment registration record
form).
z The exact wording of any messages that appear on your screen.
z A description of what happened and what you were doing when the problem
occurred.
z A description of how you tried to solve the problem.

10 Before you begin
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Installing the software 1-1
Chapter 1
Installing the software
This chapter describes how to install the Inspection Plus software. It supplements the
information described in the ‘Software installation’ section of the installation manual titled
Probe systems for machine tools (Renishaw part no. H-2000-6040) and the Readme file
on the CD.
Contained in this chapter

Installing the software ...................................................................................................... 1-2
Setting and adjusting the software ................................................................................... 1-2

1-2 Installing the software
Installing the software

It is important that the software is installed to suit the type of controller and options
available. Do this as described below:
1. First, refer to Appendix B, “Features, cycles and limitations” to determine whether

the Inspection Plus software is suitable for your needs.
2. Next, choose which cycles you require (see the section titled “Macro numbers and
functions” in the preliminary part of this manual titled “Before you begin”).
3. Load the probe at B0 cycles on File1 (loading these cycles is mandatory).
4. If required, load the probe at B90 cycles on File2.
5. If required, load the C-axis and datum sphere calibration cycles on File3.
Setting and adjusting the software

After installing the software, you will need to customise the settings. Chapter 11, Settings,
macros and variables” contains descriptions about general software settings, customising
the software, and how to configure the option settings.

Optional inputs 2-1
Chapter 2
Optional inputs
Many of the macros make use of standard optional inputs. Instead of describing them
each time they are required, they are described once in this chapter. You will be referred
to this chapter from other chapters whenever a standard optional input is required.
Details of each non-standard optional input that is required by a macro is provided in the
relevant macro description.

Optional inputs ................................................................................................................. 2-2

2-2 Optional inputs
Optional inputs
The examples described below assume that the controller has been configured for metric
values (millimetres). The equivalent inch measurement values are shown in brackets.
Bb b= Angle tolerance of the surface, e.g. 30 degrees ± 1 degree inputs A30.B1.

Example: B5. to set a tolerance of 5 degrees.
Ee e= Experience value.
Specify the number of a spare tool offset where an adjustment value to
the measured size is stored (see Chapter 12, “General information”).
Example: E91. causes the experience value stored in tool offset 91 to be
applied to the measured size.
Ff f= This can be either one of the following:

1. The percentage feedback that is used when updating a tool offset
((see Chapter 12, “General information”). Enter a value between 0
and 1 (0 % and 100 %).
Default: 1 (100 %).
2. The feedrate that is used in protected positioning macros O9610 and
O9810 (see Chapter 4, “Protected positioning cycles”).
Example: F3000 sets a feedrate of 3000 mm/min.
(F120 sets a feedrate of 120 in/min.)
Hh h= The tolerance value of a feature dimension being measured.

Example: For dimension 50.0 mm +0.4 mm –0 mm, the nominal
tolerance is 50.2 mm with H.2.
(For dimension 1.968 in +0.016 in –0 in, the nominal
tolerance is 1.976 in with H.008.)
Mm m= The true position tolerance of a feature. This is a cylindrical zone about

the theoretical position. See Chapter 12, “General information”.
Example: M.1 sets a true position tolerance of 0.1 mm.
(M.004 sets a true position tolerance of 0.004 in.)
Qq q= This is the probe overtravel distance for use when the default values are
unsuitable. The probe will then travel beyond the expected position when
it searches for a surface.
Default: 4 mm (0.16 in) in the Z axis and 10 mm (0.394 in) in the X and Y
axes.
Example: Q8. sets an overtravel distance of 8 mm.
(Q.3 sets an overtravel distance of 0.3 in.)

Optional inputs 2-3
Rr r= This is an incremental dimension that is used in external features, such as

bosses and webs, to give a radial clearance from the nominal target
surface prior to a Z axis move.
Default: 5 mm (0.200 in).
Example: R10. sets a radial clearance of 10 mm.
(R.4 sets a radial clearance of 0.4 in.)
R–r –r = This is similar to Rr, except that the clearance is applied in the opposite
direction to force an internal boss or web cycle.
Default: 5 mm (0.200 in).
Example: R–10. sets a radial clearance of –10 mm.
(R–.4. sets a radial clearance of –0.4 in.)
Ss s= The number of the work offset to be updated.

S0 The external work offset.
S1 to S6 G54 to G59.
S8 Active SET UP INFO (see “Using probe cycles in a Mazatrol
program and updating the SET UP INFO” in “Before you
begin”).
S101 to S400 (G54.1 P1 to G54.1 P300) : Additional offsets option.
New work offset = active work offset + error.
New external offset = external offset + error.
Example: S3 will set G56
Note that additional work offsets G54.1 are not available on all machines.
Tt t= This is the Mazatrol tool data or ISO tool offset that is to be updated.
About Mazatrol tool data

T <1000 A milling tool is to be updated.
T >1000 A turning tool is to be updated.
T+ Update the diameter of a milling tool.
T– Update the length of a milling tool
T = 1000 Update the X-wear compensation of a turning tool.
T = 2000 Update the Z-wear compensation of a turning tool.

2-4 Optional inputs
About the suffix code number

A suffix code number is used to update the correct tool edge (see the
examples below). It is used only with Mazatrol tool data and not with ISO
tool offsets.
A = 0.01, B = 0.02 … Z = 0.24
Note there is no I or O suffix.
Hence, J = 0.09, P = 0.14, Z = 0.24 etc.
Note: If you wish to update a ‘heavy tool’, add 0.6 to the suffix code
number (see example T10.62 below).
Examples: with #120 in O9724 set to Mazatrol tool data:

Without a suffix
T10. Update the diameter of tool 10, which is a milling tool.
T–14. Update the length of tool 14, which is a milling tool.
T1012. Update the X-wear compensation of tool 12, which is a
turning tool.
T2008. Update the Z-wear compensation of tool 8, which is a
turning tool.
With a suffix
T10.02 Update the diameter of tool 10B, which is a milling tool.
T10.62 Update the diameter of heavy tool 10B, which is a milling
tool.
T–14.02 Update the length of tool 14B, which is a milling tool.
T1012.09 Update the X-wear compensation of tool 12J, which is a
turning tool.
T2008.18 Update the Z-wear compensation of tool 8T, which is a
turning tool.
About ISO tool offsets

T+ Update a milling tool.
Diameter: To update the diameter of the milling tool, enter a whole
positive number for the tool (e.g. 9.).
Length: To update the length of the milling tool, enter .1
immediately after the tool number (e.g. 9.1).
T– Update a turning tool.
Note that a suffix number is not used with ISO tool offsets.

Optional inputs 2-5
Examples: with #120 in O9724 set to ISO offsets:

T10. Update the diameter of tool 10, which is a milling tool.
T14.1 Update the length of tool 14, which is a milling tool.
T–8. Update tool 8, which is a turning tool.
Uu u= Upper tolerance limit.

If this value is exceeded, no tool offset or work offset is updated and the
cycle stops with an alarm. Where applicable, this tolerance applies to both
size and position..
Example: U2. to set the upper tolerance limit to 2 mm.
(U.08 to set the upper tolerance limit to 0.08 in.)
Vv v= Null band.
This is the tolerance zone in which no tool offset adjustment occurs.
Default: 0.
Example: V.5 for a tolerance zone of ±0.5 mm.
(V.02 for a tolerance zone of ±0.02 in.)
Ww w= Print the output data.

W1. Increment the feature number only.
W2. Increment the component number and reset the feature number.
Example: W1.

2-6 Optional inputs

Variable outputs 3-1
Chapter 3
Variable outputs
This chapter lists the variable outputs that are produced by some of the macros. You will
be referred to this chapter from other chapters when a variable output is produced.


3-2 Variable outputs
Variable outputs (probe at B90) – table 1
Single surface Web/ pocket Bore/boss C-axis PCD bore/boss
G65P9611 G65P9612 G65P9614 G65P9618/ G65P9619

G65P9840
# 135 X position Z position
# 136 Y position Y position Y position Y position
# 137 Z position Z position Z position PCD
# 138 Size Size Size Size
# 139 4th angle Angle
# 140 X error Z error
# 141 Y error Y error Y error Y error
# 142 Z error Z error Z error PCD error
# 143 Size error Size error Size error Height error Size error
# 144 Angle error Angle error
# 145 True position True position True position True position

error error error error
# 146 Metal condition Metal condition Metal condition Metal condition
# 147 Direction Hole number

indicator
# 148 Out of tolerance flag (1 to 7)
# 149 Probe error flag (0 to 2)

Angled single Angled 3-point Feature to C-axis

surface web/pocket bore/boss feature measure
G65P9621 G65P9622 G65P9623 G65P9634 G65P9650/

G65P9841
# 135 X incremental
distance
# 136 Y position Y position Y position Y incremental

from start distance
# 137 Z position Z position Z position Z incremental

from start distance
# 138 Size Size Size Minimum

from start distance
# 139 Angle C position
# 140 X error
# 142 Z error Z error Z error Z error
# 143 Size error Size error Size error Minimum

distance error
# 144 Angle error C error

# 147 Direction
indicator

Single surface Web/ pocket Bore/boss C-axis PCD bore/boss
G65P9811 G65P9812 G65P9814 G65P9818/ G65P9819

G65P9842
# 135 X position X position X position X position
# 136 Y position Y position Y position Y position
# 137 Z position PCD
# 138 Size Size Size Size
# 139 4th angle Angle
# 140 X error X error X error X error
# 142 Z error PCD error
# 143 Size error Size error Size error Height error Size error
# 144 Angle error Angle error

# 147 Direction Hole number

indicator

Angled single Angled 3-point Feature to C-axis

surface web/pocket bore/boss feature measure
G65P9821 G65P9822 G65P9823 G65P9834 G65P9850/

G65P9843
# 135 X position from X position X position X incremental

start distance
# 136 Y position Y position Y position Y incremental

from start distance
# 137 Z incremental
distance
# 138 Size Size Size Minimum

from start distance
# 139 Angle C position
# 140 X error X error X error X error
# 142 Z error
# 143 Size error Size error Size error Minimum

distance error
# 144 Angle error C error

# 147 Direction
indicator

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Protected positioning cycle 4-1
Chapter 4
Protected positioning cycles
As the probe moves around the workpiece it is important that the stylus is protected
against a collision with the workpiece. This chapter describes how to use the protected
positioning cycles. After they are set correctly, the probe will stop moving in the event of a
collision.

Probe protected positioning (probe at B90) – O9610 ...................................................... 4-2
Probe protected positioning (probe at B0) – O9810 ........................................................ 4-4

4-2 Protected positioning cycle (probe at B90)
Probe protected positioning (probe at B90) – O9610
X
Y
Figure 4.1 Probe protected positioning (probe at B90)
Description
It is important to protect the probe’s stylus against damage should it collide with an
obstacle as the probe moves around the workpiece. When this cycle is used, the machine
will stop in the event of a collision.
Application
The probe is selected and moved to a safe plane. At this point the probe is made active. It
then moves to a measuring position using this macro call.
In the event of a collision the machine will stop. Either a PATH OBSTRUCTED alarm is
generated or error flag #148 is set (see the M1. input).
Format
G65 P9610 Xx Yy Zz [ Ff M1. ]
where [ ] denote optional inputs.
Example: G65P9610 Z10. F3000. M1.

Protected positioning cycle (probe at B90) 4-3
Compulsory inputs
Xx x= The target radius / diameter position for the probe positioning move. It
must be programmed with respect to either G122.1 or G123.1.
Yy y= The target position for the probe positioning move.
Zz z= The target position for the probe positioning move.
Optional inputs
Ff f= The modal feedrate for all protected positioning moves.
The feedrate will be modal to this macro and subsequent feedrate calls
are unnecessary unless a change of feedrate is required. The maximum
safe fast feedrate established during installation must not be exceeded.
M1. This will set a probe trigger flag (but with no PATH OBSTRUCTED
alarm).
#148 = 0 No probe trigger.
#148 = 7 Probe triggered.
Example
Proprietary G and M codes.
T01M06 Select the probe.
M81 Switch on the probe.
G65P9610Z-10.X30.F3000 Protected positioning move.
G65P9611X20.T1003.1 Single surface measure.
M82 Switch off the probe.

Probe protected positioning (probe at B0) – O9810
X
Y
Figure 4.2 Probe protected positioning (probe at B0)
Description
It is important to protect the probe’s stylus against damage should it collide with an
obstacle as the probe moves around the workpiece. When this cycle is used, the machine
will stop in the event of a collision.
Application
The probe is selected and moved to a safe plane. At this point the probe is made active. It
then moves to a measuring position using this macro call.
In the event of a collision, the machine will stop. Either a PATH OBSTRUCTED alarm is
generated or error flag #148 is set (see the M1. input).
Format
G65 P9810 Xx Yy Zz [ Ff M1. ]
where [ ] denotes optional inputs.
Example: G65P9810 Z10. F3000. M1.

Protected positioning cycle (probe at B0) 4-5
Compulsory inputs
Xx x= The target radius / diameter position for the probe positioning move. It
must be programmed with respect to either G122.1 or G123.1.
Yy y= The target position for the probe positioning move.
Zz z= The target position for the probe positioning move.
Optional inputs
Ff f= The modal feedrate for all protected positioning moves.
The feedrate will be modal to this macro and subsequent feedrate calls
are unnecessary unless a change of feedrate is required. The maximum
safe fast feedrate established during installation must not be exceeded.
M1. This will set a probe trigger flag (but with no PATH OBSTRUCTED
alarm).
#148 = 0 No probe trigger.
#148 = 7 Probe triggered.
Example
Proprietary G and M codes.
M81 Switch on the probe
G65P9810X30.Z-10.F3000 Protected positioning move.
G65P9811X20.T1008 Single surface measure.

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Calibrating the probe 5-1
Chapter 5
Calibrating the probe
Before a probe is used, the probe and stylus must be calibrated correctly. Only when they
are calibrated accurately can you achieve total quality control over your manufacturing
process.
This chapter explains why it is so important that the probe is calibrated and then describes
how to use the macros that are provided to calibrate it.

Why calibrate a probe? .................................................................................................... 5-3
Calibrating in a bored hole or on a turned diameter ......................................................... 5-3
Calibrating in a ring gauge or on a datum sphere ............................................................ 5-3
Calibrating the probe length ............................................................................................. 5-4
Calibration cycles – an overview ...................................................................................... 5-4
Before calibrating a probe using a datum sphere ............................................................ 5-5
Calibrating the probe length (probe at B90) – O9601 ...................................................... 5-6
Establishing the position of a bore/boss (probe at B90) – O9600 .................................... 5-8
Calibrating the stylus Z and Y offsets (probe at B90) – O9602 ...................................... 5-10
Calibrating the vector stylus ball radius (probe at B90) – O9604 ................................... 5-12
Example 2: Full calibration on an external feature ......................................................... 5-17
Calibrating the probe length (probe at B0) – O9801 ...................................................... 5-19
Establishing the position of a bore/boss (probe at B0) – O9800 .................................... 5-21
Calibrating the stylus X and Y offsets (probe at B0) – O9802 ....................................... 5-23
Calibrating the vector stylus ball radius (probe at B0) – O9804 ..................................... 5-25

5-2 Calibrating the probe
Example 4: Full calibration on an external feature ......................................................... 5-30
Calibrating on a datum sphere (O8000) ......................................................................... 5-32

Editing macro O8000 .............................................................................................. 5-33
Calibrating on a datum sphere S2 (O8001) ................................................................... 5-35

Editing macro O8001 .............................................................................................. 5-35

Why calibrate a probe?

When you fit a probe into the machine shank/holder, it is not necessary for the probe’s
stylus to run true to the spindle centre line. A small amount of run-out can be tolerated, but
it is good practice to set the stylus mechanically on-centre to reduce the effects of spindle
and tool orientation errors. Without calibration, stylus run-out will lead to inaccurate
results. By calibrating the probe, run-out is automatically accounted for.
As each Renishaw probe is unique, it is important that you calibrate it in the following
circumstances:
z When a probe system is to be used for the first time.
z When a new stylus is fitted to the probe.
z When it is suspected that the stylus has become distorted or that the probe has
crashed.
z At regular intervals to compensate for mechanical changes of your machine tool.
z If repeatability of relocation of the probe shank is poor. In this case, the probe may
need to be recalibrated each time it is selected.
Three different operations may be used to calibrate a probe. They are:
z Calibrating in either a bored hole or on a turned diameter of known size.
z Calibrating either in a ring gauge or on a datum sphere.
z Calibrating the probe length.
Calibrating in a bored hole or on a turned diameter

Calibrating a probe either in a bored hole or on a turned diameter of known size
automatically stores values for the offset of the stylus ball to the spindle centre line. The
stored values are then used automatically in the measuring cycles. Measured values are
compensated by these values so that they are relative to the true spindle centre line.
Calibrating in a ring gauge or on a datum sphere

Calibrating a probe either in a ring gauge or on a datum sphere with a known diameter
automatically stores one or more value for the radius of the stylus ball. The stored values
are then used automatically by the measuring cycles to give the true size of the feature.
The values are also used to give true positions of single surface features.

5-4 Calibrating the probe
NOTE: The stored radii values are based on the true electronic trigger points. These
values are different from the physical sizes.
Calibrating the probe length

Calibrating a probe on a known reference surface determines the length of the probe,
based on the electronic trigger point. The stored value for length is different from the
physical length of the probe assembly. Additionally, the operation can automatically
compensate for machine and fixture height errors by adjusting the probe length value that
is stored.
Calibration cycles – an overview

Nine calibration cycles are provided with the Inspection Plus software. Four cycles are
used in conjunction with one another to fully calibrate a probe at the B90 position and four
are used in conjunction with one another to fully calibrate a probe at the B0 position.
The function of each macro is summarised below.
Macros O9600 and O9800 Used to establish the position of a bore or boss.
Macros O9601 and O9801 Used to establish the length of the probe in its tool shank.
Macros O9602 and O9802 Used to establish the off-centre values of the stylus.
Macros O9604 and O9804 Used to establish the vector radius values of the stylus
ball.
Macros O8000 and O8001 Macro O8000 combines all of the above macros into a
complete calibration solution. Macro O8001 establishes
the radius of the stylus ball and the stylus offset with the
probe oriented at B180. They are used only in conjunction
with a datum sphere to fully calibrate a probe/stylus
configuration.
For complete calibration of a probe system, use macros O9600, O9601, O9602 and
O9604 for calibrating a probe at the B90 position, or O9800, O9801, O9802 and O9804
for calibrating a probe at the B0 position. Examples of full calibration procedures in each
axis are described in the sections "Example 1 (or 3): Full calibration in an internal feature"
and "Example 2 (or 4): Full calibration on an external feature" later in this chapter.
Alternatively, if you have a datum sphere use either macro O8000 or O8001.

Before calibrating a probe using a datum sphere

This chapter describes how to fully calibrate a probe and stylus using a datum sphere.
This is the method recommended by Renishaw. If you choose to use this method to
calibrate your probe and stylus, you will need to purchase a suitable datum sphere from
Renishaw. Contact your nearest Renishaw sales office and quote part number
A-1034-0519.

5-6 Calibrating the probe (probe at B90)
Calibrating the probe length (probe at B90) – O9601
Tt
Tool offset
Xx
Reference height
Figure 5.1 Calibrating the probe length (probe at B90)
Description
The probe is positioned adjacent to a X axis reference surface. When the calibration cycle
is completed the active probe tool offset is adjusted to the reference surface.
Application
First load an approximate tool offset. Position the probe adjacent to the reference surface.
When the cycle is run the surface is measured and the tool offset is reset to a new value.
The probe then returns to the start position.
Format
G65 P9601 Xx Tt
Example: G65 P9601 X50. T20
Compulsory inputs
Tt t= Active tool offset number.
Xx x= Reference surface position.

Calibrating the probe (probe at B90) 5-7
Outputs
The active tool offset is set.
Example: Setting X, Y and Z values in the work offset

This example assumes that the G122.1 (radius mode) is active.
O0001
Proprietary G and M codes
G65P9610X100.F3000 Protected positioning move.
G65P9601X50.T1 Update the probe length in the X axis.
G65P9610X100. Protected positioning move.

Establishing the position of a bore/boss (probe at B90) – O9600
4 8
1 2
5 6
3 7 Xx
Z
Dd
Figure 5.2 Establishing the position of a bore/boss (probe at B90)
Description
The probe is positioned either inside or above a calibration artefact (a bore or boss) at a
height suitable for calibration. When the cycle is completed, the centre position of the bore
or boss is established.
Application
Clamp the artefact on the machine at an approximately known position. The probe to be
calibrated is positioned either inside or above the artefact on the approximate centre
position, with spindle orientation active.
When the cycle is run, four moves are made. The spindle is then rotated through
180 degrees and four more moves are made. Finally, the probe is returned to the start
position.
Format
G65 P9600 Dd [ Xx Ss ]
Example: G65 P9600 D50.005 X50. S1.
Compulsory inputs
Dd d= Size of the calibration artefact.

Optional inputs
Xx x= The absolute X axis measuring position when calibrating on an external
feature. If this is omitted, a ring gauge cycle is assumed.
For optional input Ss, see Chapter 2, “Optional inputs”.
Example: Establishing the position of a bore

Run a complete positioning and calibration program as follows.
Set the exact X,Y, Z feature positions in a work offset (for example, using G54).
O0002
G54 Select the work offset.
G65P9610Z0.Y0.F3000 Protected positioning move over the hole.
G65P9610X–5. Protected positioning move into the hole.
G65P9600D50.S1. Calibrate in a 50 mm (1.97 in) diameter bored hole and
update G54.
G65P9610X100.F3000 Protected positioning move retract to 100 mm (3.94 in).
M30 End of the program.

Calibrating the stylus Z and Y offsets (probe at B90) – O9602
1 2
#752
Y
3 Xx
Z
Dd
Figure 5.3 Calibrating the stylus Z and Y offsets (probe at B90)
Description
The probe is positioned inside a pre-machined hole at a height suitable for calibration.
When this cycle is completed, the stylus offset amounts in the Z and Y axes are stored.
Application
Pre-machine a hole with a suitable boring bar so that the exact centre of the hole is
known. Position the probe to be calibrated inside the hole, and the spindle on the known
centre position with the spindle orientation active.
When the cycle is run, four measuring moves are made to determine the Z-offset and
Y-offset of the stylus. The probe is then returned to the start position.
Format
G65 P9602 Dd [ Xx ]
Example: G65 P9602 D50.005 X50.
Compulsory input
Dd d= Nominal size of the feature.

Optional input
feature. If this is omitted a bore cycle is assumed.
Outputs
The following data will be stored:
#752 = Z axis stylus offset.
#753 = Y axis stylus offset.
NOTE: The actual variable is dependent on #112 that is set in O9724.
Example: Stylus Z, Y offset calibration

Set the exact X,Y, Z feature positions in a work offset (for example, using G54).
O0002
G65P9602D50. Calibrate in a 50 mm (1.97 in) diameter bored hole.

Calibrating the vector stylus ball radius (probe at B90) – O9604

Additional vector moves (7 to 14)
at every 30
#751 #750
1 2
5 6
3 Xx
Z
Dd
Figure 5.4 Calibrating the vector stylus ball radius (probe at B90)
Description
height suitable for calibration. When the cycle is completed, the stylus ball radius values
are stored. A total of 12 calibration radii at 30 degree intervals are established.
Application
Clamp the artefact on the machine table at an approximately known position. The probe to
be calibrated is positioned either inside or above the artefact on the approximate centre
When the cycle is run, 14 moves are made to determine the radius values of the stylus
ball. The probe is then returned to the start position.
Format
G65 P9604 Dd [ Xx Ss ]
Example: G65 P9604 D50.005 X50. S1.

Compulsory inputs
Optional inputs
Outputs
#750 = Z+, Z–, stylus ball radius (ZRAD)

#751 = Y+, Y–, stylus ball radius (YRAD)
Additional vector calibration data:
#760 = 30 degree stylus ball radius (VRAD)


Example: Vector stylus ball radius calibration

Set the approximate X, Y, Z feature positions in a work offset (for example, using G54).
O0004
G65P9604D50.001 Calibrate in a 50.001 mm (1.9685 in) diameter ring gauge.

Example 1: Full calibration in an internal feature

This example describes how to fully calibrate a probe in an internal feature using macros
O9600, O9601, O9602 and O9604.
1
14
2
13
3
X+
4 6
Y+
7
5
Z+
8 to 12
Figure 5.5 Full calibration in an internal feature (probe at B90)
It assumes the following conditions:
z The G122.1 (radius mode) is active.
z A 50.001 mm (1.9685 in) diameter ring gauge with a known top face height value is
used.
Before running this program, do the following:
z Store the approximate length of the probe in the tool offset register.
z Set the approximate Z and Y positions and the exact X position of the ring gauge in
a work offset (for example, using G54).
O0006
G54
1. T01M06 Select the probe.
2 & 3. G65P9610Z-35.Y0.F3000 Protected positioning move.
4. G65P9610X30. Protected positioning move above the reference

surface.

5. G65P9601X20.006T1. Calibrate the probe length. The surface is at

20.006 mm (7.876 in)
6. G65P9610Z0Y0 Protected positioning move to the centre.
7. G65P9610X10. Protected positioning move into the hole.
8. G65P9600D50.S1. Establish the centre position and update G54.
9. G54 Restate the work offset.
10. G65P9610Z0.Y0. Move to the centre of the ring gauge.
11. G65P9602D50.001 Calibrate in the 50.001 mm (1.9685 in) diameter

ring gauge to establish the X,Y stylus offset.

ring gauge to establish the radius values of the
stylus ball, including the vector directions.
13. G65P9610 X100. Protected positioning move retract to 100 mm

(3.94 in).
14. M82 Switch off the probe.

Example 2: Full calibration on an external feature

This example describes how to fully calibrate a probe on an external feature using macros
O9600, O9601, O9602 and O9604.
1
2 13
12
3
4 7 to 11
6 X+
Y+
5 Z+
Figure 5.6 Full calibration on an external feature (probe at B90)
z The G122.1 (radius mode) is active.
z A 50.001 mm (1.9685 in) diameter boss with a known X-reference surface is used.
z Set the approximate Z and Y positions and the exact X surface height of the boss in
a work offset (for example, using G54).
O0006
G54
2 & 3. G65P9610Z-35.Y0. Protected positioning move.
4. G65P9610X30.F3000 Protected positioning move above the reference

surface.

5. G65P9601X-15.T1. Calibrate the probe length. The X surface is at

-15 mm.
6. G65P9610Z0.Y0. Protected positioning move to the centre.
7. G65P9600D50.X-10.S1. Establish the centre position and update G54.
9. G65P9610Z0.Y0. Move to the centre of the boss.
10. G65P9602D50.001X-10. Calibrate on the 50.001 mm (1.9685 in) diameter

boss to establish the Z,Y stylus offset.
11. G65P9604D50.001X-10. Calibrate on the 50.001 mm (1.9685 in) diameter

boss to establish the radius values of the stylus
ball, including the vector directions.
12. G65P9610X100. Protected positioning move retract to 100 mm

(3.94 in).

Calibrating the probe length (probe at B0) – O9801

Tt Tool offset
X
Y
Zz Reference height
Figure 5.7 Calibrating the probe length (probe at B0)
Description
The probe is positioned adjacent to a Z axis reference surface. When the calibration cycle
is completed the active probe tool offset is adjusted to the reference surface.
Application
Load an approximate tool offset. The probe should be positioned adjacent to the reference
surface.
When the cycle is run, the surface is measured and the tool offset is reset to a new value.
The probe is then returned to the start position.
Format
G65 P9801 Zz Tt
Example: G65 P9801 Z–10. T20
Compulsory inputs
Tt t= Active tool offset number.
Zz z= Reference surface position.
Outputs
The active tool offset will be set.

Example: Setting X, Y and Z values in work offset G54

This example assumes that the G123.1 (diameter mode) is active.
O 0001
G65P9810Z10.F3000 Protected positioning move.
G65P9801Z-10.T1 Update the probe length in the Z axis.
G65P9810Z100. Protected positioning move.
M30 End of the program

Establishing the position of a bore/boss (probe at B0) – O9800
Zz
4 8
1 2
5 6
3 7
Y
Dd
Figure 5.8 Establishing the position of a bore/boss (probe at B0)
Description
height suitable for calibration. When the cycle is completed, the centre position of the bore
or boss is established.
Application
Clamp the artefact on the machine at an approximately known position. The probe to be
calibrated is positioned either inside or above the artefact on the approximate centre
When the cycle is run, four moves are made. The spindle is then rotated through
180 degrees and four more moves are made. Finally, the probe is returned to the start
position.
Format
G65 P9800 Dd [ Zz Ss ]
Example: G65 P9800 D50.005 Z50. S1.
Compulsory inputs

Optional inputs
Zz z= The absolute Z axis measuring position when calibrating on an external
Example: Establishing the position of a bore

Set the approximate Z and C feature positions in the Mazatrol set-up information.
O0004
G52.5 and G53.5 Select the Mazatrol set-up information.
G65P9810X0.Y0.F3000 Protected positioning move over the hole.
G65P9810Z–5. Protected positioning move into the hole.
G65P9800D25.001S1. Calibrate in a 25.001 mm (0.9843in) diameter ring gauge and
update G54.
G65P9810Z100.F3000 Protected positioning move retract to 100 mm (3.94 in).

Calibrating the stylus X and Y offsets (probe at B0) – O9802

Zz
4
1 2
#702
X
3
Y
Dd
Figure 5.9 Calibrating the stylus X and Y offsets (probe at B0)
Description
The probe is positioned inside a pre-machined hole at a height suitable for calibration.
When this cycle is completed, the stylus offset amounts in the X and Y axes are stored.
Application
Pre-machine a hole with a suitable boring bar so that the exact centre of the hole is
known. Position the probe to be calibrated inside the hole, and the spindle on the known
centre position with the spindle orientation active.
When the cycle is run, four measuring moves are made determine the X offset and
Y offset of the stylus. The probe is then returned to the start position.
Format
G65 P9802 Dd [ Zz ]
Example: G65 P9802 D50.005 Z50.
Compulsory input

Optional input
feature. If this is omitted, a bore cycle is assumed.
Outputs
#702 = X axis stylus offset
#703 = Y axis stylus offset
Example: Stylus X, Y offset calibration

O0002
G65P9802D25.001 Calibrate in a 25.001 mm (0.9843 in) diameter bored hole.

Calibrating the vector stylus ball radius (probe at B0) – O9804

Additional vector moves (7 to 14)
at every 30°
Zz
4
#701 #700
1 2
5 6
3
Y
Dd
Figure 5.10 Calibrating the vector stylus ball radius (probe at B0)
Description
height suitable for calibration. When the cycle is completed, the stylus ball radius values
are stored. A total of 12 calibration radii at 30 degree intervals are established.
Application
Clamp the artefact on the machine table at an approximately known position. The probe to
be calibrated is positioned either inside or above the artefact on the approximate centre
When the cycle is run, 14 moves are made to determine the radius values of the stylus
ball. The probe is then returned to the start position.
Format
G65 P9804 Dd [ Zz Ss ]
Example: G65 P9804 D50.005 Z50. S1.
Compulsory inputs

Optional inputs
feature. If this is omitted a ring gauge cycle is assumed.
Outputs
#700 = X+, X–, stylus ball radius (XRAD)

#701 = Y+, Y–, stylus ball radius (YRAD)
Additional vector calibration data:

Example: Vector stylus ball radius calibration

O0004

G65P9804D25.001 Calibrate in a 25.001 mm (0.9843 in) diameter ring gauge.



Example 3: Full calibration in an internal feature

This example describes how to fully calibrate a probe in an internal feature using macros
O9800, O9801, O9802 and O9804.
4 3
5 2
6
7
X+
13 14
Y+
8 to 12
Z+
Figure 5.11 Full calibration in an internal feature (probe at B0)
z The G123.1 (diameter mode) is active.
z A 25.001 mm (0.9843 in) diameter ring gauge with a known front face height value is
used.
z Set the approximate X and Y positions and the exact Z position of the ring gauge in
a work offset (for example, using G54) or in the Mazatrol set-up information (G53.5).
O0006
G54
2 & 3. G65P9810X35.Y0.F3000 Protected positioning move.
4. G65P9810Z20. Protected positioning move above the reference

surface.
5. G65P9801Z10.T1. Calibrate the probe length.

6. G65P9810X0Y0 Protected positioning move to the centre.
7. G65P9810Z0. Protected positioning move into the hole.
8. G65P9800D25.S1. Establish the centre of the ring gauge and update

G54.
10. G65P9810X0.Y0. Move to the centre of the ring gauge.
11. G65P9802D25.001. Calibrate in the 25.001 mm (0.9843 in) diameter

ring gauge to establish the X,Y stylus offset.

ring gauge to establish the radius values of the
stylus ball, including the vector directions.
13. G65P9810 Z100. Protected positioning move retract to 100 mm

(3.94 in).
M30 End of the program

Example 4: Full calibration on an external feature

This example describes how to fully calibrate a probe on an external feature using macros
O9800, O9801, O9802 and O9804.
1
4 3 2
5
6 X+
12 13 Y+
7 to 11 Z+
Figure 5.12 Full calibration on an external feature (horizontal probe)
z The G123.1 (diameter mode) is active.
z A 25.001 mm (0.9843 in) diameter boss with a known Z-reference surface is used.
z Set the approximate X and Y positions and the exact Z surface height of the boss in
a work offset (for example, using G54) or in the Mazatrol set-up information (G53.5).
O0006
G54
4. G65P9810Z10. Protected positioning move above the reference

surface.
5. G65P9801Z-20.T1. Calibrate the probe length. The Z surface is at

-20 mm.

6. G65P9810X0.Y0. Protected positioning move to the centre.
7. G65P9800D25.S1.Z-10. Establish the centre position of the boss and

update G54.
9. G65P9810X0.Y0. Move to the centre of the boss.
10. G65P9802D25.001Z-10. Calibrate on the 25.001 mm (0.9843 in) diameter

boss to establish the X,Y stylus offset.
11. G65P9804D25.001Z-10. Calibrate on the 25.001 mm (0.9843 in) diameter

boss to establish the radius values of the stylus
ball, including the vector directions.
12. G65P9810Z100. Protected positioning move retract to 100 mm

(3.94 in).
13 M82 Switch off the probe.

5-32 Calibrating on a datum sphere (O8000)
Calibrating on a datum sphere (O8000)

Using a Renishaw datum sphere (part number A-1034-0519) is the quickest and most
accurate method of calibrating the spindle probe. The centre of the sphere can be
established automatically without the need for a dial test indicator (DTI) or calibration bars.
The automatic routine provides a complete calibration solution, calculating the probe
length, radius of the stylus ball, and stylus offset for both B0 and B90 orientations.
Program O8000 is used for sphere calibration and must be edited to suit individual
applications. The approximate sphere centre and probe length must be entered into a
spare work and tool offset.
During the program, the ‘B’ axis is rotated firstly to B0 and then to B90 before returning to
B0. All ‘B’ axis moves take place at the machine reference position. Before running the
cycle, clearances must be checked to avoid any collision.
The following figures explain sphere calibration in greater detail:
Element 1
Establish the XY centre

of the datum sphere.
Calibrate the XY stylus

offset and the radius of
the stylus ball.
Element 2
For B90 orientation,
establish the Z centre of
the datum sphere.
Calibrate the ZY stylus
offset and radius of the
stylus ball.

Calibrating on a datum sphere (O8000) 5-33
Element 3
For B0 orientation,
calibrate the probe
length.
Editing macro O8000

Read the following variable descriptions then edit macro O8000 as described.
O8000(REN AUTO SPHERE CAL MK IV S1)

(SET APPROXIMATE PROBE LENGTH IN TOOL OFFSET BEFORE RUNNING)
(SET APPROXIMATE SPHERE CENTRE IN A WORK OFFSET OR VARIABLE)
(#1=1 G54)
(#1=6 G59)
(#1=7 MAZATROL SETUP INFO)
#1=#0(SET WORK OFFSET NUMBER) Select the work offset to be used for
the sphere centre.
#2=#0(SETTING SPHERE DIAMETER Input the diameter of the sphere.
SIZE)
#3=#0(STYLUS BALL DIAMETER) Input the diameter of the stylus ball.
#4=#0(ISO TOOL OFFSET B0) If using ISO tool offsets, select the offset
number where the probe length will be
stored (probe at B0).
#6=#0(TOOL NUMBER) Select the tool number for the probe. If

using Mazatrol Tool Data, this number is
used to update the probe length.

5-34 Calibrating on a datum sphere (O8000)
#7=0(MULTI STYLUS REQUIRED. Select if calibration of multiple styli

0 = NO, 11 OR 12 = YES) is required.
#24=0(*SETUP INFO ONLY* X RADIAL Enter the sphere X centre.

DIST MACHINE C/L TO SPHERE C/L) Setup info only. Default: 0
#25=0(*SETUP INFO ONLY* Y DIST Enter the sphere Y centre.

MACHINE C/L TO SPHERE C/L) Setup info only. Default: 0

Calibrating on a datum sphere S2 (O8001) 5-35
Calibrating on a datum sphere S2 (O8001)

Using a Renishaw datum sphere (part number A-1034-0519) is the quickest and most
accurate method of calibrating the spindle probe. The centre of the sphere can be
established automatically without the need for a dial test indicator (DTI) or calibration bars.
The automatic routine calculates the radius of the stylus ball and stylus offset for B180
orientation.
Program O8001 is used for sphere calibration on S2 and must be edited to suit individual
applications. The approximate sphere centre must be entered into a spare work offset.
During the program, the ‘B’ axis is rotated to B180. All ‘B’ axis moves take place at a
machine reference position. Before running the cycle, clearances must be checked to
avoid any collision.
The following figure explains sphere calibration in greater detail:
Element 1
Establish the XY centre

of the datum sphere.
Calibrate the XY stylus

offset and the radius of
the stylus ball.
Editing macro O8001

Read the following variable descriptions then edit macro O8001 as described.
O8001(REN AUTO SPHERE CAL MKIV S2)

(PROBE LENGTH MUST BE CALIBRATED ON S1)
(SET APPROXIMATE SPHERE CENTRE IN A WORK OFFSET OR VARIABLE)
(#1=1 G54)
(#1=6 G59)
(#1=7 MAZATROL SETUP INFO)
#1=#0(SET WORK OFFSET NUMBER) Select the work offset to be used for
the sphere centre.

5-36 Calibrating on a datum sphere S2 (O8001)
#2=#0(SETTING SPHERE DIAMETER Input the diameter of the sphere.

SIZE)
#3=#0(STYLUS BALL DIAMETER) Input the diameter of the stylus ball.
#7=0(MULTI STYLUS REQUIRED. Select if calibration of multiple styli

0 = NO, 11 OR 12 = YES) is required.
#24=0(*SETUP INFO ONLY* X RADIAL Enter the sphere X centre.

DIST MACHINE C/L TO SPHERE C/L) Setup info only. Default: 0
#25=0(*SETUP INFO ONLY* Y DIST Enter the sphere Y centre.

MACHINE C/L TO SPHERE C/L) Setup info only. Default: 0

Standard measuring cycles 6-1
Chapter 6
Standard measuring cycles
This chapter describes how to use the non-vector measuring cycles with vertically-
mounted and horizontally-mounted probes.

X Y Z single surface measurement (probe at B90) – O9611 ........................................... 6-2
X Y Z single surface measurement (probe at B0) – O9811 ........................................... 6-13

6-2 Standard measuring cycles (probe at B90)
X Y Z single surface measurement (probe at B90) – O9611
X
Y
Figure 6.1 Measurement of a single surface (probe at B90)
Description
This cycle measures a surface to establish the size or position.
Application
The probe, with its tool offset active, should be positioned adjacent to the surface. The
cycle measures the surface and returns to the start position.
There are two possibilities, as follows:
1. The surface can be treated as a size, where the tool offset is updated in conjunction
with the Tt and the Hh input.
2. The surface can be treated as a reference surface position, for the purpose of
adjusting a work offset using the Ss and Mm inputs.
Format
G65 P9611 Xx or Yy or Zz [ Cc Ee Ff Hh Ii Mm Qq Ss Tt Uu Vv Ww ]
Example: G65 P9611 X50. E90 F0.8 H0.2 M.2 Q10. S1. T20. U.5 V.5 W2.

Standard measuring cycles (probe at B90) 6-3
Compulsory inputs
Xx x= The target radius / diameter position for the probe positioning move.
It must be programmed with respect to either G122.1 or G123.1.
or
Yy y= The surface position or size.
or
Zz z= The surface position or size.
Optional inputs
Cc c= Inputs Cc and Ii are used with the reference touch option. This option
eliminates thermal growth errors from within the probe results, helping to
maintain measuring accuracy.
c = 1. Takes the error from the reference diameter and stores it in #134.
c = 2. Takes the error stored in #134 and adds it to the results of the
measured diameter.
C=1
C=2
Chuck
Figure 6.2 Reference touch option
Ii i= This is the maximum tolerance used with the Cc input. This input is
compulsory if the Cc input is used.
For other optional inputs, see Chapter 2, "Optional inputs".

Example: X and Z single surface measurement
8 1
7
5
X 4
Y 6
2
3
Z
Figure 6.3 Probe movements

2. G65P9610X–8.Y0.F3000 Protected positioning move to the start position.
3. G65P9611Z0.T2010.01 Single surface measure.
4. G65P9610X10. Protected positioning move.
5. G65P9610Z–6. Protected positioning move.
6. G65P9611X0T11.02 Single surface measure.
continue
Data for the following tools is updated by the error of the surface position:
z The Z-wear compensation of turning tool 10A.
z The diameter of milling tool 11B.

Web/pocket measurement (probe at B90) – O9612
Xx
Rr
Zz, Yy Zz, Yy
X
Y
Z Xx
R-r
Zz, Yy
Figure 6.4 Measurement of a web or pocket feature (probe at B90)
Description
This cycle measures a web or pocket feature. It uses two measuring moves along the Z Y
axis.
Application
Position the probe to the expected centre line of the feature and at a suitable position in
the X axis with the probe and probe offset active. Run the cycle with suitable inputs as
described.

Format
G65 P9612 Zz [ Ee Ff Hh Mm Qq Rr Ss Tt Uu Vv Ww ]
or
G65 P9612 Yy [ Ee Ff Hh Mm Qq Rr Ss Tt Uu Vv Ww ]
or
G65 P9612 Xx Zz [ Ee Ff Hh Mm Qq Rr Ss Tt Uu Vv Ww ]
or
G65 P9612 Yy Xx [ Ee Ff Hh Mm Qq Rr Ss Tt Uu Vv Ww ]
Example: G65 P9612 X50. Z100. E91 F0.8 H0.2 M.2 Q10. R10. S1. T20. U.5 V.5 W2.
Compulsory inputs
Zz z= Nominal size of the feature when measured in the Z axis.
or
Yy y= Nominal size of the feature when measured in the Y axis.
Xx x= The absolute X axis position when measuring a web feature. If this is

omitted, a pocket cycle is assumed.
Optional inputs
See Chapter 2, "Optional inputs".
Outputs
See Chapter 3, "Variable outputs".

Example 1: Measuring a web
1 5
4
2
3
X
Y 3
G54

2. G65P9610Z-10.Y0.X30.F3000 Protected positioning move.
3. G65P9612Y50.X10.S2 Measure a 50.0 mm (1.968 in) wide web.

continue
The feature centre line in the Y axis is stored in the work offset 02 (G55).

Example 2: Measuring a pocket (referred datum)
6 1
5
X
Y 4
3
G54

2. G65P9610X100.Y0.F3000 Protected positioning move.
3. G65P9610X–10. Protected positioning move.
4. G65P9612Y30.S2 Measure a 30.0 mm (1.181 in) wide pocket.

continue
The error of the centre line is referred to the datum point Y0 and the revised Y0 position is
set in work offset 02 (G55).

Bore/boss measurement (probe at B90) – O9614
Xx
Rr
Dd dia Dd dia
X
Y
Xx
Z
R-r
Dd dia
Figure 6.7 Measurement of a bore or boss feature (probe at B90)
Description
This cycle measures a bore or boss feature. It uses four measuring moves along the Z Y
axis.
Application
the X axis with the probe and probe offset active. Run the cycle with suitable inputs as
described.

Format
G65 P9614 Dd [ Ee Ff Hh Mm Qq Rr Ss Tt Uu Vv Ww ]
or
G65 P9614 Dd Xx [ Ee Ff Hh Mm Qq Rr Ss Tt Uu Vv Ww ]
Example: G65 P9614 D50.005 X100. E92 F0.8 H0.2 M.2 Q10. R10. S1. T20.
U.5 V.5 W2.
Compulsory inputs
Xx x= The absolute X axis position when measuring a boss feature. If this is

omitted, a bore cycle is assumed.
Optional inputs
Outputs

Example 1: Measuring a boss
5 1
4
2
X 3
Y
3
Z
G54

2. G65P9610Z-20.X30.Y0.F3000 Protected positioning move.
3. G65P9614D50.X10.S2.R10. Measure a 50.0 mm (1.968 in) diameter

boss.
continue
The feature centre line in the Z and Y axis is stored in the work offset 02 (G55).

Example 2: Measuring a bore (referred datum)
6 2
5 1
X
3
Y
Z 4
G54
2. G65P9610Z-20.Y0.F3000 Protected positioning move.
3. G65P9610X-10. Protected positioning move.
4. G65P9614D30.S2 Measure a 30.0 mm (1.181 in) diameter bore.
continue
The error of the centre line is referred to the datum point Z0, Y0 and the revised Z0, Y0
position is set in work offset 02 (G55).

X Y Z single surface measurement (probe at B0) – O9811
X
Y
Figure 6.10 Measurement of a single surface (probe at B0)
Description
This cycle measures a surface to establish the size or position.
Application
The probe, with its tool offset active, should be positioned adjacent to the surface. The
cycle measures the surface and returns to the start position.
There are two possibilities, as follows:
1. The surface can be treated as a size, where the tool offset is updated in conjunction
with the Tt and the Hh input.
2. The surface can be treated as a reference surface position, for the purpose of
adjusting a work offset using the Ss and Mm inputs.
Format
G65 P9811 Xx or Yy or Zz [ Cc Ee Ff Hh Ii Mm Qq Ss Tt Uu Vv Ww ]
Example: G65 P9811 X50. E90 F0.8 H0.2 M.2 Q10. S1. T20. U.5 V.5 W2.

Compulsory inputs
Xx x= The target radius / diameter position for the probe positioning move.
or It must be programmed with respect to either G122.1 or G123.1.
Yy y= The surface position or size.
or
Zz z= The surface position or size.
Optional inputs
Cc c= Inputs Cc and Ii are used with the reference touch option. This option
eliminates thermal growth errors from within the probe results, helping to
maintain measuring accuracy.
c = 1. Takes the error from the reference diameter and stores it in #134.
c = 2. Takes the error stored in #134 and adds it to the results of the
measured diameter.
C=1
C=2
Chuck
Figure 6.11 Reference touch option
Ii i= This is the maximum tolerance used with the Cc input. This input is
compulsory if the Cc input is used.

Example: X and Z single surface measurement

X
Y
1
Z
3
5
4
7 2
6
G54
3. G65P9810Z–8. Protected positioning move to the start position.
4. G65P9811X0.T10.02 Single surface measure.
5. G65P9810Z10. Protected positioning move.
7. G65P9811Z0T1011.01 Single surface measure.
continue
Data for the following tools is updated by the error of the surface position:
z The diameter of milling tool 10B.
z The X-wear compensation of turning tool 11A.

Web/pocket measurement (probe at B0) – O9812

Zz
Zz
R-r Rr
Xx, Yy Xx, Yy
X
Y
Xx, Yy
Figure 6.13 Measurement of a web or pocket feature (probe at B0)
Description
This cycle measures a web or pocket feature. It uses two measuring moves along either
the X axis or the Y axis.
Application
the Z axis with the probe and probe offset active. Run the cycle with suitable inputs as
described.

Format
G65 P9812 Xx [ Ee Ff Hh Mm Qq Rr Ss Tt Uu Vv Ww ]
or
G65 P9812 Yy [ Ee Ff Hh Mm Qq Rr Ss Tt Uu Vv Ww ]
or
G65 P9812 Xx Zz [ Ee Ff Hh Mm Qq Rr Ss Tt Uu Vv Ww ]
or
G65 P9812 Yy Zz [ Ee Ff Hh Mm Qq Rr Ss Tt Uu Vv Ww ]
Example: G65 P9812 X50. Z100. E92 F0.8 H0.2 M.2 Q10. R10. S1. T20. U.5 V.5 W2.
Compulsory inputs
Xx x= Nominal size of the feature when measured in the X axis.
or
Yy y= Nominal size of the feature when measured in the Y axis.
Zz z= The absolute Z axis position when measuring a web feature. If this is

Optional inputs
Outputs

Example 1: Measuring a web
1
4
X
Y 2
4 3
Z 5 6
G54
2. G65P9810X-10.Y0.F3000 Protected positioning move.
4. G65P9812Y50.Z0.S2 Measure a 50.0 mm (1.968 in) wide web.
continue
The feature centre line in the X axis is stored in the work offset 02 (G55).

Example 2: Measuring a pocket (referred datum)
1
X
Y
3 4
2
Z
5 6
3. G65P9810Z-10. Protected positioning move.
4. G65P9812Y30.S8 Measure a 30.0 mm (1.181 in) wide pocket.
continue
The error of the centre line is referred to the datum point X0 and the revised X0 position is
set in work offset 02 (G55).

Bore/boss measurement (probe at B0) – O9814

Zz
Zz
Rr
R-r
Dd dia Dd dia
X
Y
Dd dia
Figure 6.16 Measurement of a bore or boss feature (probe at B0)
Description
This cycle measures a bore or boss feature. It uses four measuring moves along the X Y
axis.
Application
the Z axis with the probe and probe offset active. Run the cycle with suitable inputs as
described.
Format
G65 P9814 Dd [ Ee Ff Hh Mm Qq Rr Ss Tt Uu Vv Ww ]
or
G65 P9814 Dd Zz [ Ee Ff Hh Mm Qq Rr Ss Tt Uu Vv Ww ]

Example: G65 P9814 D50.005 Z100. E91 F0.8 H0.2 M.2 Q10. R10. S1. T20.
U.5 V.5 W2.
Compulsory inputs
Zz z= The absolute Z axis position when measuring a boss feature. If this is

Optional inputs
Outputs
Example 1: Measuring a boss
X 4 1
Y 3 2
Z
5 6
4
G54
4. G65P9814D20.Z–10.S2.R10. Measure a 20.0 mm (0.787 in) diameter boss.
continue
The feature centre line in the X and Y axis is stored in work offset 02 (G55).

Example 2: Measuring a bore
X 4 1
Y 3 2
Z
4 5 6
G54
4. G65P9814D25.S2 Measure a 25.0 mm (0.984 in) diameter bore.
continue
The feature centre line in the X and Y axis is stored in work offset 02 (G55).

Vector measuring cycles 7-1
Chapter 7
Vector measuring cycles
This chapter describes how to use the vector measuring cycles with both vertically-
mounted and horizontally-mounted probes.

Angled single surface measurement (probe at B90) – O9621 ......................................... 7-2
Angled web or pocket measurement (probe at B90) – O9622 ......................................... 7-4
Angled single surface measurement (probe at B0) – O9821 ........................................... 7-9
Angled web or pocket measurement (probe at B0) – O9822 ......................................... 7-11

7-2 Vector measuring cycles (probe at B90)
Angled single surface measurement (probe at B90) – O9621
NOTE:
Angles are in the range ±180 degrees.
+Aa (positive) angle: Counter-clockwise
Dd direction.
–Aa (negative) angle: Clockwise direction.
Y o
90
Aa
o o
Z 180 0
o
-90
Figure 7.1 Measuring an angled surface
Description
This cycle measures a surface feature using one vectored measuring move along the Z Y
axis.
Application
Position the probe to the expected reference point of the feature and at a suitable position
in the X axis, with the probe and probe offset active. Run the cycle with suitable inputs as
described.
Format
G65 P9621 Aa Dd [ Ee Ff Hh Mm Qq Ss Tt Uu Vv Ww ]
Example: G65 P9621 A45.005 D50.005 E91 F0.8 H0.2 M0.2 Q10. S1. T20. U.5 V.5 W2.
Compulsory inputs
Aa a= Direction of probe measurement measured from the Z+ axis direction.
Dd d= Nominal distance to the surface (radius).
Optional inputs
See Chapter 2, “Optional inputs”.

Vector measuring cycles (probe at B90) 7-3
Outputs
Example: Angled single surface measurement
50.0
45 o
Z
Figure 7.2 Measuring a single angled surface
G54
2 1 1 & 2. T01M06 Select the probe.
3
9 M81 Switch on the probe.
4
8
3 & 4. G65P9610Z–40.Y20.F3000 Protected positioning move.
5 5. G65P9610X8. Protected positioning move to the
7
start position.
6 6. G65P9621A45.D50.T10.01 Single surface measure.

X 7. G65P9610X40. Protected positioning move.
Y
8 & 9. M82 Switch off the probe.
Z
The diameter of tool 10A is updated by the error of the surface position.
Figure 7.3
Probe movements

Angled web or pocket measurement (probe at B90) – O9622
Aa
Y+
Aa
180° 0°
A-a
Z+
Dd
Aa
NOTE:
+Aa (positive) angle: Counter-clockwise direction.
Aa
Figure 7.4 Measuring an angled web or pocket (probe at B90)
Description
This cycle measures a web or pocket feature using two vectored measuring moves along
the Z Y axis.
Application
Position the probe to the expected centre line of the feature and at a suitable position in the X
axis, with the probe and probe offset active. Run the cycle with suitable inputs as described.

Format
G65 P9622 Aa Dd [ Ee Ff Hh Mm Qq Rr Ss Tt Uu Vv Ww ]
or
G65 P9622 Aa Dd Xx [ Ee Ff Hh Mm Qq Rr Ss Tt Uu Vv Ww ]
Example: G65 P9622 A45.005 D50.005 X50. E91 F0.8 H0.2 M0.2 Q10. R10. S1.
T20. U.5 V.5 W2.
Compulsory inputs
Aa a= Angle of the surface to be measured from the Z+ axis direction.
Xx x= The absolute X axis position when measuring a web feature. If this is

Optional inputs
Outputs

Example: Angled web measurement
50.0
-10
30º
Figure 7.5 Measuring an angled web (probe at B90)
G54
2 1 1 & 2. T01M06 Select the probe.

8
3 M81 Switch on the probe.
4
3 & 4. G65P9610Z0.Y0.F3000 Protected positioning move.
7
5 5. G65P9610X10. Protected positioning move.
6. G65P9622A30.D50.X–10.S2 Measure a 50.0 mm (1.9685 in)

6 6
wide web at 30 degrees.

X
Y Continue
Z The feature centre line in the Z axis is stored in the work offset S02 (G55).
Figure 7.6
Probe movements

3-point bore or boss measurement (probe at B90) – O9623
90°
Bb
Aa
180° 0°
Cc
Rr
-90°
Dd
NOTE:
R-r
Figure 7.7 3-point bore or boss measurement (probe at B90)
Description
This cycle measures a bore or boss feature using three vectored measuring moves along
the Z Y axis.
Application
Position the probe to the expected centre line of the feature and at a suitable position in the X
axis, with the probe and probe offset active. Run the cycle with suitable inputs as described.
Format
G65 P9623 Aa Bb Cc Dd [ Ee Ff Hh Mm Qq Rr Ss Tt Uu Vv Ww ]
or
G65 P9623 Aa Bb Cc Dd Xx [ Ee Ff Hh Mm Qq Rr Ss Tt Uu VvWw ]
Example: G65 P9623 A45.005 B150.0 C35.005 D50.005 X50. E92 F0.8 H0.2 M0.2
Q10. R10. S1. T20. U.5 V.5. W2.

Compulsory inputs
Aa a= The first angle for vector measurement, measured from the Z+ axis
direction.
Bb b= The second angle for vector measurement, measured from the Z+ axis
direction.
Cc c= The third angle for vector measurement, measured from the Z+ axis
direction.
Xx x= The absolute X axis position when measuring a boss feature. If this is

Optional inputs
Outputs
Example: 3-point bore measurement (referred datum)

2 1
8
3 G54
4 1 & 2. T01T00M06 Select the probe.

7
5
3 & 4. G65P9610Z100.Y100.F3000 Protected positioning move.
5. G65P9610X40. Protected positioning.
6 6. G65P9623D30.A30.B150. Measure a 30.0 mm

C–90.S2 (1.181 in) diameter bore.
X 7. G65P9610X100. Protected positioning move.
Y
Z
8. G91G28X0. Reference return.
Figure 7.8
Continue
Probe movements
The error of the centre line is referred to the datum point Z0,Y0 and the revised Z0,Y0

Angled single surface measurement (probe at B0) – O9821

0°
NOTE:
Dd
90° –90° direction.
X+
Aa
180°
Y+
Figure 7.9 Measuring an angled surface (horizontal probe)
Description
This cycle measures a surface feature using one vectored measuring move along the X Y
axis.
Application
Position the probe to the expected reference point of the feature and at a suitable position
in the Z axis, with the probe and probe offset active. Run the cycle with suitable inputs as
described.
Format
G65 P9821 Aa Dd [ Ee Ff Hh Mm Qq Ss Tt Uu Vv Ww ]
Example: G65 P9821 A45.005 D50.005 E91 F0.8 H0.2 M0.2 Q10. S1. T20. U.5 V.5 W2.
Compulsory inputs
Aa a= Direction of the probe measurement measured from the X+ axis direction.
Dd d= Nominal distance to the surface (radius).
Optional inputs
Outputs

Example: Angled single surface measurement
50.0
X+
45°
Y+
Figure 7.10 Measuring a single angled surface (probe at B0)
5 6
3
2
X
Y 4 1
G54
3. G65P9810Z0. Protected positioning move to the start position.
4. G65P9821A–135.D10.T10 Single surface measure.
The diameter of tool 10 is updated by the error of the surface position.

Angled web or pocket measurement (probe at B0) – O9822

90° NOTE:
Dd +Aa (positive) angle: Counter-clockwise
direction.
X+ –Aa (negative) angle: Clockwise
direction.
A - a Aa
–90°
Figure 7.12 Measuring an angled web or pocket (probe at B0)
Description
This cycle measures a web or pocket feature using two vectored measuring moves along
the X Y axis.
Application
the Z axis, with the probe and probe offset active. Run the cycle with suitable inputs as
described.

Format
G65 P9822 Aa Dd [ Ee Ff Hh Mm Qq Rr Ss Tt Uu Vv Ww ]
or
G65 P9822 Aa Dd Zz [ Ee Ff Hh Mm Qq Rr Ss Tt Uu Vv Ww ]
Example: G65 P9822 A45.005 D50.005 Z50. E92 F0.8 H0.2 M0.2 Q10. R10. S1.
T20. U.5 V.5 W2.
Compulsory inputs
Aa a= Angle of the surface to be measured from the X+ axis direction.
Zz z= The absolute Z axis position when measuring a web feature. If this is

Optional inputs
Outputs

Example: Angled web measurement
-10
50.0
30°
Figure 7.13 Measuring an angled web (probe at B0)
6
7 8
X
Y
Z 5 4 3
6 2
1
G54
1 & 2. T01M06 Select the probe.
6. G65P9822A30.D50.Z–10.S2 Measure a 50.0 mm (1.9685 in) wide web at 30°.
Continue
The feature centre line in the X axis is stored in work offset S02 (G55).

3-point bore or boss measurement (probe at B0) – O9823

0°
X+
Aa
Y+
Cc
90° –90°
Bb
NOTE:
direction.
180°
Dd
R-r
Rr
Figure 7.15 3-point bore or boss measurement (probe at B0)
Description
This cycle measures a bore or boss feature using three vectored measuring moves along
the X Y axis.
Application
the Z axis, with the probe and probe offset active. Run the cycle with suitable inputs as
described.

Format
G65 P9823 Aa Bb Cc Dd [ Ee Ff Hh Mm Qq Rr Ss Tt Uu Vv Ww ]
or
G65 P9823 Aa Bb Cc Dd Zz [ Ee Ff Hh Mm Qq Rr Ss Tt Uu VvWw ]
Example: G65 P9823 A45.005 B150.0 C35.005 D50.005 Z50. E90 F0.8 H0.2 M0.2
Q10. R10. S1. T20. U.5 V.5W2.
Compulsory inputs
Aa a= The first angle for vector measurement, measured from the X+ axis
direction.
Bb b= The second angle for vector measurement, measured from the X+ axis
direction.
Cc c= The third angle for vector measurement, measured from the X+ axis
direction.
Zz z= The absolute Z axis position when measuring a boss feature. If this is

Optional inputs
Outputs

Example: 3-point bore measurement (referred datum)
7 8 9
X 6 5 4 3 2
1
Z
G54
1 & 2. T01M06 Select the probe.
5. G65P9810Z–10. Protected positioning.
6. G65P9823D30.A30.B150. Measure a 30.0 mm

C–90.S2 (1.181 in) diameter bore.
8 & 9. M82 Switch off the probe.
Continue
The error of the centre line is referred to the datum point X0,Y0 and the revised X0,Y0

Additional cycles 8-1
Chapter 8
Additional cycles
The Inspection Plus software contains a number of macro cycles that cannot be described
under the headings used in previous chapters of this manual (see chapters 4 to 7
inclusive). This chapter describes how to use these cycles.

Storing multi-stylus data (probe at B90) – O9630 ............................................................ 8-5
Loading multi-stylus data (probe at B90) – O9631........................................................... 8-7
Determining feature-to-feature data in the ZY plane (probe at B90) – O9634 ................. 8-9
Determining feature-to-feature data in the X plane (probe at B90) – O9634 ................. 8-13
Storing multi-stylus data (probe at B0) – O9830 ............................................................ 8-20
Loading multi-stylus data (probe at B0) – O9831........................................................... 8-22
Determining feature-to-feature data in the XY plane (probe at B0) – O9834 ................. 8-24
Determining feature-to-feature data in the Z plane (probe at B0) – O9834 ................... 8-28

8-2 Additional cycles (probe at B90)
Bore/boss on PCD measurement (probe at B90) – O9619

NOTE:
90 o
Aa Kk Kk
180o 0o
Dd
–90o
Cc PCD Xx Xx
Figure 8.1 Bore/boss on PCD measurement (probe at B90)
Description
The macro measures a series of bores or bosses on a pitch circle diameter (PCD). All
probe moves occur automatically and return to the start position at the centre of the PCD.
Application
1. The probe is positioned at the centre of the PCD above the component. It moves to
all features of the bore/boss and measures each feature automatically. At the end of
the cycle it then returns to the PCD centre.
2. The macro makes use of the bore/boss macro which is nested within the moves.
This means that the macro nesting level is four deep, which means that this macro
cannot be nested inside a customer macro.
3. If a 'probe open' condition occurs during any of the moves between bore/boss
features, a PATH OBSTRUCTED alarm occurs. The probe then stays in position
instead of returning to the start position as is usual. This is done for safety reasons
because the return path to the centre line of the PCD may be obstructed.

Additional cycles (probe at B90) 8-3
Format
Boss: G65 P9619 Cc Dd Xx [ Aa Bb Ee Hh Mm Qq Rr Uu Ww ]
or
Bore: G65 P9619 Cc Dd Kk [ Aa Bb Ee Hh Mm Qq Rr Uu Ww ]
Example: G65 P9619 C28.003 D50.005 K11. A45.005 B2. E90 H0.2 M0.2
Q10. R10. U.5 W2.
Compulsory inputs
Cc c= PCD. The pitch circle diameter of the bore/boss feature.
Dd d= Diameter of the bore/boss.
Kk k= Absolute Z axis position at which the bore is to be measured.
Xx x= Absolute Z axis position at which the boss is to be measured.
Optional inputs
Aa a= Angle measured from the Z axis to the first bore/boss feature.
Default: 0.
Bb b= The number of bore/boss features on the PCD.

Default: 1.
Outputs
The feature measurements will be stored in variables #135 to #149 (see Chapter 3,
"Variable outputs").
The data listed below is output to the printer. For details of the print macro output format,
see Chapter 12, “General information”.
z Diameter of each bore/boss.
z ZY absolute position, angle position, and pitch circle diameter of each feature.
z Feature number.
z Error of size and position.

Uu u= When the upper tolerance is exceeded, the macro continues to the end
and print data is output for each feature.
Depending on how #704 #[#111 + 4] is set, either the UPPER
TOLERANCE EXCEEDED alarm message is displayed and the process
stops, or flag #148 is set and the process continues. For details, see
“Alarm settings (#704)” in Chapter 11, “Settings, macros and variables”.

Storing multi-stylus data (probe at B90) – O9630
Probe 1 Probe 2
K11 K12
Calibration data Calibration data
Figure 8.2 Storing multi-stylus data (probe at B90)
Description
This macro is used to store stylus calibration data that is established during the calibration
cycles. The data is stored in a spare set of macro variables.
Stored data for each probe can be recalled using macro O9631.
Application
Calibrate the stylus using macros O9602 and O9604. Run macro O9630 to store the
calibration data #750 to #767. The values are recalled when macro O9631 is run.
NOTE: All # numbers shown are with the base number set to 750 in O9724.
Format
G65 P9630 Kk
Example: G65 P9630 K11.

Compulsory input
Kk k= This is the multi-stylus probe number that is used for storing calibration
data.
The active calibration data is stored in the macro variables shown in the following table.
The actual variables used are dependent on the #112 setting in O9724
Active data K11 K12
Ball radius X #750 #768 #772
Ball radius Y #751 #769 #773
Offset X #752 #770 #774
Offset Y #753 #771 #775
Vector radius #760 #784 #792
NOTE: Spare macro variable locations, in which the calibration data can be stored, are
dependent on the machine options available and the variables that are already used by
your programs. These can be moved, depending on the #112 setting in O9724.
Example: Multi-stylus store K11

O0003
G54
G65P9610X-5.F3000 Protected positioning move for X.
G65P9604D50.001 Calibrate in or on a reference feature (ring gauge or datum

sphere).
G65P9630K11 Store the calibration values for multi-stylus K11.

Loading multi-stylus data (probe at B90) – O9631
Probe 1 Probe 2
K11 K12
Calibration data Calibration data
Figure 8.3 Loading multi-stylus data (probe at B90)
Description
This macro is used (in conjunction with O9630) to load stored calibration data for a
specific probe/stylus configuration into the active calibration variable range. It must be run
before using the probe and stylus.
Application
The program must be run immediately before a measuring cycle to select the correct
probe calibration data. The Kk input determines the data that is to be loaded.
Format
G65 P9631 Kk

Compulsory input
Kk k= This is the multi-stylus probe number that is used for loading stored data.
For a specific probe/stylus configuration, the Kk input number must be the
same as that used when storing the data with O9630.
The actual variables used are dependent on the #112 setting in O9724
Active data K11 K12
Ball radius X #750 #768 #772
Ball radius Y #751 #769 #773
Offset X #752 #770 #774
Offset Y #753 #771 #775
NOTE: Spare macro variable locations, in which the calibration data is stored, are
Example: Multi-stylus load K11

G54
G65P9610X–10.F3000 Protected positioning move.
G65P9631K11 Load the calibration values for multi-stylus K11.
G65P9614D30.S2 Measure a 30.0 mm (1.181 in) diameter bore.
continue

Determining feature-to-feature data in the ZY plane (probe at B90)

– O9634
NOTE:
direction.
Dd
P2
Yy
Aa
P1
Zz
Figure 8.4 Determining feature-to-feature data in the ZY plane (probe at B90)
Description
This is a no-movement macro that is used after two measuring cycles to determine
feature-to-feature data.
Application
Data for P1 and P2 must already be stored in variables #130 to #134 (for P1) and #135 to
#147 (for P2) by running suitable measuring cycles.
NOTE: The order P1 and P2 is important because the data calculated is that of P2 with
respect to P1.
Values for P1 are obtained by programming G65 P9634 without any inputs after the first
measuring cycle.
Values for P2 are obtained by running a second measuring cycle. The feature-to-feature
data is established by programming G65 P9634 with suitable inputs after the second
measuring cycle.

Format
G65 P9634 Zz [ Ee Ff Hh Mm Ss Tt Uu Vv Ww ]
or
G65 P9634 Yy [ Ee Ff Hh Mm Ss Tt Uu Vv Ww ]
or
G65 P9634 Zz Yy [ Bb Ee Hh Mm Ss Uu Ww ]
or
G65 P9634 Aa Dd [ Bb Ee Hh Mm Ss Uu Ww ]
or
G65 P9634 (with no inputs).
Examples: G65 P9634 Z100. E90 F0.8 H0.2 M0.2 S1. T20. U.5 V.5 W2.
or
G65 P9634 Y100. E90 F0.8 H0.2 M0.2 S1. T20. U.5 V.5 W2.
or
G65 P9634 Z100. Y100. B2. E90 H0.2 M0.2 S1. U.5 W2.
or
G65 P9634 A45.005 D50.005 B2. E90 H0.2 M0.2 S1. U.5 W2.
NOTES:
1. Updating a tool offset with the T input is possible only if either O9611 or O9621 is
used for P2 data. Otherwise an alarm (T INPUT NOT ALLOWED) results.
2. This cycle cannot be used in conjunction with the web/pocket cycle macro O9612.
3. Angles. The ZY plane is with respect to the Z+ axis direction. Use angles in the
range ±180 degrees.
4. When G65P9634 (without any inputs) is used, then the following data is stored:
from #135 to #130
#136 #131
#137 #132
#138 #133
#139 #134

Compulsory inputs
Aa a= The angle of P2 with respect to P1 measured from the Z+ axis (angles
between ±180 degrees).
Dd d= The minimum distance between P1 and P2.
Yy y= The nominal incremental distance in the Y axis.
Zz x= The nominal incremental distance in the Z axis.
(No inputs) This is used to store output data of the last cycle for P1 data.
Optional inputs
Example 1: Measuring the incremental distance between two

holes
1. G65P9610Z30.Y50.F3000 Protected positioning move.

1 2
3
3. G65P9614D20. P1 20 mm (0.787 in) bore.
7
8 4. G65P9634 Store data.
6
9 and 10 6. G65P9610Z80.Y78.867 Move to the new position.

4 and 5
X 7. G65P9610X–10. Protected positioning move.
Y
8. G65P9614D30. P2 30 mm (1.181 in) bore.
Z
Figure 8.5 And either this

Probe movements
9. G65P9634Z50.Y28.867M.1 Incremental distance measure with
0.1 mm (0.0039 in) true position
tolerance.
or this
9. G65P9634A30.D57.735M.1

Example 2: Surface to bore measurement


1
2 3. G65P9611Z0. P1 at the Z0 mm (0 in) position.
4. G65P9634 Store data.

8 and 9
6
7
5
6. G65P9610Z–50. Move to the new position.
3 and 4 7. G65P9610X–10. Protected positioning move.

X
Y 8. G65P9614D20.5 P2 20.5 mm (0.807 in) bore.
Z
9. G65P9634Z–50.H.2 Measure distance –50 mm (–1.97 in).
Figure 8.6
Probe movements

Determining feature-to-feature data in the X plane (probe at B90)

– O9634
NOTE:
P2
+Aa
+Xx
P1 Xx
+Dd
X+
Y–
P2
+Aa
–Xx Z+
P1
–Dd
Figure 8.7 Determining feature-to-feature data in the X plane (probe at B90)
Description
Application
respect to P1.
measuring cycle.
Values for P2 are obtained by running a second measuring cycle, and the feature-to-
feature data is established by programming G65 P9634 with suitable inputs after the
second measuring cycle.

Format
G65 P9634 Xx [ Ee Ff Hh Mm Ss Tt Uu Vv Ww ]
or
G65 P9634 Aa Xx [ Bb Ww ]
or
G65 P9634 Dd Xx [ Bb Ww ]
or
G65 P9634 (with no inputs)
Examples: G65 P9634 X50. E90 F0.8 H0.2 M0.2 S1. T20. U.5 V.5 W2.
or
G65 P9634 A45.005 X50. B2. W2.
or
G65 P9634 D50.005 X50. B2. W2.
or
NOTES:
1. Updating a tool offset with the T input is possible only if O9611 is used for P2
data. Otherwise an alarm (T INPUT NOT ALLOWED) results.
2. Angles. These are with respect to the ZY. Use angles in the range ±180 degrees.
from #135 to #130
#136 #131
#137 #132
#138 #133
#139 #134
Inputs
Aa Xx or Dd Xx inputs
1. +Dd/–Dd values should be used to indicate the direction of P2 with respect to P1.
2. +Aa angles (counter-clockwise).
3. Angles between ±180 degrees.
Zz only input
+Xx/–Xx values should be used to indicate the direction of P2 with respect to P1.

Compulsory inputs
Aa a= The angle of P2 with respect to P1 measured from the XY plane (angles
Xx x= The nominal incremental distance in the X axis.

or
Dd d= The minimum distance between P1 and P2 measured in the ZY plane.

or
Optional inputs

surfaces
1 2. G65P9610X30. Protected positioning move.

2 3. G65P9611X20. P1 20 mm (0.787 in) surface.
5
4. G65P9634 Store data.
3 and 4
5. G65P9610Z50. Move to the new position.
6 and 7
6. G65P9611X15. P2 15 mm (0.591 in) surface.
7. G65P9634X–5.H.1 Feature to feature at –5.0 mm

X (–0.197 in).
Y
Z
Figure 8.8
Probe movements

Example 2: Measuring an angled surface


1
2
5 3. G65P9611X20. P1 at the 20 mm (0.787 in) position.
3 and 4 4. G65P9634 Store data.
6 and 7
5. G65P9610Z57.48 Move to the new position.
6. G65P9611X10. P2 at the 10 mm (0.394 in) position.

X
and either this
Y
Z
7. G65P9634D27.48X–10.B.5 Measure the slope between points P2
and P1 with an angle tolerance of ±0.5
Figure 8.9 degrees.
Probe movements
or this
7. G65P9634A–20.X–10.B.5 Measure the slope of –20 degrees (in the

clockwise direction) with an angle
tolerance of ±0.5 degrees.

Bore/boss on PCD measurement (probe at B0) – O9819

0°
NOTE:
direction.
Cc PCD
X+
Y+ 90° –90°
Z+
Zz Dd Kk
Aa
180°
Zz
Kk
Figure 8.10 Bore/boss on PCD measurement (probe at B0)
Description
The macro measures a series of bores or bosses on a pitch circle diameter (PCD). All
probe moves occur automatically and return to the start position at the centre of the PCD.
Application
1. The probe is positioned at the centre of the PCD above the component. It moves to
all features of the bore/boss and measures each one automatically. At the end of the
cycle it then returns to the PCD centre.
2. The macro makes use of the bore/boss macro which is nested within the moves.
The macro nesting level is four deep, which means that this macro cannot be nested
inside a customer macro.

3. If a 'probe open' condition occurs during any of the moves between bore/boss
features, a PATH OBSTRUCTED alarm occurs. The probe then stays in position
instead of returning to the start position as is usual. This is done for safety reasons
because the return path to centre line of the PCD may be obstructed.
Format
Boss: G65 P9819 Cc Dd Zz [ Aa Bb Ee Hh Mm Qq Rr Uu Ww ]
or
Bore: G65 P9819 Cc Dd Kk [ Aa Bb Ee Hh Mm Qq Rr Uu Ww ]
Example: G65 P9819 C28.003 D50.005 K11. A45.005 B2. E91 H0.2 M0.2
Q10. R10. U.5 W2.
Compulsory inputs
Cc c= PCD. The pitch circle diameter of the bore/boss feature.
Dd d= Diameter of the bore/boss.
Kk k= Absolute Z axis position at which the bore is to be measured.
Zz z= Absolute Z axis position at which the boss is to be measured.
Optional inputs
Aa a= Angle measured from the X axis to the first bore/boss feature.
Default: 0.
Bb b= The number of bore/boss features on the PCD.

Default: 1.
Outputs
The feature measurements will be stored in variables #135 to #149 (see Chapter 3,
"Variable outputs").
The data listed below is output to the printer. For details of the print macro output format,
see Chapter 12, “General information”.
z Diameter of each bore/boss
z XY absolute position, angle position, and pitch circle diameter of each feature.

z Feature number.
z Error of size and position.
Uu u= When the upper tolerance is exceeded, the macro continues to the end
and print data is output for each feature.
Depending on how #704 #[#111 + 4] is set, either the UPPER
TOLERANCE EXCEEDED alarm message is displayed and the process
stops, or flag #148 is set and the process continues. For details, see
“Alarm settings (#704)” in Chapter 11, “Settings, macros and variables”.

Storing multi-stylus data (probe at B0) – O9830

Probe 1
K11
Calibration
data
Probe 2
K12
Calibration
data
Figure 8.11 Storing multi-stylus data (probe at B0)
Description
This macro is used to store stylus calibration data that is established during the calibration
cycles. The data is stored in a spare set of macro variables.
Stored data for each probe can be recalled using macro O9831.
Application
Calibrate the stylus using macro O9802 and O9804. Run macro O9830 to store the
calibration data #700 to #717. The values are recalled when macro O9831 is run.
Format
G65 P9830 Kk

Compulsory input
Kk k= This is the multi-stylus probe number that is used for storing calibration
data.
The actual variables used are dependent on the #111 setting in O9724.
Active data K11 K12
Ball radius X #700 #718 #722
Ball radius Y #701 #719 #723
Offset X #702 #720 #724
Offset Y #703 #721 #725
Example: Multi-stylus store K11

O0003
G54
T40T0M06
G65P9802D50.001 Calibrate the stylus offset.
G65P9804D50.001 Calibrate in or on a reference feature (ring gauge or datum sphere).
G65P9830K11 Store the calibration values for multi-stylus K11.

Loading multi-stylus data (probe at B0) – O9831

Probe 1
K11
Calibration
data
Probe 2
K12
Calibration
data
Figure 8.12 Loading multi-stylus data (probe at B0)
Description
This macro is used (in conjunction with O9830) to load stored calibration data for a
specific probe/stylus configuration into the active calibration variable range. It must be run
before using the probe and stylus.
Application
The program must be run immediately before any measuring cycle to select the correct
probe calibration data. The Kk input determines the data that is to be loaded.
Format
G65 P9831 Kk
Compulsory input
Kk k= This is the multi-stylus probe number that is used for loading stored data.
For a specific probe/stylus configuration, the Kk input number must be the
same as that used when storing the data with O9830.
The actual variables used are dependent on the #111 setting in O9724.

Active data K11 K12
Ball radius X #700 #718 #722
Ball radius Y #701 #719 #723
Offset X #702 #720 #724
Offset Y #703 #721 #725
Example: Multi-stylus load K11 and K12

G54
T40T0M06
G65P9810Z–10.F3000 Protected positioning move.

continue

Determining feature-to-feature data in the XY plane (probe at B0)

– O9834
NOTE:
direction.
–Aa (negative) angle: Clockwise
direction.
Dd
P1
Xx Aa
P2
Yy
Figure 8.13 Determining feature-to-feature data in the XY plane (probe at B0)
Description
Application
respect to P1.

measuring cycle.
Values for P2 are obtained by running a second measuring cycle. The feature-to-feature
measuring cycle.
Format
G65 P9834 Xx [ Ee Ff Hh Mm Ss Tt Uu Vv Ww ]
or
G65 P9834 Yy [ Ee Ff Hh Mm Ss Tt Uu Vv Ww ]
or
G65 P9834 Xx Yy [ Bb Ee Hh Mm Ss Uu Ww ]
or
G65 P9834 Aa Dd [ Bb Ee Hh Mm Ss Uu Ww ]
or
G65 P9834 (with no inputs).
Examples: G65 P9834 X100. E90 F0.8 H0.2 M0.2 S1. T20. U.5 V.5 W2.
or
G65 P9834 Y100. E90 F0.8 H0.2 M0.2 S1. T20. U.5 V.5 W2.
or
G65 P9834 X100. Y100. B2. E90 H0.2 M0.2 S1. U.5 W2.
or
G65 P9834 A45.005 D50.005 B2. E90 H0.2 M0.2 S1. U.5 W2.
NOTES:
1. Updating a tool offset with the T input is possible only if either O9811 or O9821 is
used for P2 data. Otherwise an alarm (T INPUT NOT ALLOWED) results.
2. This cycle cannot be used in conjunction with the web/pocket cycle macro O9812.
3. Angles. The XY plane is with respect to the X+ axis direction. Use angles in the
range ±180 degrees.
4. When G65P9834 (without any inputs) is used, the following data is then stored:
from #135 to #130
#136 #131
#137 #132
#138 #133
#139 #134

Compulsory inputs
Aa a= The angle of P2 with respect to P1 measured from the X+ axis (angles
Dd d= The minimum distance between P1 and P2.
Yy y= The nominal incremental distance in the Y axis.
Optional inputs

holes
1
2
3
6
X 4 and 5
7
Y
Z 8
9 and 10
3. G65P9814D20. P1 20 mm (0.787 in) bore.
4. G65P9834 Store the data.
6. G65P9810X80.Y78.867 Move to the new position.
8. G65P9814D30. P2 30 mm (1.181 in) bore.

And either this
9. G65P9834X50.Y28.867M.1 Incremental distance measure with 0.1 mm (0.0039 in)

true position tolerance.
or this
9. G65P9834A30.D57.735M.1
Example 2: Surface to bore measurement
8 and 9
X 7
Y
Z 6
3 and 4
2 1
5
3. G65P9811X0. P1 at the X0 mm (0 in) position.
6. G65P9810X50. Move to the new position.
8. G65P9814D20.5 P2 20.5 mm (0.807 in) bore.
9. G65P9834X50.H.2 Measure the distance 50 mm (1.97 in).

Determining feature-to-feature data in the Z plane (probe at B0) –

O9834
P1 P1
+Dd –Dd
P2 P2
+Zz –Zz
+Aa +Aa Zz
X+
Y– NOTE:
Z+
Figure 8.16 Determining feature-to-feature data in the Z plane (probe at B0)
Description
Application
respect to P1.
measuring cycle.
Values for P2 are obtained by running a second measuring cycle The feature-to-feature
measuring cycle.

Format
G65 P9834 Zz [ Ee Ff Hh Mm Ss Tt Uu Vv Ww ]
or
G65 P9834 Aa Zz [ Bb Ww ]
or
G65 P9834 Dd Zz [ Bb Ww ]
or
Examples: G65 P9834 Z50. E90 F0.8 H0.2 M0.2 S1. T20. U.5 V.5 W2.
or
G65 P9834 A45.005 Z50. B2. W2.
or
G65 P9834 D50.005 Z50. B2. W2.
or
NOTES:
1. Updating a tool offset with the T input is possible only if O9811 is used for P2 data.
Otherwise an alarm (T INPUT NOT ALLOWED) results.
2. Angles. These are with respect to the XY. Use angles in the range ±180 degrees.
from #135 to #130
#136 #131
#137 #132
#138 #133
#139 #134
Inputs
Aa Zz or Dd Zz inputs
1. +Dd/–Dd values should be used to indicate the direction of P2 with respect to P1.
2. +Aa angles (counter-clockwise).
3. Angles between ±180 degrees.
Zz only input
+Zz/–Zz values should be used to indicate the direction of P2 with respect to P1.

Compulsory inputs
Aa a= The angle of P2 with respect to P1 measured from the XY plane (angles
Zz z= The nominal incremental distance in the Z axis.

or
Dd d= The minimum distance between P1 and P2 measured in the XY plane.
Zz z= The nominal incremental distance in the Z axis.

or
Optional inputs

surfaces
3 and 4 1
2
X 5
Y
Z 6 and 7
3. G65P9811Z20. P1 20 mm (0.787 in) surface.
6. G65P9811Z15. P2 15 mm (0.591 in) surface.
7. G65P9834Z–5.H.1 Feature to feature at –5.0 mm (–0.197 in).

Example 2: Measuring an angled surface
X 1
3 and 4 2
Y
Z 5
6 and 7
1. G65P9810X47.48Y50.F3000 Protected positioning move.
3. G65P9811Z20. P1 at the 20 mm (0.787 in) position.
6. G65P9811Z10. P2 at the 10 mm (0.394 in) position.
and either this
7. G65P9834D27.48Z–10.B.5 Measure the slope between points P2 and P1 with

an angle tolerance of ±0.5 degrees.
or this
7. G65P9834A–20.Z–10.B.5 Measure the slope of –20 degrees (in the clockwise

direction) with an angle tolerance of ±0.5 degrees.

This is page is intentionally left blank.

C-axis cycles 9-1
Chapter 9
C-axis cycles
This chapter describes how to use the C-axis macros that are supplied as part of the
Inspection Plus software.

C-axis measurement (probe at B90) – O9618 (S1) / O9840 (S2) .................................... 9-2
C-axis find (probe at B90) – O9650 (S1) / O9841 (S2) .................................................... 9-5
C-axis measurement (probe at B0) – O9818 (S1) / O9842 (S2) ...................................... 9-7
C-axis find (probe at B0) – O9850 (S1) / O9843 (S2) .................................................... 9-10

9-2 C-axis cycles (probe at B90)
C-axis measurement (probe at B90) – O9618 (S1) / O9840 (S2)

Yy
NOTE:
Angle correction to the C-axis:
X+ Positive (+) angle: Counter-clockwise direction.
Negative (–) angle: Clockwise direction.
Y+
Xx
Y0 (C0)
Figure 9.1 C-axis measurement
Description
This macro is used to find the slope of a surface between two points X1 and X2. The
C-axis can then be rotated to compensate for the surface error.
Application
The C-axis must be positioned to the expected angular position of the feature; that is, the
surface normal to the X axis. If the Ss input is used, the work offset register is adjusted by
the error amount.
NOTE: To make the new work offset active on most machines, it is normally necessary to
re-state the work offset and move to the angular position after the cycle.
Format
G65 P9618 or P9840 Yy Xx [ Qq Bb Ss Ww ]
Example: G65 P9618 Y100. X50. Q10. B2. S1. W2.
Compulsory inputs
Yy y= The Y axis distance between the X1 and X2 measurement positions.
Xx x= The expected surface position in the X axis.

C-axis cycles (probe at B90) 9-3
Optional inputs
Bb b= Set a tolerance on the angular position of the feature. It is equal to half the
total tolerances
Example: With a component dimension of 45 degrees ±.25 degrees, the
C-axis would be positioned to 45 degrees and B.25 tolerance.
For other optional inputs, see Chapter 2, “Optional inputs”.
Outputs
#139 This will show the measured position in the C-axis.
#143 This will show the (X1 – X2) value.
#144 This will show the angle correction value.
NOTE: Different machines and applications may require the C-axis system variable
number to be changed. This is done by editing macro O9618 to suit your machine when
the macro is installed.
Edit as follows:
#3 = 5 (C-axis number). Change the axis number as required.
Axis direction change

Edit as follows:
#4 = 1 (1 = clockwise, and –1 = counter-clockwise). Change as required.

Example: Set the C-axis to a milled flat
7 1
X
5 45°
3 C0
Y
Z
4 4
2. G0C45. Position the C-axis to 45 degrees.
3. G65P9610Z0Y0X40.F3000 Position 40 mm (1.575 in) above the surface.
4. G65P9618Y50.X20.S1.B5. Measure at 50 mm (1.9685 in) centres, update G54

and set a tolerance of 5 degrees.
5 & 6. G65P9610X200. Protected positioning move.
continue

C-axis find (probe at B90) – O9650 (S1) / O9841 (S2)
Figure 9.3 C-axis find (probe at B90)
Description
This cycle will take two readings by moving the C-axis. External features can also be
measured by moving the X axis. The results can be used to update a work shift.
Application
The stylus must be programmed to a start position that is either above an external feature
or inside an internal feature. The C-axis must be engaged before calling up the cycle.
The inclusion of an Xx input indicates that an external feature is to be measured.
Format
G65 P9650 or P9841 Dd [ Xx Qq Rr Hh Ss ]
Compulsory inputs
Dd d= The linear width of the feature.
Optional inputs
Hh h= Half the total positional tolerance.
Qq q= Amount of scan past the nominal surface position and the clearance for
external features.
Default: 5 mm.
Rr r= Clearance move amount in ‘C’ for an external feature only (angle value).
Default: 5 mm plus the ball radius converted into an angle.

Xx x= The absolute X position at which a reading is taken when measuring a

external feature.
For the Ss optional input, see Chapter 2, “Optional inputs”.
Example: Bore
Bore size = 20.0
X position = X60.0
Y position = Y0
Z position = Z–40.0
X100.0Y0Z20.0C0 Move to the safe position.
G65P9610Z–40.0 Move over the bore.
G65P9610X60.0 Move into the bore.
G65P9650D20.0 Measure the bore.
G65P9610X100.0 Move out of the bore.
G65P9610Z20.0 Move to the start position.
NOTE:
The C-axis positioning feed can be optimised for this cycle.
The measure feedrate = (#23×0.25)
Sample of macro O9650:
#23=3000 (C POSITIONING FEED DEG/MIN)

C-axis measurement (probe at B0) – O9818 (S1) / O9842 (S2)

Yy
NOTE:
Angle correction to the C-axis:
Positive (+) angle: Counter-clockwise
direction.
Negative (–) angle: Clockwise direction.
X+
Xx
Y0 (C0)
Y+
Figure 9.4 C-axis measurement (probe at B0)
Description
This macro is used to find the slope of a surface between two points X1 and X2. The
C-axis can then be rotated to compensate for the surface error.
Application
The C-axis must be positioned to the expected angular position of the feature; that is, the
surface normal to the X axis. If the Ss input is used, the work offset register is adjusted by
the error amount.
NOTE: To make the new work offset active on most machines, it is normally necessary to
re-state the work offset and move to the angular position after the cycle.
Format
G65 P9818 or P9842 Yy Xx [ Qq Bb Ss Ww ]
Example: G65 P9818 Y100. X50. Q10. B2. S1. W2.

Compulsory inputs
Yy y= The Y axis distance between the X1 and X2 measurement positions.
Xx x= The expected surface position in the X axis.
Optional inputs
Bb b= Set a tolerance on the angular position of the feature. It is equal to half the
total tolerances.
Example: With a component dimension of 45 degrees ±.25 degrees, the
C-axis would be positioned to 45 degrees and B.25 tolerance.
For other optional inputs, see Chapter 2, “Optional inputs”.
Outputs
#139 This will show the measured position in the C-axis.
#143 This will show the (X1 – X2) value.
#144 This will show the angle correction value.
NOTE: Different machines and applications may require the C-axis system variable
number to be changed. This is done by editing macro O9618 to suit your machine when
the macro is installed.
Edit as follows:
#3 = 5 (C-axis number). Change the axis number as required.
Axis direction change

Edit as follows:
#4 = 1 (1 = clockwise, and –1 = counter-clockwise). Change as required.

Example: Set the C-axis to a milled flat
7 1
6
X
5 45°
Y 3 C0
Z
4 4
2. G0C45. Position the C-axis to 45 degrees.
3. G65P9810Z0Y0X40.F3000 Position 40 mm (1.575 in) above the surface.
4. G65P9818Y50.X20.S1.B5. Measure at 50 mm (1.9685 in) centres, update

G54 and set a tolerance of 5 degrees.
5 & 6. G65P9810Z200. Protected positioning move.
continue

C-axis find (probe at B0) – O9850 (S1) / O9843 (S2)
Figure 9.6 C-axis find (probe at B0)
Description
This cycle will take two readings by moving the C-axis. External features can also be
measured by moving the Z axis. The results can be used to update a work shift.
Application
The stylus must be programmed to a start position that is either above an external feature
or inside an internal feature. The C-axis must be engaged before calling up the cycle.
The inclusion of an Zz input indicates that an external feature is to be measured.
Format
G65 P9850 or P9843 Dd [ Zz Qq Rr Hh Ss ]
Compulsory inputs
Dd d= The linear width of the feature.
Optional inputs
Hh h= Half the total positional tolerance.
Qq q= Amount of scan past the nominal surface position and the clearance for
external features.
Default: 10 degrees.
Rr r= Clearance move amount in ‘C’ for an external feature only (angle value).
Default: 5 mm plus the ball radius converted into an angle.

Zz z= The absolute Z position at which a reading is taken when measuring an

external feature.
For the Ss optional input, see Chapter 2, “Optional inputs”.
Example: Bore
Bore size = 20.0
X position = X60.0
Y position = Y0
Z position = Z–40.0
X100.0Y0Z20.0C0 Move to the safe position.
G65P9810X60.0 Move over the bore.
G65P9810Z–40.0 Move into the bore.
G65P9850D20.0 Measure the bore.
G65P9810Z20.0 Move out of the bore.
NOTE:
The C-axis positioning feed can be optimised for this cycle.
The measure feedrate = (#23×0.25)
Sample of macro O9850:
#23=3000 (C POSITIONING FEED DEG/MIN)


Alarms and error messages 10-1
Chapter 10
Alarms and error messages
When an error occurs during use of the Inspection Plus software, an alarm number or
message is generated. This is displayed on the screen of the Mazatrol Matrix control.
This chapter describes the meaning and likely cause of each alarm message that may be
displayed. It then describes typical actions you should take to clear the fault.

General alarms............................................................................................................... 10-2

10-2 Alarms and error messages
General alarms
Format:
#148 flag
3006= 1 (OUT OF TOLERANCE) Updates the offset if the 1
1 (OUT OF POSITION) cycle start button is 2
1 (ANGLE OUT OF TOLERANCE) pressed to continue. 4
1 (DIA OFFSET TOO LARGE) 5
1 (UPPER TOL EXCEEDED) No offset update if the 3

1 (EXCESS STOCK) cycle start button is 6
pressed to continue.
Action Press cycle start to continue.
Format: #3000 = 91 (MESSAGE)
91 (FORMAT ERROR)
91 (A INPUT MISSING)
91 (B INPUT MISSING)
91 (C INPUT MISSING)
91 (D INPUT MISSING)
91 (I INPUT MISSING)
91 (J INPUT MISSING)
91 (K INPUT MISSING)
91 (X INPUT MISSING)
91 (Y INPUT MISSING)
91 (Z INPUT MISSING)
91 (XYZ INPUT MISSING)
91 (DATA #130 TO #139 MISSING)
91 (H INPUT NOT ALLOWED)

91 (T INPUT NOT ALLOWED)
91 (X0 INPUT NOT ALLOWED)
91 (Y0 INPUT NOT ALLOWED)
91 (IJK INPUTS 5 MAX)
91 (SH INPUT MIXED)

91 (ST INPUT MIXED)
91 (TM INPUT MIXED)
91 (XY INPUT MIXED)
91 (ZK INPUT MIXED)
91 (XYZ INPUT MIXED)
91 (K INPUT OUT OF RANGE)

Action: Edit the program and start again from a safe start position.
This is a reset condition.

Alarms and error messages 10-3
Format: #3000 = 86 (PATH OBSTRUCTED)

Cause: The probe has made contact with an obstruction. This alarm occurs only
during a protected positioning cycle.
Action: Edit the program. Clear the obstruction and start again from a safe position.
Format: #3000 = 88 (NO FEED RATE)

Cause: This alarm occurs only during a protected positioning cycle.
Action: Edit the program. Insert the F___ code input and start again from a safe
position.
Format: #3000 = 89 (NO TOOL LENGTH ACTIVE)

Action: G43 or G44 must be active before the cycle is called.
Edit the program and start again from a safe position.
Format: #3000 = 92 (PROBE OPEN)

Cause: This alarm occurs if the probe is already triggered before a move.
The stylus may be in contact with a surface or the probe has failed to reseat.
This could be due to swarf trapped around the probe eyelid.
Action: Clear the fault and start again from a safe start position.
Format: #3000 = 93 (PROBE FAIL)

Cause: This alarm occurs if the probe did not trigger during the move.
The surface was not found or the probe has failed.
Action: Edit the program and start again from a safe start position.
Format: #3000 = 94 ( XY STYLUS OFFSET TO LARGE)

Cause: This alarm occurs if the X Y stylus offsets are too large.
Action: True up the stylus and recalibrate the probe.
Format: #3000 = 95 (CHECK SETTINGS #107 #108 #120)

Cause: This alarm occurs if the settings in O9724 are set incorrectly.
Action: Edit the program O9724 with correct values.

10-4 Alarms and error messages

Settings, macros and variables 11-1
Chapter 11
Settings, macros and variables
This chapter describes how to customise the Inspection Plus software and provides
details about the macro variables used in the software.

Customising the software ............................................................................................... 11-2
Editing the settings macro (O9724) ........................................................................ 11-2
Setting the tool offset (#120) ................................................................................... 11-3
Variable base number setting (#111 and #112) ...................................................... 11-4
Selecting the call method from a Mazatrol program ............................................... 11-4
Alarm settings (#704) .............................................................................................. 11-4
Process alarms ....................................................................................................... 11-5
Use of macro variables .................................................................................................. 11-5

Local variables ........................................................................................................ 11-5
Common variables .................................................................................................. 11-5
Common retained variables .................................................................................... 11-7

11-2 Settings, macros and variables
Customising the software

Editing the settings macro (O9724)
The settings macro (O9724) is called at the beginning and end of each cycle to establish
the necessary modal information. If the default values are not suitable you will need to
change the values during installation by editing this macro.
The following options of macro O9724 will need to be set:
z Machine type (either type Mark IV or e-series).
z Tolerance alarms or flag only (FMS type application).
z Tool offset type.
z Variable base number.
z Diameter or radius programming mode.
z Diameter or radius programming in G68.5 mode (for Mark IV only).
The examples in this chapter are for general guidance only. Note that the exact
programming format may not suit either your machine set or recommended method as
specified by your machine builder.
#106 Tool offset length + head length
#107 = #0 MATRIX ‘M’ series = 1 (E tower)

MATRIX ‘T’ series = 2 (IV INTEGREX)
#108 = #0 1 = G122.1 Radius programming.

2 = G123.1 Diameter programming.
#110 = #0 0 = Radius programming in G68.5 mode

(F167.5 = 0).
1 = Diameter programming in G68.5 mode
(F167.5 = 1)
#111 = 700 See "Variable base number setting (#111 and

#112)" later in this chapter.
#112 = 750 See "Variable base number setting (#111 and

#112)" later in this chapter.
#114 = 0 Head length. This is taken from parameter BA62.

#119 = 3000 (FAST FEED MM) The fast feedrate of the cycles can be adjusted by
#119 = 50 (FAST FEED INCH) this variable to suit the machine characteristics and
should be optimised.
NOTES:
1. The fast feedrate of the Z axis P9726 basic move macro is at the #119*.6 value
(1.8 metres/min as standard).
2. The fast feedrate of all Z axis positioning moves is also at the #119*.6 value
3. The fast feedrate of all XY axis positioning moves is at the #119 value
#120 = 1 (SELECT OPTIONS) See “Setting the tool offset (#120)” below.
#123 = .05 (POSITION ZONE MM) This is the zone at either the start or end of the
block in which the cycle is aborted with either a
PROBE OPEN or PROBE FAIL.
Setting the tool offset (#120)

The Inspection Plus software must be set to suit the machine tool offset option type in
use. In the settings macro (O9724), edit the first line of the program by changing the value
of #120. The default value as supplied is #120 = 1. This value is for tool information being
stored in Mazatrol tool data. If this default value is not suitable, change #120 to one of the
values listed in the table below:
Tool offset type Value of #120
Mazatrol tool data #120 = 1
ISO tool offset type A #120 = 2
ISO tool data #120 = 3
ISO tool offset type B #120 = 4
ISO tool offset type C #120 = 5
ISO tool offset type D #120 = 6
Table 11.1 Software setting option #120
Machine parameters F94.7 and F93.3 control which offset area is to be used in ISO
programs. Consult the Mazak Parameter Manual for details.

Variable base number setting (#111 and #112)

The base number defines the first variable in the set of variables used for setting and
calibration data. The default values are 700 (#700) and 750 (#750). A default value may
be changed by editing the settings macro O9724. The base number edit is found near the
top of this macro:
#111 = 700 (EDIT HORIZ BASE NO.)
#112 = 750 (EDIT VERT BASE NO.)
See “Use of macro variables” later in this chapter for a full list of the variables affected.
Before editing, check the availability of the variables.
Selecting the call method from a Mazatrol program

All Renishaw cycles are intended to be called directly from a Mazatrol program using the
sub-program unit and ‘MEASURE MACRO’ function.
However, a ‘SUB PROGRAM UNIT’ cannot be prioritised, so it is suggested that the

‘PROCESS END’ function is used within the program.
O9724(REN SETTINGS)
(1 = MAZATROL TOOL DATA)
(2 = ISO TOOL OFFSET A)
(3 = ISO TOOL DATA)
(4 = ISO TOOL OFFSET B)
(5 = ISO TOOL OFFSET C)
(6 = ISO TOOL OFFSET D)
#120 = 1 (SELECT W/O OPTIONS)
Alarm settings (#704)

Using #704 #[#111 + 4], the software can be set to operate in either of the following
modes.
z Stop the machine at the end of the measuring cycle with an alarm message and set
the alarm flag #148.
z Set the alarm flag #148 only, allowing the process to continue.
#[#111 + 4] = 0 If one of the conditions (*) listed below in “Process alarms” occurs, the
cycle stops with an alarm message and flag #148 is set as
appropriate. Otherwise flag #148 = 0 is set and the cycle continues.

#[#111 + 4] = 1 If one of the conditions (*) listed below in “Process alarms” occurs, flag
#148 is set as appropriate but the cycle does not stop. Otherwise flag
#148 = 0 is set and the cycle continues.
Process alarms
* No alarm #148 = 0
* Out of tolerance #148 = 1
* Out of position #148 = 2
* Upper tolerance exceeded #148 = 3
* Angle out of tolerance #148 = 4
* Diameter offset too large #148 = 5
* Excess stock #148 = 6
NOTE: If it is necessary to switch this option on and off during the program, then the
following line in macro O9724 may be deleted during installation. #704 can then be
programmed.
#[#111+4] = 0(SELECT ALARM METHOD).
Use of macro variables

Local variables
#1 to #32 These are used within each macro as required for calculation etc.
Common variables
#100 to #105 Not used by this software.
#106 Tool length + head length.
#107 M or T series.
#108 Radius or diameter programming.
#109 Chuck centre line in X.
#110 Radius or diameter programming in G68.5 mode.
#111 Variable base number (horizontal) B0.
#112 Variable base number (vertical) B90.
#114 Machine head length.

#116 Active tool length, which is calculated in macro O9723.
#117 Modal feedrate value used in the protected positioning macros (O9610
and O9810).
#118 RADIUS TOO LARGE flag macro O9612 (O9812), O9614 (O9814),
O9622 (O9822), and O9623 (O9823) (also used for temporary ATAN
store in macro O9731).
#119 Fast feedrate value. This is set in macro O9724 at 3000 mm/min
(50 in/min) default value.
#120 Setting variable used in macro O9724.
#121 Print option. The component number is incremented by 1 with each

program heading. To reset, state #121 = 0.
#122 Print option. The feature number is increment by 1 with each print
macro call program. To reset, state #122 = 0.
#123 Start and end of block position zone normal setting 0.05 mm
(0.002 in). If the skip position is within this zone, the cycle aborts with a
PROBE OPEN or PROBE FAIL alarm.
#124 Stored X skip position at the end of the basic move macro O9726.
#125 Stored Y skip position at the end of the basic move macro O9726.
#126 Stored Z skip position at the end of the basic move macro O9726.
#127 X average skip position at the end of the X diameter move macro
O9721.
#128 Y average skip position at the end of the Y diameter move macro
O9722.
#129 Inch/metric multiplier (0.04/1.0).
#130 to #134 Output data #135 to #139 is stored when the feature-to-feature macros
O9634 and O9834 are used.
#135 to #149 See Chapter 3, "Variable outputs".
#150 onwards Not used by the software.

Common retained variables

The actual common retained variables that are used are determined by the values set in
#111 and #112 in the settings macro O9724. Default values are 700 for #111 and 750 for
#112 (see “Variable base number setting (#111 and #112)” earlier in this chapter).
Vertical cycles use the same common retained variables as the horizontal cycles but in
the 750 series (default).
Example: Horizontal cycle Equivalent vertical cycle

retained variable retained variable
#700 #750
#701 #751
#700 [111+0] (XRAD) X calibration radius.
#701 [111+1] (YRAD) Y calibration radius.
#702 [111+2] (XOFF) X axis stylus offset.
#703 [111+3] (YOFF) Y axis stylus offset.
#704 [111+4] Flag or alarm selection (see “Alarm settings [#704]” earlier in this
chapter).
#705 [111+5] (Reserved for other software packages.)
(a) (c)
(b)
X
#706
(Basic move
control factor)
X
1 2 3
Move 1: Fast feed to find the surface. a = Fast feed.

Move 2: Recover off the surface. b = Gauge feed
(30 mm/min).
Move 3: Gauge feed 30 mm/min (1.2 in/min). c = Return.
Figure 11.1 Basic move control factor
#706 [111+6] Basic move control factor (see Figure 11.1). This is used to control the
back-off distance in the basic move before the final gauge move. It
should be fine-tuned on installation to suit the machine.

A default value of 0.2 is installed by the software. The actual factor

should normally be between 0 and 1.0. Reduce the value to reduce the
back-off distance.
#707 #[#111+7] (Reserved for other software packages.)
#708 #[#111+8] (Reserved for other software packages.)
#709 #[#111+9] Active vector radius used in macros O9621 and O9821, O9622 and
O9822, and O9623 and O9823.
#710 to #749 These are reserved for vector calibration data and multi-stylus storage
as described below:
#710 (30 degrees)

#711 (60 degrees)
#712 (120 degrees)
#713 (150 degrees) Vector calibration data.
#714 (210 degrees)
#715 (240 degrees)
#716 (300 degrees)
#717 (330 degrees)
#718
#719 Multi-stylus data K11.
#720
#721
#722
#724
#725
#734
#735
#736
#738
#739
#740
#741

#742
#743
#744
#746
#747
#748
#749
The actual variables available are the limiting factor and depend on the control options
available.


General information 12-1
Chapter 12
General information
This chapter contains general information and reference material that is relevant to the
Inspection Plus software package.

Tolerances ..................................................................................................................... 12-2
True position tolerances ................................................................................................. 12-3
Experience values Ee .................................................................................................... 12-3

Reason for using this option ................................................................................... 12-3
Additional spare tool offsets .................................................................................... 12-4
Printing ........................................................................................................................... 12-4

Setting the print parameter ..................................................................................... 12-4
Example of printing a macro output ........................................................................ 12-5
Considerations when using vector cycles O9621 (O9821), O9622 (O9822) and
O9623 (O9823) .......................................................................................................... 12-5
Use of 3-point bore/boss macros O9623 and O9823 ............................................. 12-5
Mathematical precision ........................................................................................... 12-6
Effect of vector calibration data on results .............................................................. 12-6
General probing applications ......................................................................................... 12-6

Example 1: Part identification ................................................................................. 12-6
Example 2: Probe measure every nth component .................................................. 12-7
Output flow (bore/boss and web/pocket cycles) ............................................................ 12-9

12-2 General information
Tolerances
Uu, Hh and Vv apply to size and tool offset updates only.
Uu e
c
Hh d
Vv
b a
a = Nominal size.
b = Null band. This is the tolerance zone where no tool offset adjustment occurs.
c = Area where the Ff input is effective in percentage feedback. F (0 to 1) gives 0% to 100%

feedback to the tool offset.
d = OUT OF TOLERANCE alarm occurs. The tolerance value that applies to the size of the
feature is defined by input Hh.
e = Uu upper tolerance. If this value is exceeded no tool offset or work offset is updated and
the cycle stops with an alarm. This tolerance applies to both size and position where
applicable.
Figure 12.1 Size and tool offset update tolerances

True position tolerances

For a true position tolerance (Mm input), see the figure below.
Axis of datum Possible axes
True position
Tolerance 0.1
(Mm input)
Figure 12.2 Cylinders centred on true positions
Experience values Ee
The measured size can be adjusted by an amount stored in a spare tool offset.
Example
Measure a 40 mm diameter and update tool offset 20.
G65P9814 D40. T20 E91 The experience value stored in tool offset 91 will be
added to the measured size.
Reason for using this option

Component clamping forces in some applications can influence the measured size.
Therefore, an adjustment value to relate measurement to a traceable standard, such as a
co-ordinate measuring machine, is desirable. Thermal effects can also be compensated
by this means.

Additional spare tool offsets

The range of spare tool offsets can be extended when either a Type B or Type C tool
offset option is installed on the machine.
Experience no. A type B type C type
E1 to En
E201 to E20n
E601 to E60n
where ‘n’ is the tool offset number.
From the table you can see that you should add either 200 or 600 to the tool offset
number.
These additional tool offset registers can safely be used for both ‘Ee’ experience values.
The tool offset number is not used as a normal tool offset location.
Printing
Setting the print parameter
Two methods can be used for printing:
through the RS232 port (this is an option from Mazak), and
to the hard drive.
The setting of parameter DPR 14 controls where the DPRNT is sent to. Setting the
DPR 14 parameter to 1 will print to the RS 232 port while setting it to 4 will print to the
hard drive. See the Mazak parameter manual for the RS 232 settings.
When printing to the hard drive, the control creates a file C:\MC_sdg\print\print.txt. When
print commands are executed, text is added to the bottom of this file.
To find this file, do the following:
1. Move the pointer to the bottom left-hand side of the screen to display the Windows
start menu.
2. Click the Start button. The standard Windows menu is displayed.
3. Click the My Computer icon.

4. Find the file C:\MC_sdg\print\print.txt. You can now transfer this file to either the
USB, Flash card or floppy disk.
5. Delete the file C:\MC_sdg\print\print.txt. A new file will be created when the next
DPRNT command is done.
Example of printing a macro output

--------------------------------------------------------------------------
COMPONENT NO 31 FEATURE NO 1
--------------------------------------------------------------------------
POSNR79.0569 ACTUAL 79.0012 TOL TP 0.2000 DEV -0.0557

POSN X-45.0000 ACTUAL -45.1525 TOL TP 0.2000 DEV -0.1525
POSN Y-65.0000 ACTUAL -64.8263 TOL TP 0.2000 DEV 0.1737
+++++OUT OF POS+++++ ERROR TP 0.1311 RADIAL
ANG -124.6952 ACTUAL -124.8578 DEV -0.1626
---------------------------------------------------------------------------
COMPONENT NO 31 FEATURE NO 2
---------------------------------------------------------------------------
SIZE D71.0000 ACTUAL 71.9072 TOL 0.1000 DEV 0.9072
+++++OUT OF TOL+++++ ERROR 0.8072

POSN X-135.0000 ACTUAL -135.3279 DEV -0.3279
POSN Y-65.0000 ACTUAL -63.8201 DEV 1.1799
Considerations when using vector cycles O9621 (O9821), O9622

(O9822) and O9623 (O9823)
Vectored cycles involve the mathematical operation of squared values. This can lead to
precision errors if large values are used. The following factors must be considered:
Use of 3-point bore/boss macros O9623 and O9823

These macros are used to establish the centre and diameter of a bore or external feature.
There is however a practical limitation to the use of the macros. It is advisable to use the
largest distance between contacts, that is practical. The minimum conditions to give
reliable data are as follows:
168 degrees total span.

48 degrees between any two points.
The software does not check the minimum condition inputs.
The accuracy of the result deteriorates if the minimum conditions are not followed.

Mathematical precision
The mathematical precision of the controller is a limiting factor if large values are used.
The Mazatrol Matrix ‘T’ controller works within an accuracy of eight significant figures.
Because of the mathematical operations concerned, an error may accumulate if large
values for probing positions about the centre are used for calculation. It is suggested that,
at this moment, X Y co-ordinate values of ±300.00 mm (30.000 in) from the feature centre
are not exceeded for any position around a bore, to retain a resultant resolution of better
than 0.01 mm (0.001 in).
Effect of vector calibration data on results

The vector calibration cycle establishes true calibration data at each 30 degree increment.
A small error due to the probe trigger characteristics may occur at intermediate angles
between the 30 degree calibration points. However this error is small for standard
machine tool probes with standard styli.
NOTE: For better accuracy, always use the standard bore/boss cycles (O9614 and
O9814) where possible.
General probing applications

Example 1: Part identification
If a group of components can be identified by a single feature, a probe can be used to
inspect that feature and decide which component is present. This is done by using data
from the output chart following a measuring program.
74 A
72 70 B
C
Each part surface is known to be within ±0.5
Figure 12.3 Part identification

G65 P9810Z84.F3000 Protected move to the start position.
G65P9811Z70. Single surface measure (target C surface).
IF[#137GT73.]GOTO100 If the result is greater than 73.0, go to N100.
GOTO400
N100(PROGRAM TO MACHINE A)
continue 'A’ component
GOTO400
N200(PROGRAM TO MACHINE B)
continue 'B' component
GOTO400
N300(PROGRAM TO MACHINE C)
continue 'C' component
N400
M30
Example 2: Probe measure every nth component

Often it is a requirement to probe every nth component in the interests of reducing overall
cycle time.
The following programming method can be employed:
O5000(PART PROGRAM)
#100=0 Reset the counter.
#101=5 Count limit.
N1
(START OF MACHINING)
conventional part programming
N32
(START OF PROBE ROUTINES)
IF[#100LT#105]GOTO33 If the counter is less than 5, jump to N33.

T01M06 (PART INSPECTION) Select the inspection probe.
probing routines
#100=0 Reset the counter to zero.
N33
(CONTINUE MACHINING OR END)
#100=#100+1 Increment the counter.
rest of machining program
M99P1 Return to N1.
M30

Output flow (bore/boss and web/pocket cycles)
Measure N10
Y If error flag N
#149 NEO If U input
If #149 Y N If size
If E input
NE 2 error
Probe fail Size adjust If position Y

#3000 experience error
N11
N Flag #148 = 3
Output variables If H input
#135 to #149
Probe Y
open N If size N If flag only
If W input
#3000 error #120.4 = 1
Upper
Flag #148 = 1 tolerance
Print data to exceeded
RS232 port #3006
N10 If flag only Y END

#120.4 = 1
If size N
error
Out of
tolerance
#3006
#3000 alarms must reset the machine.

N13
#3006 cycle start to continue.

N13 N15 N19
N N N
If M input If T input If S input
N If position If V band N Work offset

error exceeded update
Flag #148 = 2 Y
If F input END
Y Set F = 1
If flag only
#148 = 1
If position N Update tool offset

error error x F
Out of N
If radius
position
too large
#3006
N15 Flag #148 = 5
If flag only Y
#120.4 = 1
Out of
tolerance
#3006
N19

Probing with G68.5 active A-1
Appendix A
Probing with G68.5 active
Contained in this appendix

Introduction ...................................................................................................................... A-2
Program example ............................................................................................................. A-2

A-2 Probing with G68.5 active
Introduction
This chapter describes how to use the probe with G68.5 active and with the B-axis at an
angle. Program G68.5 as described in the Mazak Matrix programming manual.
Only Renishaw cycles O9800 to O9834 (probe at B0) can be used with G68.5 active. The
9600 cycles must not be used (probe at B90).
If you are using either a Renishaw MP700 or OMP400 probe, the probe must be switched
off when moving the B-axis head and switched on again when the head is in its new
position, followed by a 2 second dwell.
When G68.5 is being used, work offsets cannot be updated.
NOTE: Before running any cycles in G68.5 mode, #110 in macro O9724 must be set
accordingly.
Program example
G90G21G80G17
M901 S1.
G109L1 Upper turret.
G28U0
G28W0
G28V0
T040M06
M200 Select the milling mode.
M250 Unclamp the B axis.
G0B45. Rotate the B axis to 45 degrees.
()
G52.5
G53.5
G68.5X0.Y0.Z0.I0.J1.K0.R45. Rotate the co-ordinates 45 degrees.
M81 Probe on.
G65P9810Z17.5F3000 Start of the probing cycles.
G65P9810X0Y0
G65P9814D15.Z-3.
G65P9811Z7.5

Probing with G68.5 active A-3
G28U0
G28W0
G28V0
M202 Select the turning mode.

M82 Probe off.
G69.5
M30

A-4 Probing with G68.5 active

Features, cycles, and limitations B-1
Appendix B
Features, cycles, and limitations
Contained in this appendix

Features of the Inspection Plus software ......................................................................... B-2
Cycles .............................................................................................................................. B-2
Limitations ........................................................................................................................ B-3

B-2 Features, cycles, and limitations
Features of the Inspection Plus software

z Protected positioning.
z Measurement of internal and external features to determine both size and position.
This includes:
f Obtaining a hardcopy printout of feature data.
f Applying tolerances to both size and position.
z Additional features for feedback of errors include:
f Experience values can be applied to the measured size.
f Percentage feedback of the error can be applied.
f Null band zone for no-tool offset update.
z Calculation of feature-to-feature data.
z Calibration of multiple styli.
z 4th axis datum setting and tolerancing.
z Angular measurement of features.
z Software option to turn off the tolerance alarms and provide a flag-only alarm.
Suitable for FMS and unmanned applications.
z Built-in stylus collision and false trigger protection for all cycles.
z Diagnostic and format error checking routines for all cycles.
z Active set-up information updating.
z ISO tool data and Mazatrol tool data updating.
z Program restarts are allowed even if a Renishaw probe cycle is used prior to the
program restart position.
Cycles
z Protected positioning.
z Measurement:
f XYZ single surface.
f Web/pocket.
f Bore/boss (four measuring points).

Features, cycles, and limitations B-3
z Vectored measurement:
f 3-point bore/boss.
f Web/pocket.
f Single surface.
z Additional macros:
f 4th axis measurement.
f Bore/boss on a PCD.
f Multi-stylus calibration.
Limitations
z The probe cycles will not run if ‘mirror image’ is active.
z Macro variable availability must be considered.

Renishaw plc T +44 (0)1453 524524
New Mills, Wotton-under-Edge, F +44 (0)1453 524901
Gloucestershire, GL12 8JR E uk@renishaw.com
United Kingdom www.renishaw.com
For worldwide contact details,

please visit our main web site at
www.renishaw.com/contact
*H-2000-6443-0E*

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Programming manual

Inspection Plus software for Mazak

for Mazatrol Matrix ‘T’ controllers

This document may not be copied or reproduced in whole or in

The publication of material within this document does not imply

RENISHAW HAS MADE CONSIDERABLE EFFORTS TO ENSURE

RENISHAW® and the probe emblem used in the RENISHAW logo

apply innovation is a trademark of Renishaw plc.

Renishaw part no: H-2000-6443-0E-A

RENISHAW PRODUCT LICENCE

3. NOTE - LIMITATION OF LIABILITY IN CONNECTION WITH USE OF THE PRODUCT

Renishaw Product Licence (EN) – Issue 1: February 2007

Special control options.............................................................................….......................................….............

Inspection probe type ..................................……..... Inspection disk(s)......................................……...............

Interface type .................................................……. ..........................................................................…...........

Tool setting probe type ................................…...…. Tool setting disk(s) ......................…......................…......

Interface type .................................................……. ..................................................................................…...

Switch (Spin) probe on ............................……....... Switch on inspection probe ..................……...................

Switch (Spin) probe off ..........................……......... Switch on tool setting .............................…….................

Start/Error signal .........................................…….... Other .....................................................….....................

Customer's name……….................................................................. Date installed ..........…...........................

Reason for deviation

Software no. and Comments and corrections

A copy of this deviation sheet will be retained by Renishaw plc.

Caution – Software safety

IMPORTANT – READ THIS

z The Mazak software version is B5A or higher.

z Option parameter O93.5 = 1 must be set.

Publication No. H-2000-6443

This page is intentionally left blank

Publication No. H-2000-6443

Before you begin

Chapter 1 Installing the software

Chapter 2 Optional inputs

Chapter 3 Variable outputs

Publication No. H-2000-6443

Chapter 4 Protected positioning cycles

Chapter 5 Calibrating the probe

Chapter 6 Standard measuring cycles

Publication No. H-2000-6443

Chapter 7 Vector measuring cycles

Chapter 8 Additional cycles

Chapter 9 C-axis cycles

Chapter 10 Alarms and error messages

Chapter 11 Settings, macros and variables

Publication No. H-2000-6443

Use of macro variables .................................................................................................. 11-6

Chapter 12 General information

Appendix A Probing with G68.5 active

Appendix B Features, cycles and limitations

Publication No. H-2000-6443

Before you begin

Comprising 12 self-contained chapters and two appendices, the manual is structured to

z Chapter 4, “Protected positioning cycles” describes how to use the protected

z Chapter 6, “Standard measuring cycles” describes how to use the non-vector

z Chapter 9, “C-axis cycles” describes how to use C-axis measuring cycles.

z Chapter 12, “General information”, contains general information and reference

Publication No. H-2000-6443

Measurement values used in this manual

List of associated publications